dahej standby jetty 2264

07 21st November 2013

2264/Design Co-ordination

Mr. B.K.Naik AUDITOR

Sr.

No.C S OBS NC

ISO 9001:2008

Clause for NC

1

2

3

4

5

6

7

8

Definition :

Confirmance (C) : Fulfillment of a requirement.

Suggestion (S) : Aeras for Improvement as suggested by Auditor

Observation (OBS) : Lapse in fulfillment of a requirement at the time of audit which is likely to turn into Non-confirmity.

Non-Confirmity (NC) : Non-fulfillment of a requirement.

(Requirement : ISO 9001: 2008 standard’s Requirement and Requirement as per Quality Management system)

Record Notes of Audit

AUDIT OBSERVATION SHEETDoc No. : QF 9001 08

Rev No. : R3

Date : 14.07.2010

of 1

Audit No. DATE

Site/Dept.

Auditee D A Gaikwad/

Vivek Shukla

Document controller is not following the DMS system as per the instruction from

client.

Final evaluation report of consultant to be prepared with consulting with H.O.

SIGNATURE

QMS certificates and Quality policy were displayed.

Procedure for Design management PR994803 Rev.03 dt.22-01-2013 Found

available.

Document Transmital MF-PLL-AFC-D-L-1829 dt.8/10/13 is approved as code 1

by client via transmital series MF/AFC/PLL/T/S/1145 recorded and found

available.

Performance rating of design consultant M/s Proes Consultors has been checked

for every six months recorded and found available.

Assistance in getting approval from clients for design calculation,drawing etc is

rated as average i.e. 65% from H.O. records are found available with auditee.

Initial consultant evaluation Form has been checked found available.

07 20th November 2013

2264-Dahej Standby LNG Jetty -QAQC- Civil

Mr. Subhash Gite,Mr.Santosh Sharma,Mr.Rishi Agarwal AUDITOR

Sr.

No.C S OBS NC

ISO 9001:2008

Clause for NC

13

14

15

16

17

Definition :






SIGNATURE

Audit No. DATE

Site/Dept.

Auditee

Report for Size & Gradation of aggregate dt. 11/11/13 and 04/11/13 found

available.

Final chemical test report on GGBS vide document CIVILAID:GGBS:10/861

dt.16/11/11.source-Heidberg cement ltd found available.

Punch List of Construction reference. MF/AFC/PLD/50 Rev.Ro dt.4/5/13 is

monitored and record is available.

Method Statement for survey vide doc.2264/PLNG/MS/044 is available. As built

document of pipe tug berth 2 forPile P6 report no.TB P6 is verified.Tollerance of

RL in mm not mentioned in report.

The certificate for mix design test of M-55 grade concreate approved by client

found available.

D A Gaikwad/

Vivek Shukla



Rev No. : R3

Date : 14.07.2010

of 2

07 22nd November 2013

2264/Planning & Monitoring

Mr. Shailendra Patil & Mr. Madhusudan V. AUDITOR

Sr.

No.C S OBS NC

ISO 9001:2008

Clause for NC

1

2

3

4

5

6

7

8

9

10

Definition :







Interim project completion report available.How ever lession learnt & contriant

faced and resolve shall be incorporated in project completion report

Extension of time (EOT) outward mail to PLL(Client) found available along with

delay analysis,impact schedule and delay event summary dt.06/07/2013 ref.

MF/AFC/PLL/L/S/1398

Contract specification,job specification found available.

Monthly progress reviews for october2013 found available in addition with

months lookhead program on daily basis is found available.

Project Quality plan MF/AFC/PLD-PRO-18 dt.15/07/2011 rev.02 found available.

Customer communication register maintained.Case-1-Gap between precast slabs

on approach trestle are less than 50mm causing damage to edges Ref. letter from

client MF/PLL/AFC/S/L/0178 and from Afcons(EPCC) response is 50mm gap

upto bent-20,gap was further reduced to 25mm similar to existing jetty as per

instruction by Client(PLL) during the initial site inspection, finished photograph

attached ref. letter from Afcons(EPCC) MF/AFC/PLL/L/S/1487 records found

available.

