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Lessons Learned

Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3314 Project Name: MSQ Upgradation Unit Name: FCC Gasoline Desulphurisation Client: Indian oil corporation Ltd Project Site Location: Mathura

03-03-2010 Thermowells in Difficulty in insertion of Temperature The inner diameter of these Pending No
NACEpiping specselements in case of thermowells with thermowells used to be so Approval
NACE piping spec. small tht no clearance was
available for the temperature
element to slide through the
thermowell.

Jacobs Project No: 44MM2800 Project Name: CDU/VDU, CFC LPG TREATING & ATF TREATING UNITS Unit Name: Client: MRPL Project Site Location:

19-11-2010 Detailed While preparing Level Sketches, it is not Non availability Stand Pipe Requirement of Standard sketch of NO At the time Piping can issue a standard Pending No
Engineering clear how many nozzles is possible to Standard Sketches Stand Pipes by Piping. preparation of Level sketch of Stand pipes of various Approval
weld at the same elevation in different sketches our options with level nozzle shown
planes. Also what is the minimum engineers are so that this will form the basis
distance required where the first level interacting with while preparing the level
nozzle can be welded from Bottom of various piping sketches.
stand pipe. designers and
prepare level
sketches. This takes
a lot of time to get
proper inputs from
Piping and has
resulted in delay in
issuing of Level
sketches

Jacobs Project No: 44MM2800 Project Name: CDU/VDU, CFC LPG TREATING & ATF TREATING UNITS Unit Name: Client: MRPL Project Site Location:

19-11-2010 Detailed For Instrument Air line where the piping is PMS was not checked for the Before deciding the type of Orifice NO This was observed PMS checking before deciding Pending No
Engineering Galvanized, WN Orifice flange was type of flanges to be used flange, PMS is to be checked carefully during preparation the type of orifice will avoid Approval
specified where no welding is permitted and check what is the type of flange is of PR and action these type of errors.
in GI lines specified. For this type flow taken accordingly
measurement SS carrier ring is
required to be used which is bolted
between Piping flanges.

Jacobs Project No: 44LK4100 Project Name: IRUP - EPCC-6B Unit Name: IRUP - Offsites and Utilities Client: Indian Oiltanking Ltd. Project Site Location: Vadodara

Civil Bhawani 26-03-2008 Detailed Use / Selection of Structural sections Pending No


Samanta Engineering Check whether cantilever designs are Approval
acceptable. IOCL will not prefer sections
for expansion.
MTO to clear the wastages or rolling,
assumptions
Flag for fabrication drawings, scope to be
clarified.
Underground piping is the responsibility
of Piping – PM
Electrical and Instrumentation changes
Underground piping to be IDR
Electrical / Civil to clear the corridors for
underground piping
Structural MTO to be issued with no
commitments – consider margins
FEED back from IOTL on material
consumption in the project. Track MTO on
regular basis. Poor material management.

14 January 2019 Page 1 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3188 Project Name: Lube Oil Upgradation Project Unit Name: LOBS Client: Hindustan Petroleum Project Site Location: Mumbai
Corporation Ltd.

Civil Dharmendra 19-11-2010 Pre- OSBL Valve operating platforms and crossovers Drawings for valve operating Civil should issue standard Platform NO Valve platforms were Drawings for valve operating Pending No
Kumar Commissionin erected in the tankfarm area were found platforms and crossovers are drawings to be installed by Civil / modified as per the platforms and crossovers should Approval
g/ to be not serving their purpose.At certain generally prepared alongwith Structural Contractor as required by requirement. generally be prepared after the
Commissionin locations ,the valves were found to be the foundation drawing when Piping at site. nozzle orientation and valve
g quite far away and hence totally the nozzle orientation and locations have been finalised at
inaccessible.Similarly certain crossovers valve locations are not yet site.
were found to be running into dead ends. frozen.During
construction,due to various
site restrictions these
parameters may undergo
change.

Jacobs Project No: HUSP004G Project Name: Shell Vito Unit Name: -NA- Client: Shell Project Site Location: Gulf of Mexico

Civil Parag Buwa 13-07-2018 Detailed Top Side The pipe / cable tray supports have been Clear guide lines not set by Heavy supports/ multiple line NO Alternate Support arrangement Pending No
Engineering taken from primary steel as no near by primary steel. supporting from primary steel shall be worked out wherever possible. Approval
secondary steel is available. Later primary totally avoided. Piping / electrical will JH held detailed discussion with
steel engineering contractor has not also have to consider this aspect while primary steel engineering
approved many of these. routing the lines /trays as the contractor.
supporting becomes vey difficult.
Frequent interaction of design teams
with primary steel (along with piping
and electrical) needed. In future
Loading / supports criterias for taking
supports from primary steel shall be
clearly mentioned and to be included
in the design basis.

Jacobs Project No: 18-3331 Project Name: Soda Ash Plant revamp Unit Name: Client: Saurashtra Chemicals Ltd Project Site Location:

Civil Pranab Nag 19-11-2010 Detailed Powerhouse Top of Pump foundations(4 nos) in De- We have overlooked the Vendor drawing shows dimension of NO We have provided Civil should check thoroughly Pending No
Engineering building aerator area was cast below FFL, which functional purpose of TOC from FGL, but in piping layout Steel beams above any mismatching is there or not Approval
should be 200mm above FFL. Base plate pedestal. shows indicative TOC above FFL. We pedestals to with piping and vendor drawing.
of pump was below FFL, which is not have considered vendor drawing only. maintain the base
acceptable. It could be avoided if we would have frame of pumps
discussed with piping about this above FFL.
discrepancy.

Jacobs Project No: 18-3331 Project Name: Soda Ash Plant revamp Unit Name: Client: Saurashtra Chemicals Ltd Project Site Location:

Civil Pranab Nag 19-11-2010 Detailed Powerhouse Many operating platforms(small) added We have concentrated only Before preparation of superstructure NO One Engineer was Civil should study piping drawing Pending No
Engineering Building for valve operations after construction of main platforms in piping drawings we should discuss with piping sent to site for 2 in all respect and to discuss with Approval
building.In some cases it was very difficult layout drawing. regarding requirement of all small weeks and he piping people before starting of
to accommodate those platforms after platforms for valve operations. prepared the design.
completion of building. sketches as per
requirement.

Jacobs Project No: 18-3331 Project Name: Soda Ash Plant revamp Unit Name: Client: Saurashtra Chemicals Ltd Project Site Location:

Civil Pranab Nag 19-11-2010 Detailed Piperack Piping layout has been changed many Existing structural & Civil engineer must visit site with NO We have visited site Before finalization of Piperack Pending No
Engineering structure in Sea times and accordingly civil foundation foundation drawings were piping people before finalization of 2 times and finalized structure layout in existing plant Approval
water pump area drawing has been revised 8 times. We not available at site by client. layout wherever existing structural & the layout plan. Civil Engineer should accompany
have wasted lot of work hours to revise Civil engineer should have foundation drawings are not available Piping people at site.
the design and drawings. During visited site and to measure at site.
construction at site existing structure or the actual dimension of
foundations were fouling with new existing structure before
structure. starting design.

14 January 2019 Page 2 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3342 Project Name: IRUP - HGU Unit Name: Hydrogen Generation Unit Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Civil RP madkaikar 18-03-2010 Pre- HGU 1) Use Min. 500 mm dia of pile for Pending No
Commissionin Tremie insertion Approval
g/ 2) In BOQ boring length of pile should
Commissionin be different than concrete quanity
g because boring length is calculated
from ground whereas concrete
quantity is upto cut-off level.
3) Provide width of embedded plate
for sliding plate same as sliding plate
width.
4) GI sheeting quantity should be a
part of Mechanical / erection tender.
5) Pipe sleeve quantity for electrical /
inst. trench should be a part of civil
tender.
6) Fir proofing extent should be
ascertained by Piping / Process and
inform to civil for their further
calculation
7) Tension capacity of pile should be
furnished by Pilling contractor along
with calculation

Jacobs Project No: NL688693 Project Name: Off gas treatment Unit Unit Name: Off gas treatment Unit Client: BPRR Project Site Location: Europort, Rotterdam

Civil Sachin Patil 15-06-2018 Detailed AREA-6 : PiperackIn define phase, new structure (pipe rack) Considered modeled Received modeled (new / existing) NO Approved Yes
Engineering was modeled by Lead office which was structure (piperack) was clash structures from define phase needs to
clashing with exiting pipe and this existing free but it was not. be rechecked with laser scan
pipe was not modeled by piping. thoroughly in further execute phase.
And considering half meter all around
to working area, all existing relavent
affecting elements needs to be
modeled by all disciplines respectively.

Jacobs Project No: NL688693 Project Name: Off gas treatment Unit Unit Name: Off gas treatment Unit Client: BPRR Project Site Location: Europort, Rotterdam

Civil Sachin Patil 15-06-2018 Detailed AREA-6 : PiperackIn define phase, new structure (pipe rack) Considered modeled Received modeled (new / existing) NO Approved Yes
Engineering was modeled by Lead office which was structure (piperack) was clash structures from define phase needs to
clashing with exiting pipe and this existing free but it was not. be rechecked with laser scan
pipe was not modeled by piping. thoroughly in further execute phase.
And considering half meter all around
to working area, all existing relavent
affecting elements needs to be
modeled by all disciplines respectively.

Jacobs Project No: NL688693 Project Name: Off gas treatment Unit Unit Name: Off gas treatment Unit Client: BPRR Project Site Location: Europort, Rotterdam

Civil Sachin Patil 15-06-2018 Detailed AREA-6 : PiperackIn define phase, new structure (pipe rack) Considered modeled Received modeled (new / existing) NO Approved Yes
Engineering was modeled by Lead office which was structure (piperack) was clash structures from define phase needs to
clashing with exiting pipe and this existing free but it was not. be rechecked with laser scan
pipe was not modeled by piping. thoroughly in further execute phase.
And considering half meter all around
to working area, all existing relavent
affecting elements needs to be
modeled by all disciplines respectively.

14 January 2019 Page 3 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: NL705692 Project Name: Waste Heat Utilisation Unit Name: HCU for District Heating Client: Shell Nederland Raffinaderij B.V Project Site Location: Rotterdam
(SNR)

Civil Satish Naik 13-06-2017 Detailed CIVIL Civil recevied inputs from Piping. Piping CIV keep changing for model Work should be started after receipt of NO Pending No
Engineering has done 60 & 90% model reviews on reviews on assumption vendor drawing/confirm data. If Approval
assumption basis due to non availability basis/preliminary data which progress has to be taken on
of vendor info in time. Affected Civil in many times overlooked assumption basis then piping model
budhet and schedule. and results in overrun in should only be shown in model
budget. If lean approach is reviews. Otherwise, discipline should
adopted in budget, then 60% raise CN for every small changes to
and 90% model review should maintain the budget.
be after receipt of vendor
drawing/confirm data.
Working on assumption has
overrun the budget.

Jacobs Project No: 18-3314 Project Name: MSQ Upgradation Unit Name: FCC Gasoline Desulphurisation Client: Indian oil corporation Ltd Project Site Location: Mathura

Civil V.V. Abhyankar 01-04-2011 Detailed OSBL Rack Various clashes with existing facilities. Client has not provided In preparing OSBL rack layout, due NO If we are supposed to work in Pending No
Engineering existing facilities layout & consideration shall be given for existing existing facilities then we must Approval
details. structures that are coming in way with ask for existing drawings of
our proposed rack routing. These are superstuctures as well as
joint efforts by piping & civil with client. foundation, especially.

Jacobs Project No: NL688693 Project Name: Off gas treatment Unit Unit Name: Off gas treatment Unit Client: BPRR Project Site Location: Europort, Rotterdam

Civil Vinay Prakash 23-11-2017 Detailed OTU/Area6 During the new steel modelling in Area C, Steel was modelled at same During the modelling, all the existing NO Approved No
Engineering the new steel was clashing with the location from define phase material needs to model by all
existing pipe. The same has been missed and when we started execute respective disciplines & should be
out by Hague office also during the phase, check with laser scan checked for clash free design using
discipline review. During the site visit, one for existing piping/trays is laser scan. Additionally, a site visit with
of the bidder has raised the matter. The ignored. Check with laser is laptop/ipad is required to check the
steel is redesigned to remove the clash. done only for connection model Vs actual site conditions. Photos
Entire steel modelling in all area (revamp) part. This is because of should also available if scan is not clear.
work has been reviewed with laser chronic ease which we
scanning + site visit also carried out to generally think that it will not
check/ find out the probable clash/es. clash as this steel is from
define phase only.

14 January 2019 Page 4 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44PS7300 Project Name: xx Unit Name: Multiple Units Client: O&U Reliance Jamnagar Project Site Location: Jamnagar, Gujarat

Electrical Arvind Chavan 17-05-2017 Detailed Warehouse Multiple cycles of engineering activities in Scope and DOR were not Architectural dwgs for warehouse were NO The requirements and scope Approved No
Engineering available space based on intermittent shared for warehouse. Loads issued without carrying out any shall be defined well defined
requirements. Workhour spent were not identified. engineering by other disciplines. before starting the work so that
repeatedly for the engineering Subsequently, RIL started asking for engineering can be completed at
deliverables inside warehouse. other deliverables like, warehouse one go. All stakeholders need to
lighting, earthing, lightning protection, come together and provide
etc. There were three DECs involved in clarity to DEC.
engineering activities in this area. But
the scope split was not available.
Subsequently, large number loads for
various rooms inside the warehouse
got added. A cycle of engineering
activities was repeated to cater to this
requirement. Dry type transformer,
PCC, UPS, large no 3 phase and single
phase DBs were added in the available
space in the warehouse. These
activities could have been planned in
advance had the requirements been
known earlier.
Eventually, HVAC requirement was
received for various rooms in the
warehouse. Hence another cycle of
engineering activities was required to
be repeated.
Engineering activities inside the
warehouse were not happening at one
go. There were clashes developed at
later stages. Fire water piping clashed
with light fittings.

Jacobs Project No: 44PS7300 Project Name: xx Unit Name: Multiple Units Client: O&U Reliance Jamnagar Project Site Location: Jamnagar, Gujarat

Electrical Arvind.Chavan 29-06-2017 Construction Street lighting Clash free lighting pole coordinates Street lighting poles not Reliance as Client expects clash free NO All underground facility dwgs Approved No
modelled as modeling is not coordinates of the street light poles. were attached for reference to
in the scope of work. Lighting modeling is not part of scope the lighting layout dwg. Lighting
of work. As lighting poles were not poles shifted to get the clash
modeled and lighting layouts are free coordinates.
prepared much before all other
underground services are modelled,
poles may clash with underground
piping, temporary construction
trenches for cable or pipes, etc.
Available underground facility dwgs
shall be attached for reference to the
street lighting layouts to make the
poles clash free. Subsequent recheck
based on updated reference dwgs may
be required at a later date just before
actual poles are placed at site.
Alternatively, a corridor needs to be
blocked, which shall not be occupied
by other services.

14 January 2019 Page 5 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 07Q7814N Project Name: MON11900 Unit Name: Chemical Plant Client: Monsanto Project Site Location: USA ; Lulling

Electrical Prathamesh 19-06-2017 Detailed ISBL area Unable to update background GA in Cable Piping have shifted While extracting the 2D drawings from NO After 90% model review model Approved No
Deulgaonkar Engineering tray & Power plan drawings. equipment from earlier piping 3D model, Designer should attach all will be updated due to
model to mechanical model the relevant models of Civil, Piping, availability of most of vendor
for eg:- In 3D model motor FEG and MEG so that latest data is data. Hence by that stage all
was earlier modelled in piping available in extracted 2D drawing. drawings can be released with
model no. PE800202 but later updated backgrounds. In case if
on after receipt of vendor any drawing was scheduled
data it has been transferred before 90% model review for IFA
to model no. ME800202. or IFC then in that hold of back
ground shall be mentioned on
respective drawings in case
latest vendor data is not
available.

Jacobs Project No: 07Q7814N Project Name: MON11900 Unit Name: Chemical Plant Client: Monsanto Project Site Location: USA ; Lulling

Electrical Prathamesh 31-05-2018 Detailed ISBL Mismatch between IFA/IFC issue date of In schedule date of cable trsy During initial stages of project such NO This is very difficuilt to note in to be updated Rejected No
Deulgaonkar Engineering detailed cable tray drawings and drawings was not matched issues shall bring into notice of project detailed project schedule as
miscellaneous electrical support (MES) with issue date of MES detail manager to avoid rework not only to generally one discipline will not
detail drawings. Due to this there are lot drawings. electrical but civil & piping also. looked into that detail for issue
of rework in model and in cable tray date of other discipline. These
drawings as some of supports for which mismatches shall be highlighted
civil was not able to provide MES support by projects to avoid rework.
arrangement then for those cases cable
tray rerouting was done for ease of
supporting.

Jacobs Project No: 07Q7814N Project Name: MON11900 Unit Name: Chemical Plant Client: Monsanto Project Site Location: USA ; Lulling

Electrical Prathamesh 31-05-2018 Detailed ISBL Most anticipated cable tray supporting Lack of clarity in scope of Various types of cable tray installation NO to be updated Rejected No
Deulgaonkar Engineering installation arrangements like cable trays developing tray supporting arrangement need to be finalized at
supported from steel column, top/bottom details and developing early stages of project to avoid rework
of beam & single/two tier trapeze etc. support details as and when at later date not only to electrical but
was not developed at initial stages of requirement comes up. other disciplines like civil and piping etc.
project.

Jacobs Project No: 07Q7814N Project Name: MON11900 Unit Name: Chemical Plant Client: Monsanto Project Site Location: USA ; Lulling

Electrical Prathamesh 19-06-2018 Detailed ISBL Most anticipated cable tray supporting Lack of clarity in scope of Various types of standard cable tray NO Approved No
Deulgaonkar Engineering installation arrangements like cable trays developing tray supporting installation arrangements covering
supported from steel column, top/bottom details and developing various possibilities need to be
of beam & single/two tier trapeze etc. support details as and when finalized and client approval obtained
were not developed at initial stages of requirement came up. at early stages of project itself to avoid
project. rework at later date not only to
electrical but to other disciplines like
civil and piping etc.

For example, standard supporting


arrangements for horizontal cable tray
supported from column and vertical
cable tray supported from column
when column flange thickness are
higher should have been developed at
early stage of the project.

14 January 2019 Page 6 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 07Q7814N Project Name: MON11900 Unit Name: Chemical Plant Client: Monsanto Project Site Location: USA ; Lulling

Electrical Prathamesh 19-06-2018 Detailed ISBL Mismatch / no correlation in scheduled Scheduled date of cable tray Interactive Planning session should NO Planning group shall take care Approved No
Deulgaonkar Engineering issue dates between IFA/IFC detailed drawings were not matched carefully check for correct sequencing that schedule follows logical pre-
cable tray drawings and corresponding with issue date of MES detail of various inter-related activities of requisites of inter-related
civil Miscellaneous Electrical Support drawings (Scheduled date for different disciplines and bring out drawing issue. Mismatches, if
(MES) detail drawings. Due to this civil MES drawings were discrepancies before schedule is any, shall be highlighted by
considerable rework in model and cable about 2 to 3 months after finalized. projects before schedule is
tray drawings were needed as civil was scheduled date for electrical frozen.
not able to provide MES support dwgs.) Before schedule is frozen, such issues
arrangement for tray routing envisaged shall be brought to notice of project
by electrical and cable tray rerouting was manager to avoid rework not only to
done for ease of supporting. electrical but to civil & piping also.

Jacobs Project No: UM200501 Project Name: BP Khazzan Phase 2 Unit Name: NA Client: BP Project Site Location: Muscat

Electrical Pratik 31-10-2017 PMC Phase-2 Duct bank Length of transformer apperas to be twice Vendor drgs not available 1.Construction Contractor to Install NO Pending No
Parab;Smita (Engineering than actual. Therefore Transformer Duct Bank after completion of Well Approval
Chobey by LSTK) foundation is bigger than actual Piping
transformer size. 2. Refer latest code -1 vendor drgs.
While designing transfomer foundation

14 January 2019 Page 7 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3342 Project Name: IRUP - HGU Unit Name: Hydrogen Generation Unit Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Electrical Sanjay Barve 17-03-2010 Pre- HGU -Approved Vendor List to be framed Pending No
Commissionin & firmed up properly at the start of the Approval
g/ Project
Commissionin
g -If Project Design Basis is issued by
Client/their consultant to be reviewed
critically at the start & any changes
required to be conveyed to Client by
raising TQ

-Space for LighJng Panels /Power


Panels/Welding sockets/Critical Ltg
Panels to be occupied in the model at
the start by placing Space envelopes

-NGR connected to Power Tr Neutral


to be requisitioned only after obtaining
confirmation from HT Motor Vendor
regarding Earth Fault Withstand
capacity of HT Motors

-For Pressurised Motors insist on


100% redundancy for Pressure Sw in Pr
Control units. Trip the Motor Directly
through Pr Sw contacts in case of drop
in Air Pressure & Not thru DCS

-IdenJfy the Pressurized Motors at


start & convey to process, Piping for
Utility line connections/sizing &
informing to Client on requirement of
Inst Air

-LighJng Fixtures to be provided with


external reflector

-Do not depend on KW raJngs given


by overseas Process Licensor at the
start & thereby categories motors as
LT/HT. For borderline cases (
110/132KW given by overseas process
Licensor) consider these as HT Motors
& make provision in HT switchgear,
because it has been observed that
Packge Vendors generally quote a step
higher KW ratings than what has been
indicated by overseas Process Licensor.

-RequisiJon LighJng Transformer


only once basic Lighting Design is
completed. Do not requisition it at the
start alongwith Dist & Power
Transformers. If it is decided to
requisition at the start keep sufficient
extra margin while sizing.

