Rapid P0024 PMT Qac RPT 0001 0110

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RAPID P0024 PMT QAC RPT 0001 0110
PETRONAS RAPID PROJECT
AUDIT REPORT
KL-17-AU-034
PACKAGE 1/CCSM – CONSTRUCTION AUDIT
OWNER Approval:
Name:
Date (DD-MMM-YY):
Signature:
Document Class: O
Pages modified under this revision: -
Digitally signed by
abd21281 Faezal Ibrahim Digitally signed by Stephen
Knapper
DN: cn=abd21281, 2017.11.24 DN: cn=Stephen Knapper, o=QA
Central Directorate, ou=QA,
email=Ahmad.Abdullah@r
apid-ipmt.com 08:44:24 email=stephen.knapper@rapid-
ipmt.com, c=MY
Date: 2017.11.24 08:08:52 +08'00' Date: 2017.11.24 09:41:44 +08'00'
'+08'00
0 24-NOV-17 INF-Issued for Information AHMAD ABDULLAH FAEZAL IBRAHIM STEVE KNAPPER
DATE WRITTEN BY CHECKED BY APPROVED BY
REV. STATUS – REVISION MEMO
DD-MMM-YY (name & signature) (name & signature) (name & signature)
Sections changed in last revision are identified by a vertical line in the right margin.
Electronic Filenam RAPID-P0024-PMT-QAC-RPT-0001-0110

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CONSTRUCTION AUDIT- PACKAGE01
HOLD’s
HOLD No. REF. § DESCRIPTION ACTIONS

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1. INTRODUCTION ..........................................................................................................................................................4
2. OBJECTIVE ..................................................................................................................................................................4
3. AUDIT SCOPE..............................................................................................................................................................4
4. AUDIT CRITERIA / BASIS OF AUDIT......................................................................................................................6
5. THE CONSTRUCTION AUDIT...................................................................................................................................6
5.1 AUDIT TEAM .......................................................................................................................................... 6
5.2 AUDIT SCHEDULE/ LOCATION............................................................................................................. 7
6. AUDIT PROCESS ........................................................................................................................................................7
6.1 AUDIT NOTIFICATION........................................................................................................................... 7
6.2 AUDIT EXECUTION ............................................................................................................................... 7
7. AUDIT REPORT ...........................................................................................................................................................8

7.1 AUDIT FINDINGS SUMMARY................................................................................................................ 8
7.2 AUDIT FINDING NOTE :......................................................................................................................... 8
7.3 AUDIT CONCLUSION .......................................................................................................................... 11
7.4 CLASSIFICATION OF AUDIT FINDINGS ............................................................................................ 11
7.5 ACTION BY EPCC/CONTRACTOR ..................................................................................................... 12
7.6 AUDIT FINDINGS DETAIL* 12
8. LIST OF ATTACHMENT.......................................................................................................................................... 30

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1. INTRODUCTION
This report describes the processes, findings and recommendations of an audit on the
CONTRACTOR - EPCC of the RFCC LTU and PRU Units for RAPID project, held on
Nov, 13-17, 2017 in CCSM Site Office, Pengerang, Johor, Malaysia. The audit has
been executed in accordance with the audit notification issued through Letter No.
RAPID-PMT-CCSM-LTR-1390 dated 12th Oct. 2017.
Construction Audit was accomplished, but revealed a gap in the current processes
, Quality and Project requirements which are addressed in the findings and
Classified as Corrective Action (CA), Preventive Action (PA) and Observations (OBS).
In additional, several areas of concern which requires improvement specifically
highlighted hereafter in Clause 7.1 to 7.6.
The Audit team appreciated the well organized and open-minded diverse discussions,
as well as the full support provided during the period of performing the audit sessions
from the CCSM team. The Audit team also would like to mention the cooperative and
open attitude maintained throughout the review sessions, and that access to required
information was granted by the audited parties.
2. OBJECTIVE
To verify that Construction Management & Execution are in accordance to

Approved Construction Execution Plan and Project Specifications
To verify that the Field engineering works are performed in accordance with the
Approved Design Detail and Project Specification.
To verify the status, preparation and readiness for Final Documentation,
Mechanical Completion and Pre-commissioning
To ensure that Project / Construction related documents and records are
available, traceable, retrievable and is effectively implemented and controlled
To verify the adequacy, control and implementation effectiveness of 6 Focus Areas
To identify areas for improvement.
3. AUDIT SCOPE
The Construction Audit covered the following disciplines/ activities.

Project Quality Reviews/ Previous Audit Findings Implementation Review
Construction / Site Fabrication, Installation and Erection

- Site project organization (incl. overall and construction organization & manning
chart)
- Construction Planning, Scheduling, Monitoring and Reporting
- Construction Interface
- HSSE/Construction Execution Plan
- Subcontracts Management ( incl, assessment of Subcontractors’ activities and
Subcontracting Progress Measurement)

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- Site Material Control & Storage

- Fabrication and Testing Status incl. PWHT, Hydrotest, Flushing, Leak Test, NDT,
etc.
- Site Quality Control/Inspection Status (Incl. Process verification review on 6 Focus
Areas )
Engineering Management & Field Engineering

- Field engineering organisation, staffing, procedures
- Pre-commissioning procedures, system marking, population of WINPC ( or
equivalent) database
- Review/ approval process for field changes and red line mark-up,
- Equipment installation records and compliance to vendor recommendations
- Piping material identification ( PMI) requirement, procedure, records, segregation
of materials from receipt until used
- Test Pack procedure and general quality check
- Management of shop drawings (steel structures, piping spools.)
- Records of golden welds (if any)
- Civil test records i.e. pile load test, concrete cube test, backfilled soil density test,
water retaining structures leak test, bolt torqueing records.)
- Instrument calibration records (field instruments, relief valves.)
- Review SAT/ iSAT procedures for critical mechanical, instrumentation and
electrical items and verify compliance
- Review of PDR/ VCR approval conditions related to construction and status of
compliance
- Verification of final quantities consolidation for all disciplines ( basis, procedure,
update frequency, reporting)
- Updating and management of SP database at site
- Regulatory Requirements (Government Regulations, Permits and Approval)
Material Management (incl. Material Handling and Control and Procurement)

- Procurement Progress Measurement & Material/Equipment Delivery Progress
Status
- Surplus Material Management (Scrap, wastages and unserviceable materials :
Handling and Disposal)
- Material Handling and Control (including storage, preservation and Protection)
- Control of Spare Parts and special tolls (incl. SPIR, Commissioning Spare Parts )
- Warehouse and inventory Management System
- Subcontractor Purchase Material and Control (if any)
Readiness for Mechanical Completion and Pre-Commissioning

- MC, Pre-Comm. and Comm. organization, staffing and plans/procedures
- Set-up and readiness the completion database (WINPCS)
- Commissioning spare parts, Special tools and consumables (incl. catalysts,
chemicals and lubricants) procurement status
- Training & Operating Manuals status
- Identify Vendors requirements and Vendor mobilization schedule

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- Close out actions status of HAZOP review (incl.others outstanding Process Safety
Studies)
Project Documentation Management

- Document Control Management (MDR, Distribution Matrix, Review & Approval
Process)
- Preparedness and readiness Final Documentation
- Vendor Documents status
- Red Line Markup /As Built preparation/compilation status
- Inspection and Testing documents status
4. AUDIT CRITERIA / BASIS OF AUDIT

Contract Document (TENDER N°: RAPID/CTC/04-2013-P1))
TENDER PACKAGE N°1 – EPCC OF THE RFCC, LTU, PRU, CNU UNITS FOR
RAPID PROJECT
ISO 9001:2008 Quality Management System Requirements
Petronas Technical Standards (PTS) Requirements
Relevant CODES and STANDARDS (latest edition)
Contractor Quality Requirements (RAPID-P0024-IPMT-QAC-PRC-0001-0001_0)
Project Quality Management System (RAPID-P0024-PMT-QAC-PLN-0001-0001-3)
5. THE CONSTRUCTION AUDIT
5.1 AUDIT TEAM
Lead Assessor : Ahmad B Abdullah : Central Directorate Lead Assessor

A1 : Auditor 1 - Gemma De Grato
A2 : Auditor 2 – Samruzlan Samah
A3 : Engineering Auditor :
- Piping :Muzzahhir b M Hadzir
- Civil :Jiunn Tan
- MCI :M Shahrizal
- Process/Fire Safety :Jihoon
- Instrumentation : M Feizal/SundaraMoorthy//Michael
- Telecommunication :M Razzif Farazan Ali & Rajashahridzo
- Electrical :Kinwah Tan
- Mechanical-Rotating :Uppala
- Mechanical- Static :S.King
A4 : SME
Lead By : Auditor 2 (A2) – Samruzlan Samah
Welding and NDT – Syed Sham Ariff Bin Syed Segat. (SME Welding/NDT),
Coating and Painting – Syamsul Nizam (SME Painting)
Preservation and Storage – Ridzuan (SME Preservation)
A5 : NEWS Auditor : Azzuan Abidin and Unida Izwani Md Dun

