Project Detail
Project: North Mountain Energy Project
Equipment: Air Inlet Filter Equipments
Date: May 2012 to to April 2013
Vendor Location: Fabricator of Air Inlet Filter Equipments in Cohahuila, Mexico.
Final Visual Inspection per ITP-104043-01 Rev 1 Item 19.
Item Inspected: MTT Filter Modules MTT-128-6, MTT-128-9 and End Filter Modules
Findings: Loose Hardware (Two Screws) were left within Clean Air Chamber of MTT-128-9 Filter Module-Unit 01 as well a Nut was not properly captivated by the tack weld applied at the screw end on End Filter Module.
Re-Inspection: Fraza Team has requested to Vendor Representatives to be extremely careful to ensure no loose hardware are left within the clean air chamber of Air Inlet Filter Equipments after closure and preparation for shipping. This is to prevent loose items migrate toward the turbine and cause irreparable damage on it. See Photos on Referenced Issue.
Visual Inspection per ITP-104043-01 Rev 1 Item 3.
Item Inspected: MTT Filter Modules.
Findings: Flat Bars located within the MTT Filter Modules observed with their edges in direct contact, such condition does not permit a proper blasting and painting coverage on those areas. In opinión from Fraza Team, this is an Issue, Not contemplated by the Design from Vendor.
Re-Inspection: Vendor Engineering Team have confirmed on a correction plan as follows, one of the two flat bars in each couple of them is to be removed in order to leave the other one with its edge free to be properly surface prepared and painted in accordance with the Specified Paint System. Completion of referenced rework has been confirmed by visual inspection. See Photos as illustration on referenced Issue before and after correction.
Visual Inspection on Hot Dip Galvanized Surfaces per ITP-104043-01 Rev 1 Item 13, Customer Spec 295-395435 Item 020 and ASTM A123/ASTM E376 Standards.
Item Inspected: Hot Dip Galvanized Structure Columns.
Findings: Observed a lot of areas on Galvanized Surfaces of Columns repaired by brush retouch since as explained from Vendor, the heat input from the Hot Dip Galvanizing produced a critical deviation on straightness of columns, which they tried to fix by heat application at an important number of locations, damaging locally the galvanizing, which was repaired subsequently by brush retouch. Fraza Team has reviewed this issue with Vendor Representatives and it has been confirmed and agreed, the quantity of locations repaired by brush retouch is Not Acceptable to ASTM Standards referenced above.
Re-Inspection: Per Customer Direction, all Referenced Columns have been Hot-Dip-Galvanized again in accordance with Standard ASTM A-123, as well all of them dimensionally inspected for straightness by Vendor QC Team and found acceptable to Project Requirements. See Photo as Illustration on referenced Issue.
Witness on Inspection of Tubesheet Flatness per ITP-104043-01 Rev 1 Item 11 and Vendor Workmanship Standard AIS-WQ-4.9 Rev 3.
Item Inspected: LH and RH End Filter Modules.
Findings: Local Flatness on Supports of Filter Elements on Tubesheet, Maximum Specified/Allowable Deviation of Lack of Flatness-0.125¨ per Vendor Workmanship Standard referenced above. Actual Flatness Deviations as measured, all of them exceeding 0.1875¨, by use of Specified Go No Go Device, Not Acceptable to referenced Vendor Workmanship Standard.
Re-Inspection: Vendor has conducted needed repairs to bring flatness condition to within tolerance per Project Requirements. See Photos as Illustration on Check of Flatness.
Visual Inspection per Quality Plan ITP-104043-01 Rev 1 Item 3.
Item Inspected: MTT Filter Modules.
Findings: Observed several welds at ends of internal stiffeners not properly tied into adjacent welds. This condition would produce rusting bleed out after painting.
Re-Inspection: Repairs completed by Vendor as confirmed by Visual Inspection. See Photo on described issue.
Witness on Holiday Test on Internal Coating per Quality Plan ITP-104043-01 Rev 1, Item 17 and Customer Spec 295-NM-435 Item 030.