-Keep track of all P & ID Revisions &


take note of any Electrical Heat Tracing
requirement ( if any).At the same time
Process should convey vide E-mail to
Electrical group, if any Electrical Heat
tracing requirement gets introduced in
any of the intermediate revisions of P
& ID

-Insist on reviewing all the cerJficates


of Electrical Equipments to be used in

14 January 2019 Page 8 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Hazardous area including glands fitted


to Motors during TR/TBA stage itself so
that Vendor not possessing valid
certificates can be rejected.

-Insist on reviewing S/C, Temp rise,


IP55 certificates from Panel Vendors at
TR/TBA stage itself.

-As per IOCL procedure TPIA is to be


appointed by Vendor. This is a wrong
practice as it has been observed that
TPIA appointed by Vendors carry out
inspections leniently to suit the
Vendors. Instead IOCL themselves
should appoint TPIA who are
professionals in the Field & get the
Inspections done through them. For
critical Equipments stage Inspections
shall be insisted upon so that any last
moment surprises are prevented .

-For VFD driven Motors meant for use


in Hazardous areas, combined testing
& certification of Motor with VFD at
motor manufacturer’s works is being
insisted upon by authorities even for
Exd Motors ( as in case of CGL ERTL
certification).Hence at TR/TBA stage
itself all the certificates shall be looked
into so that any such requirement can
be taken into account.
------
--xxxxx-------

Jacobs Project No: 44MM5200 Project Name: Paradip Refinery Project (PDRP) Unit Name: Delayed Coker Unit and Coke Handling System Client: Indian Oil Corporation Ltd Project Site Location: Paradip, Orissa

FEG H. S. Chugty 14-01-2011 Detailed DCU The coke drums are subjected to extreme The licensor does not share In coker drums , the licensor’s have to NO For coker drums, it is Pending No
Engineering thermal cycles during their operation . the quantum of loads one be entrusted with complete piping recommended that Approval
(Coke drum is about 10 m dia*45 m tall should consider for designing design by LSTK contractor . Perhaps piping layout and its
vessel which grows about 300 mm in the self reinforced nozzle . that is the way we can required flexibility analysis
length and about 60 mm in radial Vessel vendor demands the information for coker drum design . should be entrusted
direction during its thermal cycle). information which we are not with the licensor .
Because of its resulting piping loads and able to provide. This way the
its functioning , the plates within the shell imposed piping loads
courses bulge out with its butt welding and shape of self
edges as anchors . This phenomena is reinforced forgings
known as Banana effect . Imposed loads can be quickly
have to be controlled to minimize the finalized .
Banana effect . In coker drum operations ,
its piping design is more of an art which
the licensors do not share in totality .
These loads are required for finalizing self
reinforced forgings for nozzles .

14 January 2019 Page 9 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44MM5200 Project Name: Paradip Refinery Project (PDRP) Unit Name: Delayed Coker Unit and Coke Handling System Client: Indian Oil Corporation Ltd Project Site Location: Paradip, Orissa

FEG H. S. Chugty 14-01-2011 Detailed DCU Timing of Column internals ordering Welded internals information 1 )Timing of column ordering and NO 1 Column vendor Pending No
Engineering and interface requirements affecting and location of nozzles internals ordering if not synchronized requires Feed nozzle Approval
Column progress. .. information delayed because can affect the progress of column. size and locations
This is a problem in many projects . of delay of flow of 2) It greatly helps if a joint meeting is and manhole
Column vendors require internals related information from internals arranged between column vendor , locations to finalise
interface information like finalization of vendor. Internal vendor , Piping ,Process when his nozzle forgings
Feed nozzle sizes , Location of manholes nozzles and piping are shown in the and shell course
and other process nozzles to finalise their model . A pictorial view helps widths . Hence
nozzle forgings and shell course widths everybody in appreciating the problem ordering of column
for ordering their plates .Internals vendor and finding its most appropriate internals has to be
has to carry out certain amount of solution. immediately after
engineering to provide the information . column.
Relative location of nozzles wrt internals is 2 Nozzle orientation
also crucial .which have to be addressed for the column
in time. should be reviewed
by internals vendor
also for fulfillment
of internals
requirements .

Jacobs Project No: 44QS4300 Project Name: Pre-bid for Al Zour Refinery,KNPC Unit Name: CDU, SGU, SRU, SWS, ARU, Hydrogen, SP, Flare Client: Petrofac International Limited Project Site Location: Kuwait

FEG Narottam Patel 30-04-2015 Basic Vendor offer Other discipline members are NOT Lack of awareness what shall Other disciplines shall cooperate & YES Management to decide the way Approved No
Engineering review by other interested in reviewing vendor offers. be reviewed, inadequate review offer in timely manner. Process forward.
disciplines manpower, tight schedule in not reviewed thermal design of Air
(PETROFAC their own discipline etc. coolers, packages like reformer, fired
PREBID PROJECT) heater, desalters process / utility
requirements. Piping NOT commented
on air cooler layout issues, platform
requirements etc.

Jacobs Project No: 44QS6500 Project Name: Confidential Unit Name: XX Client: Confidential Project Site Location: confidential

FEG Prakash Vaidya 03-07-2017 Detailed SRU Unit - Item Leg height as per Nozzle orientation Model has changed after After drawing approval any change NO FEG requested Vendor to cut Approved No
Engineering no.: 1711/12/13- drawing issued by Piping was = 1050 mm. vendor GA drawing is shall be followed with proper legs to maintain 800 mm leg
V-005: Fuel Gas Leg height as per GA drawing of vendor approved. This needs to be documented design change note to all height.
KO Drum was 1050 mm. However, stress package informed to FEG by concern discipline.
for lines were issued by Piping with 800 Stress/Piping which was
mm leg height. missing.

Jacobs Project No: 44QS6500 Project Name: Confidential Unit Name: XX Client: Confidential Project Site Location: confidential

FEG Prakash Vaidya 03-07-2017 Detailed SRU Unit - Item Leg height as per Nozzle orientation Model has changed after After drawing approval any change NO FEG requested Vendor to cut Approved No
Engineering no.: 1711/12/13- drawing issued by Piping was = 1050 mm. vendor GA drawing is shall be followed with proper legs to maintain 800 mm leg
V-005: Fuel Gas Leg height as per GA drawing of vendor approved. This needs to be documented design change note to all height.
KO Drum was 1050 mm. However, stress package informed to FEG by concern discipline.
for lines were issued by Piping with 800 Stress/Piping which was
mm leg height. missing.

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

FEG Swapnaja Sawant 10-07-2017 Detailed Close coupled Stress analysis of piping for close coupled Scope clarity was not clear in Wherer possible we should locate the YES Implemented Lesson learned Pending No
Engineering equipment nozzles created a problem in RIL MEG. the beginning. Reboiler and Reboilers on the column itself so that from RIL MEG project in Approval
Nozzle loads were transmitted to the Column vendors were not stress related problems will be reduced. MEGlobal Project
vendors even after equipment is shippied. same

14 January 2019 Page 10 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 58QG88M4 Project Name: Diesel Selectivity Project Unit Name: XX Client: Flint Hill Resources Project Site Location: USA ; Pine
Bend,Minnesota

FEG Swapnil Kamble 26-07-2018 Detailed SP3D Model / The platform bracket was fouling with The spectacle blind is not The spectacle blind can be orientated NO Spectacle blind re Approved No
Engineering Platform drawingspectacle blind of nozzle correctly orientated by Piping and rotated in such a way to avoid any oriented
clash with platform bracket instead of
comment on vendor drawing to
change platform bracket orientation.
Piping need to ensure the same before
commenting.

Jacobs Project No: 44PS5400 Project Name: RSPL Chemical Complex Unit Name: Client: RSPL Ltd Project Site Location: Kurunga Village,
Dwaraka, Gujrat

Inspection Karande, 22-03-2018 Construction Area 000 FRP pipes supplied at RSPL site, were FRP Pipe thickness checked FRP Pipe thicknesses should also be NO Additional Mandrel OD / Taper checked to Additional Approved No
Anil;Kathe, Anant found to be having less thickness at max. upto 500mm length verified at the center and areas aways destructive test establish thickness after inspection stage
center and areas other than ends. from edges. from edges, considering the inspection stage manufacturing of pipe and added - Introduced
Thickness at center not observations at site. added for balance correective action taken. Destructive
checked due to instrument lots. - Introduced Distructive inspection by cutting
limitation. inspection by cutting the FRP the FRP pipes at
pipes at middle / or locations middle / or locations
suitable to ensure the desired suitable to ensure
thicknesses are being achived. the desired
- Manufacturer informed to thicknesses are
establish non distructive method being achieved.
for checking Thicknesses at
center / any desired location.
No Procedural change.

- Inspectors to take care during


Inspection to verify thickness at
various locations for FRP piping,
since weaving may leads to
uneven thickness.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Instrumentation 30-06-2005 Reformer detail Tappings provided on ducts / pipes for Licenser's scope included 1) Instrument supply can be part of Pending No
engineering instrument connections were not detail engineering as well. licenser's scope. 2) Licenser's Approval
scope matching with instrumrnt connections. However, for supply & scope to include residual detail
Also, isolation valves were not supplied by installation activities only engineering to take care of vendor
Reformer contractor. instrumentation was specific changes for instrument / piping
exlcuded. Instrument vendor interfaces.
specific changes for
connection sizes are to be
taken care by licenser for
piping engineering. This called
for extensive co-ordination
between EPCC contractor and
licenser.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Instrumentation 30-06-2005 High pressure For high perssure lines, 1/2" sch. 160 EPCC contractor provided For amine, sour water and high Pending No
Impulse piping impulse piping was provided having ID of 1/2" sch. 160 impulse piping pressure applications, impulse piping Approval
2.5mm. Choking problems faced during instead of 3/4" size. size shall be 3/4" as a minimum.
hydro testing.

14 January 2019 Page 11 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3314 Project Name: MSQ Upgradation Unit Name: FCC Gasoline Desulphurisation Client: Indian oil corporation Ltd Project Site Location: Mathura

Instrumentation 09-02-2009 As per Piping specifications NACE +HIC For control valves, PSVs, and other Pending No
compliance is required items( valves, instrument items wherever HIC is Approval
PSVs, pipes fittings etc) in Hydrogen required SS material to be specified.
service. Accordingly Valves in Hydrogen
service were specified with NACE + HIC
requirements. During offer stage all
vendors confirmed to provide however,
after order placement M/s Mekaster(PSV
vendor) raised concession request to
supply SS 304 PSVs instead of carbon steel
with HIC requirement as carbon steel
castings with HIC requirement required
imported castings and longer delivery. SS
material is acceptable for Hydrogen
service as per Licensor doc.

Jacobs Project No: 18-3342 Project Name: IRUP - HGU Unit Name: Hydrogen Generation Unit Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Instrumentation 17-03-2010 BOM For Hook up Material First lot of BOM was released to piping Pending No
for procurement before approval of Approval
hookups. However the BOM for
changes made after approval was not
sent to piping for procurement. Hence
another MR was released for this.

Jacobs Project No: 18-3342 Project Name: IRUP - HGU Unit Name: Hydrogen Generation Unit Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Instrumentation 17-03-2010 Hook ups revisions Revision was made 3 times in hook up Pending No
drawings to incorporate IOCL Approval
Comments. By the time final revision
was made, piping had issued all
isometrics to site. MTO for impulse
lines was issued to piping for
procurement as per the approved hook
ups. However the tapings shown on
Hook ups & model were different. The
lines & line mounted instruments were
installed on site as per model & hence
to match the difference between the
model & the hookup drawings extra
material was required. Please note that
non of the isometrics issued by piping
were not checked by instrumentation
due to urgency as well as shortage of
manpower.

Jacobs Project No: 07Q7814N Project Name: MON11900 Unit Name: Chemical Plant Client: Monsanto Project Site Location: USA ; Lulling

Instrumentation Ashok Gaikwad 19-06-2018 Detailed Monsanto ISBL "Process P&ID revision markup clouds/ Client requirement says that Every issued P&ID should contain NO Approved No
Engineering triangles were not placed till IFC Rev 3 no cloud or revision markup revision clouds. In case client does not
Bluebeam P&IDs.In order to prepare history required on issued IFD want the same, then the same should
Instrument index, IO list as per issued and IFC P&IDs. be kept at different layer/ level as per
P&ID revisions. It was extremely difficult CAD tool. While issuing P&IDs, process
to track the changes/ modifications made can remove such revision triangles/
by Process e.g. Line numbers, new clouds in different layers or levels to
instrument addition/ deletion, PMS meet client requirement.
changes, spec breaks etc.. It leads to re- This will help Instrumentation as well
work for Index and IO list deliverables." as Piping to track changes in new
revised P&IDs.

14 January 2019 Page 12 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 07Q7814N Project Name: MON11900 Unit Name: Chemical Plant Client: Monsanto Project Site Location: USA ; Lulling

Instrumentation Ashok Gaikwad 19-06-2018 Detailed Monsanto ISBL There were frequent changes in We started initially as per For work-hour estimation , we should NO We got the PDN approved but Change Approved No
Engineering instrument MOC. This lead to re-work, Piping Material Specification consider more man-hours for projects then schedule was impacted. management
wastage of man hours and schedule (PMS). where client is providing engineering Such issues might later lead to becomes critical in
impact. Subsequently, Material road input based on its Pilot plant and there quality issues if basic input project where
map was provided by client is no Process Licensor. documents are frequently frequent changes
and we revised our changed. are happening,
datasheets accordingly which needs to be
leading to rework. tracked properly
Two-three months down the with repesct to
line, client again came up additional work-
with a MOC change which hours / schedule.
was completely different
from the earlier guidelines
leading to re-re work.
For all MeCl service lines, the
PMS was revised causing re-
ordering of 68 instruments (
as all the inline/ Online
instruments were already
ordered on those particular
lines).

Jacobs Project No: HUSP004G Project Name: Shell Vito Unit Name: -NA- Client: Shell Project Site Location: Gulf of Mexico

Instrumentation Hemant Salunke 03-11-2017 Detailed Process Initially P&IDS indicated 1-inch process Design basis and packaged Considering the scope of NO Process connection changed Piping Instrument Approved No
Engineering Connection for connection size for all the tags of Sample Instrumentation documents instrumentation procurement, Piping from 1" to 1½" Interface document
Manual Sample Probe and Injection Quills. Later during does not call for any process and instrumentation interface need to to be prepared
Probe and datasheet preparation, it has been noted size for these items. finalized with client and vendor before during start of the
Manual that Probe / Quill OD not matching with commencement of procurement project , and same is
Chemical 1" nozzle ID. activities. required to be
Injection Quills updated as required
during project cycle.

Jacobs Project No: HUSP004G Project Name: Shell Vito Unit Name: -NA- Client: Shell Project Site Location: Gulf of Mexico

Instrumentation Hemant Salunke 05-11-2017 Detailed On-Off Valve Lead office insisted to enter details like Generally, Valve torque, We understand that model number NO Approved No
Engineering Datasheets Valve torque, Actuator Model selected Selection of actuator is part of selection at enquiry stage was insisted
with reference to the valve torque. Enter vendor detailed engineering so that Dim. Data required for piping
the torque value of selected actuators, and these fields in datasheets can be provided. This could have been
during enquiry stage of datasheets. This kept 'By Vendor'. Based on provided as cataluge data ( worst case )
activity could lead to rework in case lead office requirement ,all to accommodate in avaiable space, but
selected actuator model and other details enquiry datasheets were datasheets could have been with
changed during TBE / Model selection updated with specific vendor "VTA" which could have saved effort
stage. information , which lead to during Enquiry as well as Purchase
rework at late stage due to stage.
selection of different vendor
for actuator.

Jacobs Project No: 18-3293 Project Name: IRUP - DHDT Unit Name: DHDT Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Instrumentation M S Deshmukh 15-06-2010 Detailed Instrument process hook-up were Hook-up material shall be discussed Pending No
Engineering prepared considering the material as with client before hook-up /MTO Approval
specified in piping class as per design preparation
philosopy. In piping class for high pressure
application flange valves were specified
and accordingly Hook-up were prepared.
As per Gujarat refinery practise for high
pressure application all valves shall be of
butt weld design. Hence all the hook-ups
and MTO were completely revised.

14 January 2019 Page 13 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44AC0200 Project Name: 200 KTPA PVC-2 Plant Unit Name: ISBL and OSBL Client: TCI SANMAR CHEMICALS SAE Project Site Location: Port Said, Egypt

Instrumentation Makarand 29-06-2017 Detailed TCI SANMAR As per O2 Analyser vendor VC Gas / Vapour getting Expansion of Gas/ Vapour service Line NO Two options without Increasing Any expansion of Approved Yes
Kulkarni Engineering EGYPT: 200 recommendation the minimum Laser Condensed due to expansion shall be avoided for O2 Analyser (Laser line size are worked out & pipe line in the
KTPA PVC-2 Path length required is 305 mm. Hence 6" of 6" line & Condensate is Type) Installation. submitted to vendor for his gas/Vapor services
line needs to be expanded to provide getting accumulated in the review/confirmation ( Vendor requires a thorough
required Laser path length. However as expanded portion. Reply is awaited) 1) Inclined checking with
per Past project feedback there was Nozzle @25 Deg instead of 90 process for the
condensate formation in the line which Deg orientation & 2) Piping possibility
resulted in to malfunctioning of Analyser. Loop arrangement. ( Refer condensation
attachment for schemes) formation and as far
as possible avoid
expansion of pipe
line in gas/vapor
services. The related
Check list requires
updations

Jacobs Project No: 58SR034M Project Name: BP Process Safety Automation Unit Name: BP Whiting Refinery Client: BP North American Products Project Site Location: Whiting, Indiana

Instrumentation Manish Kadam 23-02-2018 Detailed BP PSA: Electronic transmitter MOC requirement In BP PSA Project -DDU unit, There are instances in the project NO This lesson learned is Approved No
Engineering 58SR034M - revised due to revised pipe spec after PO Instrument group issued PO engineering cycle, when we are in mainly related to
Distillate was issued, causing the rework on the for Electronic transmitter to hurry of issuing the deliverables for a intimation of revison
Desulphurization enquiry & the delay in transmitter M/s ROSEMOUNT. However late change in the engineering design of deliverable ,
(DDU) Unit delivery at site. Piping group revised their however we forget or don’t care to which could have
hydrogen service pipe spec inform this change to the other been easily captured
for NACE material disciplines which may affect their in JPI revisons or at
requirement & it was not deliverables. In above case, if piping least by
communicated to Instrument group had informed instrument group communicating
group. Almost three weeks about the change in pipe spec material within task force.
after revising the pipe spec, then instrument group would have
instrument group came to taken timely action to revise their
know about pipe spec transmitter MOC requirement.
revision. Ultimately revised
quote obtained from the
vendor for NACE certified
material & revised PO issued
to the vendor.

Jacobs Project No: 07OW814M Project Name: Naphtha Debottleneck Project Unit Name: Feed Preparation and Light Ends Area Client: Exxon Mobil Project Site Location: Baton Rouge

Instrumentation Murugiah, 28-05-2018 Detailed All Difficulty in identifying instrument tags in Not adding permanent tag Piping should communicate with NO - Pending No
Navaneethan Engineering PDS model in initial stages of project. numbers in PDS model. Piping instrumentation team for the Approval
department refers P&IDs for permanent/complete tag numbers for
tag numbers which shows adding inline instruments in PDS
short forms of instrument tag database. Piping can refer instrument
numbers. index and correlate the tag numbers
with P&ID. Doing this can save lot of
time for instrumentation & piping thus
enabling to identify tags in model and
verify various instrumentation
deliverables.

Jacobs Project No: 18-3314 Project Name: MSQ Upgradation Unit Name: FCC Gasoline Desulphurisation Client: Indian oil corporation Ltd Project Site Location: Mathura

Instrumentation P.Venkatram 17-11-2010 Construction MSQ upgradationSome Orifice plates were lost during Piping contractor did not Prepare a tag wise in-line instruments New orifice plates Orifice plates to be kept under Pending No
flushing activities of pie lines piping prepare a check list of all in check list before flushing and the were procured on dafe custody and installed after Approval
contractor. Hence, new orifice plates line instruments before orifice plates to be kept under safe urgent basis from flushing of lines.
were procured on urgent basis from site flushing of lines custody site by client
by client

14 January 2019 Page 14 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 58RH97M4 Project Name: Ammonium Thiosulfate (ATS) Unit Name: XX Client: Flint Hill Resources Project Site Location: USA ; Pine
Bend,Minnesota

Instrumentation Sachin Palange 25-05-2017 Detailed ATS Space reservation for Displacer LT Checking of platform Check and inform the requirement of NO The The above aspect is Approved No
Engineering dimensions for displacer LT access/maintenance area, head access/maintenacne covered in the Draft
clearance for displacer Level area is already 3D model check list.
Transmitter to piping in advance. considered in the
Typical Inst Catlogue can be referred.. model

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Instrumentation Venkatram 19-02-2018 Detailed MEGLOBAL On - Off valves RFQ issued to Vendors as Valve manufacturer list is Before issuing any RFQ to vendors NO Approved No
Paluvoy Engineering per Manufacturer list. However, Client available in RFQ summary approval is required from client with
insisted it be issued to Piping valve sheet. regards to piping valve manufacture
manufacturers as mentioned in Pipe list.
specs.

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Instrumentation Venkatram 12-06-2018 Detailed MEGLOBAL Orifice D and D/2 Tapping was considered D and D/2 Tapping was Hence flange tap shall be considered NO Before finalzing D Approved No
Paluvoy Engineering for line sizes higher than 10 inch as per considered for line sizes for orifice upto line sizes 16 inch if and D/2 tapping,
client standard, higher than 10 inch as per piping spec does not allow flange other check the weldneck
however D/2 tap location (measured from client standard. than weld neck. dimension and if is a
face of flange ) was not feasible as weld constsrain then
neck flange dimension itself was almost change to flange tap
equal to D/2 value for line sizes 12 inch, in the stage of MR
14 inch and 16 inch and as per client preparation.
piping specification constraint other
flanges i.e. socket weld flange could not
be included.