SIGNATURE


Rev No. : R3

Date : 14.07.2010

Page 1 of 1

Daily progress report(DPR) is maintained and found available.It is reported to

H.O. and client.

Customer feedback form from July-2013 to Sep-2013 found available.

Bar chart for physical progress with planned activities found available.

Audit No.

Site/Dept.


Vivek Shukla

Master list of records doc. No. MF/AFC/PLD/PRO/04 R3 found available.

DATE

07 22nd January 2013

2264/Quantity Surveying

Mr. Salunke & Mr.Santosh singh AUDITOR

Sr.

No.C S OBS NC

ISO 9001:2008

Clause for NC

1

2

3

4

5

6

7

8

9

10

Definition :






Staff productivity ratio found 16.80% against the target of 20.51%.

SIGNATURE

Record of subcontractor evaluation for selection and registration is available in

format no. QF 9940 1B.

Subcontractor performance evaluation for M/S Excel Manag. Services for the

month of september-13 records are available. Format QF-9940-02 rev.03,avearge

rating is A very good.

Waste management report of pile driving for 1320mm,914mm and 1270mm dia

pipes records are available percentage of wastage is 0.66%.reconicilation of

wastage is 0.81% against 9830MT.Concreate wastage is 0.43% against 22800

cubicmeter and for cement 0.72%,GGBS is 0.48% is monitor and records found

available.

Recocilation of wastage for Structural steel is 3.07% as on 31/10/2013 against total

receipt of 2566MT.

Reinforcement including laps & chairs is 3.96% against total receipt of 5268.510MT

records found available.

Previous Internal audit report no.6 dt.04/06/2013 is available with auditee.

Measurementbook i.e .Work done activity detail for October-2013 is found

available for M/S Excel measurement services bill dated.30/10/2013.

D A Gaikwad/

Vivek Shukla



Rev No. : R3

Date : 14.07.2010

Page 1 of 1

Audit No. DATE

Site/Dept.

Auditee

Manpower deputation & schedule of work at site is monitiored found available

Procedure for subcontractor selection & evaluation is checked by verifying records

of (catwalk,tower staircase & hand rails works) sub-contractor M/S Excel

Management services reg no. 204747.Quotations for 3 parties for the similar work


2264/Stores &Purchase

Mr. Siddharth Kumar & Mr. Madhavan AUDITOR

Sr.

No.C S OBS NC

ISO 9001:2008

Clause for NC

1

2

3

4

5

6

7

8

9

10

11

12

13

Definition :






Material issue voucher(MIV) found available.Last issued material is 30 lit Diesel

for 951- equipment code are rediable.

SIGNATURE

Quotation for material,code 49130092 i.e. 4 x15 kg/cm2" Pressure gauge

comparative sheet is not available/maintained in SAP.

M/s Doshi sales & services vendor reg. no. 100374 .Case-1-PO-450092775 with

delivery challan no.13358 and receipt note no.-5000270732 dt. 11/10/13 along with

Tax invoice & test calibration & warranty certificate no.121341020850384

dt.10/4/13 found available.

Vendor performance evaluation is carried out and records of the same is evident.

All the vendors are above B grade.

Store inventory list is not maintaine properly and updated.last update is on

30/09/13.

Multifunction meter SAP code 20119581 part no-0302-2096-07 make- cummins

QTY-1 is not found as mentioned in inventory list

Swtich handle code-20122860 Qty-3 location 3-B and Diode dtud(FWD)-code-

20119166 Qty-3,make model-cummins/40KVA not found as per inventory list

Wastage of reinforcement, steel is 3.741% excluding laps & chairs as on 30/9/13

against total receipt 5268MT records found available.