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5.2 AUDIT SCHEDULE/ LOCATION

The Construction Audit was held CSM /EPCC Package 01 Site Office, Pengerang,
Johor, Malaysia (incl Site /Project Areas
Detail as per Terms of Reference at Attachment-1
6. AUDIT PROCESS
6.1 AUDIT NOTIFICATION
The audit has been executed in accordance with the notification Letter No. RAPID-
PMT-CCSM-LTR-1390 dated 12th Oct. 2017, sent to the CCSM (CONSORTIUM OF
CTCI CORP., CHIYODA CORP., SYNERLITZ (MALAYSIA) S/B AND MIE
INDUSTRIAL S/B). The audit notification includes the audit purpose, scope, the
agenda, organization, planning, baseline references, and names of the auditors
enabling the auditees for proper and timely preparation.
6.2 AUDIT EXECUTION

The audit commenced with an Entry Meeting, led by the Lead Auditor on 13TH Nov.
2017 and attended by auditees as per Attachment-2.
After the Entry Meeting, the Auditors followed the audit program as listed on the
Approved TOR. Objective evidences of the availability of documents has been
regularly requested/ asked by the auditors during the audits.
The audit was closed in an exit meeting in the afternoon of 16th Nov, 2017 attended
by the auditees and the audit team as per Attachment-2. . Auditors presented and
detailed the findings to the auditees and gave recommendations for improvements.
As per 10th Nov. 2017 CCSM data, The Construction Audit for Package01 was
performed at the Progress of:
Overall Construction progress of 87.67% against planned 90.74%
Engineering Progress at 100%
Procurement Progress at 99.28%
Overall Project Progress at 94.49%

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7. AUDIT REPORT
Based on Random sampling of CONTRACTORS documents the Audit Findings can be

Summarized as below:
7.1 AUDIT FINDINGS SUMMARY
TABLE 1 : Summary of Construction Audit Finding : EPCM‐ Package01/CCSM
DISCIPLINE STR CA PA OBS Total
Construction/Site Management 1 2 1 4
Material Management 1 2 3
MC Preparation and Pre‐Commissioning 1 3 4
Project Documentation Management 1 6 7
Engineering & Field engineering
Piping/MCI 5 3 8
Civil 1 6 7
Process/Fire Safety 2 2 3 7
Telecommunication 3 3 6
Electrical 1 5 3 9
Mechanical‐ Rot & Static 5 4 9
Instrumentation 1 10 2 13
TOTAL : 4 3 36 34 77
Note : STR ( Strength) / CA( Corrective Action) / PA(Preventive Action) /OBS( Observation)
 Total Topics Assessed : 11

 Number of Satisfactory Topics : 8
 Topic Compliance : 72.7 %
The Audit finding details which required action by EPCM are listed in Section 7.6
7.2 AUDIT FINDING NOTE :
i. Construction and Site Management

Overall, The Works and housekeeping at Package 01 work site is considered
as in good control.
Several safety and security issues are highlighted in form of CA and PA in
section 8. Auditor highlighted that CCSM require monitoring closely the
function and sufficient numbers of competent Safety & security (Including
safety officer, Flag/signal man, Charge man etc.) for the project.

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ii. Material Management

The preservation and storage issues still not completely resolved at
Package01. CCSM require looking into all preservation finding history and
current PA/Observation for improvement.
The Surplus material management plan to be clearly specified for better
control, Preservation shall also to cover the Tools / Spare parts from Pre-
Commissioning works and sensitive part installed at site ( such as control
valves and others instrumentation/electrical items)
iii. Preparation for Mechanical Completion and Recommissioning

The basic planning for Mechanical Completion, Recommissioning and
Commissioning are in place.
Several Observation on organization, planning and monitoring the test
equipment are recommended for proper execution
iv. Project Documentation Management

Through sampling, Auditors detected total of 6 observations related to control
of project documentation, especially for an error that detected on inspection
report.
Several detected error on Inspection records were corrected immediately by
CCSM before the exit meeting, However CCSM is recommended to
introduce right program in rechecking the balance or future record
( especially the NDE and Hydro test Report )
v. Field Engineering
Piping and MCI
Total 5 PA’s and 3 OBS’s were issued for CCSM action. Auditor also require
CCSM to recheck on outstanding of Engineering deliverable as CCSM is
claiming the engineering progress are at 100% ( see KL-17-PA-675 ) .
CCSM also require to resolve the issue of 5% RT counter/ Spot check on
PAUT as per requirement of Job Bulletin issued by PMT (KL-17-PA-677)
Civil,Structural and Building

Overall, No issue on Field engineering highlighted and several finding issued
are related to ongoing and works issues
Process/ HSE ( Fire Safety )

The significant HSE issues are on uncontrolled preservation of fire fighting
/hydrant connection flanges at construction site ( See KL-17-PA-682). And
the supporting large bore piping that are not fireproofed. ( see KL-17-PA-681)

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Telecommunication
Telecom Auditor raised the critical PA on OTDR that did not follow the right
procedure/method as require by Instrument & Telecom Cables & Fibre Optic
Cable Spec.( See KL-17-PA-683). CCSM to resolve the discrepancy
immediately.
CCSM also require to generate several work statement/method that require
for next telecom works (telecommunication cable and cable routing work
statement/ drawings – see KL-17-PA-684 and 685)
Electrical
Mainly the findings are on discrepancy to the RAPID-FE1-TPX-ELE-DES-
0001-0004; Project Specification - Electrical Installation Design Philosophy,
as below (See KL-17-PA-686 to 690):
o Inspection check-list is not available for Ex Electrical Equipment
o Incompliance of the Outdoor light fittings and junction boxes
provided outside Substation
o Escape lightings with battery back-up are not provided in both
Substation
o HV Switchgear control cables are routing thru cable cellar without
proper glanding and terminated directly to the control terminals
Mechanical ( Static & Rotating)

Findings on rotating and static are on installation/ workmanship and general
communication wth Vendor.CCS to respond se to all issued PA’s by
providing the evidence of rectification and right information document from
Vendor.
Instrumentation
Total 13 findings ( 1 CA’s,10PA’s & 2 OBS’s ) are issued out and mainly
related to control and preservation and workmanship and sequence.

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7.3 AUDIT CONCLUSION

In General, The Construction Audit considered as differed as it’s supposed to carry
out at 75% construction progress while currently the construction is at 87.6%.
Nevertheless, the delay is not affecting the efficiency as package01 was extensively
audited through others audit program (Q Assessment and DNV/ Third party Audit)
Construction Audit observed the following:
x Safety and security control / monitoring need to be improved in all area
x To strengthen the Control of inspection records and inspection data
management.
x Significant finding on electrical and Instrumentation due to incompliance to
Project Specifications.
x Also special attention require on all engineering issue and deliverable as through
random check, certain engineering documents still not at final status.
x Systematic work method/ statement or procedure require for Telecommunication
works and testing.
x CONTRACTOR to finalize and perform the spot/cross check Radiographic
Inspection on PAUT joints as required by Job Bulletin.
7.4 CLASSIFICATION OF AUDIT FINDINGS

Corrective Action (CA) – Formal, documented action to eliminate the cause of
a detected nonconformity or other undesirable situation
Preventive Action (PA) – Formal, documented action to eliminate the cause
of a potential nonconformity or other undesirable potential situation
Observation (OBS) **– Comment, suggestion or opportunity for improvement
(OFI)
Strength (STR) – Finding that validates good work or positive conditions
beyond expected norms
Note : ** Does not require formal documented response from CONTRACTOR , however
CONTRACTOR is advised to initiate preventive steps to mitigate these concerns as it could lead to
potential CA / PA in the future if not managed effectively

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7.5 ACTION BY EPCC/CONTRACTOR