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Instrumentation Venkatram 12-06-2018 Detailed MEGLOBAL Orifice D and D/2 Tapping was considered D and D/2 Tapping was Hence flange tap shall be considered NO Before finalizing D Approved No
Paluvoy Engineering for line sizes higher than 10 inch as per considered for line sizes for orifice upto line sizes 16 inch if D/2 tapping, check
client standard, higher than 10 inch as per piping spec does not allow flange other the flange weld neck
however D/2 tap location (measured from client standard. than weld neck. dimensions and if it
face of flange ) was not feasible as weld is a constrain then
neck flange dimension itself was almost change this to
equal to D/2 value for line sizes 12 inch, Flange tap during
14 inch and 16 inch and as per client MR preparation.
piping specification constraint other
flanges i.e. socket weld flange could not
be included.

Jacobs Project No: 44AA8500 Project Name: 5th Reactor PVC Expansion Project Unit Name: DMD Client: Reliance Industries Ltd. Project Site Location: Dahej

Instrumentation Vivek Bhadane 09-06-2017 Detailed PVC 5th Reactor ################ ################ 1. Ensure latest vendor drawing to be NO Pending No
Engineering provided to piping. 2. Vendor Approval
document distribution matrix shall
indicate all vendor drawing notification
to piping. 3. Instrument to check
whether the valve is modelled as per
latest available vendor drawing.

14 January 2019 Page 15 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44AA8500 Project Name: 5th Reactor PVC Expansion Project Unit Name: DMD Client: Reliance Industries Ltd. Project Site Location: Dahej

Instrumentation Vivek Bhadane 03-07-2017 Detailed PVC 5th Reactor Reactor flush botom valve was fouling Valve was not modelled as 1.Ensure latest vendor drawing to be NO In case of special Approved No
Engineering Expansion with agitator gear box. per actual vendor drawing. provided to piping valve such as Flush
2.Vendor document distribuJon bottom valves,
matrix shall indicate all vendor drawing special attention is
notification to piping. required in checking
3.Instrument to check whether the the dimensions and
valve is modelled as per latest available clashe check in the
vendor drawing 3D model. Pro
active initiative is
required.

Jacobs Project No: 44AA8500 Project Name: 5th Reactor PVC Expansion Project Unit Name: DMD Client: Reliance Industries Ltd. Project Site Location: Dahej

Instrumentation Vivek Bhadane 03-07-2017 Detailed PVC 5th Reactor Reactor flush botom valve was fouling Valve was not modelled as 1.Ensure latest vendor drawing to be NO This is a repate LL Rejected No
Engineering Expansion with agitator gear box. per actual vendor drawing. provided to piping and hence rejected
2.Vendor document distribuJon
matrix shall indicate all vendor drawing
notification to piping.
3.Instrument to check whether the
valve is modelled as per latest available
vendor drawing

Jacobs Project No: 44LK4100 Project Name: IRUP - EPCC-6B Unit Name: IRUP - Offsites and Utilities Client: Indian Oiltanking Ltd. Project Site Location: Vadodara

MEG 26-03-2008 Detailed Place order only after issue of TBA. Pending No
Engineering Critical - Address the deviations and check Approval
whether they are acceptable. Check for
interfaces with piping and instruments
and communicate.
Vendor follow – shall be with JE. Consider
even instrumentation
Vendor drawing review – 25 days.
Distribution of vendor drawings from
projects
Receive document in hard copy.

Jacobs Project No: 44AA8900 Project Name: Food Grade Refined Sodium bicarbonate project Unit Name: RBC Client: Nirma Ltd. Project Site Location: Bhavnagar, Gujrat

MEG Jeetu Thakur 04-10-2018 Detailed Preliminary Normally, the equipment layouts are During IFA stage of the This will avoid rework in equipment NO Pending No
Engineering planning of cable prepared considering the space required equipment layout, MEG or layout later stage and have better Approval
tray routing and for equipment and maintenance space piping dept. need to have clarity.
building beam only. We normally missed the cable trays joint meeting with E&I and This is successfully implemented in RBC
dept in routing, no. of trays and overall height civil dept. to finalize the project.
equipment layoutrequired for cable tray as well as the preliminary cable routing and
beam depth. beam depth in building. This
Due to this at some places there will be will be again reviewed at the
very less space for location of cable trays 30%, 60% and IFC stage of
and it will have head room problem. layouts (equipment and cable
trays).

14 January 2019 Page 16 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44AA8900 Project Name: Food Grade Refined Sodium bicarbonate project Unit Name: RBC Client: Nirma Ltd. Project Site Location: Bhavnagar, Gujrat

MEG Jeetu Thakur 06-12-2018 Detailed Value For LP condensate pump, the process Since RBC plant is of Food LP condensate pumps P-2512A and P- NO Pending No
Engineering Engineering Licensor has provided the MOC of pumps grade plant, therefore the 2513A are used for cleaning of the Approval
as 1.4408 (Austenitic steel). process licensor has provided carbonation columns and leaf filter,
JE opinion the opinion MOC of pumps CS higher grade of material for TSBS & MSBS lines respectively. As
(A 216 Gr. WCB) is suitable for given all pumps which is not such the wash water generated as a
application which they have already required. result of the cleaning of these
implemented in past project. Also, these LP condensate equipment is sent out of the battery
pumps interconnected piping limit of the RBC plant. Wash water
and upstream & downstream generated as a result of carbonation
equipment are of Carbon column cleaning is sent to V-2507 and
steel material. then it is sent to small decarbonator C-
2503. Finally, soda solution is sent to
4th stream soda ash plant. Similarly,
the wash water along with the sludge
slurry from the filter is sent to R-112 in
4th stream soda ash plant
However, JE recommended to use CS
(A 216 Gr. WCB) for casing and
impeller instead of 1.4408 specified by
licensor. As we have previously
procured pumps for similar
applications in 4th Stream & 6th
Calciner Debottlenecking Project (P504
J/K/L/M), Material of Construction for
supply & return line for the pumps are
also Carbon Steel. Proposal was also
raised to replace mechanical seals with
gland packing as in previous
installations the pumping temperature
was max 149 deg C where as in present
case the pumping temperature was. 90
deg C
Client has agreed the JE suggestion.
However, this suggestion is not
implement in RBC project since RBC
project is new for Nirma and they don’t
want to take any risk. Therefore, it is
not implemented on the project and
recorded as Value Engineering.

Jacobs Project No: 07Q7814N Project Name: MON11900 Unit Name: Chemical Plant Client: Monsanto Project Site Location: USA ; Lulling

MEG Mrunal 10-07-2017 Detailed ISBL Static Mixer (Tag 1-1076) was modelled During bid stage Sulzer had Static Mixers may have requirement of NO Explain by "may Rejected No
Sharma;ES Engineering without any downstream straight length. recommended a upstream and downstream straight have requirement".
Vishwanathan Mixer had to be remodeled based on downstream straight length run. This must be kept in mind and What ab RFQ stage
vendor feedback received post order of 4 to 5D . Post order, in layout to be planned accordingly. consideration?Can
response to Jacobs query, we now inform
Sulzer replied that at least 3D piping while
to 5D downstream straight releasing RFQ as a
length is mandatory for the typical? Pl resubmit
said static mixer after changes.

14 January 2019 Page 17 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44QS6500 Project Name: Confidential Unit Name: XX Client: Confidential Project Site Location: confidential

MEG Parag 05-07-2017 Detailed Seal piping for Seal piping for UG Tank mounted pumps: Vendor could not route the Vendor scope seal piping in such cases NO Approved No
Bam;Rakesh Engineering UG Tank For UG Tank mounted pumps, pre- seal piping due to various (i.e. various other equipment,
Chaudhari mounted pumps. fabricated seal piping (Plan 53B) by other equipment, instruments and piping present in
Vendor was ordered by Client. The seal instruments and piping vicinity) shall be ordered as "Site
system location was informed and Layout present in vicinity. fabricated piping" instead of "Pre-
mark-up was provided (various times), to fabricated piping" at Vendor shop.
the Vendor. However due to many other
instruments/piping and its nozzles on UG
Tank, the seal piping routing was not
getting finalized. Even after model file
was shared with Vendor to update piping
suitably, the routing was still
obstructing/clashing with the other
instruments / equipment / piping or
access ways.

Jacobs Project No: 44QS6500 Project Name: Confidential Unit Name: XX Client: Confidential Project Site Location: confidential

MEG Parag 05-07-2017 Detailed Seal piping for Seal piping for UG Tank mounted pumps: Vendor could not route the Vendor scope seal piping in such cases NO repeeated hence Rejected No
Bam;Rakesh Engineering UG Tank For UG Tank mounted pumps, pre- seal piping due to various (i.e. various other equipment, rejected.
Chaudhari mounted pumps. fabricated seal piping (Plan 53B) by other equipment, instruments and piping present in
Vendor was ordered by Client. The seal instruments and piping vicinity) shall be ordered as "Site
system location was informed and Layout present in vicinity. fabricated piping" instead of "Pre-
mark-up was provided (various times), to fabricated piping" at Vendor shop.
the Vendor. However due to many other
instruments/piping and its nozzles on UG
Tank, the seal piping routing was not
getting finalized. Even after model file
was shared with Vendor to update piping
suitably, the routing was still
obstructing/clashing with the other
instruments / equipment / piping or
access ways.

Jacobs Project No: CE41994M Project Name: 93/94 Emulsion handling project Unit Name: Debottlenecking of various units Client: Suncor Energy Inc/Jacobs Calgary Project Site Location: Alberta ,Canada

MEG Sandeep Patil 23-07-2018 Detailed Centrifugal During squad check of GA drawings Piping shall inform specific Piping shall inform specific NO Quality & MEG Approved No
Engineering pumps, submitted by Vendors for pumps, Piping requirement of flanged requirement of flanged baseplate drain together shall do
Progressive dept commented to include "flanged" baseplate drain during during requisition prepration stage communication with
cavity pumps baseplate drain instead of threaded drain. requisition prepration stage itself so MEG will take care. Piping on this.
Since API 610 / API 676 standards require itself so MEG will take care.
threaded drain, Vendors provided
threaded drain in compliance with these
standards. Due to Piping comment to
make it flanged, Vendors aksed extra
price for the same.

Jacobs Project No: CE41994M Project Name: 93/94 Emulsion handling project Unit Name: Debottlenecking of various units Client: Suncor Energy Inc/Jacobs Calgary Project Site Location: Alberta ,Canada

MEG Sandeep Patil 23-07-2018 Detailed Flocculant Mixer During GA drawing review of Mixer, MEG There is no enough space / During technical bid evaluation, MEG NO Approved No
Engineering / 93T-3311 noticed that, there is no enogh space / overhead clearance above should check with Piping dept the
overhead clearance above mixer for mixer. space / overhead clearance available
removal of shaft. When asked to Vendor above mixer for removal of shaft, in 3D
for installation / removal procedure, model (if available) and get
Vendor confirmed to provide additional confirmation from Vendor for easy
break flange on the shaft for easy removal removal without any obstruction
without any obstruction. (meaning vendor will provide
breakflanges as required without any
impact during post order or relocates
flanges).

14 January 2019 Page 18 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44LK4100 Project Name: IRUP - EPCC-6B Unit Name: IRUP - Offsites and Utilities Client: Indian Oiltanking Ltd. Project Site Location: Vadodara

Piping R. Ulman 26-03-2008 Detailed Do not release MTO without PMs Pending No
Engineering approval. Do not take deviation to Approval
Tender. Follow the book. Agree on a
sequence of deliverables.
Archiving and stress analysis for critical
lines, loading on pipe racks and revisions –
subsequent.
MTO to be IDR – 24” and above.
Wastage of redness on Panipat
Changes to be minimized controlled.
Task force – stress / spec and process and
piping to seat together.
Check special notes and monitor critical
RFQs of DHDT shall be followed on
Package-6B.
IBR / Non-IBR MTOs
MTOs for drains, vents for steam traps
and standardization
Steam tracing MTOs / work to be started
immediately.
Fire fighting is critical and understand the
requirement in detail.
Sub-contractor list to be obtained from
IOTL and understand the requirement.
Consequences of revised inputs to be
communicated to IOTL on immediate
basis.

Jacobs Project No: 44NC6900 Project Name: DRI Plant Unit Name: DRI Plant Client: Midrex Inc. USA Project Site Location: Hidd, Bahrain

Piping Vinayak Yadav 18-04-2011 All applicable Civil deliverables, which were dependent The original schedule issued Civil & Piping deliverable schedule to Piping deliverable Pending No
areas on the piping deliverables, were ahead of by MTI, was not having be matched before accepting TAA advance to match Approval
schedule to the piping schedule. proper dependence, caused the civil deliverables.
pressure on piping team to
advance their deliverables.

14 January 2019 Page 19 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: HUSP004G Project Name: Shell Vito Unit Name: -NA- Client: Shell Project Site Location: Gulf of Mexico

Piping Design Abhijit Mansute 12-12-2017 Detailed Topsides The Dimensions callout on the equipment The equipment was checked The designers need to double check NO Drg mistake was 1)Vendor drgs shall Approved No
Engineering arrangement/ layout drawing for one of against the vendor drawings when they are marking up the check corrected be referred for
the equipment was showing wrong length. and 3D model and the latest prints of the reference documents for overall dimensions
dimensions were marked on checking the deliverables. Checkers and there is no need
the equipment lists for need to make sure to check all the data to repeat these in
further checking, but while wrt to latest information instead of the General
writing the latest dimensions spot checking even if the no of arrangement to
on the markup designer made equipments run in to 100 of numbers avoid duplication
a typo error and then the like in this case. Equipment list shall be /quality .PM to push
same markups were used for updated and the originating back/convince client
further checking. department in this case Mechanical /Lead office to avoid
and shall be pursued to update their entering these
documents before being used for the overall dimensions
checking of piping deliverables. This in these drgs
will minimize the possible misses. 2)Any updation if
required based on
client insistence
then such
dimensional details
as per client
requirement shall be
issued by concern
discipline with
official revision -here
Mechanical
equipment list and
followed by piping
from quality point of

Jacobs Project No: HUSP004G Project Name: Shell Vito Unit Name: -NA- Client: Shell Project Site Location: Gulf of Mexico

Piping Design Abhijit Mansute 18-07-2018 Detailed Utility and FW Technical leadership and decision making Technical leadership of JH in A good technical leader having single NO Pending No
Engineering piping Important decisions on the general layout offshore and making a single point decision making on important Approval
and piping arrangement were handled point decision making issues and challenges helps keep things
through JH Engineering Manager for both through the Project together than the multiple terminals
JH & JI scope of work engineering manager in JH for single issues.
had a advantage and helped
making faster decisions in
layouts, vendor skid piping
and interfaces between
multiple parties.
The position also had an
advantage of overlooking the
big picture and make efficient
decisions

Jacobs Project No: HUSP004G Project Name: Shell Vito Unit Name: -NA- Client: Shell Project Site Location: Gulf of Mexico

Piping Design Abhijit Mansute 18-07-2018 Detailed Utility & FW 3D Software expertise and Piping Given the newness of the A high team spirit and strong trust NO Pending No
Engineering piping leadership in JI team requirement of Vito- first among the team members is key Approval
greenfield offshore job, it was ingredient in the successful
important to have the strong achievement of the goals on the project
team with knowledge and
understanding of the nature
of the project and expertise in
the software knowledge to
handle the continuous layout
improvement changes, strong
piping backgrounds to
efficiently handle the changes
and scope increase in last few
crucial months on the project.

14 January 2019 Page 20 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: NL767161 Project Name: K81 Decomplexing Unit Name: Decomplexing Client: NAM / ONEGas Project Site Location: Southern North Sea

Piping Design Ajaykumar Patel 18-07-2017 Construction K14-FA-1P Re-work and re-issue of isometrics Mis-communication of Any changes during fabrication & NO Correctede as per Any area where Approved No
Construction dept. & construction period need to be field co-ordinate modification
fabricator affected piping informed. received required client to
deliverables. provide latest LFM
model/perfect co-
ordinate /scenario of
that location to
consider for detail
design and avoid
modification at site.
In case of any
change in that need
to be communicated
prior to issue of
those area
isometrics/drags
Site team also need
to verify tie in
location vs drags
released for IFC
before
prefabrication/execu
tion planning

Jacobs Project No: NL767161 Project Name: K81 Decomplexing Unit Name: Decomplexing Client: NAM / ONEGas Project Site Location: Southern North Sea

Piping Design Ajaykumar Patel 18-07-2017 Detailed All project Miss alignment between as built drawings Structural and Piping Alignment meetings are required NO Structural team put Agreement with Approved Yes
Engineering and LFM laser scan interface problem while before starting the PDMS modeling additional notes on client whether LFM
modeling existing situation drg to add additional to be followed or As
plat/member to take built drg to be
care of mismatches followed needs to be
at site due to establish since start
mismatch between of project and
LFM model and As followed by all
built drgs dicipline.In this case
civil followed as built
drgs where as Piping
followed LFM model.

Jacobs Project No: 44014600 Project Name: Resid Upgradation Project Unit Name: Delayed Coker Unit and Coke Handling System Client: Chennai Petroleum Corporation Project Site Location: Manali, Chennai
Limited

Piping Design Ashish 21-06-2017 Detailed OHCU & OSBL JMMS Implementation Implementation of JMMS for The path forward for JMMS should be NO Approved No
Naik;Vineet Singh Engineering the project was informed at decided at the initial stage of project &
the mid stage of the project. all concerned parties (EDS / Piping /
If we need to implement the Procurement / Projects) shall align
system the provision for the themselves to succesfully implement
same should be initiated at the system. Otherwise, midway JMMS
FEED stage so that system can implementation of any project creates
produce desired results. lot of trouble due to change in
requisition criteria and combination
and segregation of RFQ's has resulted
in lot of rework and we need to re-
align the system.

14 January 2019 Page 21 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44014600 Project Name: Resid Upgradation Project Unit Name: Delayed Coker Unit and Coke Handling System Client: Chennai Petroleum Corporation Project Site Location: Manali, Chennai
Limited

Piping Design Ashish 21-06-2017 Detailed OHCU & OSBL For CPCL project, all material requisition The above problem could In future, separate material requisition NO Approved No
Naik;Vineet Singh Engineering floated were never segregated seperately have been avoided if material for different areas should be created so
for OHCU & OSBL area as per project requisition for OSBL & OHCU as to easily identify ordered items area
directives. Moreover, we had single were not clubbed together. wise.
warehouse for storage for all ordered
material at site. During fabrication of
piping, we faced lot of problem for
identifyng of ordered items against area-
wise MTO requirement as we had
separate piping contractors for OSBL &
OHCU areas.

Jacobs Project No: NL784490 Project Name: New European PDH – Kallo Unit Name: PDH Client: Borealis Project Site Location: Kallo

Piping Design Binodh Nair 12-02-2018 Basic All Areas SPPID and Piping specifications were not Cocurrent Enginnering To start detailing activity only after NO None Approved No
Engineering in place before start of modelling practice adhered in schedule. proper Input to work as per procedure,
activity.Pipe spec being client deliverable maintain quality and avoid rework,
is still not issued.Piping has to start save work hours and increase
modelling work with Dummy spec and productivity. Minimum input criteria
with Licensor P&ID so as to give down line for detailing need to be defined.
inputs to stress and civil.

Jacobs Project No: 44QS6500 Project Name: Confidential Unit Name: XX Client: Confidential Project Site Location: confidential

Piping Design Binoth 13-06-2017 Detailed All area's Non metallic pipe class (1N103AA - GRE) / Delay in finalization of pipe All input shall be obtained by client at NO Such items are not Approved No
Nair;Yogita Patil Engineering PMRC's. class with PMRC's affected beginning so that modelling activity code standardized
modelling / piping isometrics. can be done at earliest. but are custom built
so fixing vendor &
adjusting PMS/3D
library are the
crucial activities

Jacobs Project No: 44QS6500 Project Name: Confidential Unit Name: XX Client: Confidential Project Site Location: confidential

Piping Design Binoth 13-06-2017 Detailed Sulphur lines Occurance of WN flanges in fully jackted Addition of SR elbows and Availability of all required piping NO Approved No
Nair;Yogita Patil Engineering pipe classes. cross equal in jacketed pipe components shall be obtained at
class & RSO flanges ( in place beginning so that modelling activity
of WN) in core pipe class for can be done.
jackted lines in later
stage.delay in modelling of
jacktted lines.

Jacobs Project No: 58SI693M Project Name: Texas Borstar Project Unit Name: PE1 Client: Texas Borstar Project Project Site Location: Pasadena, TX

Piping Design Chandrashekar 31-08-2017 PMC Phase-1 Gas Phase Piping had utilized the PDP Process Data Change in Equipment sizes in At start of 3D modeling it is NO There is need of Rejected No
Chilakwad (FEED) Reactor area Sheets and Equipment List to develop the Gas Phase reactor area worthwhile to discuss with Process (or good understanding
S3D Modeling at start FEED. It was Clinet) if they foresee any major between process
understood that there will be no major changes in equipment sizes during and other
changes in dimensions of eqpts once they FEED stage compared to data in PDP teams.Process to
are formally issued for FEED stage. package. Such eqpts can be identified give alarm to other
However at later stage it was obserced and same can be taken on priority to discipline where
that there were major changes in Eqpt fix the eqpt sizes at early stage so that they feel potential
sizes in Gas phase reactor area which such rework at later stage can be changes may occur.
resulted in major change/rework in Piping avoided
and Civil structure S3D modeling

14 January 2019 Page 22 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44AA9540 Project Name: IMP III Unit Name: SASREF Client: SASREF Project Site Location: Jubail

Piping Design Farooq Ansari 18-06-2018 Detailed OPA/OPC/OPD/OJacobs ZATE (Home Office) had claimed Home Office normally Dumps Identify the necessary input NO No Remark None Rejected Yes
Engineering PU that Input documents required to make the Input documents on documents required to generate a
Update / Modify Existing Piping Plan server and give us the access particular deliverable. Generate an
Layouts (PPL) are uploaded on JPI. But to retrieve Inpur documents excel showing what is avalable and
when we started to make these drawings from the dump. what not. Work only on the drawing
either one of the inputs or more that one for which all Input documents are
inputs were missing and we could not available and reporting Home Office
complete the PPL. This loses the MHRS of why the other drawings / documents
opening the relevant documents and
other reference documents but then
could not complete the job. Then we
inform Home Office, they upload the
documents and then later we had to
revisit these documents to complete the
drawings.