Item Inspected: LH End Plenum Module.
Findings: Six Paint Voids detected on internal stiffeners,.
Re-Inspection: All Voids detected have been repaired by paint re-touch and after permitted drying time in accordance with the Paint Manufacturer Data Sheet all of them have been Holiday Tested again with acceptable results. See Photo as Illustration on Holiday Test.
Visual Inspection per Quality Plan ITP-104043-01 Rev 1 Item 3.
Item Inspected: RH Plenum Module.
Findings: Per Drawing-6MT-GT-1076826-02 Rev 3, Joint of Pad Plate of Lifting Lug to Module Structure, specified Fillet Weld size of 3/16” all around, Actual as measured, Undersized Fillet weld less than 1/8" on the side of the joint connecting with the limit of the module. Issue produced per Not Compliance to specified offset of ¼” between the lifting lug pad plate and the limit of module, really an offset less tan 1/8” was done there, therefore there was not enough offset to apply there a fillet size of 3/16” as specified, Not Satisfactory.
Re-Inspection: Per Customer Direction, lifting lugs have been removed, fitted-up again and welded in accordance with Drawing Requirements. See Photo as Illustration of described issue.
Visual Inspection per Quality Plan ITP-104043-01 Rev 1 Item 3.
Item Inspected: Transition Unit 01 Panel Weldment per Drawing 6MT-GT-1094435-01 Rev 1.
Findings:Joints of lifting lug to connection ribs, specified Fillet Weld Size 1/4¨ all around per Welding Symbols. Actual as measured, undersized fillet weld less than 3/16¨.
Re-Inspection: Vendor has completed on repair to bring fillet weld to required weld size as well specified PT Examination on referenced lifting lug welds has been conducted again. See Photo on described Issue.
Review on Engineering Documents per Quality Plan ITP-104043-01 Rev 1 Item 2.
Item Inspected: RH Plenum Module.
Findings: Fraza Team has reviewed on Drawing-8VT-CT-507826-01 Rev 3 and No Welding Symbols are shown for Joint of Side Skin to Module Structure.
Re-Inspection: Per Observation from Fraza Team the Vendor Engineering Team has issued a revisión of referenced drawing reflecting on missing welding symbols.This timely observation from Fraza Team has prevented making a wrong interpretation of welding symbols on Drawings and accordingly a wrong welding aplication.
Benefits to Our Customer: By using Fraza Inspection Team, Customer saved a lot of of time and money preventing excessive expenses per back charges for Re-works at field site per unacceptable issues on Flatness of Tubesheets, Weld Preparation,Welding, Surface preparation, Painting, Engineering, Galvanizing, Loose Items at Clean Air Chamber and Not Compliance to Project Specifications, if Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: High Valley Energy Unit 03
Equipments: Air Inlet Filter Equipments
Date: Januray 2018 to June 2018
Vendor Location: Fabricator of Air Inlet Filter Equipments in Coahuila, Mexico.
Visual Inspection on Trial Assembly per Vendor ITP-HV-78506 Rev 1, Item 9 and Drawing HVE-452T05-01 Rev 3.
Item Inspected: Trial Fitted Inlet Transition.
Findings: Both interface points in which converge the three transition panels identified as HV05-16, HV05-18 and HV05-22(RHV05-16, RHV05-18 and RHV05-22 on Opposite Side) show a gap of 1” x 2” approximately. This Gap is a serious risk to get contamination with dirty air from exterior toward chamber of clean air in transition.
Re-Inspection: Repairs completed properly by Vendor to prevent this risk of contamination with dirty air. See Photos as Illustration of Referenced Issue as originally found.
Review of Quality Requirements per Vendor ITP-HV-78506-316&318&320 Rev 2 Item 2.
Item Inspected: Equipments Trial Fitted.
