This is the initiative we need from Daelim construction. Do not hesitate to ask in the future.

NCR-103-103113-02 This could be an observation because the respective joint was not offered for inspection. More over joint configuration is a Non-essential variable for WPS (Ref. ASME BPV code Sec IX- QW256) Ncr-103-103113-17 All sub-contractor are instructed to keep Argon purity certificate for each cylinder batch, also DAELIM inspector will keep close monitoring on every batchs arrival. NCR-103-103113-020 This could be an observation because nowhere is mentioned the frequency of the monitoring of the temperature / humidity log. Common temperature and humidity log is prepared and its distributed to all subcontractors for monitoring on daily basis. NCR-103-103113-21 General meeting was called to discuss root causes and analyses with all subcontractors, All welders having repair rate over 5% (joint based) is stopped from production weld, they will be reinstated only after training and retesting. DAELIM inspectors are instructed to raise NCR on subcontractors if repair rate exceeds over 5% on joint based. Quality tool box talk will be conducted on weekly basis to address current welding defects and preventive action.

As you know regarding above mentioned subject, it was observed on 3rd October-2013 during my daily Surveillance i found drawing no. C016103L3A-ER-230135-02-Rev-4,Spool-B,joint No.1 & 2 was welded without fit-up inspection and that day i instructed your piping inspector to issue AYTB internal NCR ,and you piping inspector has fallow my instruction and issued NCR to AYTB construction(DL-AY-NCR-04). But on 12-Nov. your welding inspector Mr.Jothish was requested Daelim RT for those joint without clear your internal NCR (DL-AY-NCR-04), without fit-up inspection and welding inspection. It is clear violation of work procedure for fabrication-A554-E-103-QA-GEN-PRO-046,

Para-8.12.13, QC piping inspector will also verify and document work compliance before welding of spools. It means Daelim QC inspector not required at your shop, your QC can take any decision without daelim QC? However we need justification & action regarding above mentioned subject, unless otherwise we will revoke your welding QC inspector Mr.Jothish approval for MFC Daelim project. Please find the attached photograph of that spool.

This is not the issue of threatening. This is an ignorance by AYTB QC inspectors. If DAELIM subcontractor doesn't follow the SADARA Procedure and specification it will turn to the efficiency of respective QC inspector. As per approved ITP (SMITP-F-001-04 activity 4.2) shows the fit-up inspection which is hold point for sub-contractor and contractor. This is the responsibility of the QC inspector to verify the fit-up inspection as per approved checklist. If the QC inspector failed to do his job and the spools forwarded to the next activity it is a clear violation. Moreover it is a team work and sub-contractor QC inspector must update any issue to the contractor QC inspector. If all the decision are to be taken by sub-contractor then no need for the organization chart and no need to follow the project Quality schedule 'Q' instructions. Therefore it is kindly informed AYTB that many issues are still pending and the AYTB is not fulfilling the required applications. I hope your team will coordinate and we will complete this project with an excellent HSE & Quality goals. And Please prepare and submit of JCC & Re submit of WPS with Rectification, which those of rejected with Commands at last week. COMPANY log book #387QCP for welding and consumable control procedure rev-2 and ITP for welding of on plot piping rev-2 have been submitted on 6-Nov-13. Weld identification numbering also revised as per CIMS requirement in the rev2 of welding and consumable Quality control procedure, also procedure for weld repair (A554-E-103-QA-GEN-PRO-119) Rev-1 submitted on 11-Nov-13 Kindly find attached the Welders Repair Rate List for last week. The rejection rate nowadays is going out of control. Just revoking the welders is becoming ineffective. In this case we all have to pay some extra effort to our assigned areas. SADARA Quality Lead Mr. Mike is not satisfied with this performance, and he wants to reduce rejection rate. He is blaming the QC Personal also for this situation. Let everybody start close

monitoring of the welding activity and pass the massage up to ground level, every welder should know the minimum quality requirement. We have to meet each welder to provide him any guidance / support required. I would suggest all the concerned QC Inspectors to conduct Quality Tool Box Talks every Sunday addressing the defects, causes of the defects and give them suggestions to improve the quality.