Jacobs Project No: 58RH38M4 Project Name: PAC Propylene Project Unit Name: XX Client: Flint Hill Resources Project Site Location: USA ; Port Arthur, Texas

Piping Design Gajanan Patil 23-06-2017 Detailed PROPYLENE Unable to place the structural trunnion SP3D issue Generally Piping Stress group prefers NO IT enabled the options in SP3D. Support library Approved No
Engineering Pipe trunnion for Supporting, Since the Since this was Projec t specific update should be
requiremnt for structural trunnion was requirment. done very well
from the Client specific & hence this inclduing call-outs
type of supports need to be added in on isometrics so as
Support Library of SP3D. to avoid cycling
during isometric
production

Jacobs Project No: 58RH38M4 Project Name: PAC Propylene Project Unit Name: XX Client: Flint Hill Resources Project Site Location: USA ; Port Arthur, Texas

Piping Design Gajanan Patil 23-06-2017 Detailed 24h-100 Exchnager Nozzle Mismatch in Connection Piping design to ensure Nozzle No. to be updated in P&ID as NO As there was NO process impact, Approved No
Engineering routing of piping from/To to per Vendor Drawing.Discussed with connections were retained as it
Mechanical equipment nozzle Process team regarding impact on is, and informed Vendor to
are correctlyconnected as per process parameters if Process Inlet and change the Nozzle Tag no /
latest P&IDs as well as Vendor Outlet are changed as indicated in Description in Vendor Drawing.
Drawing. Model. Discussed with Process team
regarding impact on process
parameters if Process Inlet and
Outlet are changed as indicated
in Model.

Jacobs Project No: NL688693 Project Name: Off gas treatment Unit Unit Name: Off gas treatment Unit Client: BPRR Project Site Location: Europort, Rotterdam

Piping Design Ganesh Ingulkar 15-11-2017 Detailed BP OUT Primary supports unavailability in Support catalogue needs to Correct supports are not available in NO none Rejected No
Engineering catalogue be finalized & should be PDMS catalogue, sometimes impacting
readily available during define the piping deliverable dates
phase

Jacobs Project No: NL685893 Project Name: TAR 2019 Project Portfolio Unit Name: CDU3 & FW Client: BPRR Project Site Location: Europort, Rotterdam

Piping Design Ganesh Ingulkar 24-04-2018 Detailed BP TAR2019 During IDC package review in Bluebeam If any comments on IDC Other departments from Lead office NO Assign one dedicated person none Approved No
Engineering session, apart from piping department of package which we have need to check/review the IDC package from each department to review
Lead office, other departments not received from other in a given time, it takes piping team to IDC package.
reviewing/checking the piping departments in a later stage correct or change the things before
deliverables in given time frame. then it takes some more time issuing RFC package to client.
to implement or change,
which leads to delay the RFC
package.

14 January 2019 Page 23 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44QS4300 Project Name: Pre-bid for Al Zour Refinery,KNPC Unit Name: CDU, SGU, SRU, SWS, ARU, Hydrogen, SP, Flare Client: Petrofac International Limited Project Site Location: Kuwait

Piping Design Kireet Dave 10-04-2015 Basic Package 1 & 2 1) We should have clear scope, Pending No
Engineering for KNPC, deliverable and schedule. Approval
2) Time to review documents
3) Use iso format to sketch isos
mentioning line number with PID.
4) Job notes with available info to be
prepared. Responsibilities to be
defined for Area leads and team.
Update Job notes with new
instructions during project cycle.
5) Team to do self-entry of MTO in
excel. Keep Proper control / record of
all MTO / documents generated (hard /
soft copy).
6) Inputs to be available - Instrument
hook, PIDs with complete info – vendor
scope battery limits, equipment
changes, line list, PID revision log etc.
to be considered in MTO.
7) Package limits to be marked on
equipment layout while sending
vendor Requisition. Equipment tags to
be mentioned while sending
Requisition and while receiving offers
since all disciplines other than
mechanical work area wise and require
equipment number.
8) Vendor drg review requirement /
comments to be discussed at start.
9) PID notes also to be highlighted.
Proper PID markup to be done for
changes, assumptions.
10) In excel MTO, Remarks column to
be filled for all things – instrument tag,
special item tag, utility station, steam
tracer, drip leg, steam ring, manhole
vents, etc. to be mentioned. It is useful
for checking and incorporating revision
changes.
11) Special item for which MTO is to
be taken to be identified if all items are
not marked on PID.
12) Info to civil to be discussed with
team in detail at project start. Basis of
loading for structure / pipe rack to be
discussed in detail with civil. Civil
should give proper basis. Piping Should
have clear idea about how much and
up to what extent information is
required to avoid unnecessary efforts
from piping side.
13) Loop criteria to be discussed while
starting MTO and should be noted in
MTO. Stress should also be involved for
kick off.
14) All documents to be kept on
project server.
15) MTO to be precise matching
sketches and PID. It avoids repeated
checking and audit findings will be
clear. Extra elbows for expansion, DE
changes to be considered while
discussing with client.
16) All documents to be initialed and
dated. Assumptions if any, to be clearly
documented.
17) Back up to be kept for all
important communication, deliverable.
18) Company / project colour code to

14 January 2019 Page 24 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

be followed.
19) projects should keep common
record (soft file) for info like TQ, DCN
receipt and its revision, addendums,
area wise equipment vendor info, PID
revisions, client comment closure, etc.
where possible discipline wise
responsibility to be marked so all
disciplines do not have to review all
TQs, DCN etc.
20 ) In between changes has to
reviewed by all disciplines together
including project and has to be
addressed to client immediately. In
NRP Project, 4500 lines becomes 8300
after bill 1 and still there was no
schedule extension asked for Bill 2.
There was no identification of any
change on p&id by Process, nor any
line list was provided. Addition of
lines, line number changes and
modification of existing lines was not
been identified and all efforts had to
be addressed by piping within very
short period of time. This was the
critical moment and was not addressed
properly in NRP.
21) UG drawing preparation and issue
procedure should also be discussed at
project start.
22) Resources should be mostly from
same office. Due to erratic schedule
changes and requirements, getting
help from demob staff of other offices
is difficult. Also their demob dates are
not linked to project schedule changes
as mentioned in point 1.

14 January 2019 Page 25 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44QS4300 Project Name: Pre-bid for Al Zour Refinery,KNPC Unit Name: CDU, SGU, SRU, SWS, ARU, Hydrogen, SP, Flare Client: Petrofac International Limited Project Site Location: Kuwait

Piping Design Kireet Dave 17-04-2015 Basic Package 1 & 2 Project is estimation for Bid Pending No
Engineering 1) We should have clear scope, purpose and not Basic Approval
deliverable and schedule. Engineering
2) Time to review documents
3) Use iso format to sketch isos
mentioning line number with PID.
4) Job notes with available info to be
prepared. Responsibilities to be
defined for Area leads and team.
Update Job notes with new
instructions during project cycle.
5) Team to do self-entry of MTO in
excel. Keep Proper control / record of
all MTO / documents generated (hard /
soft copy).
6) Inputs to be available - Instrument
hook, PIDs with complete info – vendor
scope battery limits, equipment
changes, line list, PID revision log etc.
to be considered in MTO.
7) Package limits to be marked on
equipment layout while sending
vendor Requisition. Equipment tags to
be mentioned while sending
Requisition and while receiving offers
since all disciplines other than
mechanical work area wise and require
equipment number.
8) Vendor drg review requirement /
comments to be discussed at start.
9) PID notes also to be highlighted.
Proper PID markup to be done for
changes, assumptions.
10) In excel MTO, Remarks column to
be filled for all things – instrument tag,
special item tag, utility station, steam
tracer, drip leg, steam ring, manhole
vents, etc. to be mentioned. It is useful
for checking and incorporating revision
changes.
11) Special item for which MTO is to
be taken to be identified if all items are
not marked on PID.
12) Info to civil to be discussed with
team in detail at project start. Basis of
loading for structure / pipe rack to be
discussed in detail with civil. Civil
should give proper basis. Piping Should
have clear idea about how much and
up to what extent information is
required to avoid unnecessary efforts
from piping side.
13) Loop criteria to be discussed while
starting MTO and should be noted in
MTO. Stress should also be involved for
kick off.
14) All documents to be kept on
project server.
15) MTO to be precise matching
sketches and PID. It avoids repeated
checking and audit findings will be
clear. Extra elbows for expansion, DE
changes to be considered while
discussing with client.
16) All documents to be initialed and
dated. Assumptions if any, to be clearly
documented.
17) Back up to be kept for all
important communication, deliverable.

14 January 2019 Page 26 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

18) Company / project colour code to


be followed.
19) projects should keep common
record (soft file) for info like TQ, DCN
receipt and its revision, addendums,
area wise equipment vendor info, PID
revisions, client comment closure, etc.
where possible discipline wise
responsibility to be marked so all
disciplines do not have to review all
TQs, DCN etc.
20 ) In between changes has to
reviewed by all disciplines together
including project and has to be
addressed to client immediately. In
NRP Project, 4500 lines becomes 7925
excluding vessel trim after bill 1 and
still there was no schedule extension
asked for Bill 2. There was no
identification of any change on p&id by
Process, nor any line list was provided.
Addition of lines, line number changes
and modification of existing lines was
not been identified and all efforts had
to be addressed by piping within very
short period of time. This was the
critical moment and was not addressed
properly in NRP.
21) UG drawing preparation and issue
procedure should also be discussed at
project start.
22) Resources should be mostly from
same office. Due to erratic schedule
changes and requirements, getting
help from demob staff of other offices
is difficult. Also their demob dates are
not linked to project schedule changes
as mentioned in point 1.

Jacobs Project No: 60SS0000 Project Name: Essar Program Unit Name: -NA- Client: Essar Oil Project Site Location: Stanlow, UK

Piping Design Nilesh Ghadge 05-09-2018 Detailed U-COME-1 For U-COME-1, UK Lead Office Found 2 1) Stress was UK Office Scope 1) Stress Analysis need to be done NO Pending No
Engineering anchors are missing from respective for U-COME-1 & U-COME-2 where major design work is done. 2) Approval
Isometrics after IFC issue of these Project. 2) Stress related Any routing changes should be
Isometrics. information not passed from updated in Stress Analysis & Stress
UK office to Gigaplex office. 3) Dept. should revert updated markup to
Stress copies not got updated layout. 3) Responsible office Stress
as per latest Piping model for dept. should do squad/IDC check while
U-COME-1. 4) UK Stress did issuing Isometrics. 4) PDMS admin
not performed IDC/Squad should ensure all support selected
check during any stage of ISO from library should appear in
issuing. 4) At one place Isometrics properly.
Anchor was in model but not
appearing in ISOmetric due to
PDMS Support library issue.

Jacobs Project No: 07PG1840 Project Name: K5 Utilization Project Unit Name: K5 Unit Client: Shell Chemical Project Site Location: Geismar, Louisiana

Piping Design Praful Sakore 29-12-2017 Detailed N/A Support placing : Numbering and PDS and Piping Support All support placement output should NO Synchronized database will save none Approved No
Engineering dimensional output on isoface were standard should be be verified and confirmed with Lead time for both offices.
manual input. This should fetch data from synchronized and verified by Office.
PDS System automatically. Manual input Lead Office. If amnual input
may get errorneous output. to be added then same
should be marked on Support
std.

14 January 2019 Page 27 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 07PG1840 Project Name: K5 Utilization Project Unit Name: K5 Unit Client: Shell Chemical Project Site Location: Geismar, Louisiana

Piping Design Praful Sakore 29-12-2017 Detailed CWA-01/CWA-02Piping Specification : MESC Codes and Delay from Shell/BTR EDS All specs should be validated by Lead YES This will save time at the time of Spec Requests Approved No
Engineering Component Description in Paper spec group. Office before Phase-4 DQS and IFC stage. always creates
copy and PDS Spec were mismatch or additional work
missing for sizes mentioned in Paper during detail
Spec. Same is corrected Later date. engineering. There
Individual EDS request need to raise from Should be some
Piping Design. Changed MESC codes need checking required
to correted. either from
Catalogue group or
from Material group
.Database shall be
own by Piping
Materail Enginnering
group.

Jacobs Project No: 07PG1840 Project Name: K5 Utilization Project Unit Name: K5 Unit Client: Shell Chemical Project Site Location: Geismar, Louisiana

Piping Design Praful Sakore 29-12-2017 Detailed CWA-01/CWA-02Inst Dim Data request required excessive Input validation of Inst Dim Inst Dim data to be verified / placed YES This issue lead to more co- None Approved No
Engineering followup for Correct output on Iso face. data not done at the time of and checked at the time of Input, also ordination and delay in issue of
Input. all PDS input table should be Isometrics.
provided/updated in PDS. Procedure
Guideline should be set at Project for
checking of instrument data
correctness in PDS database.
Also if there is change in instrument
after IFC issue of isometrics then Piping
should get information with controlled
way.

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Piping Design Samir Kulkarni 22-08-2018 Detailed UnderGround Major Revision of U/G Firewater Isos 1. Grade level was revised 1. Consider squad check of U/G Isos by YES All iso revised wrt U/G Isos squad check to be None Approved No
Engineering after drain system study. 2. Civil. 2. Ensure HPP and grade is final new Grade Elevation added in work in work
Alignment of Civil & Piping and in the model prior to IFC Isos
Design for grade level missing

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Piping Design Samir Kulkarni 22-08-2018 Detailed ISBL and OSBL Iso revisions not envisaged but had due 1. DQS for stress packages It needs to be recognized that Piping NO Detailed analysis and None Approved No
Engineering to 1. Final stress package close out and PE stamping were not in Design requires staffing at back end of characterization of ISO revision
comments 2. Instrument final vendor sync with Iso IFC releases the project. Project Budget and is maintained separately.
data 3. NCR 4. Civil Structural progress plan. 2. To maintain Iso plan, Resoruce plan shall keep this
(sequencing issue) cut sheet data (from bid) was contengency to cover the revisions.
used). Once the data was
finalized, validation excercize
produced revisions 3. Vendor
fabrication issues 4. Parallel
work

14 January 2019 Page 28 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Piping Design Samir Kulkarni 22-08-2018 Detailed ISBL and OSBL Linewise PMR (for LB lines) had major 1. Linewise PMR 2. Focus 1. PMR must be conducted as block NO None Approved No
Engineering impact/challanges in detailed only on LB lines review (and not linewise). 2. All lines
engineering; 1. Complete information for (LB + SB) shall be considered for
Stress analysis (package-wise) could not modeling to ensure progression of
be provided in one go and thereby other discipline activities. 3. Model
rework. 2. Input to Civil/structural design review methodology shall be part of
was given in piecemeal with progression PEP and Client's buying must be taken.
of linewise PMR. Thereby casuing rework
in structural engineering and
construction. 3. Input for vendor data
review especially in nozzle orientation,
cleats, platform, etc. 4. Piping Isos and
Structural steel were issued in parallel
affecting revisions in both deliverables.
5. Representation of other discipline in
PMR/60% could not be ensured.

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Piping Design Samir Kulkarni 22-08-2018 Detailed ISBL and OSBL Lot of time P&IDS were not available for 1. This case was observed PIDs under cadding shall be available in NO None Approved No
Engineering checking , yellowing off or adding red during PIDs undergoing separate session to facilitate yellow off
mark up during isometric checking. This cadding. The cadding and mark up addition as required.
had created many problems during iso schedule was not in line with
checking . Piping had to revisit p&ids isometric release. 2 - PIDs
again and again for yellowing off or undergoing cadding were not
adding red mark up or checking kept in separate session
incorporation of red mark up etc.

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Piping Design Samir Kulkarni 22-08-2018 Detailed ISBL and OSBL Lines were added in p&id without taking Addition of lines in p&id was No line mark up to be added on PID YES Suggest to Change Procedure . None Approved No
Engineering proper numbers from Piping. Lines were not done in controlled way. without Line number. Process Should add line
added with dummy numbers. Piping numbers in p&id and Line list .
design found many lines in p&id without Currently for Houston Projects
proper number. Hence many lines get Line numbers are assigned by
missed from total number of lines for Piping.
tracking and also from line list

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 14-07-2015 Detailed OSBL/ISBL Plot plan never issued for engineering. On Clariant project the very basic and Lead office responsibility Pending No
Engineering essential document Plot Plan never Approval
issued for engineering or construction.
This document is used to be with
piping instead of CSA as deliverable.
Basic plot plan was prepared
considering preliminary equipment
dimensions. However in actual
equipment sizes increased. Hence
future expansion space need to utilise
for current facilities. For such changes
plot plan should be always deliverable
document. Piping most of the time
were depend on CSA to update the
grading level in PDMS model.

14 January 2019 Page 29 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed CSA coordination with piping It is noticed that most of the time CSA Pending No
Engineering reluctant to convey any structural Approval
modifications information to piping.
For any mdification CSA need to put
piping in place in PDMS and do
modifications. Then only model will be
clash free. But not following this,
results in rework for piping.

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed OSBL/ISBL Squad check of enquiry For vendor packages, vendor scope not Pending No
Engineering document clearly defined at the enquiry stages Approval
itself. For example supports for piping
from Regen towers, chiller nozzle load
informations not available.

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed OSBL/ISBL Instruments in PDMS database Pending No
Engineering updated by JPSG DTS from revised Approval
cutsheets but that is not being
informed to piping. This was again
rework for piping.

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed OSBL/ISBL For HP vent and LP drains, consistancy Pending No
Engineering in type of valves are not followed in Approval
P&IDs. Piping is following the Spec and
P&ID only.

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed OSBL Piping Design basis For SS pipes all field weld were Pending No
Engineering removed after complition of OSBL Approval
detailing. This results in large amount
of rework. To avoid field weld for SS
pipes could have finalise at early stage
of engineering in piping design basis.

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed OSBL/ISBL Process description JEM was not provided with the atleast Pending No
Engineering basic process description which could Approval
have helped piping team in the routing
and which is the basic need. For this
we always has to depend on client
process review from model.

14 January 2019 Page 30 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed OSBL/ISBL Plot plan not issued for design On Clariant project the very basic and Pending No
Engineering essential document Plot Plan never Approval
issued for engineering or construction.
This document is always be with piping
instead of CSA as deliverable. Basic plot
plan was prepared considering
preliminary equipment dimensions.
However in actual equipment sizes
increased. For such changes plot plan
should be always deliverable
document. Piping most of the time
were depend on CSA to update the
grading level in PDMS model.

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed OSBL/ISBL Project execution stratergy Area 600 piping detailing transferred Pending No
Engineering to mumbai at late stages. Equipment Approval
nozzle orientations alread fixed and
fabricated. Hence there was no room
for any nozzle related changes or
supprts from vessels.

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed OSBL/ISBL On project Client always concern for Pending No
Engineering the pump piping & supporting design. Approval
Client was not comfertable with no. of
bends put near the pumps. Howebver
this was required to pass th line in
stress analysys. This was done because
client has selected the non API pumps
which have very less allowable nozzle
loads.

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed OSBL/ISBL P&IDs revisions are not properly Pending No
Engineering handled by the JPSG process. We have Approval
seen almost 12 revisions of P&IDs on
project. Process always used to update
he P&IDs live on JPI. Instead of that
P&ID rev. note system to information
for piping could have implemented.

Jacobs Project No: 44I03378 Project Name: Clariant PP Catalyst Plant Unit Name: Chemical Plant Client: Clariant Chemicals (Jacobs Project Site Location: USA
Louisville-Lead office)

Piping Design Satish Gunjal 15-07-2015 Detailed OSBL/ISBL Control group not aware of Inst. Control group never issued the Pending No
Engineering Instrument Hook up Instrument Hook up document on the Approval
document project. Hook up is prepared by JPSG
piping and issued at late stage of
project. It creats no of "HOLD"s while
doing the IFC. Information on
instrument cut shhets made available
not on time. Hence this affects the
project schedule.

14 January 2019 Page 31 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: NL786990 Project Name: Appllo LPP2 Unit Name: LPP2 Client: Jacobs Engineering Project Site Location: Frankfurt, Germany

Piping Design Satish Gunjal 04-04-2018 Basic ISBL Use of ALM software to model the ALM modeling procedure is ALM procedure of pipe modeling of NO none Approved No
Engineering existing piping/equipment is not so more time consuming. existing plant found not so efficient if
efficient if compared with the rendere compared to render model method.
model reference method of modeling.