CONTRACTOR shall respond to the Corrective Action (CA) and Preventive Action
(PA) within five (5) working days upon receiving the official report and provide the
following information.
y The ACTION plan to take (or have already taken) to CORRECT the situation or
condition identified:
y The DATE by which the above action was or will be completed:
y The ACTION plan to take (or have already taken) to eliminate the CAUSE of the
situation or condition identified and:
y The DATE by which the above action was or will be completed:
CONTRACTOR is recommended to Monitor Status of audit findings in weekly meeting

and is advised to close audit findings in 30 days
7.6 AUDIT FINDINGS DETAIL*

The purpose of this report is to communicate the results of the subject audit. The
addressee is considered the primary contact for the area or topics that were subject to
audit and is responsible for ensuring that any findings reported below are addressed
and closed out in a timely manner.
A summary of corrective or preventive action requests, as well as observations, is

listed below.
* THIS AUDIT REPORT IS EXTRACTED FROM RAPID PMC’S QMS DATABASE

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Audit Report Audit Type Originating Location Actual Status

# Start Date
KL-17-AU- Audit - RAPID PMC 13Nov17 Open
034 ContractorCONSORTIUM
OF CTCI CORP.,
CHIYODA CORP.,
SYNERLITZ (MALAYSIA)
S--B AND MIE
INDUSTRIAL S--B -
RAPID/CTC/04-2013-P1
Organization Contractor - Construction
Client Petroliam Nasional Berhad (PETRONAS)
Project Refinery and Petrochemical Integrated Development (RAPID) Project - R8MY
Name & No.
Lead Auditor Ahmad Abdullah Team Members Azzuan Hjabidin; Feizal Ghazali; Jihoon Hyun; Muzzahir
Mohmadhadzir; Rajashahridzo Rajamohddin; Seakking
Cheng; Syamsulnizam Abdulghani; Uppala
Sivaramakrishnaiah; Gemma De Grato; Jiunn Tan;
Samruzlan Samah [email protected],
[email protected],
[email protected]
OSR 5.; 9.; 10.; 11.; 12.; 13.; 14.; 15.; 16.; ISO Element(s) 8.1; 8.2; 7.4; 8.5.1; 8.5.2; 9.0; 9.1; 6.3; 8.5; 8.7; 10.0; 10.2;
Section(s) 17.; 18.; 19.; 21. 8.3; 8.5.5; 7.5.2; 7.5.3
Entry Meeting Attendees - 13Nov17 People Contacted Exit Meeting Attendees - 16Nov17
Samruzlan Samah - CD-Auditor; Huang Ding Mu - CCSM Samruzlan Samah - CD-Auditor; Gemma De Grato - CD-
Gemma De Grato - CD-Auditor; Ahmad Warehouse Supervisor Auditor; Ahmad Mirza - CD-Auditor; Uppala Sivaramakrish -
Mirza - CD-Auditor; Uppala PTA-Rotating; Nurul Nadia Nor Azman - Civil - Core
Sivaramakrish - PTA-Rotating; Nurul Engineering; M Faiz M Nor - Piping - QA/QC Engineering;
Nadia Nor Azman - Civil - Core Saiful Rizal - Piping - QA/QC Engineering; M Faris Zulkhifli -
Engineering; M Faiz M Nor - Piping - Electrical - QC Engineering; Mohd Zhariq Bin Mat Isa -
QA/QC Engineering; Saiful Rizal - Piping Mechanical - QC Engineering; Mukesh Rana - Construction
- QA/QC Engineering; M Faris Zulkhifli - Management - UPT1; Nickle Chang - PTP; Tan Kin Wah -
Electrical - QC Engineering; Mohd Electrical - QC Engineering; Tan Jiunn - Principal Engineer -
Zhariq Bin Mat Isa - Mechanical - QC CVS; S.K. Cheng - Principal Engineer - Mech - Static; Jason
Engineering; Mukesh Rana - Chang - CCSM Project Manager; Winner Hsiao - CCSM
Construction Management - UPT1; Project Quality Manager; Tony Huang - CCSM Site Quality
Nickle Chang - PTP; Tan Kin Wah - Manager; Chang Zong-Lin - CCSM DSQM; Muhamad
Electrical - QC Engineering; Unida Ridzuan Abdullah - CD SME Preservation; Jihoon Hyun -
Izwani Md Dun - NEWS Admin; Azzuan HSED - Core Engineering; Sundaramoorthy Kanagasabai -
Abidin - NEWS Admin; Syamsul Nizam - Sr. Engineering I&C; Raja Shahridzo - Telecoms Engineer;
SME Coating - CD; Tan Jiunn - Principal Nor Syamrin Wagirin - UPT-1 Project Manager; Robert
Engineer - CVS; S.K. Cheng - Principal Schroedter - UPT -1 Construction Manager; Huang Ding Mu -
Engineer - Mech - Static; Ikmal Rahm CCSM Warehouse Supervisor; Kaysee Anne A. Dugang -
Reduan - SME Preservation - CD; Syed CCSM QA Engineer; Tino Chang - CCSM Civil
Sham Ariff Bin Syed Segat - SME Superintindent; M. Aziehan - Project Engineer - UPT-1;
Welding / NDT; Jason Chang - CCSM Rozuman Yahaya - Project Engineer - UPT-1; Saiful Rizal -
Project Manager; Winner Hsiao - CCSM AM UPT-1
Project Quality Manager; Tony Huang -
CCSM Site Quality Manager; Josh Chan
- CCSM Instrument Supervisor; Chang
Zong-Lin - CCSM DSQM; James W. Liu
- CCSM HSE Manager; Muhamad
Ridzuan Abdullah - CD SME
Preservation; Hope Sun - CCSM PSM;
Jihoon Hyun - HSED - Core
Engineering; Sundaramoorthy
Kanagasabai - Sr. Engineering I&C;
Raja Shahridzo - Telecoms Engineer;
Nor Syamrin Wagirin - UPT-1 Project
Manager; Robert Schroedter - UPT -1
Construction Manager; Terrapong Ma-In
- CCSM Equipment Supervisor; Huang

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Ding Mu - CCSM Warehouse

Supervisor; Kaysee Anne A. Dugang -
CCSM QA Engineer; Tino Chang -
CCSM Civil Superintindent
Audit Scope Project Quality Reviews / Construction / Site Fabrication, Installation and Erection / Engineering Management & Field
Engineering / Material Management / Readiness for Mechanical Completion and Precommissioning / Project Documentation
Audit 11 Topics Assessed
Results 8 Number of Satisfactory Topics
72.7% Topic Compliance
4 Number of Strengths Identified

34 Number of Observations / OFIs
36 Number of Preventive Actions
3 Number of Corrective Actions
77 Total Number of Findings

Audit The Construction(75%) Audit was accomplished as per approved TOR
Remarks
Strength Organization Status

KL-17-ST-110 Construction Issued
Description The Project Handover and System Turnover team prepared a high-level detailed of project final document handover
index (dated 28-Oct-2017 / Rev.1) which indicates assigned personnel that covers both electronic and hard copy of
documents and data progressively.
Recommendation This is a good practice which can be shared to other EPCCs to ensure proper coordination.

Description CONTRACTOR managed the changes through NPIR.

NPIR is properly signed by CONTRACTOR, endorsed by OWNER.
3 NPIRs were forwarded to Re-HAZOP and recommendations had been properly closed.
Recommendation CONTRACTOR to consistently monitor the remaining NPIR and ensure all are in order

Description FAP in FAR and SUB are well maintained.

Recommendation TO continue the good practice and control till end of the project

Description During a site walkabout, it is noticed that temporary construction power supply from Diesel Generator and Distribution
Panels are provided with marking, signage or barricade. A notice was posted on the panel where only the authorized
personnel are allowed to operate the temporary power supply panels.
Recommendation CONTRACTOR shall maintain this good practice.