Tagging of material stored shall be maintained proper as per QMS procedure of

storage of material.

Master list of records doc.no.QR9001 04 rev.02 dt.1/12/2008 page 1 to 3 found

available with auditee.

Quality management procedure for Purchase of cement PR9925 01 rev06

dt.6/11/12 found available

Last audit report 06 dt.04/06/2013 was not available with auditee.

Procurement process verified by checking records of indent no. 2000078064.

Purpose of material indent is not indicated in SAP Procurement.

Audit No. DATE

Site/Dept.


Vivek Shukla


Page 1 of 1


Rev No. : R3

Date : 14.07.2010


2264-Dahej Standby LNG Jetty/CPE

Mr. Sushil T Jawalekar,Mr. Pranay D Datta. AUDITOR

Sr.

No.C S OBS NC

ISO 9001:2008

Clause for NC

1

2

3

4

5

6

7

8

9

10

Definition :






SIGNATURE

Organisation Chart Rev 4 dated 24/12/12.indicating roles and responsibilities

found available.

Preventive maintenance process was verified by checking preventive maintenance

records of 40 KVA diesel generator (Sr.no.DG15492) order no.1023934 in SAP

system

Decommissiong process for Schwing Stetter/CP30 dt.15/11/2013 via Service no.-

013c060/80200405/870 and form no.8571CP06 found available.

Preventive maintenance chart as per the format no. QF 9952- CP 10 (R1) is

available to track the preventive maintenance of equipments at site.

For Preventive maintenance of various equipment there is no checksheet found

available.For better tracebility document no. shall be same as per Master list of

ISO documents list and SAP document no list.

Weekly equipment breakdown report is maintained and found available.

Equipment cost statement vide Document no.-QF9952CP06 for the month of

Octomber-2013 found available.

Hired equipment moinitering summary doc.no.QF 9952 CP07 found available.

Method statement for prventative maintainance found available on SAP.

Consumption for crawler crane 122 tonnes capacity found 7.85 to 8.35 lit/hour

against the set norm of 6 lit/hr which is on higher side than the company

norms.Root cause analysis report is forwarded to H.O.The same issue is still open.



Rev No. : R3

Date : 14.07.2010

Page 1 of 1

Audit No. DATE

Site/Dept.


Vivek Shukla


2264-Dahej Standby LNG Jetty -QAQC- Civil

Mr. Subhash Gite,Mr.Santosh Sharma,Mr.Rishi Agarwal AUDITOR

Sr.

No.C S OBS NC

ISO 9001:2008

Clause for NC

1

2

3

4

5

6

7

8

9

10

11

12

Definition :






Organizational chart Rev04,dated 28/05/2013 found updated & displayed.

SIGNATURE

Project Execution Plan MF/AFC/PLL/T/S/02066 Rev 1 dated 20/7/11 approved

vide letter no. MF/PLL/AFC/D/L/0433 dated 22/09/11 found available.

Project Quality Plan MF/AFC/PLD/PRO/18 Rev 2 dated 15/7/11 approved vide

letter no. MF/PLL/AFC/D/L/0301 dated 19/7/11.

ITP for Coarse Aggregates rev.02 dated 15/-7/2011 found available.

The Concreate cube test for MD-5 conducted on 19/11/13 was found traceable

and the strength is 56N/mm2 for Grade concreate M-55 .Pourcard,R/f

checklist,formwork checklist found available.

Standard Deviation for grade concreate M-45 is 0.03% achieved.

Concreate pour card,cube id mark-MD5-P,Inspection checklist for batching

plant,Reinforcement Inspection checklist dt.15/10/13 were found available.

Calibration Certificate of Cube Test Machine (CTM).Certificate no.-

CTM/96/13.Cal.dt. 11/09/13,next due dt. 10/09/14 found available.

Calibration plan displayed and Calibration status format no. QF852201 found

available.