Jacobs Project No: 44I04736 Project Name: Shell AO4 - OSBL Unit Name: OSBL Client: Shell Chemical Project Site Location: Geismar, Louisiana

Piping Design Satyanarayan 08-06-2017 Detailed OSBL Changes in MPS affecting changes in Iso Civil MPS schedule was after Latest LFM data to be used during NO Pending No
Shenoy Engineering updation. Piping IFC schedule. execute phase of project. Approval

Jacobs Project No: 58SI714M Project Name: InEOSRedstone LAO project Unit Name: 04403 Jacobs House Client: INEOS LAO Project Site Location: US Gulf Coast

Piping Design Srinivas N 06-12-2017 Detailed Inline Inline instrumentation Dimensional data PO for Inline Instrumenations PO for inline Instrumentation to NO IFC issued as soon as Action by PM to push back Approved No
Engineering Instrument was not available as per the Intial IFC were not placed as per placed as per schdeule .So that Timely dimesnions received Projects/Procurement/Instrumen lead office/Client to
Isometric schedule. Schedule. Inline instrumentation dimenisonal tation place the order of
Due to this IFC isometrics schedule had to data is made available to piping design such items in time so
be revised & which lead to bunching for meeting IFC isoschdeule. that there is smooth
effect/Very Challenging schedule on working of
Piping Design for Issue of isometric to engineering and
maintain end date of IFC isometric. avoid delay.
Inline instrumentation dimensional data
was not avaialble even at 60% model
review stage.

Jacobs Project No: 58SI714M Project Name: InEOSRedstone LAO project Unit Name: 04403 Jacobs House Client: INEOS LAO Project Site Location: US Gulf Coast

Piping Design Srinivas N 06-12-2017 Detailed Under Ground UG Piping isometrics/ Underground 3D model not inline with the 3D model shall be alligned with actual NO Revised drgs issued Action By Projects/Civil Proper sequence of Approved No
Engineering piping Plans Revisions post IFC actual grade levels at the time grade levels before the issue of U/G IFC with detail design needs
of issue of UG IFC Isos.Site surveys/finalisation of grade correction/updation to be adhered to
isometrics.Variations in grade levels for complete plot area to be as per site input avoid errors /delays
level where identified & done at the start of the project. This at site.Grade level
updated in 3Dmodel post the would provide clear front for data needs to be
issue of underground IFC Construction saving Time & Effort. captured and input
isometrics & UG Piping Plans to be given discipline
IFC isometrics, IFC UG Piping for further detailing
Plans had to be revised .PM to push
accordingly. site/construction/clie
nt to get the data in
beginning

Jacobs Project No: NL7810 Project Name: SWAN - Shell Rheinland refinery Unit Name: SDA and OSBL facility Client: Jacobs Netherland Project Site Location: Rheinland refinery-
Germany

Piping Design Sunil Kolekar 04-01-2018 PMC Phase-1 SWAN Other discipline updated/developemnts in Basically each discipline make Requested to all discipline to share NO Parallaly information is getting Pending No
(FEED) terms of data sheets/PID/MDS/design design and developement to approved design developments hence problem is resolved. Approval
philosophies being delaying to get in meet therir schedule and parallaly so that along with piping all
model targets.But concern was to stake holders(other disciplines) can be
get it parallay to piping also on same plane and reworking can
,because piping is the basic reduece for piping.
platform wherein all
disciplines input is gathering
into model.If there is a delay
happens to get such data for
piping then huge impact in
terms reworking for piping
may happen.

14 January 2019 Page 32 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 58SR034M Project Name: BP Process Safety Automation Unit Name: BP Whiting Refinery Client: BP North American Products Project Site Location: Whiting, Indiana

Piping Design Tushar Kubal 19-03-2018 Construction DDU (58SR03) TYPE-106 support was modeled to the Civil/ structural modeller Civil modeller should be careful while NO For piping checklist point will be none Rejected Yes
face of the column using the structural modelled existing column modelling existing steel. Use latest LFM : "Check all supports that attach
model but it did not match the LFM scans. wrongly. With that wrongly data for modelled as well as checking to existing steel using LFM Laser
If the support is bolted to the steel the modelled column referance purpose. Piping checker also need to Scans. (Do not use structural
support will be 6-1/2" too short so the piping modeller modelled cross check existing steel alignment model for this check)"
field will have to modify the support to Type-106 support. with LFM where piping support steel
make it work. connect with existing structure.
Checklist point need to add in piping as
well as civil structural checklist.

Jacobs Project No: 44AA9531 Project Name: NORTH JEDDAH BULK PLANT EXPANSION Unit Name: NJBP Client: SAUDI SERVO Project Site Location: NORTH JEDDAH
ELECTROMECHANICAL (SSEM)

Piping Stress Ajesh Kumar 26-04-2018 Detailed NJBP For NJBP it came to notice that major Scope definition & Project For the smooth flow of stress analysis YES Pending No
Engineering piping modification were going to happen Schedule. work always keep the track & progress Approval
hence Isometrics were not issued to JM of JZ piping scope which is to be stress
piping stress even during later stages. analysed by JM.For NJBP it came to
notice that major piping modification
were going to happen hence Isometrics
were not issued to JM piping stress
even during later stages.
Hence we took the bold decision of
Descoping the same from JM stress to
JZ stress which enabled us to finish our
scope smoothly within limited time for
90%.
This procedure can be done to reduce
the burden ahead and burning of
estimated hours and to match the
schedule.

Jacobs Project No: 44AA9532 Project Name: YANBU DISTRIBUTION HUB-IN PLANT AND INTERFACE AT YDH Unit Name: YDH Client: SAUDI SERVO Project Site Location: YanBu
ELECTROMECHANICAL (SSEM)

Piping Stress Ajesh Kumar 26-04-2018 Detailed YDH_OSBL Scope definition, Project Schedule. We finished with the tedious Raise the flag as early as possible and YES Pending No
Engineering activity of Critical line list and follow up with lead office regarding the Approval
Package formation with same.
regular follow up with Process
lead(JZ), Piping Lead(JZ) and
getting into online Blue Beam
session and finally got it done
and posted in JPI.
However with all the available
information it came to notice
that it had been taken into JZ
scope with information
digged by JM stress
Reason: Major modification is
gone to happen with site
information required which
would be easier from JZ office
informed by JZ Engg Mgr..
Very difficult to balance
workhours and give it off later
to JZ.

14 January 2019 Page 33 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 07Q7814N Project Name: MON11900 Unit Name: Chemical Plant Client: Monsanto Project Site Location: USA ; Lulling

Piping Stress Ashish Naik 25-07-2017 Detailed Complete plant In the mid of project lead office had Additional qualification Design basis should be finalize at initial NO Approved No
Engineering area added the additional criteria for lined criteria for lined piping & stages of project.
piping & cyclic lines for qualification. lead cyclic lines are not considered
office reduced the allowable stress criteria in design basis at initial stage
for the lined piping to 50% due to which of project.
stress engg required to put additional
efforts ( more work HRS) to qualify line
piping than that standard work HRS
required to pass line in stresses. lead
office demanded nozzle pro calculation
for welded supports on cyclic lines which
cause the additional efforts for stress
engineers (Extra man HRS) .

Jacobs Project No: 44AC0200 Project Name: 200 KTPA PVC-2 Plant Unit Name: ISBL and OSBL Client: TCI SANMAR CHEMICALS SAE Project Site Location: Port Said, Egypt

Piping Stress Mandar 24-07-2017 Detailed Rupture disc on no clear picture of Philosophy of Reaction Vendor is unable to provide To minimize the reaction force effect NO Approved No
Paranjape Engineering reactor force calculation for RD (rupture disc) reaction force value for RD. checked the pipe routing and process
Hence while doing working philosophy of the line. After
preliminary stress calculation the discussion with seniors the
we had tried to calculate finalized philosophy was to avoid the
reaction force value based on reaction force effect in line. Ideally RD
available information from should be located in such a way that,
vendor/ process data, but there is no direction change in
calculation force values were between RD & PSV if combine RD &
very high which created PSV are used in line. Also no direction
problem to connected pipe change in between RD and open end of
stresses, nozzle loads and civil piping routing if RD used in Open to
loading. Due to this civil atmosphere line (Reference-
loading information and Comprehensive Liquid Thrust Force
stress calculation were in hold Calculator Assumptions provided by
for long time. Jacobs Houston). By maintaining pipe
routing as described above, the
reaction force effect of RD was avoided.

Jacobs Project No: HUSP004G Project Name: Shell Vito Unit Name: -NA- Client: Shell Project Site Location: Gulf of Mexico

Piping Stress Manojkumar 12-06-2017 Detailed Floating PlatformValve list generated from SPPID had to be No awareness of If a valve list/Valve MTO is to be drawn NO Approved Yes
Lotlikar Engineering thoroughly checked to match the requirements in early stages. from SPPID then the procedures to be
requirements as sent by Houston. In VITO Had we known procedures followed and the requirements in its
every manual valve had an associated and requirements at an early presentation is to be spelt out in early
valve tags. These valve tags were alloted stage both departments stages of project so that later
by Piping engineering and input into the would have begun confusion is avoided.
SPPID system by Process designers. Once incorporating the
in the system, we can draw a list of valves requirements early into the
to process a Valve MTO . Initially we were project thus minimising the
just filling in the Valve tags in SPPID.But time required later on to
Jacobs Houston had other parameters to regularise the Valve list.Even
be filled in the SPPID module so as to get after receiving the procedure
a Valve list to suit their presentation. We from Houston we had to iron
got detailed instruction from Houston out shortcomings in the
close to the IFH issue of the PIDs. It took procedure to ensure smooth
quite some time for both Piping implementation.
Engineering and Process to understand
the procedure. We had to reschedule the
Valve list issue date and sit with Process
designers to finalise the Valve schedule. It
took almost two weeks for both
departments to fix ALL the Valves in
SPPID.

14 January 2019 Page 34 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: HUSP004G Project Name: Shell Vito Unit Name: -NA- Client: Shell Project Site Location: Gulf of Mexico

Piping Stress Manojkumar 02-04-2018 Detailed General There have been constant routing Lack of control on the Piping Piping Design need to inform any NO Approved No
Lotlikar Engineering changes taking place in Design .As a result Design changes.Also changes changes being made to the 3D model
we witnessed a lot of rework on our if done were not known to to Stress and Civil. Also some sort of
Stress files. Systems which we declared other disciplines. Control needs to be established so that
closed had to be reopened and reworked . routing change gets listed, accounted
This affected the Civil group also as they and minimised. Pipe Stress engineer
could not finalise the Pipe Support design should be involved for major changes
since supports also shifted and moved done in layout.
due to piping changes. Piping support
loads were not in sync since routings did
not match the last available Pipe Stress
results .

Jacobs Project No: 07PG1840 Project Name: K5 Utilization Project Unit Name: K5 Unit Client: Shell Chemical Project Site Location: Geismar, Louisiana

Piping Stress Rekha Inamdar 24-11-2017 Detailed K5 Utilization Being brown field revamp project, some Lead office (Jacobs- In similar future brown field revamp NO Very Important for Approved No
Engineering additional margin should have been Batonrouge) had not given projects, additional margin should be Manhour estimation
considered in stress analysis budget, for consideration for this aspect considered in stress analysis. Mumbai
consideration of existing piping beyond during finalization of budget. office should get involved while
tie-ins, qualification of existing equipment deciding the budget
nozzles, referring LFM/existing layouts,
equipment drawings. Most of the new
lines were connected to tie-ins. Hence lot
of existing piping was considered in the
stress analysis calculations and also
existing equipment nozzles were
qualified. Changes were recommended in
the existing piping. This resulted in
additional manhours consumption.

Jacobs Project No: NL760548 Project Name: I16-124 Gasoline Terminal Unit Name: Gasoline Terminal Client: Gunvor Petroleum Project Site Location: Europoort Rotterdam ,
NL

Piping Stress Rekha Inamdar 03-01-2018 PMC Phase-1 Gasoline terminalAs per piping stress job notes (issued by Caesar II software version Job notes should be read in NO Approved No
(FEED) Jacobs-Hoogvliet), Caesar II 2017 version mentioned in piping stress jon conjunction with the client Standards .
is to be used whereas as per clause no. notes was not in conjuction If case of any discrepancy , the same
2.1 of Gunvor piping stress design basis with the requirment needs to be highlighted to the Lead
(74-14-06-002), latest revision of ASME mentioned in client Office .
B31.3 should be used. Caesar II 2017 specification.
includes B 31.3 2014 version and the
latest version of B 31.3 is 2016. Caesar II
version 2018 includes B 31.3 2016
version. After discussions with the Lead
Office , the Gunvor Job Notes were
updated and it was decided to go ahead
with Caesar II version 10 – 2018 for
performing stress calculations.

14 January 2019 Page 35 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: CE706540 Project Name: Keyera SRU Rimbey Unit Name: Sulphur Recovery Unit Client: Keyera Project Site Location: Rimbey

Piping Stress Rekha Inamdar 15-06-2018 Detailed SRU Nozzle loads exceeding the vendor Negligence/lack of co- Mechanical should be more vigilant NO This is a very Approved No
Engineering allowable were informed to Calgary- ordination by mechanical while incorporating other department important point and
mechanical through VDRN and also department. comments on the vendor drawings. If many a times missed
through separate email co-ordination. any comment is to be ignored then it by Mechanical
However mechanical did not conveyed all should be done with the consent of engineers.
the nozzle loads to vendors. Mumbai and that department.
Calgary piping were not aware about this
and proceeded for IFC isometrics.
Mumbai piping-stress accidently noticed
that the required nozzle loads were not
reflected on the revised vendor drawings.
This was then informed to mechanical
and loads were conveyed to vendor to do
changes in the equipment design.

Jacobs Project No: 58SI714M Project Name: InEOSRedstone LAO project Unit Name: 04403 Jacobs House Client: INEOS LAO Project Site Location: US Gulf Coast

Piping Stress Satish Kshirsagar 22-08-2017 Detailed Static Equipment In general equipment nozzles are Requirement need to discuss Check all client specification and clarify YES Pending No
Engineering designed for bidirectional forces and aligned with respective with respective discipline. Do not Approval
moments (+/-), but client specification has discipline before placement assume.
only axial force mentioned as of Purchase order. Need to FEA analysis (Nozzle pro) performed
bidirectional capacity. Equipment Vendors have better clarity on for all Static Equipment nozzle loads, to
rejected design of nozzles for bidirectional discipline level rather than meet ASME code requirement at the
later stages of project, required extra
efforts from piping stress to perform
the activity.

Jacobs Project No: 44I04736 Project Name: Shell AO4 - OSBL Unit Name: OSBL Client: Shell Chemical Project Site Location: Geismar, Louisiana

Piping Stress Satyanarayan 08-06-2017 Detailed OSBL In 3AB area, piping routing and stress Some of the hindrances for Before finalzing piping routing and NO Pending No
Shenoy Engineering analysis was finalized considering MPS. providing MPS, were not stress analysis, feasibility of MPS and Approval
After 90 % model review, civil highlighted considered by piping design other critical supports should be
that some MPS locations needs to be and some were not known. discussed with civil.
changed since it is not feasible. This
resulted in rework of piping design and
stress analysis.

Jacobs Project No: 58SR034M Project Name: BP Process Safety Automation Unit Name: BP Whiting Refinery Client: BP North American Products Project Site Location: Whiting, Indiana

Piping Stress Tushar Kulkarni 23-06-2017 Detailed DHT-UNIT Steam out loads too high for the support As per discussion with Always checek with the process steam NO Approved No
Engineering from the column for Vendor & mechanical Houston office it was decided regardign the steamout philosophy to
design to consider column at avoid unnecessary issues in designing.
Ambient when the Piping is
steamed out.This caused
heavy loads on the first
support which is generally
rest support .Loads were too
high to design.

Jacobs Project No: 44MM2800 Project Name: CDU/VDU, CFC LPG TREATING & ATF TREATING UNITS Unit Name: Client: MRPL Project Site Location:

Process 17-03-2011 Detailed MP Steam Generator (EA-31107 A/B) was MP Steam Generator, MP Process while first issue of the P&IDs to Pending No
Engineering ordered on M/s Precision & MP Steam Steam Drum & the Piping identify such packages & inform Approval
Drum (FA-31007) was ordered on M/s Rsiers & Downcomers was Projects, FEG & Purchase to procure
Teamco separately. According to the IBR not identified as a single the entire package from a single vnedor
authority MP Steam Generator, MP package at the initial stage of
Steam Drum & the Piping Rsiers & the project.
Downcomers needs to be treated as a
single package and this entire package
needs to be ordered on a single vendor.

14 January 2019 Page 36 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3314 Project Name: MSQ Upgradation Unit Name: FCC Gasoline Desulphurisation Client: Indian oil corporation Ltd Project Site Location: Mathura

Process Adish S. Joshi 03-03-2010 Detailed Interconnections Bolt circle diameter of interconnection Discrepancy in pound rating Piping / Instruments departments need Pending No
Engineering between flanges would not match. Also for of interconnection flanges to check the instrument hook-ups Approval
intrument pressure instruments sometimes the specified in piping isometric thoroughly. Piping specs to be followed
tapping given by Tapping would be of 3/4" while the hook- and instrument hook-up by Instrument department while
piping and hook- up would be of 2" and vice versa. drawing. developing instrument hook-ups.
ups by
instruments

Jacobs Project No: 18-3314 Project Name: MSQ Upgradation Unit Name: FCC Gasoline Desulphurisation Client: Indian oil corporation Ltd Project Site Location: Mathura

Process Adish S. Joshi 06-12-2010 Pre- FCCGS Vent Due to revised operating conditions of Proces requirements Process to check piping isometrics for NO Discussed during Pending No
Commissionin Condenser : FCCGS, the air cooled condenser had to mentioned in P&IDs were critical process requirements. Process lessons learnt Approval
g/ Revamp of pipingbe revamped. missed by Piping while to identify such critical lines in line list. presentation by
Commissionin For the same the sizes of the inlet / outlet preparing drawings for Appropriate work-hrs to be considered process group.
g nozzles as well as the inlet / outlet piping modification of piping while estimating work-hrs for future
had to be increased. projects
However while doing this the earlier
symmetrical piping had to be maintained.
The same was also shown in the
construction / demolition P&IDs.
However this was missed throughout
engineering (as no model was prepared
and reviewed for revamped portion)
This problem was only noticed at site
during precommissioning stage,leading to
massive rework.

Jacobs Project No: 18-3314 Project Name: MSQ Upgradation Unit Name: FCC Gasoline Desulphurisation Client: Indian oil corporation Ltd Project Site Location: Mathura

Process Adish S. Joshi 06-12-2010 Pre- FCCGS LCN As part of FCCGS revamp one more cut For revamp of an existing Piping group need to take extra NO Discussed in Lessons Pending No
Commissionin collection level (LCN) was to be removed below tray no. 4. equipment, before preparing precaition especially for revamp Learnt presentation Approval
g/ nozzles The internal manufacturer had nozzle orientations, As-built projects. As-Built drawings need to be by process group
Commissionin accordingly changed the internals. drawings for the existing made available and studied before
g In order to measure the level, control the equipment were not studied releasing drawings for modification of
flow of liquid accumulated and initiate an and the interference of existing equipments.
interlock, 4 pairs of level instrument nozzles with column stiffening
nozzles had to be installed. ring was not noticed.
However due to incorrect elevations of
high pressure tappings, column stiffening
ring present their was fouling with these
nozzles.
The platforms and other vent drain piping
were already fabricated as this assembly
had to be installed at a height of approx.
60 m.
Due to this last minute noticing of
stiffening ring, lot of changes had to be
made causing delay.
The only fact saving grace was that the HP
tapping nozzles were not punctured till
that time.

14 January 2019 Page 37 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3314 Project Name: MSQ Upgradation Unit Name: FCC Gasoline Desulphurisation Client: Indian oil corporation Ltd Project Site Location: Mathura

Process Adish S. Joshi 06-12-2010 Pre- Flare KO drum In order to satisfy the straight length Due to large size of flare Piping need to be aware of this NO Discussed during Pending No
Commissionin nozzle requirements of the ultrasonic flow meter header, the streight length problem - which is commonn for all lessons learnt Approval
g/ interchange the inlet and outlet nozzles of the unit required for flow instruments Refinery units. presentation by
Commissionin Flare KO drum were interchanged. on flare headers is quite long. process department.
g However while doing this the slope of the This was overlooked by piping
vessel was overlooked. Due to this the group. The length required
liquid drain nozzle was at the opposite for Flow instruments was
end of the slope informed by instrument
group at a late stage in the
project. As the flare KOD is
located near unit B/L, the
required streight length of
flare header was not available
within the FCCGD unit. Hence
at a late stage, the inlet and
outlet nozzles were
interchanged to make
available the streight length.

Jacobs Project No: 18-3314 Project Name: MSQ Upgradation Unit Name: FCC Gasoline Desulphurisation Client: Indian oil corporation Ltd Project Site Location: Mathura

Process Adish S.Joshi 02-03-2010 Detailed Feed Filter The PSV was located below the flare The PSV was in vendor scope. Process to give a comment on vendor Pending No
Engineering header. As a result, outlet line was not Hence in order to minimise P&ID that the PSV to be located such Approval
sloping towards flare header. piping, vendor had located that the outlet slopes towards the flare
PSV very close to the filter. As header.
a result the PSV got loacted
below the flare header.

Jacobs Project No: 58SH203M Project Name: Victoria ADN Retrofit Project Unit Name: -NA- Client: INVISTA Project Site Location: VICTORIA,USA

Process Amol Dange 23-09-2017 Basic Refining, Step 1 Tracking changes in Input documents P&id’s were been updated by Cutoff date for PFD’s and P&ID’s used NO Approved No
Engineering and Step 2 (P&ID’s and PFD’s) lead office piping on a daily as input for calculation’s to be shared
basis causing rework in with lead office. Subsequent revisions
hydraulics. PFD’s were not in input document shall be captured
updated/marked alongside during final submission/issue.
P&id’s.