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Corrective Action Organization Response / Action By Response Response Target Status

Due Received Date
KL-17-CA-287 Construction [email protected], 05Dec17 - TBA Open
[email protected]
Requirement i. ISO 9001:2008 Section 8.3 Control of Nonconforming Product

ii. PTS 60.1502 Chemical Management Program Guideline - Section 7.9 Storage & Incompatibility / Preservation
Program Guidelines Section 7.3 Storage, 7.3.2 Level B
Description Warehouse:
i. It is found out that there is no segregation /quarantine area for all non-conforming products.
Recommendation CONTRACTOR to separate area for the materials which does not conform to the product requirements to prevent its
unintended use or delivery. On site Identification /Labeling also required ( Sample Control valve 1311FCV-4401 /Line
1311CI-WS-012J4-01-Control Valve gauge glass was found broken )

Due Received Date
[email protected]
Requirement ZETO Rules /ITB Sec 10.3.16.14 LIFTING

Description Construction vehicles movement is not monitored.
It is observed that vehicles are moving and operating without supervisor attendance.
Recommendation CONTRACTOR to monitor sufficient Safety Supervisor and Flag man involved in the Project by Submitting the complete
list to Auditor ( list of Flag Man and Safety Officer)

Due Received Date
[email protected]
Requirement Ref.#PTS 62.10.08.11 Page 11 : Internal Function Check (Note ) and PTS60.2102
Description a) System cabinets, lighting and temporary air conditioners powered on without the FGS/FAP being online for
monitoring.
B) FAP and HSSD already installed. Pending ELE to commission.
Ref.#PTS 62.10.08.11 Page 11 : Internal Function Check (Note ) and PTS60.2102
Recommendation Fire Alarm Panel and HSSD systems shall be operational immediately./
Preventive Organization Response / Action By Response Response Targe Status

Action Due Received t Date
KL-17-PA-670 Construction [email protected], 05Dec17 - TBA Open
[email protected]
Description From The CCSM Piping Installation and status data, The Plan for Hydrotest is not comprehensively tabulated and the
following is not sighted:
i. The slipaged on Hydrotest work on Oct is not systematically analyzed and documented for lesson learnt and
improvement ( Required to be tested : 320 test Pack, tested only 147 test Pack.
ii. The man power planning for managing the overall hydro test work is not sighted (currently only 16 hydro tester, qc Pip,
10 ( Elecco Pip), QC pip. 10 (TCC ) and QC pip. 3 (CTCI).
iii. CCSM Estimated total test package of 5,656 nos. which will be prepared by 2 subcontractors. During audit, it is found
only 900 nos. (16%) are completed Hydrotest and none of them are being reinstatement.
Recommendatio It is recommended for CONTRACTOR to come out with strategic mitigation plan to expedite test package to be
n completed before MC which is on 31 May 2018 (7 month to go/Detail plan to be generated in order to catch for 960 T/P
(test pack) in Dec, 620T/P in Jan18 etc.) Plan shall include the man power,hydrotest water and equipment planning

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Preventive Action Organization Response / Action By Response Response Target Status

Due Received Date
[email protected]
Description Found wrong coating system between pipe and valve for line system 1311-C1-PM-01623-01. Refer photo
Recommendation CONTRACTOR to verify correct coating system for applicable line system (either HT or LT lines)

Due Received Date
[email protected]
Description Lot 72 Laydown Area:
Preservation of piping material, valves and attachment to be well taken care of. Cross contamination and corrosion is
visible.
Recommendation To provide pipe end cover, wrapping of valves, proper pipe stacking, dunnage and pallets to be provided sufficiently.

Due Received Date
[email protected]
Description The Surplus Material Management is not clearly stated in the Site Material Control Procedure as indicated in the ITB
Section 5.2.17.2 "an inventory shall be made by the Contractor of surplus material, including scraps, wastages and
unserviceable material supplied and/or remaining in the hands of the Contractor upon completion of work.
i. Surplus Material Management Plan is not sighted at the time of audit.
ii. There is no indication of managing or controlling the surplus items at work site.
Recommendation EPCC Contractor to review and revise the Site Materials Control Procedure - RAPID-P0001-CCSM-CON-PRC-1300-
0033 Section 5.13 to align with the requirement in ITB Sec 5.2.17.2

Due Received Date
[email protected]
Description Lot 109 Laydown Area :
Equipment that identified as commissioning spare part and material not stored as per Supplier recommendation (e.g.
GE Parts : )
Recommendation
Items to be stored at enclosed area/ building as recommended by GE/Supplier

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Due Received Date
[email protected]
Description 1. Stress report are being tracked and updated
2. Stress reports (e.g.RAPID-P0001-CCSM-PIP-RPT-1311-3001 Rev.C) still have comments and yet to be finalized
(e.g. nozzle load exceeded allowable loads).
Recommendation 1. Contractor to expedite the final stress report for metallic pipes and ensure inclusion of Acoustic Induced Vibration.
2. Contractor to expedite the final stress report for GRE pipes (especially check against surge force) and update the
location of the thrust block if necessary
3. Contractor to ensure that the test packages are using the latest isometric drawing which reflected the approved
stress calculation report for respective system/line.
CONTRACTOR to recheck on all Engineering deliverable status and resolve any pending issue, as currently the
engineering progress is 100%.

Due Received Date
[email protected]
Description As per ASME B31.3, clause M345 there are additional pressure test requirement shall be conducted which is sensitive
leak test for Category M Fluid service only
Recommendation 1. Contractor to conduct sensitive leak test for Category M Fluid Service as per Code Requirement
2. Failure to conduct the sensitive leak test, Contractor to issue and obtain OWNER's approval for a PDR with mitigation
and risk assessment plan for not conducting the test.

Due Received Date
[email protected]
Description PAUT already carried out in-lieu of RT without full compliance of Job Bulletin.
a. CCSM confirmed that no RT countercheck is performed for the joints examined by PAUT as per Job Bulletin
b. CCSM has yet to perform the internal audit but it is noted the PAUT execution is still within 6 months
c. PDR submitted but still not yet approved by OWNER
Recommendation a. Contractor to perform RT countercheck per Job Bulletin requirement
b. Contractor to plan and perform the internal audit per Job Bulletin requirement at every 6 months interval
c. Alternatively to obtain OWNER's approval for the PDR the soonest.

Due Received Date
[email protected]
Description It is observed that CCSM only has execution plan for baseline thickness measurement for the equipment. No plan
issued for piping yet.
Ref. # RAPID-P0024-PMT-PMG-MEM-0001-0314 - Perform Baseline Thickness Measurements and Installation of
Baseline Thickness Measurements
Recommendation Contractor to plan and execute thickness measurement baseline reading for piping similar to what is already done for
equipment. It is reminded all baseline thickness measurement activities shall be completed before Mechanical
Completion.

Document Number
Rev. Page
0 18 / 30

Due Received Date
[email protected]
Description CCSM confirmed that the insulation cladding material is Aluminum instead of Aluminized Steel Type 2 as per spec.
Ref. # RAPID-FE1-TPX-MEC-DES-0001-0401 Hot Insulation
Recommendation C08a} Contractor to comply or raise PDR subject to Owner's approval

Due Received Date
[email protected]
Description The skid framing for Fuel Gas (1311-A406) does not come with drain holes
Recommendation To provide drain holes at perimeter of skids to drain rain water after each rain event

Due Received Date
[email protected]
Description Fireproofing is provided surrounding structure near the pumps handling hydrocarbon. However pipe supports that
supporting large bore piping are not fireproofed.
Ref. # PTS 80.47.10.30
3.3.4 Pipe rack and pipe supports
Recommendation Fireproofing requirements for Piping support shall be verified against PTS requirements and apply fireproofing when
required.

Due Received Date
[email protected]
Description Hydrants are not yet installed to prevent damage during construction.
However some of hydrant connection flanges are not well preserved, or already deformed.
Recommendation Hydrants and Monitor connections shall be covered to prevent contamination, egress of foreign material and sign shall
be provided to prevent vehicle collision

Document Number
Rev. Page
0 19 / 30

Due Received Date
[email protected]
Description Fibre Optic cable from FAR to Camera and for the Instrumentation usage has been pulled. The OTDR has been
performed in October 2017. However, the conducted OTDR test did not follow the right procedure/method such as
tested at 1550nm instead of 1310nm, no clear test result has been shown to confirm the test is passed, no proper
tagging on the test result, pass/fail threshold is not per the project spec., and some of the test failed according to the
cable specification (<0.45 dB/km)
Ref # RAPID-FEI-TPX-INC-SPN-0001_0011_1 Instrument & Telecom Cables & Fibre Optic Cable Spec
Recommendation 1) To test at 1310nm and 1550nm wavelength. If time constraint, Contractor to test at least at 1310nm length since this
wavelength will be used during Operation (network switch)
2) To get email confirmation from OTDR equipment manufacturer on the right way to read the OTDR from the test
result. This is due to since the test result has 2 different result readings (from the table and from the graph) and it
sometimes provides 2 different results/reading. OTDR equipment manufacturer to confirm which reading should the
Contractor refer in determining the final OTDR result.
3) To provide a proper and clear tagging at each of the test result (showing the cable from/to, the purpose of the cable
(telecom/CCTV/instrumentation))
4) To update the OTDR equipment with the correct pass/fail threshold before the test being conducted.
5) To provide summary table to simplify the OTDR reading result in a single excel page.