Findings: Fraza Team has requested Vendor QC Team to confirm from Project Requirements if Welding application mainly on Major Seams specified to be continuous seal welded is acceptable after disassembling of Equipments which have been Trial Assembled. Vendor has to consider the distortion normally produced by the heat input during the completion of continuous seal welding of those joints after trial assembly. Such distortion produced after the Trial Assembly will cause the individual sections of the Equipment will not fit properly in their interfaces during the final assembly at Jobsite, losing totally the value and objective of having performed a trial assembly in the Fabrication Workshop.
Re-Inspection: Considering the observation from Fraza Team, Customer has confirmed to Vendor all equipments have to be 100% welded in accordance with Approved Drawings before Trial Assembly.
Dimensional Inspection per Vendor ITP-HV-78506 Rev 1, Item 14 and Drawing HVE-452T07-01 Rev 2.
Item Inspected: Expansion Joint, Inlet Flange(Field Interface Flange to connect to Vertical Duct).
Findings: Inspection on Flange Flatness, Maximum allowable deviation of Flatness for Inlet Equipments, 3mm per Tolerances on referenced Drawing. Actual Deviation on Corners of Inlet Flange as measured by use of a straight line, 8mm, Out of tolerance.
Re-Inspection: Vendor has completed on needed repairs to bring flatness of inlet flange to within referenced tolerances. See Photo on described Issue as found originally.
Visual Inspection on Primer Coating per ITP-HV-78506 Rev 1, Item 14 and Painting Specification HV76556-PS-01 Rev 3.
Item Inspected: Vertical Duct Tag-HV03-4 Unit 01.
Findings: A lot of areas, mainly on external side, observed with Mud-Cracking.
Re-Inspection: Repairs completed by Vendor by Reblasting and Re-Primer Coating on all defective áreas in accordance with Project Requirements. See Photos as illustration on Referenced Issue as found Originally.
Benefits to Our Customer: By using Fraza Inspection Team, Customer saved a lot of of time and money preventing excessive expenses per back charges for Re-works at field site per unacceptable issues on Dirty Air Contamination to Clean Air, Trial Assy, Flange Flatness, Painting and Not Compliance to Project Specifications if Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: Lowland F80 Unit 02
Equipments: Air Inlet Filter Equipments
Date: January 2019 - March 2019
Vendor Location: Fabricator of Air Inlet Filter Equipments in Nuevo Leon, Mexico.
Witness on Pneumatic Test on Air Manifold Assy per Vendor Quality Plan QCIP 162234 Rev 0 Item 10.4 and Documents referenced below.
Item Inspected: Air Manifold Assy of Filter Module.
Findings: A Not Acceptable loss of pressure was detected due to a leak located on the weld of square tube to the cover plate.
Re-Inspection: The pressure was lowered to zero, the area with leak was repaired by welding and the pneumatic test was carried out again, without detecting leaks or pressure drops. The area repaired by welding on Manifold has been Re-Coated by Spray Cold Galvanizing in accordance with Project Requirements. Test Pressure, 100 Psi, Holding time of 15 Minutes, In Accordance with Vendor Standard 3LL-AT-6.7 Rev 2, section 6.2. See Photo of Leak detected.
Final Inspection per Vendor Quality Plan QCIP 162234 Rev 0, Items 4.4 and Customer Specification-9LL-1026536 Rev 3.
Item Inspected: Splitter Silencer per Drawing 5LL-MU1028448 Rev 2.
Findings: An Excessive Gap of approximately 7/8” was observed between a Side Baffle and the Side Wall of Silencer.
Re-Inspection: Correction completed by Vendor to get a proper assembly of side baffle to side wall of silencer. See Photo on referenced issue as originally found.
Benefits to Our Customer: By using Fraza Inspection Team, Customer saved a lot of of time and money preventing excessive expenses per back charges for Re-works at field site per unacceptable issues on assembly and manifold air tightness, if Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: South Gulf Energy
Equipments: Air Inlet Filter Equipments
Date: May 2011 to to November 2011
Vendor Location: Fabricator of Air Inlet Filter Equipments in Cohahuila and Nuevo Leon, Mexico.
Visual Inspection on welds per ITP-AI-6513-02 Rev 2 Item 3, Drawing 6513-02 Rev 3 and Customer Specification AI-8712-08 Rev 5.
