This area of investigation was directed toward addressing the influence design and construction practices have (or will have) on the Utility Units’ Asset Management Program.
DESIGN AND CONSTRUCTION ISSUES FOR MODIFICATIONS | PLANT INTEGRITY MANAGEMENT
Table lists the issues addressed and the resultant findings.
|Design & Construction for Modifications|
|How is responsibility for implementing approved design changes/unit upgrades determined?||Projects with an expected cost of less than SR $15 million is the responsibility of the Safaniya GOSP; larger projects are the responsibility of the Saudi Aramco corporate projects organization.|
|How is Quality Assurance addressed throughout design and construction?||There are QA/QC procedures within Safaniya GOSP that have the intent of ensuring that projects being implemented are completed correctly with appropriate materials.
However, there was limited quality control of a construction contractor during a new project. An example was the preparation of the grout for the pumps, 1412 B/C/D, which was done not following industry practice. It was prepared in a wheel barrel. Inspection in the field showed that it was starting to crack, with oil seeping into the cracks.
|How are codes and standards applied during design?||Design is work performed in accordance with industry and Saudi Aramco standards.|
|What specifications are produced for new or replacement equipment? How is design fitness- for-service ensured?||The specifications produced are developed based on the process and operating conditions (current and future) to be met by new or replacement equipment and systems. Fitness for services is accomplished though staged design reviews at the 30%, 60%, and 90% completion gates. There was one project, BI-169 for the Safaniya Water System upgrade, which was accepted from the contractor that did not meet its intended function.|
|Have steps been taken to reduce the need for inspections/ PMS as part of equipment fabrication (e.g. through the use of preferred fabricators)?||Safaniya and Saudi Aramco, in general, work with approved vendors.|
|What safety and hazard assessment studies are carried out at the design stage (e.g. HAZOP, HAZID, PHA, SIL, etc.)?||As directed by the plant.|
|How is redesign safety addressed?||Though application of the latest safety design standards and application safety assessments when required.|
|How are plant modifications addressed in the Asset Register?||New equipment are entered into SAP.|
|How are actions or changes arising from construction work listed and tracked?||Information not available.|
|What input do the unit operations, maintenance and engineering staffs have to the design and construction of modifications?||Machinery engineers review project designs, but do not participate in the selection of vendors for projects done in central engineering. As a result, incorrectly specified equipment has been purchased resulting in higher maintenance costs. Additionally, The Reliability group does not get involved in is the review of new projects from a reliability and maintainability perspective.|
The key findings from the Design and Construction for Modifications area are summarized as follows:
• The acceptance and implementation of the newly installed Safaniya Water System upgrade, which because of its design, does not allow for maximum through-put for oil separation has resulted in a requirement that require additional resources over and above that originally anticipated. Recommendation: Improve the process and oversight of design/construction/commissioning activities carried out by contractors. This should include selection and training of Saudi Aramco personnel to ensure those with sign-off authority have sufficient knowledge and understanding to ensure contractors meet all specified requirements.
• There was no evidence that unit/site level personnel have input into upgrade projects, especially in the area of vendor selection and reliability and maintainability issues. Recommendation: Develop a process that allows for input of site field experience into upgrade design review process.