Due Received Date
[email protected]
Description The installation method statement for Telecommunication System cable is not being produced by Contractor (fiber optic
cable, PAGA cable, CCTV cable and Telephone cable)
Recommendation Contractor to produce method statement for Telecommunication System cable

Due Received Date
[email protected]
Description The redundant fiber optic cable (A&B) shall be in totally diverse physical routing. Contractor could not provide the cable
routing drawing for the cable (between FAR and Substation) to prove that the planned fiber optic cable routing is
physically diverse. No info for the Instrumentation related fiber optic cable (whether it is physically diverse routing or not)
Recommendation 1) Contractor to provide the cable routing drawing for the cable (between FAR and Substation) to prove that the planned
fiber optic cable routing is physically diverse.
2) Contractor to confirm on the Instrumentation related fiber optic cable drawing as well (whether it is physically diverse
routing or not)

Due Received Date
[email protected]
Description During a site walkabout to SUB-131 on 13/11 AM, it is noticed that hot work i.e., grinding and HVAC ducting work are
being performed inside the substation using electric grinder. Sparks are spreading around the surrounding area. The
substation LV Switchgears already energized.
During the Audit, Site Superintendent (Mr. Lee Hsien Neng) instructed the worker to perform the work outside
substation.
Recommendation This is a safety issue/ concern.
CONTRACTOR shall not allow hot work inside the Substation. Necessary safety warning sign shall be in place and
restrict this from happening again.

Document Number
Rev. Page
0 20 / 30

Due Received Date
[email protected]
Description Ex Electrical Equipment inspection check-list is not available and equipment initial inspection has not been performed
for all Ex equipment installed at Site.
Recommendation As per IEC 60079-14, on completion of the erection and prior to first use, initial detailed inspection for the equipment
and installation shall be carried out in accordance with Annex C.
CONTRACTOR shall comply with the above requirement where Ex Equipment check-list shall be produced and all Ex
Electrical Equipment shall be inspected by a competent/ experienced personnel having Ex training certificate.
Every inspection done shall be recorded with check-list signed off by Inspector.

Due Received Date
[email protected]
Description Outdoor light fittings and junction boxes provided outside Substations (e.g. Transformer areas, Capacitor Bank area
etc.) and FARs are not compliance to Project Specifications and requirements.
Ref.# RAPID-FE1-TPX-ELE-DES-0001-0004; Project Specification - Electrical Installation Design Philosophy;
Recommendation CONTRACTOR shall comply with the Project requirements where outdoor lighting and lighting junction box shall be Ex
type. Cable with armored instead of wires in conduct shall be provided and installed.

Due Received Date
[email protected]
Description Escape lightings with battery back-up are not provided in both Substation SUB-131 and SUB-132, Battery rooms and
ENMCS rooms.
This is not compliance to Project Specification and requirements. ( RAPID-FE1-TPX-ELE-DES-0001-0006; Project
Specification - Lighting System Design Philosophy; Clause 6.4 Escape Lighting)
Recommendation CONTRACTOR shall provide escape lighting with battery back-up as per Project Specification and requirements where
an adequate escape luminaires shall be provided in all buildings to light the way for personnel leaving the building along
defined escape routes.

Due Received Date
[email protected]
Description During a site walkabout to SUB-131 and SUB-132, it is noticed that HV Switchgear control cables are routing thru cable
cellar without proper glanding and terminated directly to the control terminals. This is not compliance to Project
Specification and requirements.
Ref.# RAPID-FE1-TPX-ELE-DES-0001-0002; Project Specification - Electrical Design Basis and Philosophy; Clause
8.8.8 Cable Accessories.
RAPID-FE1-TPX-ELE-DES-0001-0004; Project Specification - Electrical Installation Design Philosophy; Clause 11.4
Cable Connections
RAPID-FE1-TPX-ELE-STD-0001-0020; Design Standard - Power Installation Standards; Sheet 16 of 25.
Recommendation CONTRACTOR shall comply with Project specification and requirements where all power and control cables shall be
terminated via cable gland plate with cable gland. Cable armoring/ braiding to be earthed on to enclosure via a metal
gland.

Document Number
Rev. Page
0 21 / 30

Due Received Date
[email protected]
Description STATIC: The "sliding" plate of Exchange saddle " 1311- E-206 a/b/c/d" is NOT installed accordance with STD DWG.
Based on alternative design provided : - - Four bolts clamp
with "double-nuts" - which will hindrance the sliding movement during operation for these four exchangers. - Unable
to notice these bolting are drilled with "slotted hole" at sliding saddle ( ? ) . Refer Vendor Exchanger Dwg ( Saddle
details) Doc No : RAPID-P0001-1014-MEC-DWG-1300-0013_00 ( Vendor by CTCI-M.)
Recommendation Double NUT shall be lifted ( about 10mm ) to allow for sliding movement.
- Slotted Bolt-Hole shall be drilled at sliding bolting on this Sliding saddle-side as per Vendor Saddle Drawing

Due Received Date
[email protected]
Description STATIC : a) RFCC Reactor Packing's support ring & support grid installation record ( 1311 A016) was requested ,
CTR to provide evidence of Inspection record ? b) Licensor's review
is required by Axens ( 1311-A-106) - on the packing, packing support grid, support beam and Hold-down beams
drawings, refer to Licensor Doc RAPID-LR2-AXN-PRO-SPN-1311-0166 ( pg 4/ 4 ) ? Pending evidence from CTR
Recommendation CONTRACTOR to show evidence of a) Inspection record ,", b ) Licensor review is done

Due Received Date
[email protected]
Description ROTATION: 1330-K-002B MES Regeneration Compressor Cylinder support/mounting plate anchor bolt was bent and
touching the bolt hole.
Levelling spindle or jack bolt is tilted and not properly installed; it is inclined and may lead to slippage and disturb the
levelling and alignment prior to final grouting.
Recommendation To straighten the anchor bolt and ensure the mounting plate anchor bolt holes have a minimum 3 mm (1/8 in.) annular
clearance to allow for field alignment of mounting plates.
To correct the positioning of the levelling spindle to be vertically straight prior to final grouting.

Due Received Date
[email protected]
Description ROTATION : Several cracks were observed on the final grout surface of some of the pumps (1311-p-210A).
Mounting plate Jackscrews / jack bolts are still embedded in the grout of many pumps and very hard to loosen.
Recommendation To remove the jack screws before final tightening of the anchor bolts and fill the holes with a flexible sealant (silicone
etc.).
To consult the grout supplier and seek procedure to fill the cracks before anchor bolts final tightening and final
alignment activity.

Document Number
Rev. Page
0 22 / 30

Due Received Date
[email protected]
Description ROTATION : Several PD Pumps (Metering Pumps) were directly grouted to foundation without any base plate or
mounting plate or sole plate.
Recommendation OWNER has issued the NCR to CONTRACTOR and NCR was closed with a comment that OWNER has accepted it.
Since it is a deviation to Project Specification, even though OWNER has approved the direct grouting of equipment to
foundation without mounting plate, CONTRACTOR SHALL submit a FPDR (Fields PDR) for OWNER's proper approval
and Records.

Due Received Date
[email protected]
Description a) EMC Earth mesh not installed at FAR below false floor. Therefore EMC type earting is not available even as system
cabinets have been powered up and SAT is progressing.
b) Contractor is currently using a looped single point earthing to the FAR Earth Ring.
c) No proper study or records for this deviation to specifications.
d) EMC MCT earthling to the earth ring is not performed.
Recommendation MAC approved signed RFI shall be provided within a week. Fail to provide the SAT needs to be stopped. Proper risk
assessment to be done and action steps to be taken to ensure proper and safe reinstatement of the grid when it is
ready to be installed.

Due Received Date
[email protected]
Description Location of HSSD nozzles at ineffective positions. Too close to cabinet roof for effective detection of incipient smoke
particles which would come from the cabinet vents. ( ref.# PTS 32.30.20.11)
Recommendation To relocate the HSSD piping higher (~300mm from the ceiling panels), for more effective detection.

Due Received Date
[email protected]
Description Use of unarmored cable for MACP at FAR-131.
Ref # RAPID-FE1-TPX-INC-SPN-0001-0011 and RAPID-FE1-TPX-INC-DES-0001-0006
Recommendation To replace cable type as per cable specification with proper cable gland. Other MACP in front of battery room is
armored. Inconsistent.

Due Received Date
[email protected]
Description In RFCC area, Power and Instrument cable trays are installed adjacent each other without maintain 300mm gap. This
tray shall modify to meet the requirement and ensure the same was maintained in all the areas.
Ref # RAPID-FE1-TPX-INC-DES-0001-0005
Recommendation All the areas, CONTRACTOR to ensure minimum 300 mm distance maintained between Electrical and Instrument, if not
same needs to be modified.