. Please be informed that tomorrows Weekly Quality Meeting is cancelled due to various scheduled engagements, We look forward to meet you next week, Please disseminate our message to those individual that belongs to your Department. Thanks for the mails and pictures of Fabrication shop inspection. Hopefully today you will get the official reply by the Daelim QC departments with the observations and comments of fabrication shop inspection carried out on Thursday 21 November 2013. Just for your information please before issue the RFI you must be available with all the requirements as we discussed in shop inspection meetings. 1. 2. 3. 4. NSH must be in the position of all approved Daelim Procedures and ITPs. Your welding, piping and coating QC inspectors must be available. RFI must be reached to Daelim office 24 hours in advance the starting of activity. Must be in the position of approved WPS and JCC for the welders.

I hope NSH have all these requirements so you may start the work because we need to accomplish our goals with great HSE and excellent quality procedures as per the satisfaction of SADARA
MFC need above WPSs to be reviewed urgently as it holds construction progress. Adnan is on leave; Robert Plummer is out office till November the third, so we need your support to complete the review on urgent basis.

Your continuous support is highly appreciated

We understand that KAEFER has used unqualified people to do chartek application and then calling manufacturer for a meeting to accept the job doesnt make any sense other than wasting our valuable time. DAELIM QC has raised LBE regarding this issue(PFA)

We understand that you have qualified blaster and spray applicator, but the final finish for the 2nd coat chartek is rendered by qualified mason and roller applicators . Our Qc inspector found that those people who were qualified for this purpose were missing from MFC site. We refrain to call for any meeting or discussion unless you have a valid explanation for this. Please note that we are escalating this issue to NCR. Today our tool box topic is fire; first of all we must know what the fire is, so it will be help full to extinguish the fire. Fire is the combination of three things. Combustible material, oxygen & temperature, if we stop oxygen supply to the fire, there will be no fire, same way if we remove combustible material from fir or decrease the temperature fire will be extinguished. Thats all Let sought our safety slogan.

Same CV was rejected earlier through transmittal no. MFC-T-TCC-QM-137, but TCC again submitted this without valid certificate. A) Welding ITP for on plot piping (SMITP-W0011-01 Rev-1) has been revised to cover all NDE requirements and inspection points also defined for SADARA inspection, NDT request format also added in revision 2. B) All NDT coordinators are instructed to complete 1st RT request before issuing 2nd request to NDT Company. C) NDT coordinators are instructed to send NDT request to concerned PID inspector through email on daily basis. D) RT done on 7 joint remaining joint is already scheduled. E) RT request is prepared for welders who involved in the 101 weld joints that had long delay between RT request and date of RT. F) Two NDT coordinators have been assigned to avoid any trouble in future. G) We are monitoring and controlling our subcontractors as per requirement of schedule Q. H) We have enough RT crew to do RT, AUT is not required also we dont have any backlog for more than 14 days.

Actually ARCC should provide daily welding inspection report (DWIR) to DAELIM inspectors for visual inspection at each end of the day but practically this is tough task for ARCC so we have given concession to provide next morning but ARCC not providing DWIR on time, we are

receiving DWIR after 3 days of the production and sometimes after a week, so there is large gap between actual production date & visual inspection date. After visual inspection only that data will be entered in CIMS or WENDS (ARCC system) from which ARCC NDT coordinators selecting joints for RT. ARCC is the one who making request & schedule for RT. After getting result from third party DAELIM NDT coordinators are informing immediately to each subcontractor if there is any repair or reshoot including ARCC. ARCC should expedite their reporting system it will be helpful to us also to monitor each welders performance and on times stop/removal of the bad welders without damaging many joints. Awareness session was conducted with all welding team (including welders, welding foreman, supervisor & welding inspectors) regarding selection of proper WPS as per Isometric drawing. Welding team has been instructed to take help of area welding inspector before adopting any WPS.
The question is not hold or witness point. Our aims and goals are same to complete the project as per the required quality of work. If sub-contractor QC Inspectors accepts the joints without proper quality requirements so it is Contractor prime responsibility either to revoke the QC Inspector or to keep a cross checks on the quality. I am sure you have seen the attached photos of the accepted fit-up by sub-contractor QC Inspectors. As per approved procedure these type of fit-up are not acceptable. We must follow the requirements and approved procedure. If you have any doubt on any fit-up inspection which is rejected unnecessary then you must raise the issue with proper evidence and proof. I hope as a head of Subcontractor Quality team you will take action on this matter and will instruct all your sub ordinates.