Jacobs Project No: NL784490 Project Name: New European PDH – Kallo Unit Name: PDH Client: Borealis Project Site Location: Kallo

Process Dharmendra 04-06-2018 PMC Phase-1 Smart Plant Line size changed on connecting branch While updating line size of a Mark ups on Blue Beam should be YES Similar incident has happened in Let us discuss . Is it Rejected Yes
Desai;Anindyasun (FEED) Piping and line while correcting size on the main line. particular line its connected complete in all respect. Mutiple mark INEOS where column overhead only designers
dar Das Instrumentation It went without notice of designer and line and equipment nozzle get ups should be avoided. In this case line was changed to 2" from 30" responsibility or
Diagrams checker while updating SPPID. It was automatically updated if the team from Hague should have avoided line in SPPID. should this be
brought to our notice by Hague project line break is not put on last minute changes. extrapolated to
manager showing error on compressor proper line on SPPID. engineer too.
KO drum inlet line size change from 16" to Designer and checker should follow
2". Even the inlet nozzle on KO drum was Quality should be given check list and should not succumb to
picked up to 2" size. precedence over schedule. schedule pressure.
We should avoid last minute
2" line was hydrogen inlet line added to updates in hurry and without Line break shuld be propely provided
reactor effluent line of 16". schedule. on the lines with different line
numbers to avoid such a mistakes.
For epeated last minutes
comments, check print and
back checking steps were not
followed.

14 January 2019 Page 38 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44LW0700 Project Name: S-PVC Project Unit Name: S-PVC Client: TCI Sanmar Project Site Location:

Process Kamaljit Kaur 06-12-2010 Detailed Reactor and Piping did not consider slope for slurry Piping did not consider slope Many process requirements are Pending No
Engineering Slurry section lines - which was noticed during model for slurry lines from Reactor specified in P&IDs in the form of Approval
review by client, resulting in rework by to Slurry run down pump - notes - piping need to satisfy these
Piping. although there was a note in requirements.
the P&IDs.

Jacobs Project No: NL403099C Project Name: Shell Program (various Projects) Unit Name: -NA- Client: Shell Nederland Raffinaderij B.V Project Site Location: Rotterdam
(SNR)

Process Kaustubh Divekar 13-09-2017 Operating Feed effluent Intermediate equipment and piping are In Feed effluent exchangers Transient temperature study is NO Required for Fixed Approved No
Plant exchangers of not designed for higher temperatures of Hydrotreater/ Desulfurizer required before the start of project to tubesheet
Hydrotreater resulting due to transient upset cases. units cold feed is heated to know the maximum possible exchanegers.
unit for Shell the reaction temperature temperature that can be seen by Transient
refinery with reaction product coming equipment or piping due to transient temperature
from Reactor outlet in failure cases like Feed pump condition
circulation loop and flows trip/General power failure. specification , is part
downstream to the high and of standard Heat
low pressure separators. exchanegr datasheet
When there is feed pump Template..
failure cold side feed is not
available for heat exchange
between hot reaction product
coming out of reactor and
flow continues downstream
due to high pressure
difference between two
separators causing higher
temperatures in intermediate
exchangers and piping than
design temperature.

Jacobs Project No: 58SI693M Project Name: Texas Borstar Project Unit Name: PE1 Client: Texas Borstar Project Project Site Location: Pasadena, TX

Process Kuntal Kotnis 26-10-2017 PMC Phase-1 IPDS For control valve and pump hydraulics, For this project, pipe line For FEED projects, if piping MTO is NO Approved No
(FEED) verification of pipe line length. lengths for control valve available at the time of hydraulic
hydraulic calculations were calculations, estimated pipe lengths
confirmed with line length may be utilised wherever isometrics
measurement done by piping are not available in order to save time
for their MTO. Due to this and improve efficiency and accuracy.
considerable time was saved
by not having to refer 3D
model.

Jacobs Project No: 44NC4100 Project Name: Expansion at Soda Ash Plant Unit Name: Client: Nirma Ltd. Project Site Location: Bhavnagar, Gujarat

Process Madhukar 06-12-2010 Detailed No. of demolition P&IDs required to be during work-hour estimation, For revamp project like NIRMA, intial Pending No
Ajagekar Engineering prepared were more than actually workhours required for site visit is very important to Approval
anticipated. preparation of new P&IDs understand exact scope of work, client
and updation of existing requirement and efforts required.
P&IDs were considered.
Process has to spent
additional hors in preparing
demolition P&IDs. In order to
locate vapour header as per
NIRMA requirement, no. of
other lines need to be
rerouted, for which piping
asked for demolition P&IDs
and additional tie in points.

14 January 2019 Page 39 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: NL760548 Project Name: I16-124 Gasoline Terminal Unit Name: Gasoline Terminal Client: Gunvor Petroleum Project Site Location: Europoort Rotterdam ,
NL

Process Mangesh Shirsat 20-12-2017 PMC Phase-1 Surge calculation No proper orientation in pressure vs When we select all segment We realized that WANDA is not picking NO We can utilize this lesson learn Approved No
(FEED) result distance graph. in circuit. We thought that the segments for distance in result extraction method from
WANDA will automatically measurement as per flow direction and future surge calculation.
pick up the distances (0 to we need to manually select the pipe
2000 m approx.) as per flow segments as per flow direction and
direction. then need to plot the graphs. The
procedure to extract the graph of
(Pressure Vs Distance) in WANDA is
that, we have to select the piping
components in the system and then do
the selection to plot the specific graph.

Jacobs Project No: 18-3342 Project Name: IRUP - HGU Unit Name: Hydrogen Generation Unit Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process Manoj Alawani 06-12-2010 Detailed Condensate Vessels in steam / condensate service not Neither Piping nor Process Henceforth it is decided that IBR YES As per earlier practive all Approved No
Engineering Flash Drums identified as ‘IBR’. This resulted in nor FEG paid attention to IBR applicability to be checked and suitable 1) Changes informed Statutory requirements were
Amendment of vessel enquiry. applicability. note to be added in equipment data to vendors by taken care by Piping. However
sheet by Process. This will not be left to 'Enquiry Amendment' to minimize such problems in
Piping to decide. 2) Standard note future it is decided that
"IBR Applicable - Yes henceforth Process will identify
/ No" added in vessel IBR applicability in the PDS itself.
and exchanger
datasheet '
3) New WI is
prepared for
deciding applicability
of IBR.

Jacobs Project No: 18-3342 Project Name: IRUP - HGU Unit Name: Hydrogen Generation Unit Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process Manoj Alawani 06-12-2010 Detailed Isolation valve downstream of emergency This requirement was not Standard Note to be added in all YES Valve orientation Pending No
Engineering depressurization valve was installed at mentioned in P&ID. Also P&ID's: PSV isolation valves on flare changed at site. New Approval
site with stem vertically upward. This is Piping missed this lines and isolation valves for WI is issued for
not as per OISD standard (OISD accepts requiement - applicable to all Emergency Depressurization valves review of Licensor
valves with stem either vertically isolation valves on lines going shall be installed either with stem BEP.
downward or in horizontal position) to flare. vertically downwards or in horizontal
position.

Jacobs Project No: 18-3342 Project Name: IRUP - HGU Unit Name: Hydrogen Generation Unit Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process Manoj Alawani 06-12-2010 Detailed Instrument hook-Fluid phase not indicated for pressure Missing information in process to indicate fluid phase in YES Impulse piping Approved No
Engineering ups (Pressure instruments in IPDS. Resulted in incorrect Instrument data sheets Instrument datasheets (though 'phase' corrected at site
instruments) orientation of impulse piping by provided by Licensor. is a standard input in Jacobs IPDS before
Instrument group for Pressure format; same was not mentioned in commissioning. New
Instruments in Naphtha service as the IPDS submitted by licensor). WI is prepared for
phase was liquid in some part of the plant Instrument group also to discuss with review of Licensor
and vapour in some other. Process incase of any doubts BEP.

Jacobs Project No: 18-3342 Project Name: IRUP - HGU Unit Name: Hydrogen Generation Unit Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process Manoj Alawani 06-12-2010 Pre- High point vents and Low point drains Vents / Drains were missed by based on the 3-D model, piping to NO Pending No
Commissionin were missing at number of places. Vents Piping during 3D model provide HPV's / LPD's at all places Approval
g/ and drains added during pre- preparation.
Commissionin commissioning. Though standard
g vent/drain connection is 3/4" in size, in
some cases, 2" vent and drain valves were
provided based on available material.

14 January 2019 Page 40 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3342 Project Name: IRUP - HGU Unit Name: Hydrogen Generation Unit Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process Manoj Alawani 06-12-2010 Pre- -- Valves on high pressure lines having It was thought that flow The direction on the main valve is for NO Valve orientation Pending No
Commissionin integral globe valve (1" - for pressure direction is not applicable for the small bypass globe valve. It is changed before Approval
g/ equalization) were installed in reverse gate valves. However the flow better if flow direction is indicated on: commissioning
Commissionin direction during construction. As the main direction was important due (a) on P&ID's by Process (b) on
g valve was gate valve, the flow direction to the integral startup isometrics by Piping
arrow on the gate valve body was ignored. equalization globe valve.

Jacobs Project No: 07Q7814N Project Name: MON11900 Unit Name: Chemical Plant Client: Monsanto Project Site Location: USA ; Lulling

Process Mukund 05-06-2018 Detailed Monsanto-ISBL As per Project direction Rev.70 (stress Changes noticed in IFC Piping to inform/ seek process NO Procedure or work instruction Pending No
Kherdekar Engineering approved) isometrics are used for IFD PSV isometrics which resulted in approval for any changes in routing for can be deloved to ensure this Approval
calculations and holds related to lateral PSV lateral sizing changes for PSV inlet/ outlet isometrics after communication to avoid late
sizing are released. However all PSV 3 PSVs. Rev.70 (isometrics used for PSV chnages during detail
calculations were reviwed against the IFC calculation to release holds.). This is engineering last stage.
isometrics. also applicable for relocation of any
control valve after purchase/ issue.

Jacobs Project No: 44QS4300 Project Name: Pre-bid for Al Zour Refinery,KNPC Unit Name: CDU, SGU, SRU, SWS, ARU, Hydrogen, SP, Flare Client: Petrofac International Limited Project Site Location: Kuwait

Process Nilesh 07-04-2015 Basic general IniJally P&IDs mark-ups issued to piping Due to heavy time constraint, Piping could not identify changes with Approved No
Deshpande Engineering for one of the unit for all changes with this point was over looked respect to earlier issue leading to lot of
relevant revision marks against each rework
changes was not done . This lead to
confusion from piping group to identify
the latest changes / updates. .

Jacobs Project No: 44LK4100 Project Name: IRUP - EPCC-6B Unit Name: IRUP - Offsites and Utilities Client: Indian Oiltanking Ltd. Project Site Location: Vadodara

Process P. Parimala 06-12-2010 Pre- Coker VGO-HDT As per the P&ID a 4" LP Steam line was Piping should have adheared After deciding the location / no of A new 4" line was Approved No
Commissionin Feed Tanks Tank shown going to Coker VGO-HDT Feed to the requirements as given tappings required based on vendor laid to tank farm
g/ farm tanks for tank heating and another header in the P&ID. data/ layout, piping should interact area to cater to tank
Commissionin was shown for steam tracing. Both these with process for deciding the line size / heating and the
g lines were tapped from the main IRUP number of tappings. steam tracing line
steam header. Note 21 also stated that was retained as it
depending on the pressure of steam was already laid.
required for tracing tapping to be taken
from main IRUP Steam header (Area wise)
for distribution in that area. At site all the
lines required for steam tracing were
tapped from the 4" line and separate
header was not provided for steam
tracing. Due to this, during commissioning
it was observed that steam at adequate
pressure was not available for tank
heating.

Jacobs Project No: 44NY9800 Project Name: MEG Debottlenecking 180% Project Unit Name: Client: Reliance Industries Ltd. Project Site Location: Dahej

Process Pulkit Kakadia 22-09-2014 Detailed EOEG Pump PDS has to pass through long Hydraulic calculations for In DBN project, existing isometrics for NO Pending No
Engineering approval cycle. pumps were done using piping and existing Instruments details Approval
length based on plot plan. for revised flow to be considered for
pump hydraulic calculations.

14 January 2019 Page 41 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44LK5100 Project Name: Diesel Hydrotreater Project Unit Name: DHT, HGU, SRU, SWS, ARU, Utilities and Offsites Client: Hindustan Petroleum Project Site Location: Mumbai
Corporation Ltd.

Process R. M. Kamat 06-12-2010 PMC Phase-2 Underground LSTK contrator selected 2" as minimum In the ITB document, Process Process BEDB to be updated to include YES In 1st revisio of LSTK Pending No
(Engineering OWS lines line sizes for underground OWS lines - / Piping / Civil design basis do minimum OWS line sizes as per work contractor P&ID, the Approval
by LSTK) which should be 4" minimum. not indicate minimum instruction IND-WI-P-04. minimum required
required OWS line sizes. LSTK OWS line sizes are
contractor has selected OWS marked. BEDB to be
line sizes of 2" as minimum. revised to include
this standard
requirement. For
CPCL project, this
requirement is
mentioned in the
P&ID for OWS
prepared by Jacobs.

Jacobs Project No: 18-3293 Project Name: IRUP - DHDT Unit Name: DHDT Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process R. V. Bandekar 06-12-2010 Construction PSV isolation At many places PSV isolation valves and Ignorance by piping of OISD PSV isolation valves, Emergency YES Note to this effect Pending No
valves isolation valves of Emergency guideline and BEDB Depressurization valves, its isolation should be indicated Approval
depressurization system were installed requirement for PSV isolation valves, control valves and its isolation in PID for future
with stem vertically upwards. valves. valves which are installed on vent lines projects
to flare shall be installed either with
valve stem vertically downwards or in
horizontal position as per OISD.

Jacobs Project No: 18-3293 Project Name: IRUP - DHDT Unit Name: DHDT Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process R. V. Bandekar 06-12-2010 Construction High Pressure Spacer was indicated in PID for stacked Although spacer was For stacked high pressure heat YES WI for Heat Approved No
Exchangers high pressure exchangers 2091-E-14A/B. indicated in PID it was not Exchangers spacer requirement should Exchanger is
However, it was not specified in PDS and specified in Exchanger PDS be specified in PDS also. updated, mentioning
was missed in Exchanger purchase order. and piping also did not inform requirement of
the same to FEG spacers for high
pressure stacked
heat exchangers.

Jacobs Project No: 18-3293 Project Name: IRUP - DHDT Unit Name: DHDT Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process R. V. Bandekar 06-12-2010 Detailed Vessel/ Column In many vessels upper nozzle of level While preparing nozzle Critical nozzle orientation should be NO Critical nozzle Pending No
Engineering nozzle transmitter was located in impingement orientation piping/ FEG did checked by Process also. FEG should orientation is being Approval
orientation plate /baffle plate section not realise this thing. Also in ensure the quality of fabricated checked by Process
vendors fabrication drawing drawing submitted by vendor for on going projects
the impingement plate / and will be
baffle was not marked clearly continued for future
projects

14 January 2019 Page 42 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3293 Project Name: IRUP - DHDT Unit Name: DHDT Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process R. V. Bandekar 06-12-2010 Detailed Air Cooled Special inlet and outlet piping Licensor PDS for aircoolers did Any specific requirement with respect YES Issue was rectified by Approved No
Engineering Exchangers/ arrangement specified in legends P&ID by not specify that number of to inlet and / or outlet piping manifold informing this
Number of tube licensor required number of bays / bays / nozzles should be in of air-cooled exchangers should be requirement to
bundles number of air-cooled exchanger (2091-AC- factorial of 2 to maintain clearly specified in process datasheet. vendors. WI /
01) nozzles to be in factorial of 2. This was required symmetry of the Checklist for Review
a requirement to ensure that flow of two inlet and outlet piping. This of Licensor Package
phase line gets equally divided across requirement was missed out is issued - which
different air cooler bundles. Though in PDS issued by Jacobs includes this point
licensor P&ID did not specify special Process for Engineering. for check by Process
piping requirement, similar piping Dept.
arrangement was also required for 2091-
AC-02 due to two-phase flow. The
datasheets did not contain any specific
note to this effect. This point was realized
while reviewing offers received from
different vendors where 6 or 7 numbers
of bundles were specified.

Jacobs Project No: 18-3293 Project Name: IRUP - DHDT Unit Name: DHDT Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process R. V. Bandekar 06-12-2010 Detailed Spray nozzles for Spray nozzle was ordered at the end of Project were of the opinion Although adequate information of this NO Approved No
Engineering wash water detailed engineering stage. that this item can be item was provided in PID, the same
injection into air fabricated at site. However, should have been tagged as a
cooler inlet pipe spray nozzles are specialized equipment or special piping item. Also
items and need to be ordered it should have been ordered much
to specialized vendor earlier considering special nature of
this item.

Jacobs Project No: 18-3293 Project Name: IRUP - DHDT Unit Name: DHDT Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process R. V. Bandekar 06-12-2010 Pre- Recycle Gas RGC suction strainer differential pressure Inferior work of installation of Instead of tubing, installation of pipes YES Thereafter, all Approved No
Commissionin Compressor transmitter tappings broke down at 40 tubing by instrumentation is preferred for high pressure impulse instrument tubings
g/ kg/cm2g pressure in hydrogen service contractor - Rohini Electricals. connections. If tubing is done for in high pressure
Commissionin resulting in fire. Further, the tubing was not impulse lines of instruments in high service were
g hydrotested. pressure service it should be properly replaced by piping.
hydrotested.

Jacobs Project No: 18-3293 Project Name: IRUP - DHDT Unit Name: DHDT Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Process R. V. Bandekar 06-12-2010 Pre- High Pressure Bolts of short length were procured for Piping did not take into While deciding bolt length of flange Pending No
Commissionin Exchangers connected piping of High pressure account the spacer width joint connected to high pressure Approval
g/ exchangers, 2091-A~F and 2091-E-02. while deciding bolt length for exchanger nozzle, spacer width should
Commissionin piping connected to high be taken into account by piping
g pressure exchangers

Jacobs Project No: 18-3188 Project Name: Lube Oil Upgradation Project Unit Name: LOBS Client: Hindustan Petroleum Project Site Location: Mumbai
Corporation Ltd.

Process R. V. Bandekar 07-12-2010 Detailed Sea Cooling Sea Cooling Water line sizing in case of During initial stage of line For any unit when special piping NO Calculation were recheked and Approved No
Engineering Water Lines-OSBLcement lining sizing the cement lining material is involved care shall be taken necessary modifications were
thickness for calculting the to determine the piping spec and made.
pipe ID were considered as thickness requirements. Specially if this
avialable from standard EIL is related to pipe spec which is already
spec. But later on HPCL being used by client, this information
provided their separate chart can be sought from client at intital
for line thickness stage of project when first sizing
consideration in case of calculations are done.
cement lining based on line
size. Due to this the line sizing
calculations were rechecked
and some sizes had to be
revised.

14 January 2019 Page 43 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44AB6000 Project Name: Phosphoric Acid Plant Unit Name: ISBL and OSBL Client: Nirma Ltd. Project Site Location: Bhavnagar, Gujarat

Process Rupesh Mistry 21-12-2017 Detailed 7300- Post Big bore CS impregnated graphite piping, Axial pumps suction and If big bore graphite piping is expected NO Approved No
Engineering treatment resulting into heavy piping and higher discharge piping in tripple in future projects, specific attention
load and additional support than expected effect evaporator section has needs to be given on specifying design
graphite piping with 500 to pressure to avoid heavy piping
700 mm ID. The design component
pressure of piping was selcted
based on shut off pressure.
Maximum expected shut off
pressure was 5.5 barg. After
discussion with vendors, it
was found that these piping
comes into short spools of 1
to 1.5m length with flange
and needs to be supported at
regular intervals. Only solid
graphite piping can not take
more than 3 barg. CS
impregnated graphite piping
weight was very heavy. After
analysing this, and taking
credit for static head, design
pressure of few piping
componets were relaxed to
slightly lower values

Jacobs Project No: 44AB6000 Project Name: Phosphoric Acid Plant Unit Name: ISBL and OSBL Client: Nirma Ltd. Project Site Location: Bhavnagar, Gujarat

Process Rupesh Mistry 21-12-2017 Detailed 7300- Post Change in dimensions (length) of graphite Missing details like tube Lack of important data not only caused NO Approved No
Engineering treatment heat exchangers (almost 3 times in some length, shell ID in exchanger to and fro communications but also
section case) causing issues related to change in PDS. Licensor only specified delayed the delivery of long lead item
big bore graphite piping routing and also total heat transfer area and order placement and rework in other
change in support of exchanger and basic required geometrical discipline . In future, if such missing
platform for operational requirement for details were not specified. information is there on basic geometry
these exchangers leading to rework in civil Also in exchangers where and may have impact on layout, it is to
and piping phase change was occuring, be highlighted and emphasis shall be
heat release curves were not made on getting all details.
given inspite of asking.
Vendors were left open hand
to design exchangers based
on their experience and were
only asked to provide
meachanical guarantee and
compliance on allowable
pressure drop and vibration
free design. However
operating parameters were
also not proper in some case
for vendors to give guarantee.
Piping modelling was done on
some initial dimesions
provided by TENOVA and all
civil drawings were issued
based on that

14 January 2019 Page 44 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: NL705692 Project Name: Waste Heat Utilisation Unit Name: HCU for District Heating Client: Shell Nederland Raffinaderij B.V Project Site Location: Rotterdam
(SNR)

Process Satish Naik 13-06-2017 Detailed PROCESS Rework on S&T Thermal Design For S&T HX (3 nos.), it was If JEM was not involved in define phase NO Pending No
Engineering advised to JEM to prepare then thermal design needs to be Approval
only process datasheets as verified in execute phase. WH to be
there were no changes considered in execute phase
expected in thermal which estimation.
design done in the define JEM process to be involved from the
phase. However, in the define phase. This will have following
project interest, JEM process advantages in execute phase in:
had done verification & found 1. avoiding issues & conflicts.
that E1322 was under 2. removing BEDEP & Piping Model
designed. Thermal design for validation WH.
the same was updated 3. providing competative proposal to
without CN (WH were the client.
absorbed by JEM) affected
budget & schedule.