Document Number
Rev. Page
0 23 / 30

Due Received Date
[email protected]
Description a)CONTRACTOR not provided pipe sleeve between dummy trench and the junction box location.
B) In RFCC 1 area in-between substation and pipe rack, dummy trench shall be provided with slab for future cable
pulling. However, CONTRACTOR installed with permanent paving. Also CONTRACTOR to clarify the dummy trench
design made by CONTRACTOR for Electrical trench cross over to be clarified.
Recommendation a) Pipe sleeve shall be installed.
B)Slab shall be installed. Electrical trench crossing duct bank installation needs to be confirm by CONTRACTOR.

Due Received Date
[email protected]
Description As per PTS Instrument support shall be painted, CONTRACTOR installed support without white color paint for
Instrument support and stanchion.
Recommendation PDR shall be issued for OWNER review and approval.

Due Received Date
[email protected]
Description In between RFCC 1 pipe rack and substation, a crane was struck in top of the instrument trench. There may be
potential possibility of damage of instrument cables.
Recommendation The affected portion needs to excavate and physical inspection shall be carried out. All the cables in this trench shall be
megger again and submit the report for OWNER review. Also where the cable trench are closed and barricade to be
marked and the crane or heavy vehicle not allowed in top of Trench.

Due Received Date
[email protected]
Description a) 1311-TRV-8207 after pop test, POP up test validity period to be follow as per Standard and Project requirement.
B) Plug tied with carbon steel wire on stainless steel valve body. Complete wire got corroded.
C) Preservation procedure during flushing and hydro test not specified.
Recommendation a) General validity period of pop test is 6 month, CONTRACTOR to check the same.
B) Carbon steel wire shall be replaced with stainless steel wire. Pickling and passivation to be carried out on the
corroded area.
C) To avoid water ingression and debris, CONTRACTOR to provide preservation procedure to be submitted for review.

Document Number
Rev. Page
0 24 / 30

Due Received Date
[email protected]
Description a)1311-JEI-1214, CONTRACTOR removed the outer sheath and armour, coiled kept inside tray. Possibility of water
ingression and short circuit with cable tray.
B) Also the welding earthling was connected to the structure nearer to the Junction box, possibility of high voltage
transfer into Instrument cable and potential damage on the cabinet side.
c) Most of the JB cable glanding and termination carried out, however, earthing for the Junction box not done.
Recommendation a) Cable shall be terminated once outer sheaths is removed. And also cable end shall be secured properly and not in
contact with structure.
B) Frequent field surveillance needs to be carried out and issue the site instruction for connecting the welding machine
earthing. Since the cabinet is powered on, the welding eathing shall connected only on the designated identified
location.
c) Earthing shall be performed once the cable is connected.

Due Received Date
[email protected]
Description Control valve installed at site and positioner are not covered properly. Also the welding and grinding sparks are fall on
this valve.
Recommendation a) To avoid water ingression and debris during flushing and Hydro test, CONTRACTOR to provide preservation
procedure to be submitted for review.
B) For the special valves which already installed, specific procedure needs to be obtain from the Vendor.
C) Industrial standard procedure to protect the Valve shall be carried out.
Observation Organization Status

Construction Issued
KL-17-OB-657
Description During the audit it has been observed the following RT report of KOSTEC NDT Consultancy (TCC) does not contain
reject length 1) RT report (RT-6887) for date 17/5/2017 2)RT report (RT-104) for date 14/5/2017
Recommendation Immediate action from TCC to reflect RT reject length on the RT report in NEWS. Monitoring to be performed on others
by CONTRACTOR

KL-17-OB-658 Construction Issued
Description Commissioning Equipment list of tools need further update including the calibration equipment log.
Recommendation EPCC to specify all commissioning equipment tools in the proper master list and plan for calibration ( wth right
sensitivity/tolerance ).

Description System / Sub-system Wise Schedule with Schedule Basis Memorandum is still under review and approval at the time of
audit.
Recommendation EPCC Contractor to finalize the Level 4 Pre-commissioning and Commissioning Schedule as per Contractual
requirements of beginning of Pre-Commissioning (P/C)- 4 months.

Document Number
Rev. Page
0 25 / 30

Description Precommissioning ( instrumentation)

a) Pre-comm organization chart and person not yet mobilized.
B) Loop checking folder and its database not established by CONTRACTOR
Recommendation a) Team shall be mobilized including MAC person, MMS and PLC system. MAC person should have DCS and ESD
Engineer from Yokogawa.
B) In-house software shall be established at the earliest.

Description CONTRACTOR did not attached painting report for painted spools after hydrotest (refer to RFI No. P1-CCSM-ELECO-
RFI-PA-859 (PT693), P1-CCSM-ELECO-RFI-PA-869 (PT698) and P1-TCC-RFI-PA-1456 (PT2328))
Recommendation CONTRACTOR to improve and to attach painting reports which incl. DFT record, coating system, surface preparation
methods etc. for references

Description Found RFI (Request For Inspection) which attached in completed Test Package is not completely updates and signed
by OWNER/PMC, CONTRACTOR and Subcontractor.
Recommendation CONTRACTOR to consistently updates RFI with all information in RFI format after complete the inspection/test for
record purposes.

Description Found pressure gauges reading shown in photo (which are used as evidences) are not tally with test pressure stated in
ISO drawing. E.g. test package serial no. 262 (Test Package No. 11P-02-01-TP-031A System No. 1, 1311-11P-02-01) -
test pressure is 11.6 barg however photos shown 5.3 barg.
Recommendation CONTRACTOR to ensure evidence photos are consistent with the actual test/inspection results.

Description Attachment 3 - P1 RFCC Turnover MP and Organization dated 20Oct2017, Rev. 1 does not reflect the recent changes /
additional member in the team organization.
Recommendation EPCC Turnover Team to update the organization respectively.

Description Setting up of the WinPCS is yet to be completed in the next two weeks timeframe.
Recommendation EPCC to ensure that all systems and subsystem are populated and run smoothly as per planned.

Document Number
Rev. Page
0 26 / 30

Description Hydrotest, Test pack no: 124-10-01-TP-011, system 1312-124-10-07, serial no: 2746, test pack A/G Piping has Piping
System examination report unsigned BUT CCSM has signed off Control Sheet for appear to proceed
Recommendation It is recommended for Contractor to come out with mitigation plan to improve their control system prior to proceed from
one phase to the next phase.

Description CCSM does not differentiate the piping that is in this category (RT requirement reduced from 100% to 20%) in the
QA/QC system. As such, CCSM cannot determine when the additional penalty will be imposed for these lines when a
repair is required.
Recommendation Contractor to modify the CMS data and differentiate these lines from the normal lines so as to impose additional penalty
in case RT result is rejected. It is noted however, that there is no RT rejection for these lines yet since the approval of
PDR.

Description a. It is observed that final colour for Bolt & nut are different in the piping and equipment. Also noted that the bolts & nuts
coating are damaged, thus initiating external corrosion. In addition, it is observed that tack weld on the anchor bolt
washer is not protected with primer to avoid further corrosion.
b. It is also observed that the green colour is painted over blue colour on the bolt and nut
Recommendation a. Contractor to check and repair the damaged coatings after bolt tightening. Contractor apply at least primer as
temporary mitigation on the welded joints of the anchor bolt to prevent further degradation
b. Contractor to check if the correct coating is applied on the bolt. There shall be no cases of lower temperature coating
used for bolts to be used in higher temperature service. Colour code shall follow Project Specification

Description It is observed that there are SS plates welded intermittently to CS plates. There are already crevice corrosion observed
on the CS plates
Recommendation Contractor to full weld the plates together to avoid crevice corrosion.

Description The stair landing foundation riser height is too high i.e.>300mm for 1311-STR-1600. This comment is applicable to other
areas.
Recommendation Additional concrete riser is required. To recheck other areas for same rectification

Description The bolt protrusion length at the knee brace support is too long for platform support at 1311-RCK-1100
Recommendation To match the length of bolts similar to the other knee brace support

Document Number
Rev. Page
0 27 / 30

Description As per RAPID-P0024-PMT-PMG-MEM-0001-0322 , Building and Door Nameplate, no evidence of building and door
name plates has been establish
Recommendation To match the length of bolts similar to the other knee brace support
Observation Organization
Description As per RAPID-P0024-PMT-PMG-MEM-0001-0322 , Building and Door Nameplate, no evidence of building and door name plates ha
Recommendation To submit one pre-production sample to SCRM for approval before fabrication as per Memo

Description The double doors of 6850-SUB-132 upon swing out is clashing with the lighting just next to the door
Recommendation Door stopper is required

Description The stair handrails color for 6750-SUB-131 has faded and its color does not comply to project specification. This
comment is applicable to other SUB.
Recommendation Re-paint color of handrails

Description HVAC duct, cable trenches, and lighting fixtures are already installed in SUB.
May cause obstruction to INERGEN distribution piping and nozzles.
Recommendation CONTRACTOR shall carefully monitor and review ISOMETRIC Drawing of INERGEN distribution piping and nozzles
and actual installation to prevent future obstruction with other installations.