Item Inspected: Filter Modules Identified as AI801-AI802-AI803. .
Findings: Several Locations with Spatter in Clean Air Chamber, Not aceptable to Referenced Customer Spec Section 8.5.
Re-Inspection: Proper Cleaning up to remove any spatter from Clean Air Chamber Completed by Vendor before Blasting and Painting. This is to prevent loose spatter particles migrate toward the turbine and cause irreparable damage on it. See Photos as Illustration as originally found.
Visual Inspection on Weld Preparation per Inspection and Test Plan ITP-AI-6513-02 Rev 2 Item 3, Drawing 6513-03 Rev 2 and Customer Specification AI-8712-08 Rev 5.
Item Inspected: Transition Bracings Assembies.
Findings: Bracing item 5AI-RA87383-01, with weld preparation of Square Tube to pad plate observed with an excessive root gap produced per no enough length of the Square Tube Section.
Re-Inspection: Per Vendor decision the referenced Bracing have been permanently discarded and a new Bracing has been Fabricated. See Photos as Illustration on referenced issue.
Visual Inspection on Structural Bolted Connections per ITP-AI-6513-02 Rev 2 Item 15, Assembly Drawing 5AI-RA6513-01 Rev 0 and Customer Specification AI-8712-08 Rev 5.
Item Inspected: Beams and Columns.
Findings: Bolts fastening connection angles to Beam Item RT18 show ends of bolts flush with nut outer face or within nut body after tightening.
Re-Inspection: Vendor has re-tightened the bolts/nuts on referenced bolted connections leaving the end of the bolts at least flush with the outer face of the nuts, Acceptable to following statement per section 2.3.2 from AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts, “The bolt length used shall be such that the end of the bolt extends beyond or is at least flush with the outer face of the nut when properly installed. Corrections conducted by Vendor in accordance with Referenced Project Requirements. See Photo as Illustration on described Issue.
Witness on Leakage Pressure Test per ITP-AI-6513-02 Rev 2 Item 18.
Item Inspected: Manifold Assy of Filter Module # AI825.
Findings: Air Pressure Test at 109 psi during 15 Minutes, Detected Pressure Drop of 7 psi, Out of tolerance per Vendor Document AIS-WQ-6.8 Rev 2 section 6.8. Leak produced per crack observed at the Cover of Solenoid Valve which was replaced.
Re-Inspection: Air Pressure Test conducted again at 103 psi with No Leaks and No Pressure Drops during 20 Minutes. Acceptable per Vendor Document AIS-WQ-6.8 Rev 2 and ITP-AI-6513-02 Rev 2 Item 18. See Photo as Illustration of referenced Test.
Dimensional Inspection on Trial Assembly per Inspection and Test Plan ITP-AI-6513-02 Item 6, Drawing GA-5682-02 Rev 3 and Vendor Trial Assembly Standard AIS-WQ-5.8 Rev 3.
Item Inspected: Trial Fitted Transition.
Findings: Straightness of Lines of Slotted Boltholes on Outlet Flange: Actual Deviation as Measured: 5/32¨ to 3/16¨- Not Acceptable to Vendor Trial Assembly Standard AIS-WQ-5.8 Rev 3 Section 8.1.
Re-Inspection: Vendor has conducted needed corrections to bring the Straightness of lines of Slotted Boltholes to within referenced Tolerances, Max Straightness Deviation as Measured after Corrections, 1/16¨, Acceptable to Vendor Trial Assembly Standard referenced above. See Photo as Illustration on referenced Issue.
Visual Inspection on welds per ITP-AI-6513-02 Rev 2 Item 3, Drawing 6519-01 Rev 2 and Customer Spec 54-RUTSS-007 Rev 5.
Item Inspected: Filter Modules Trial Assembled.
Findings: Drawing 6519-01 Rev 2 specifies for stitch welds on Clean Air Chamber as done, however It is Not Acceptable to Section 8.3.3 of Customer Spec 54-RUTSS-007 which specifies for “all structural strength welding, all welds in places that are not self-draining and all welds of edges of tightly contacting surfaces Shall be continuous welds”.