Jacobs Project No: NL705692 Project Name: Waste Heat Utilisation Unit Name: HCU for District Heating Client: Shell Nederland Raffinaderij B.V Project Site Location: Rotterdam
(SNR)

Process Satish Naik 13-06-2017 Detailed GEN Schedule impact due to late design Design changes were done BDEP validation to be done before WH NO Pending No
Engineering changes (BDEP quality issue) after issuing approved define Estimation for Execute Phase. Approval
phase BDEP. Though these JEM leads to be involved from the
design changes were define phase, at least for process and
incorporated in execute piping disciplines. This will have
phase with CN impacted following advantages in execute phase
project schedule. in:
1. avoiding issues & conflicts.
2. removing BDEP & Piping Model
validation WH.
3. providing competative proposal to
the client.

Jacobs Project No: 44AC0200 Project Name: 200 KTPA PVC-2 Plant Unit Name: ISBL and OSBL Client: TCI SANMAR CHEMICALS SAE Project Site Location: Port Said, Egypt

Process Saumya 21-06-2017 Detailed OSBL (Tie-in Improper pipe spec break at tie-in points Not envisaged After Piping comments on squad check NO Approved No
Chakraborty;Sunil Engineering P&IDs) on tie-in P&IDs; Spec. break not shown at of P&IDs, it was rectified. Lessons
Satai tie-in points. As Piping was not supposed learnt is to indicate pipe spec break at
to use existing plant specs, these would tie-in points if new piping specifications
have caused problem during downstream are to be used for new scope in
engineering by Piping discipline. existing project.

Jacobs Project No: 44AC0200 Project Name: 200 KTPA PVC-2 Plant Unit Name: ISBL and OSBL Client: TCI SANMAR CHEMICALS SAE Project Site Location: Port Said, Egypt

Process Saumya 21-06-2017 Detailed ISBL ESS and PSVs inlet flange rating changed to 600 # For such high pressure ESS system and HP steam system PSVs NO For such high pressure system, Approved No
Chakraborty;Sunil Engineering OSBL Boiler system, we must check with inlet flange rating changed to 600 # we must check with API 526
Satai package P&ID API 526 tables at the and pipe class break had to be shown tables at the beginning of the
beginning of the project, on concerned P&IDs. project, rather than waiting for
vendor data receipt to avoid
further repercussion on
engineering of Piping.

Jacobs Project No: 44AC0200 Project Name: 200 KTPA PVC-2 Plant Unit Name: ISBL and OSBL Client: TCI SANMAR CHEMICALS SAE Project Site Location: Port Said, Egypt

Process Saumya 21-06-2017 Detailed BFW line design Pipe was considered as SS304 and also of As per ASME BPVC Section 1, Issue was discussed, line is changed to NO Approved No
Chakraborty;Sunil Engineering pressure for 300 # rating PG-61.1, BFW pump CS, as same was the MOC of vendor
Satai PRDS inlet lines differential head is estimated scope piping and also vendor intimated
based on 3 % higher than to keep design pressure as highest limit
highest setting of PSVs on of 300 # rating.
steam drum.

14 January 2019 Page 45 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44MM2800 Project Name: CDU/VDU, CFC LPG TREATING & ATF TREATING UNITS Unit Name: Client: MRPL Project Site Location:

Process Saumya 29-10-2010 Detailed CDU/VDU MP The MP steam generator (exchanging This system was not indicated In case of equipment which are under YES The related This problem encountered with Approved No
Mukhopadhyay Engineering steam generator heat with process fluid and BFW) and as a IBR package by EIL. Also scope of IBR and are closely interlinked equipment (EA- IBR of State of Tamil Nadu.
corresponding steam drum are identified this is not communicated to by IBR piping should be ordered as a 31107 and FA- Similar system (LP steam) with
as IBR applicable equipment. The us by client (though similar package item to avoid such incidence. 31007) and exactly similar configuration has
exchanger and steam drum are ordered system are existing in their associated piping been approved by IBR of State of
on different vendors. However IBR existing CDU/VDU plant and (riser /downcomer) Gujarat.
Chennai opines that this should be no such requirement on are ordered on single
treated as a package and should be ordering it to a single vendor vendor.
engineered and executed by same was reported). This is a new
vendor. This lead to a lot of negotiations requirement from IBR.
and redefining the scope of the
equipment in order to place the order on
single vendor.

Jacobs Project No: 44MM2800 Project Name: CDU/VDU, CFC LPG TREATING & ATF TREATING UNITS Unit Name: Client: MRPL Project Site Location:

Process Saumya 06-12-2010 Detailed Nozzle Nozzle orientation of Tray columns were Nozzle orientation of Tray Nozzle orientation of columns should NO Nozzle orientation of Pending No
Mukhopadhyay Engineering orientation of changed at advanced stage of equipment columns were not properly be finalized after review of column Columns is being Approval
Columns fabrication reviewed by FEG/ piping with internals vendor drawings and with reviewed by process
respect to column internals input from piping, process and for on going projects
vendor drawing instrumentation.

Jacobs Project No: 44MM2800 Project Name: CDU/VDU, CFC LPG TREATING & ATF TREATING UNITS Unit Name: Client: MRPL Project Site Location:

Process Saumya 06-12-2010 Detailed Sand removal Sand Removal nozzles cum manholes on Elevation of sand removal For Sand filters or similar filter, NO Pending No
Mukhopadhyay Engineering nozzle for Sand Sand Filters were not located at minimum nozzles cum manhole was elevation of sand removal nozzle Approval
Filters distance from support grid. reviewed by piping/FEG. Also should be reviewed carefully by piping
it was not specified at / FEG from maintenance view point.
minimum distance from Also elevation of such nozzles should
support grid in PDS by be specified as minimum from
licensor and PDS issued by supporting grid in Process PDS.
Process

Jacobs Project No: 18-3199 Project Name: Offsites & Storages (EPCC 8) for IOCL Panipat Naphtha Cracker Unit Name: Offsites & Storages Client: Indian Oiltanking Limited Project Site Location: IOCL, Panipat

Process Saumya 07-12-2010 Detailed Top suction and A pump having very high capacity was top Piping were not aware of the For high capacity pumps, type of pump NO Approved No
Mukhopadhyay Engineering top discharge entry and top discharge type. Pump type of pump used for the should be checked by piping with MEG.
pumps suction nozzle on the tank was at lower service. Accordingly if required, height of such
elevation than pump suction nozzle. type of pump to be lowered while
making foundation in order to ensure
proper suction all the time.

Jacobs Project No: 18-3177-01 Project Name: MSQ Upgradation Unit Name: ISOM Client: Indian Oil Corporation Ltd Project Site Location: Panipat

Process Sutosh Devershi 11-02-2010 Pre- Location of Control valve No PV 1764 was located on LSTK contractor deleted the At site control valve PV 1764 indicated NO Pending No
Commissionin control valve ground floor instead of locating close to note indicated in Licensor’s on inlet line [No 6”-P-301-1752- Approval
g/ provided on stabilizer inlet nozzle. P&ID for the control valve PV B2A1(B5A)-IH] to stabilizer 301-C201
Commissionin stabilizer inlet 1764. was located on ground floor. Licensor’s
g line. P&ID indicates that the same valve to
be located on platform as close as
possible to stabilizer 301-C-201 inlet
nozzle. However LSTK contractor has
deleted this note from the P&ID. Due
to this valve is located at convenient
place by piping.
Therefore do not delete any note or
any write-up from Licensor’s P&ID.

14 January 2019 Page 46 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3177-01 Project Name: MSQ Upgradation Unit Name: ISOM Client: Indian Oil Corporation Ltd Project Site Location: Panipat

Process Sutosh Devershi 11-02-2010 Pre- piping system for In P&ID, in front of some valves alpha NO Pending No
Commissionin NHT area bet may appear. For example Letter Approval
g/ "M" stands for monel trim valve. Also
Commissionin first isolation valve on line joining to
g above indicated line shall have monel
trim. However at site the monel trim
valves were not provided. Also P&ID is
not indicating any letter like "M" in
front of those valves. At some places
P&ID is indicating letter "M" i.e. monel
trim valve however at site valve trim
was CS & not Monel.
Therefore while reviewing the P&ID
received from LSTK it shall be carefully
checked for the MOC. Also while
checking piping system at site the
same shall be checked carefully.

Jacobs Project No: 18-3177-01 Project Name: MSQ Upgradation Unit Name: ISOM Client: Indian Oil Corporation Ltd Project Site Location: Panipat

Process Sutosh Devershi 11-02-2010 Pre- Make-up Gas High pressure drop in Make-up gas Treater bed is chocked due to Dirt / rust which were accumulated in NO Pending No
Commissionin Treater treaters 301-V-214 / 215 when hydrogen accumulation of dirt / rust. Make-up Gas Treater inlet pipeline has Approval
g/ is lined-up from battery limit. chocked the bed. Lot of time is wasted
Commissionin in opening, removing the top part of
g bed to remove dirt / rust, replacement
of fresh bed material. Therefore pre-
commissioning / flushing to be carried
out properly & ensure tat dirt & rust is
removed from the piping.

Jacobs Project No: 44QS6500 Project Name: Confidential Unit Name: XX Client: Confidential Project Site Location: confidential

Process Umesh Joshi 20-06-2017 Detailed SRU Block Silencers were added on PSV outlet lines Decibel level data of PSVs are Generally, silencers are not required on NO If JE Houston spreadsheet is Approved No
Engineering in LP Steam service at much later stage available from vendor at outlet lines of PSVs in LP Steam service. used for PSV and its inlet/outlet
(after receipt of PSV vendor data) which much later stage. However, requirements of some clients line sizing, it gives estimated
resulted in difficulty in accomodating are strigent. Even decibel level of more decibel level. It can be used for
silencers in existing layout & 3D than 110 dB for accidental relief like preliminary screening & later
Modelling. New structures were required PSVs is not acceptable. If the criteria is can be verified with vendor data.
afor supporting the silencers. strigent, many PSVs relieving to Based on preliminary screening,
atmosphere may qualify for silencer at advance information could be
the outlet line. passed on to Piping, Civil.

Jacobs Project No: 44QS4300 Project Name: Pre-bid for Al Zour Refinery,KNPC Unit Name: CDU, SGU, SRU, SWS, ARU, Hydrogen, SP, Flare Client: Petrofac International Limited Project Site Location: Kuwait

Projects Abhijit Morbale, 21-04-2015 Basic General Lesson None of the discipline was taking the It is not clearly defined which UG composite review drawing to be YES Civil discipline was forced to take Pending No
Prashant Babele Engineering Learnt responsbility of overall underground disicpline owns complete prioritized once proper layout complete ownership of Approval
system. responsibilty of Underground definitions are available. Piping, Civil, Underground system because at
composite. Undeground Electrical and Instrument departments client side civil owns the same.
system for this project was to give due importance to fix corridors/ Underground expertise has been
based on flooded philosophy vide layer management on AutoCAD. deputated from Petrofac Sharjah
and we don't have any UG facilities should be given utmost to provide training to Jacobs
expertise on the flooded priority. As it is difficult to add anything personnel.
Underground system. missed out at a later date. Also, the UG
facilities are the once which are first to
be completed at site.

14 January 2019 Page 47 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Projects Jayesh 24-06-2017 Detailed Piping RFQ's Piping has wasted a lot of work hours Delay in finalising the The Procurement strategy for Piping NO Pending No
Bhave;Nitin Engineering preparing RFQ's which, we later found Procurement Strategy of Bulk Items to be finalised at the early Approval
Phatak out, were no longer required and this Piping Bulk Items stages of the project to avoid such
resulted in Delay for issuing RFQ's which delays.
were actually required

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Projects Jayesh 24-06-2017 Detailed Piling Design Civil had to re-design the Piles due to Client has asked Stress to re- An agreement to be reached with YES Pending No
Bhave;Nitin Engineering change in Future Pipe loads furnished by calulcate the future Pipe Client at Project initiation stage Approval
Phatak Stress Design loads (based on regarding the Basis for calculation of
available free space) as the future Pipe Design loads and the same
riginal loads that they to be mentioned in the Piping Stress
furnished were too high. Design basis.

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Projects Jayesh 24-06-2017 Detailed Stress loads for Multiple meetings, discussions and work Not having a work instruction A pre-agreed Piping load input format YES Pending No
Bhave;Nitin Engineering Civil Piling Design hour expenditure to finalise the load which clearly states what (in terms of content and when it has to Approval
Phatak format in which stress is supposed to give input stress is supposed to be issued) for civil piling design is
input to Civil for their Piling Design. give to Civil in order to required to avoid delays and
facilitate piling Design. unnecessary discussions.

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Projects Jayesh 24-06-2017 Detailed Workhours for Decrease in Productivity due to the work Only 2 hours (per TBE) were Workhours for any activity to be NO Approved No
Bhave;Nitin Engineering piping TBE's hour expenditure for finalising the piping considered for preparation of decided appropriately during proposal
Phatak TBE's TBE's when in fact a lot of stage
hours were required to
expedite TQ replies from
Bidders and to incorpoarte
(T2/T3) comments from Lead
office on these TBE's

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Projects Jayesh 26-07-2017 Detailed Foundation Revision in Foundation Loads of While issuing the Foundation FEG to validate the Platform YES Pending No
Bhave;Nitin Engineering Loads of Major Equipment (due to addition of Platforms Loads for Civil Piling Design requirment and Pipe Loads with piping Approval
Phatak Equipment and Piping) which is Impacting the Civil (PV Elite Calcuations), FEG prior to issuing the the foundation
Pile Design has furnished the loads Loads to Civil
without considering the
Platforms (in Model) and the
pipe Loads on the Equipment
and Civil has designed the
Piles as such. Later, FEG had
to run the Calculations once
again and Civil had to re-
validate their Pile Design.

14 January 2019 Page 48 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Projects Jayesh 26-07-2017 Detailed Equipment Finalsing th Equipment Locations with Piping had placed couple of Piping to first check with Civil regarding NO Approved No
Bhave;Nitin Engineering location Client without realising the Existence of Equipments in the Expansion existence of Expansion Bays on
Phatak Expansion Bay in the Piperack Bay of Piperack.Since, it is not Piperacks and refrain from placing
recommended as a good Equipments at this location.
enginnering practice to do so,
Piping had to relocate these
Equipments which caused re-
work in terms of Stress
Analysis and Modelling and
getting Client confirmation
for the same.

Jacobs Project No: 58RH444H Project Name: Confidential - MEG Unit Name: 4401 Client: Confidential Project Site Location: US Gulf Coast

Projects Jayesh 20-09-2017 Detailed Modelling of Delay in Furnishing the Cleat info to Static Not modelling the small bore Even though Small bore lines are YES Pending No
Bhave;Nitin Engineering Small Bore Lines Equipment Vendors (Mainly Columns) lines (downcomers from modeled very late in the project, Piping Approval
Phatak Equipment) should model all small bore lines
connected to Equipment to ensure
cleat info can be furnished to Vendor
at the right time.

Jacobs Project No: 58SR034M Project Name: BP Process Safety Automation Unit Name: BP Whiting Refinery Client: BP North American Products Project Site Location: Whiting, Indiana

Projects Mukund Ghadge 03-07-2017 Detailed Piperack In existing plant, new cable tray supports The lasser scan data was not While modeling of new cable trays and NO Approved No
Engineering and pipe supports are planned on new clear enough to identify free piping, study of existing pipe rack for
cantilever taken from existing piperack space on existing pipe rack. free place available is necessary. Use of
column. Therefore to avoid clashes such free space for new pipes or cable
with existing pipe and cable trays can save supporting cost.
tray, new onecs are placed
baside pipe rack on cantilever.

Jacobs Project No: NL6921 Project Name: SDA Unit Name: SDA Client: Shell P & T Project Site Location: -NA-

Projects Pawan Gupta 18-05-2017 Detailed SDA- Piping JEM asked about the Field Weld Field weld philosophy and This philosophy need to be defined in NO Approved No
Engineering General philosophy and requirement of Field spliting philosophy to be start otherwise result in spliting of iso
welds to be followed in project . JNL finalised in bignning and hence the work hours
instructed to follow the readable and
logical splits with Field weld.

Jacobs Project No: NL6921 Project Name: SDA Unit Name: SDA Client: Shell P & T Project Site Location: -NA-

Projects Pawan Gupta 18-05-2017 Detailed Hycon WUS Requirement such as Vibration Damper, Requirment for vibration Such requiremene should be known in NO To minimize work at height at Approved No
Engineering location of saddle needs discussion since damper was informed by TBA stage so that provision for space site, Shell decided to implement
beginning and early involvement for vendor after tba stage . requirement can be maded in design the concept of pre-dressed
Predressing vendor stage to avaoid clash with piping column - all piping, instruments,
structure, insulation is installed
on the column in workshop -
before erecting the column at
site. This was a new concept
implemented successfully on
SDA project

Jacobs Project No: NL6921 Project Name: SDA Unit Name: SDA Client: Shell P & T Project Site Location: -NA-

Projects Pawan Gupta 18-05-2017 Detailed SDA- Piping Interlinking of PDMS and JPI has caused PDS administration was For next project for PDMS /JPI/EDB NO Approved No
Engineering more and more attention to resolve the lacking to solve the issue on linkage proper training should be given
programmable errors time to user to save time during issue of
deliverables

14 January 2019 Page 49 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: NL6921 Project Name: SDA Unit Name: SDA Client: Shell P & T Project Site Location: -NA-

Projects Pawan Gupta 18-05-2017 Detailed SDA- OSBL Pipe Ferris structure design was different than Contractor desing was Philosophy of design to be frozen in NO Approved No
Engineering rack desing Jacobs original design resulted in Several different than design by the start of the project .
Clash of Piping

Jacobs Project No: NL6921 Project Name: SDA Unit Name: SDA Client: Shell P & T Project Site Location: -NA-

Projects Pawan Gupta 18-05-2017 Detailed SDA- General Interface between Piping and Interface drawing not This drawing will provide better clarity NO Approved No
Engineering Instrumentation - At the beginning of prepared for working hands from scope point of
project Piping & Instrumentation view (Normally it is observed that
Interface drawing to be prepared jointly Complete information is not available
to define the scope of each discipline on PEFS, it is not practical). Especially
against each type of instrument. when we are working in workshare
environment.

Jacobs Project No: 44NY9800 Project Name: MEG Debottlenecking 180% Project Unit Name: Client: Reliance Industries Ltd. Project Site Location: Dahej

Projects Pulkit Kakadia 22-09-2014 Detailed EOEG Pump PDS has to pass through long Hydraulic calculations for In DBN project, existing isometrics for NO PDS updated with Approved No
Engineering approval cycle. pumps were done using piping and existing Instruments details hydaulic calculation
length based on plot plan. for revised flow to be considered for performed using
pump hydraulic calculations. existing isometrics
and issued for
engineering

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 construction pms As per piping specification (18-2698-000- Pending No
L-02-0004-A4), ITB (Page No. – 00952) Approval
½”f to 6” ‘J2A’ specification seamless
galvanized pipe. But approved QAP (Code-
1) Refer IOTL/IOCL-M/QAP/88 Dated April
30, 2004 is indicating the ½”f to 6”f GI
pipes as per IS 1239 ERW heavy.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Construction hydrotest SECTION 2 INFORMATION REQUIRED- Pending No


Exchanger E-25 (Naptha Fuel Approval
Superheater) filled with N2 (0.5 Kg/w)
has been received at site ITB requires
hydrotesting of heat exchangers in
foundation . We have to decide on
followingi. After hydrotesting whether
again N2 gas needs to be filled or not,
document is silent about this.ii. The
timing for hydro test needs to be
discussed. If we delay hydrotest and keep
vessel filled with nitrogen then it will
delay piping erection frontiii. Specify for
how much duration exchanger can be
kept without N2 purging.iv. As per
hydrotesting procedure, clause 3.27
confirm whether testing to be carried out
for all exchangers or only critical
ones.Please clarify at the earliest.

14 January 2019 Page 50 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Construction painting SECTION 2 INFORMATION REQUIRED- Pending No


Refer Table 6.2 of painting specification, Approval
Heat resistant silicone Aluminium paint (F-
12), Note Given for hard dry specifies
curing gradually for 6 hours at 177oC in
service as per manufacture’s
recommendation.DAELIM has procured
Bombay Paints make F-12 paint.
Catalogue for F-12 paint recommends
curing at 200 oC for 90 minutes to
achieve effective performance. Maximum
operating temp for one particular line as
per line-list is 40 oC but since Design
temperature is around 300 oC. paint
system as per clause 8.3 (F-12) has to be
selected ( as per previous RFI reply on
above ground piping design temp of pipe
to considered for paint selection).Please
advise on 1.What is the method for
curing- what are the precautions,
parameters to be taken care of2.When
should the curing be done- immediately
after painting before drying or after some
time or any time convenient3.Any
manufacturer ,s equivalent paint which
doesn’t need this heat curing.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Construction painting SECTION 2 INFORMATION REQUIRED- 1. Pending No


Painting specification VSS-2002 specifies Approval
design temperature as reference for
selection of Paint system. However it is
not clear to us whether it indicates the
pipeline design temperature. It is felt that
the basis for painting should be the
maximum operating temperature.
Please confirm2. Please refer line index
submitted by DAELIM (DALM-E-805)If we
use design temperature as criteria for
selecting painting system, Paint system
for uninsulated CS piping for temp range
60 Deg C to 120 Deg C shall be(F9+F11)
i.e. Finish coat for almost all paint system
in the plant will be Heat Resistant
aluminium Paint.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Construction fire fighting The fire fighting system drawing for Pending No
substation #32 (DHDT area) from M/s Approval
Vijay Fire does not indicate water spray
system for the two new 2 transformers
(16 Mva)As per ITB document for “scope
of work piping” part III- water spray
system to be provided for transformers
more than 10Mva rating.PID of M/s Vijay
Fire is silent in this regard.