Description UG valve pit, Cable manholes are flooded.

Barricade is provided but Safety Sign is not matched with situation.
Recommendation Check drain, UG pits need to be dry for maintenance access.

Document Number
Rev. Page
0 28 / 30

Description Water spill found in Substation. Proper control and monitoring is required
Recommendation Water spills, ingress of rain water shall immediately removed. Systematic monitoring required

Description Overall Telecommunication System equipment and/or cable installation delay of about:
1) CCTV System Equipment: 1-4 month (depending on the zone)
2) Telephone Equipment: 1-4 month (depending on the zone)
3)PAGA System & Cable: 1-4 month (depending on the zone)
All the projected installation completion date is on December 2017 and testing on January 2017.
Recommendation 1) To expedite the Telecom equipment & cabling installation progress to meet the planned schedule date
2) To share with UPT on the revised schedule date

Description The DTRS fixed radio coaxial cable (connection from the radio to the FAR rooftop antenna)was left out to be installed at
site
Recommendation 1) Contractor to install the coaxial cable as per the requirement

Description The IP Dome camera inside each FAR and Substation (airlock) CAT 6 cable was left out to be installed at site
Recommendation Contractor to install the CAT6 cable as per the requirement

Description During a site walkabout to SUB-131 and SUB-132 Transformer area, it is noticed that some cables already terminated
to the Transformer however, there are cable gland holes without cable terminated and not covered. In additional, bolts
and nuts have been removed from the terminal box.
Recommendation CONTRACTOR shall provide proper protection to cover the gland plate holes before cable termination. Also all bolts
and nuts on the terminal box shall be installed before and after cable termination.

Description During a site walkabout, it is noticed that Power Outlets are provided without sunshade which is not compliance to
Project requirements.
Recommendation CONTRACTOR shall provide/ install sunshade for Power Outlets as per Project requirements.

Document Number
Rev. Page
0 29 / 30

Description During a site walkabout on 13/11 AM, personnel access into SUB-131 (LV room energized) is controlled whereby the
entrance is guarded and visitors are required to surrender their pass and register their details.
However on 15/11 AM, personnel access into the same SUB-131 (LV room energized) is not controlled whereby the
entrance is not guarded (no personnel manning the station). Auditors are freely walking in and out of the substation.
Recommendation To ensure consistency in implementing access control to energized Substations 24/7 to avoid incidents and
unauthorized access.

Construction Issued
KL-17-OB-685
Description STATIC : Flame arrestor - for Air-Pre-Heater ( VCR ) on 1311/1312 -F101 & F102 , JZ Hamworthy- - is needed by
Licensor's PID. CTR intention to delete the flame arrestor is Non-compliance to Licensor requirement, therefore it is
unacceptable . Alternative feasible technical solution to be sorted out by CTR .
Recommendation CTR confirm that " Flame arrestor" will be provided to comply with ITB, Vendor documentation shall be updated to show
actual application.

Description STATIC : Helium Test shall be performed on the Exchanger "Tube-to-tube sheet joint" as per ASME Code ,Section V,
article 10 .. .. Based on UOP Data Sheet given in the ITB . CTR to furnish the "Helium Test" record for these two
Exchanger 1320-E-001 /1320-E-002
Recommendation CTR to show Evidence of Test record/ to furnish the "Helium Test" record for these two Exchanger 1320-E-001 /1320-E-
002

Description ROTATION : Severe water logging observed on many of the pump skids which may lead to corrosion of the base plate.
Lube Oil skid of Main Air Blower is flooded with water logging and Algae has formed severely.
Recommendation Need to consult Pump VENDOR / Re-check the slope of the baseplate to ensure the water gets drained through base
plate drain whole. If required additional drain holes may be provided in-consultation with VENDOR and with prior
approval from OWNER.
CONTRACTOR shall arrange periodic cleaning of the skid from stagnant water and find the root cause for severe water
logging. If required to provide additional drain holes in the skid after consulting VENDOR and with prior approval from
OWNER.

Description Temporary plate and bolt used for tightening the flange to the pump can potentially damage the pump flange face.
Correction of such damage is difficult to rectify.
Recommendation ROTATION : Proper temporary gasket and bolts shall be used to tightening rather than sharp plates which can damage
the flange face.

Document Number
Rev. Page
0 30 / 30

Description a) Instrument cables are coiled below pipe rack and no barrier installed in order to protect the cable.
B) Secondary cables are pulled before installing the cable trays.
Recommendation a) Proper preservation shall be carried out for the field pulled cables.
B) Before pulling secondary cable, CONTRACTOR to ensure the tray routing is completed.

Description 1311-JEI-4056, tray between junction box and sleeve not provided by the EPCC.
Recommendation Tray shall be installed.
8 LIST OF ATTACHMENTS
Attachment 1 – Terms of Reference
Attachment 2 – Attendance Sheets

AUDIT REPORT
KL-17-AU-034
CCSM – CONSTRUCTION AUDIT
Attachment 1
– Terms of Reference -

Terms of Reference ( Rev. 1)
Construction Audit of Package 01 – EPCC CONTRACTOR UPT 1 / CCSM for RAPID Project
PETRONAS Refinery and Petrochemical

Client / Project: Project No: R8MY
Integrated Development Complex
Disciplines: Construction Management
EPCC / CCSM :
th
To (Auditee): Jason Chung : Project Manager Date of Notification: 30 Oct. 2017
Winner Hsiao : Project Quality Manager
PMT Reference:
Audit No: KL-17-AU-034
i. RAPID-P0024-PMT-PMG-MEM-0001-0339
From: Lorena Villadoz- PMT QMS Manager Email: [email protected]
Type audit: Construction Audit

To verify that Construction Management & Execution are in accordance to Approved
Construction Execution Plan and Project Specifications
To verify that the Field Engineering works are performed in accordance with the
Approved Design Detail and Project Specification.
To verify the status, preparation and readiness for Final Documentation, Mechanical
Objectives of Audit: Completion and Pre-commissioning
To ensure that Project / Construction related documents and records are available,
traceable, retrievable and is effectively implemented and controlled
To verify the adequency, control and implementation effectiveness of 6 Focus Areas
To identify areas for improvement.
The Audit will cover the following scope :

Project Quality Reviews/ Previous Audit Findings Implementation Review
Construction / Site Fabrication, Installation and Erection

- Site project organization (incl. overall and construction organization & manning chart)
- Construction Planning, Scheduling, Monitoring and Reporting
- Construction Interface
- Subcontracts Management ( incl, assessment of Subcontractors’ activities and Subcontracting
Progress Measurement)
- Fabrication and Testing Status incl. PWHT, Hydrotest, Flushing, Leak Test, NDT, etc.
- Site Quality Control/Inspection Status (Incl. Process verification review on 6 Focus Areas )
Audit Scope:
Engineering Management & Field Engineering
- Field engineering organisation, staffing, procedures
- Pre-commissioning procedures, system marking, population of WINPC ( or equivalent)
database
- Review/ approval process for field changes and red line mark-up,
- Equipment installation records and compliance to vendor recommendations
- Piping material identification ( PMI) requirement, procedure, records, segregation of materials
from receipt untill used
- Test Pack procedure and general quality check
- Management of shop drawings ( steel structures, piping spools ..)
- Records of golden welds (if any)
- Civil test records i.e. pile load test, concrete cube test, backfilled soil density test, water
retaining structures leak test, bolt torquing records ..)
Page 1 of 6
- Instrument calibration records ( field instruments, relief valves.. )
- Review SAT/ iSAT procedures for critical mechanical, instrumentation and electrical items and
verify compliance
- Review of PDR/ VCR approval conditions related to construction and status of compliance
- Verification of final quantities consolidation for all disciplines ( basis, procedure, update
frequency, reporting)
- Updating and management of SP database at site
- Regulatory Requirements (Government Regulations, Permits and Approval)
Material Management (incl. Material Handling and Control and Procurement)

- Procurement Progress Measurement & Material/Equipment Delivery Progress Status
- Surplus Material Management (Scrap, wastages and unserviceable materials : Handling and
Disposal)
- Material Handling and Control (including storage, preservation and Protection)
- Control of Spare Parts and special tolls (incl. SPIR, Commissioning Spare Parts )
- Warehouse and inventory Management System
- SubContractor Purchase Material and Control (if any)
Readiness for Mechanical Completion and Pre-Commissioning