Percentage wastage of fine aggregate is 9.24%.The same for coarse aggregate is

1.17 %for 10mm and 1.58% for 20mm recroded for the month of October-2013.

As stated in ITP Flakiness/Elogation test vide code IS:383/IS:2386 once in a

week record was not available with auditee.

Impact value test once in a month as stated in ITP report was not available with

auditee,



Rev No. : R3

Date : 14.07.2010

Page 1 of 2

Audit No. DATE

Site/Dept.


Vivek Shukla


2264-Standby Jetty /QAQC- Mechanical

Mr. Kartikayen,Mr. Nilesh Patil AUDITOR

Sr.

No.C S OBS NC

ISO 9001:2008

Clause for NC

1

2

1

2

3

4

5

6

7

8

Definition :






Master list of records vide doc.QF 9001/04 R0 Dt.31/05/2012 found available and

displayed.

Organizational chart Rev.04 dated 28/05/2013 available & displayed.

SIGNATURE

Raw material inspection & identification format MF/AFC/PLD/QF/40 dated

11/1/11 Rev. 0 found available.

Previous Audit 06 dt.04-06-2013 report is found available.

Records found available for repair joint of Rewelding.

ITP for structure steel fabrication & Erection ITP no.-MF/AFC/PLD/ITP-18

REV.02 DT.29/12/2011 Found available.

ITP for painting for pile MF/AFC/PLD/ITP-17 dated 22/9/11 rev 1 is available.

Calibration report for Welding machineMEMCO-Sr.no.-M/43476 found

available.As per standard BS:7570:2000 Validation accuracy for standard grade

power source for voltage & current is +or - 10% which is not mentioned on

calibration report.

Client technical specification found available.

Electrode baking oven sr. no. HIEC/II/08/09/84 Calibrated on 03/10/2013 next

calibration due is 02/10/2014. Certificates found available.



Rev No. : R3

Date : 14.07.2010

Page 1 of 1

Audit No. DATE

Site/Dept.


Vivek Shukla


2264/Execution- Pilling(Samart Jack-up)

Mr. Ratan Salunke AUDITOR

Sr.

No.C S OBS NC

ISO 9001:2008

Clause for NC

1

2

3

4

5

6

7

8

9

10

11

Definition :






SIGNATURE

QMS certificates and Quality Policy are displayed found available.

Sequence of Pile driving for MD Pile no.-9 drawing no.

AFC/2264/KRA/DAH/049 is Under progress.

Method statement for MD driving of pile sequence ref. MF/PLL/AFC/DIL/1158

Rev-1 dt.19/10/12 under code 1 by samarat jackup found available.

Pile driving for MD-02,Ref.drawing no.-MF/AFC/PLD/DWg/MD/02 sheet 2 of

2 rev-R0 Pile no.-09 is under progress.Pile driven criteria is 42 blows/25cm for

terimination. 72mtr pile is driven.

Current pile detail pile 09 MD-02 from 59.75 mtr to 60 mtr blows recorded is

18,from 70.25mtr to 70.50mtr,77 bloss are recorded which is more than the

required blows so that Pile is Terminated.

Guide fixing record found available .

As per the time cycle & lean principle, In 12 hr 1 pile is driven & for jackup

shifting 12hrs time is taken,For MD-01 jackup shifting on 10/11/13 and pile

driving is completed in 8 days total no. of pile is 14.

Work sequence for Piling for one week i.e. 18/11/13 to 24/11/13 is displayed and

target is achived upto 20/11/13/.

MD-05 to MD-08 all piling as well as civil work is completed.

Look ahead schedule for 3 weeks i.e. from 17/11/13 to 14/12/13 is found

available.

Constraint analysis are evaluated and remedials action has been taken with the

responsibilties and target record found available.



Rev No. : R3

Date : 14.07.2010

Page 1 of 1

Audit No. DATE

Site/Dept.


Vivek Shukla

dahej standby jetty 2264

Documents