14 January 2019 Page 51 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Construction Welding Ø Daelim has procured directly mounted Pending No
dissimilar pressure transmitter for all classes of Approval
materials piping. Ø Regarding welding of (SS 316)
PT on NACE piping (with HIC
requirements) arrange to clarify following
for Ex. (PT 1508 on line 3”-P-302-1513-
A27A).Ø Dissimilar welding precautions to
be taken such asi) qualifications of SS filler
wire (ER-309)ii) SR requirementsiii)
Hardness requirementsiv) Any other
specific requirements for dissimilar
weldingØ Presently for all NACE piping,
electrodes / filler of only tested / qualified
batches are being used.

Jacobs Project No: BC-2698-02 Project Name: DHDT & MSQ Upgradation Unit Name: Offsites and Utilities Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Construction PMS Drg no: - i) 5283-A1-005 (sheet 1 of 3), Pending No
Rev.Fii) Piping Material Spec. IOTL-366-0- Approval
PL-039-01 (sheet 1 of 3), Rev.C As per
the above drawing nozzle N1 of water
seal drum 64” NB is of DIN 2633 standard
to which 64”-FL-399-0101-A1A is to be
connected. However in the PMS of IOTL
under A1A class 64” flange type &
standard is not given. IOTL has not
procured flange to DIN 2633 standard.
Please suggest further course of action.

Jacobs Project No: BC-2698-07 Project Name: DHDT & MSQ Upgradation Unit Name: MSQ- NHT, ISOM, RS, SWS, TGT Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Construction pms DRG. / DOC. NO(s): CIR-0017-MSQ-020PP- Pending No
IS-0003 Sht ½ & 2/2CIR-00017-MSQ- Approval
020PP-IS-0002 Sht 1/1P&ID CR-00017-
MSQ-020-1131 Rev 3 As per the above
drawings - 1) 2” isolation valves provided
on vessel 020-V-21 SP1/ SP2 are having
two piping class specifications top
isolation valve tag no as per drawing is
51321 (falling under class
A3A,A13A,A33A) and bottom isolation
valve tag no is 51392 ( falling under class
A2A –IBR). Please check and clarify.2)
Specification for bottom drain valve on
the stand pipe is considered under A3A
class, where as P&ID marks A3A class
after isolation valve. So, should the valve
be considered under A2A class. Please
check and clarify.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Construction Material non- As per contract, positive material A deatiled procedure should be All rejected materials Pending No
conformity in identification was carried out for all AS / developed for PMI to check material were replaced. Approval
PMI test SS material items before fabrication and non-conformity and unifrom marking
also after erection / installation (before system of various metallurgy in LSTK
Hydrotest). This PMI was applied for all ware house
piping, heater coils, storage tanks and
vessels. Approx. 269 cases of material
non-conformity in various units

14 January 2019 Page 52 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 construction PMS SECTION 2 INFORMATION REQUIRED- 1) Pending No


As per PMS high point vent indicated as Approval
V4 type i.e. with isolation valve for the
piping classes A1A, A27A, A33A, A1K,
B2A, B27A, F2D and J2A but Daelim
isometrics do not show isolation valve for
vent for the same.We have asked Daelim
to follow PMS.2) PMS indicates that for
piping classes E14A, E35A, E52A, E5E,
F2A, F2D, F36M vent and drain shall be
provided with double valves, even in
these categories also Daelim isometrics
do not indicate valve on vent. However
we have asked Daelim to provide vents as
per PMS. Some of the Daelim isometric
nos. randomly checked by us is given
below for your reference.a) ISO-DALM-IS-
301-SH-2701 C, D - F2Db) ISO-DALM-IS-
301-SH-0801 A - F2Dc) ISO-DALM-IS-301-
P-0203 A - F36Md) ISO-DALM-IS-301-P-
0204 A - F36Me) ISO-DALM-IS-301-P-
0205 A - F36Mf) ISO-DALM-IS-301-P-0206
A - F36Mg) ISO-DALM-IS-301-P-0207 A -
F36Mh) ISO-DALM-IS-301-P-0210-0215 -
F36Mi) ISO-DALM-IS-301-P-0218 C,E,G,I -
E35A3) PMS does not indicate type of
vent to be used for the following piping
classes. A2A, A3A, A5A, A9A, A11A, A14A,
A16A, A35A, A6K, A11K, A37K, B1A, B5A,
B9A, B14A, B35A, B38A, B2D, B5D, B1K,
B11K, B50K, B16M, B26M, D1A, D2A,
D5A, D14A, D16A, D52A, D2D, D5D, D5E,
E1K, E36M, F14A, F52A.Please confirm
the followinga) For Sr. 1 and 2 valves are
to be provided for vents as per PMS.b)
Type of vents and drains to be provided
for Sr.No. 3.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Construction Nitrogen plant In Nitrogen plant, no vent hole was found Through checking of trunnion supports Action taken to Pending No
in trunnion supports and welding was required before welding at site. rectify the defects Approval
completed in many places. As per piping and ensured that no
support standard drawing, one no. 5 mm welding should be
dia vent hole at 20 mm distance from done without
bottom of trunnion is to be provided. providing vent holes
in trunnion supports
as per secification.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 PMC Phase-2 HP heat Party has selected non standard flanges in Detailed review during engineering Design of all the 52 Pending No
(Engineering exchangers - piping circuits as well as nozzle flanges. stage required. nos flanges were Approval
by LSTK) Non standard This would have posed maintenance changed and made
flanges problem subsequently. standard.

14 January 2019 Page 53 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 PMC Phase-2 USE OF 3 D In earlier projects, deisgn of the plant was Use of 3 D model review should be For the first time in Pending No
(Engineering MODEL REVIEW done through conventional methods done in detail covering all instrument Mathura Refinery, 3 Approval
by LSTK) which resulted in wrong MTO, fouling of connection and hook ups and branch D model review
piping, improper spacing between cable routing. After actual dimensions (Through PDS) was
equipment and other related problems of instruments are available, this carried out for all the
resulting in large number of checklist should be incorporated in 3 D model process unit of new
points by licensor and operating and programme to run for final routing. projects. It helped in
department during pre-commissioning. correct designing of
structural,
equipment layout,
pipe routing,
electrical and
instrument main
cable routing etc.
However, instrument
hook ups and
location and branch
cable routing could
not be done. Since
closed couple
instruments were
used, fouling was
noticed with
adjacent piping at
some locations.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 PMC Phase-2 Pumps OWS/CBD Philosophy for Pumps was Pending No
(Engineering followed as per the Licensor UOP and the Approval
by LSTK) P&Ids given for Piping
engineeringComment/Change in
Philosophy by IOCL during Second Model
Review was given. With this, all Pumps
were required to have OWS / CBD
connection although the same was not
called for by Licensor/ P&ID (MSQ).

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 PMC Phase-2 Piperack Finalization of OSBL Pipe rack Length in Pending No
(Engineering TGT unit was as per Indicative Piping Approval
by LSTK) Scope Drawing for MSQ PLANT
(DIH/NHT/RS), TGT, Modified SWS (Drg
No. 18-2698-L-01-0705-A0 Rev 3) (96m
Approx.)However, the OSBL pipe rack
configuration in TGT unit as given in
Indicative layout was not feasible and the
total length of Pipe rack increased up to
231m. Also the configuration of the pipe
rack had to be drastically changed. This
design change called for preparation of
piping route study, preparation of civil
information drawings for load data and
rack cross section, preparation of MTO.

14 January 2019 Page 54 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 PMC Phase-2 Pipe rack on As per the piping drawing the structural Pending No
(Engineering north side of pipe rack on north side of DHDS plant Approval
by LSTK) DHDS plant should have three tiers i.e. at elevation
105.4, 107.4 & 109.4. However structural
drawing is showing only two tiers at
elevation 105.4 and 107.4 /107.750.
There is no tier for EPCC-1 cable
duct.Please suggest the routing for EPCC-
1 cable duct & EPCC-2 pipes from DHDS
building to DHDT building.

Jacobs Project No: BC-2698-02 Project Name: DHDT & MSQ Upgradation Unit Name: Offsites and Utilities Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 PMC Phase-2 Specification for SECTION 1 QUERY – We have received a Pending No
(Engineering Welding copy of “Job Specification for Welding Approval
by LSTK) Chart” submitted to you by DAELIM,
KOREA for PMC approval. Following
points need to be clarified1. Preheat: 100
C min is specified in welding charts, where
as per B31.3 Preheat for thickness up to
25mm is 100 C min and thickness above
25mm Preheat shall be 800 C.2. No post
heating is specified in welding chart for
Alloy Steel. As per welding
specifications(LSS-104), Alloy steel welds
shall be uniformly heated to 3000C and
maintained for minimum half hour if
PWHT is not performed immediately after
welding.3. Holding Temperature for P-1
material is specified as 5950C to 6950C
(page 7 of 15). As per B31.3 Holding
temperature shall be 5930C to 6490C.4.
Rate of Heating 2000C max is specified
please clarify whether this heating rate is
for all thickness? As B31.3 does not
specify any calculation for rate of heating,
which Code/ specification has to be
followed for rate of heating.5. In welding
chart E 8018B2L and E-9018B3L
electrodes are specified for P-4 and P5A
materials, where as, as per ASME Section
II C these electrodes are discontinued
from 1983 edition.6. In technical
specifications for Stainless steel material,
IGC tests are specified. Clarify whether
IGC tests are also required for PQR tests
of SS welds?7. In Annexure-B of Piping
material Specification Impact Testing is
specified for Pipe and Fittings of carbon
steel of thickness over 19mm and alloy
steel of all thickness. Clarify whether
same is applicable for PQR/ Welder tests
at site.

14 January 2019 Page 55 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Pre- CLOSED COUPLE Earlier the Instrument hook up were of Closed coupled instruments have Prefabricated close Pending No
Commissionin TYPE Conventional type with long impluse advantage over conventional hook up coupled instruments Approval
g/ INSTRUMENTS piping. Long impluse piping results in type. In addition to this, use of pre were used in DHDT/
Commissionin frequent maintenance problem in heavy / fabricated impulse piping should be HGU and site
g congealing service and measurement maximised as NDT, Hydrotesting, fabricated close
errors. installation of instruments of impuse coupled instrument
piping are done at Vendor works. in rest of the project.
This is based on past
failure of root
coupling in OHCU
plant at Mathura
refinery. The NDT of
site in-situ welding of
root coupling is
difficult and not
reliable. This
problem is avoided
in this close coupled
instruments.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Pre- LOW GRADE LOW GRADE TAPE COAT MATERIAL : Through visula inspection should be The material was Pending No
Commissionin TAPE COAT Undergound piping of Fire fighting system done while laying underground piping supplied by Rustech, Approval
g/ MATERIAL was coated with cold tape coat and was and should be procured from reputed Calcutta. The sample
Commissionin ready for under ground laying. During vendors. of tape coat was sent
g inspection before laying, it was observed for laboratory testing
that tape coat layer got softened in and found that
atmosphere and hanging like Stalactite penetration and
condition. softening point
values were lower
than specied in TC.
The material was
rejected and
removed from site.
Subsequently
procured from other
manufacturer after
complete lab test.

Jacobs Project No: BC-2698-08 Project Name: DHDT & MSQ Upgradation Unit Name: VB Diene Reactor Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Pre- piping material Non availability of few piping material and Detailed review of procurement of In order to expedite Pending No
Commissionin and instrument instrument cables in the scope of bulk material should be done in all the site work, Approval
g/ cables contractor review meetings to avoid last moment availability of these
Commissionin crisis. materials were
g checked with IOCL
and issued to
contractor on
chargeable basis.

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Pre- Frequent As per procedure, piping circuits are HP circuits should be flushed and then Standard procedure Pending No
Commissionin blinding / hydrotested and then flushed / air blown. hydrotested to avoid repeated of hydrotesting and Approval
g/ deblinding This resulted in repeated blinding / handling / fixing of heavy blinds / flushing adopted
Commissionin during hydrotest deblinding and consumed substantial deblinds
g time specially in HP circuits.

14 January 2019 Page 56 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: BC-2698-01 Project Name: DHDT & MSQ Upgradation Unit Name: DHDT, HGU, Nitrogen Client: Indian Oil Corporation Ltd Project Site Location: Mathura

Projects R. P. Gaikwad 30-06-2005 Pre- Lekage in HP During commissiong of the unit, it was High pressure and high temp.piping Matter was referred Pending No
Commissionin exch. piping found that most of HP exchangers circuits should be examined thorougly to LSTK contractor Approval
g/ circuits inlet/outlet flange joints and other related through stress analysis at different and PMC
Commissionin piping circuits of HP exchangers were temp. and not only at design operating independently to
g leaking at moderate temp (around 110 pressure/temp. examine. Stress
deg. C) which had to be tightened with analysis at various
the bolt tensioner at required load. This set of temperatures
problem of leakage continued every time are in progress and
during start up of the unit after shutdown based on outcome of
and had to be tightened resulting in delay the analysis
in start up of the unit. modification in
piping circuits /
supporting system
will be carried out.

14 January 2019 Page 57 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 18-3342 Project Name: IRUP - HGU Unit Name: Hydrogen Generation Unit Client: Indian Oil Corporation Ltd Project Site Location: Vadodara

Projects Samir Vohra 17-03-2010 Pre- HGU 1.Start Up Blower Pending No


Commissionin Approval
g/ HTAS datasheet wrote Centrifugal
Commissionin compressor. JE process data sheet also
g issued as Start up compressor
mentioning Centrifugal compressor.
.MEG issued an inquiry with all
standard attachments for a centrifugal
compressor. Procurement proposed
and IOCL approved vendor list for
Centrifugal compressors globally. With
in a month regret letters were
received.. Process/MEG should have
realized that the delta P required is too
small for a centrifugal compressor. Also
in earlier Mathura job we had used a
Roots blower. Then some
correspondence between PMC and
Licensor was discovered where HTAS
had clarified that a Twin lobe blower
can be used. After losing 4 months we
floated the inquiry for the blower.
During technical quote review the
pioneer designer of this blower,
Dressor Roots, was rejected since they
do not offer as per API and this is their
own design.. Later IOCL material made
an “ error “ in making FOA and almost
for six months Vendor did not accept
the FOA. Finally these were the last
equipment to be delivered and even
now ( Feb 23 ,2010 ) one Motor and
LCP are not delivered.

2.Reformer Inquiry/ poor B/L


definition

This job was awarded in a hurry to JE


when IOCL had prepared the MR for
reformer package .JE was to review
and issue with in two weeks. So the
scope of work and B/L were defined by
IOCL..E&I was not part of vendor’s
scope and Piping B/L was defined as
per P&I and not as per geographical
b/l. This created coordination issues for
engineering as well as construction. JE
had to buy Instruments to be mounted
on equipment supplied by Heurty. JE
had to bring a lot of lines within
Reformer area where the space
management/ lay put was Heurty’s.

Lesson relearned : All such packages


should have a b/l on the layout as well
as P&I.

3.Kick-off meeJng/InteracJon with


IOCL, Baroda

There was small kick-off meeting


involving only Process and planning
engineers. It was stated that for all
other disciplines KOM of DHDT to be
followed,Detailed interaction with
ultimate users happened on ly after
almost 30% engineering was over. This
was a deliberate move by IOCL, HQ to
push the schedule and monitor the

14 January 2019 Page 58 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

cost.Hence IOCL detailed technical


requirements were known at late stage
which led to rework and delays.. The
handing over of KOM points from
DHDT team depended on
Communication between leads which
was effective fo4r all disciplines except
Instrumentation.

4.Process Documents

Issue of updated process documents


was not as per schedule needs.. To
meet client’s expectations many
detailed engineering activities were
started based on Licensor’s documents
like MR for equipment and
Instruments. When JE process issued
updated documents for design many
inquiries were floated. In some cases
the revised documents called for
changes and led to amendments to
inquiries delaying the procurement
process. Glaring example is Globe
Control valves. In same cases some
valves were ordered in Mar 2009
where the first inquiry was floated in
Dec ,2007.( This case is treated
separately in this document ).The
sizing of safety valve discharge lines
was done after the lines were offered
for 30% model review and bulk MTO
was ordered

First point is that enough resources


should be deployed by Process after
the kick off meeting and issue all
process documents quickly before
Detailed engineering documents are
issued for next step i.e. procurement.
Secondly why licensor’s documents
need so many revisions ? Licensor who
is giving guerentee to the client issues
a package which needs so many
changes ? An assesment is required
about the extent of review and
updation of Licensor’s documents is
done by JE Process.

After Piping issues all the isometrics


substantial changes happen on the Line
list and P&Is for utility distribution
lines. Those should appear in Final
issue of P&I.

5.Mismatch of pressures between


PSA unit and Reformer.

PSA unit is free issue to JE. Off gases


from PSA tail gas drum flow to burner
of Reformer. Reformer burner vendor (
John Zink ) needs some min pressure.
Max pressure guaranteed by UOP
leaves very little delta P for piping in
between which has control valves. JE
has increased the line size from 30” to
34”.This has been recorded with IOCL
since early 2008 with agreement that
there is no other solution.

14 January 2019 Page 59 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

6.Mandatory spares for Instruments

It took a along time to understand


manadatory spares requirements
defined in TOYO’s design basis. Since
the requirement was not clear vendors
did not quoted properly and price
implications had to be invited.This
activity led to delays and finalizing the
order.In many cases ordering of main
instruments was delayed due
mandatory spares..

7.PSU procurement procedures/Lack


of IOCL resources

We took long time in understanding


the intricacies of PSU procedures. Due
to lack of resources in IOCL materials
recommendation files were piling up
and due to some minor detail missing
files were returned to us. Many orders
were delayed due to IOCL particularly
in later stages.

Jacobs Project No: 07PG1840 Project Name: K5 Utilization Project Unit Name: K5 Unit Client: Shell Chemical Project Site Location: Geismar, Louisiana

Projects Satyanarayan 24-11-2017 Detailed LFM Training to While doing the Stress Analysis Piping Piping Engineer do not have It was noticed that Piping Engineer NO Approved No
Shenoy Engineering Piping Engineer Engineer has to coordinate with Design the training on reviewing the along with Piping Designer has to
team for getting the existing line LFM model on their desktop spend extra hours for getting requisite
information, equipment details, PC. information. If there are any
supporting condition etc. to include data comments from checker or technical
in approval package. Design team auditor or independent reviewer,then
member has to spend extra hour in Piping Engineer has to spend time with
reviewing LFM model till Piping Engineer Piping Designer again. If Piping
get the sufficient information. Engineers are equipped with LFM
review tool, then spending of extra
hours can be reduced.

Jacobs Project No: 44QS6500 Project Name: Confidential Unit Name: XX Client: Confidential Project Site Location: confidential

Projects Vinayak 06-07-2017 Detailed SPRD set up Non Availability of the SEED files caused Contractual requirement for SEED availability of SPRD ,Piping NO LL repeated. Rejected No
Deo;Vinayak Engineering additional consumption of the availability of the Piping Support library to be reviewed in detail
Inamdar workhours.Piping Support Library was not Support library and other during pre-bid stage.
available. SEED files were not clearly
mentioned. Compensation
clauses in absence of these
files were not defined.

Jacobs Project No: 44QS6500 Project Name: Confidential Unit Name: XX Client: Confidential Project Site Location: confidential

Projects Vinayak 06-07-2017 Detailed SPRD set up Non Availability of the SEED files caused Contractual requirement for SEED availability of SPRD ,Piping YES Approved No
Deo;Vinayak Engineering additional consumption of the availability of the Piping Support library to be reviewed in detail
Inamdar workhours.Piping Support Library was not Support library and other during pre-bid stage.
available. SEED files were not clearly
mentioned. Compensation
clauses in absence of these
files were not defined.

Jacobs Project No: 44MM2800 Project Name: CDU/VDU, CFC LPG TREATING & ATF TREATING UNITS Unit Name: Client: MRPL Project Site Location:

Purchase 17-03-2011 PMC Phase-1 Purchase considered only 3 lots of Piping Our standard procedure. In all the future EPCM projects at least Pending No
(FEED) bulks while estimation of manhours. 5 lots of Procurement cycle of Piping Approval
bulks to be considered by Projects

14 January 2019 Page 60 of 61


Discipline Lead Date Project Plant Area Problem Root Cause Lesson Learned Need to Action taken Remarks Approver Approval Attachment
Engr Phase or Eqpt update Comment Status
WI

Jacobs Project No: 44AA9531 Project Name: NORTH JEDDAH BULK PLANT EXPANSION Unit Name: NJBP Client: SAUDI SERVO Project Site Location: NORTH JEDDAH
ELECTROMECHANICAL (SSEM)

Water Utilities Sanchit Joshi 03-05-2018 Detailed Overall Storm The grading of entire site for NJBP was Storm water network should For such kind of projects, storm water NO Pending No
Engineering Layout Plan not graded with respect to storm disposal have been the priority for disposal arrangement should be given Approval
network. For this project we had to grading of the site, but it was priority and then site grading should be
connect proposed storm network to not considered during FEED done accordingly.
existing storm facility, hence the levels for design / 30% submission
storm water network tie in points were
fixed and governed the design. Since this
was not done initially, Finished Grade
Levels were changed during 60% stage,
which affected other disciplines. Also,
since piping levels were already fixed
during 30% submission, levels in pipe rack
area couldn't be changed later which
resulted in low velocities than specified in
SA standard for storm water flow in
channels in some areas.

14 January 2019 Page 61 of 61