- MC, Pre-Comm. and Comm. organization, staffing and plans/procedures
- Set-up and readiness the completion database (WINPCS)
- Commissioning spare parts, Special tools and consumables (incl. catalysts, chemicals and
lubricants) procurement status
- Training & Operating Manuals status
- Identify Vendors requirements and Vendor mobilization schedule
- Close out actions status of HAZOP review (incl.others outstanding Process Safety Studies)
Project Documentation Management

- Document Control Management (MDR, Distribution Matrix, Review & Approval Process)
- Preparedness and readiness Final Documentation
- Vendor Documents status
- Red Line Markup /As Built preparation/compilation status
- Inspection and Testing documents status
Contract Document (TENDER N°: RAPID/CTC/04-2013-P1))

- TENDER PACKAGE N°1 – EPCC OF THE RFCC, LTU, PRU, CNU UNITS FOR RAPID
PROJECT
ISO 9001:2008 Quality Management System Requirements
Audit Criteria / Basis Petronas Technical Standards (PTS) Requirements
of Audit: Relevant CODES and STANDARDS (latest edition)
Contractor Quality Requirements (RAPID-P0024-IPMT-QAC-PRC-0001-0001_0)
Site Quality Manual (RAPID-P0024-IPMT-QAC-QCP-0001-0002_0)
Project Quality Management System (RAPID-P0024-PMT-QAC-PLN-0001-0001-3)
EPCC /CONTRACTOR’s Project Quality Management Syastem and Procedures
Attachments No
Audit Location: CCSM /EPCC Package 02 Site Office, Pengerang , Johor, Malaysia
th
Audit Date: 13 – 16 Nov. 2017
Lead Auditor: Ahmad B Hj Abdullah – Central Directorate Lead Auditor (LA)
Page 2 of 6
A1 : Auditor 1 - Gemma De Grato
A2 : Auditor 2 – Samruzlan Samah
A3 : Engineering Auditor :
- Piping :Muzzahhir b M Hadzir
- Civil :Jiunn Tan
- MCI :M Shahrizal
- Process/Fire Safety :Jihoon
- Instrumentation : M Feizal (15-16 Nov)
- Telecommunication :M Razzif Farazan Ali & Rajashahridzo
Audit Team Members: - Electrical :Kinwah Tan
- Mechanical-Rotating :Uppala
- Mechanical- Static :S.King
A4 : SME
- Lead By : Auditor 2 (A2) – Samruzlan Samah
- Welding and NDT – Syed Sham Ariff Bin Syed Segat. (SME Welding/NDT),
- Coating and Painting – Syamsul Nizam (SME Painting)
- Preservation and Storage – Ridzuan (SME Preservation)
A5 : NEWS Auditor : Azzuan Abidin and Unida Izwani Md Dun
AUDIT ITINERARY
Invitees / Remarks /
Agenda Time Activity / Discipline
Auditee (Auditors)
Auditor and
09:00-09:15 Safety Briefing by EPCC/ CONTRACTOR
Auditees
Note 1,6 and 7
Date: Current Progress & Engineering Overview Presentation Auditors and
09:15-09:45
13 Nov 2017 by EPCC/ CONTRACTOR Auditees
(DAY 1) Auditors and
09:45-10:00 Entry Meeting by Lead Auditor ALL
Auditees
10:00-12:00 Site Walkabout ALL ALL
12:00-13:30 Lunch Break & Prayer

Construction / Site Fabrication, Installation and
Erection
- Site project organization (incl. overall and
construction organization & manning chart)
LA
- Construction Planning, Scheduling, Monitoring
and Reporting
13:30-16:30 - Construction Interface
Material Management (incl. Material Handling A1 &

and Control and Procurement) A4(preservation)
Page 3 of 6
Auditee (Auditors)
Project Quality Reviews/ Previous Audit Findings

Implementation Review ( Incl. Quality
A2
Management / Inspection & Testing )
Continue Engineering Management & Field

A3
Engineering (all relevant Disciplines )
16:30-17:30 Auditors’ Discussion All Auditors

Erection
- Subcontracts Management ( incl, assessment of
Subcontractors’ activities and Subcontracting LA
Progress Measurement)
Date: - Construction Planning, Scheduling, Monitoring
and Reporting
14 Nov 2017
(DAY 2)
Continue Material Management (incl. Material
A1 &
Handling and Control and Procurement) incl. site
09:00-12:00 A4(preservation)
verification of Preservation and Storage
Quality in Construction and 6 Focus Areas

- Fabrication and Testing Status incl. PWHT,
Hydrotest, Flushing, Leak Test, NDT, etc. A2 & A4
- Site Quality Control/Inspection Status
NEWS (Report and Traceability of Welding and

NDE’s ) A5

Engineering (all relevant Disciplines ) A3
Readiness for Mechanical Completion and Pre-

Commissioning
LA & A1
Continue Quality in Construction and 6 Focus

13:30-16:30 Areas (Traceability , Welding, NDE’s , A2 & A4
Painting/Coating)
Continue NEWS (Report Traceability of Welding
and NDE’s ) A5

Page 4 of 6
Auditee (Auditors)
Project Documentation Management (incl.

readiness and preparedness Final A1
Documentation)
Date: Erection : Assess to SUBCONTRACTOR 1*
15Nov 2017 - Reporting, Responsibilities / Work scope LA
(DAY 3) - Communication and Construction issues
* to be assigned by EPCC
09:00-12:00
Erection : Assess to SUBCONTRACTOR 2*
- Reporting, Responsibilities / Work scope A2
- Communication and Construction issues
Continue Construction / Site Fabrication,

Installation and Erection : SUBCONTRACTOR 1 LA

Erection : Assess to SUBCONTRACTOR 3 *
- Reporting, Responsibilities / Work scope A1 & A2
13:30-16:30
- Communication and Construction issues

08:30-10:00 Audit Findings Consolidation & Preparation Auditors Only

Date:
16 Nov 2017 10:00-12:00 Finding Deliberation with UPT Auditors Only
(DAY 4)
13:30-14:30 Audit Exit Meeting Preparation Auditors See note 2
14:30-16:00 Audit Exit Meeting Auditors and

See note 2
Auditees
Page 5 of 6
Special Arrangements / Requirements/Notes:
1. CONTRACTOR to arrange a room (with beamer) for Entry and Exit meeting.
2. CONTRACTOR to arrange a room for the Auditor for the duration of the audit.
3. Interviews at invitees location is preferred, if not practical the auditors’ room is optional.
4. Auditors time = includes outstanding questions/answers/evidence and is reserved for an extension (if needed) of a previous
part of the audit and consolidation of audit findings.
5. Availability of documents for evidence is required.
6. CONTRACTOR to prepare a short presentation.
7. CONTRACTOR to arrange and prepare short safety induction/safety moment.
8. CONTRACTOR to advise and accompany Auditors to the agreed areas (incl. offsite fabricators) for site verification and related
documents review (site walkabout and interview).
9. Any update to this Term of Reference will be attached to the Audit Notification to Auditee, copies to Project Directorate and
OWNER for references.
Signed: Signed: Signed:

Faezal Digitally signed by
Digitally signed by
abd21281
Ibrahim Ma. Lorena
DN: cn=Ma. Lorena, Digitally signed by Stephen
o=RAPID IPMT, Knapper
DN: cn=abd21281, 2017.10.3 ou=QA, DN: cn=Stephen Knapper, o=QA
email=Ahmad.Abdullah email=lorena.villado Central Directorate, ou=QA,
0 07:45:35 [email protected], c=MY email=stephen.knapper@rapid-
@rapid-ipmt.com Date: 2017.10.30 ipmt.com, c=MY
Date: 2017.10.28 +08'00' 08:13:42 +08'00' Date: 2017.10.30 08:42:18 +08'00'
'09:58:08 +08'00
Ahmad Bin Hj Abdullah Lorena Villadoz / Faezal Ibrahim Stephen Knapper
Central Directorate Lead Auditor Central Directorate QMS Manager / QA Audit Central Directorate Head of Quality
Manager
Distribution:
CD Head of Quality RC Programme Director SEC P2 Project Manager

CD Deputy Head of Quality RC UPT2 Project Manager SEC P2 Quality Manager
CD QA Audit Manager RC Head of Quality Auditors
CD Engineering Manager
CD QMS Manager
Page 6 of 6
AUDIT REPORT
KL-17-AU-034
CCSM – CONSTRUCTION AUDIT
Attachment 2
– Attendance Sheets -

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PETRONAS RAPID PROJECT

PACKAGE 1/CCSM – CONSTRUCTION AUDIT

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