Re-Inspection: Referenced joints have been continuous seal welded at their entire length by Vendor to comply with referenced Customer Requirements. See Photo as Illustration of described issue as originally found.
Benefits to Our Customer: By using Fraza Inspection Team, Customer saved a lot of of time and money preventing excessive expenses per back charges for Re-works at field site per unacceptable issues on Manifold Air Tightness, Lack of Cleanliness on Clean Air Chamber, dimensions, Welding, Assembly, Weld preparation and Not Compliance to Project Specifications, if Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: North High Land F60 Unit 01
Equipments: Inlet Filter Modules and Inlet Transition
Date: September 2016 - October 2016
Vendor Location: Fabricator of Air Inlet Filter Equipments in Cohauila, Mexico.
Dimensional Inspection on Trial Fitted Transition per Inspection Plan NHL-384037-01 Rev 1 Item 3.6, Drawing 5NHL-384037-01 Rev 0 and Documents as referenced below.
Item Inspected: Trial Assembled Inlet Transition-Tag NHL-384037-02.
Findings: Straightness of Lines of Boltholes on Outlet Flange, Actual Deviations as Measured, Right Flange/Left Flange, 5mm/6mm, Out of Tolerance per Vendor Trial Assembly Standard NHL-QS-5.4 Rev 3, Section 2.8.
Re-Inspection: Vendor has conducted the needed corrections to bring straightness of lines of boltholes to within Tolerances per Vendor standard referenced above. Max Deviation as measured after corrections, 2mm. See Photos on described Issue as originally found.
Benefits to Our Customer: By using Fraza Inspection Team, Customer saved a lot of of time and money preventing excessive expenses per back charges for Re-works at field site per unacceptable issues on Dimensions, if Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: South Mountain Energy Project
Equipments: Air Inlet Filter Equipments
Date: October 2017 - January 2018
Vendor Location: Fabricator of Air Inlet Filter Equipments in Nuevo Leon, Mexico.
Review on CMTRs per Quality Plan QP-1536145 Rev 0 Item 2.1, Drawing 5NM-1536145-01 Rev 1 and Customer Specification SM-426600 Item 0020-0040.
Item Inspected: Leg and Ladders Kit.
Findings: 3/4” Dia-Round-Bar for Ladder rungs, Specified Material CS ASTM A36 per Referenced Drawing. Round Bar Material described on CMTR as Grade R42 for Heat Numbers 240608, 240609, and 241749. CMTR reports 0.41 to 0.42 % Carbon, which is an Excessive % Carbon for a weldable material per Material Specifications such as ASTM A36 (0.26% C Max allowed) and other Weldable Material Specifications.
Re-Inspection: Fraza Team has been requested to Vendor QC Team to identify and segregate this Material in order to prevent it be used in this Project since serious weldability problems such as susceptibility to cracking may be present if used. Issue prevented by Vendor in accordance with observation from Fraza Team. See Photo of Reviewed CMTR.
Visual Inspection on Welds per Quality Plan QP-1536145 Rev 0 Item 3.1, Drawing 5NM-1536145-01 Rev 1 and Customer Specification 385-426600 Item 0030-0050.
Item Inspected: Filter Module Cabinet.
Findings: The SS Nozzles have been fillet welded to the Module Cabinet Wall only from external side in accordance with Drawing 5NM-1536145-01 Rev 1, however not welded from internal side. This Condition is Not In Compliance to Customer Specification 385-426600 Item 0030-0050 which specifies for "All Internal Seams to be Continuous Seal Welded". It is important to note this Customer Requirement is referenced as applicable on Vendor Quality Plan QP-1536145 Rev 0 Item 3.1.
Re-Inspection: Vendor has conducted the needed repairs to seal weld from internal side the mentioned joints in order to get Compliance to Project Requirements referenced above. See Photo on referenced Issue as originally found.
Benefits to Our Customer: By using Fraza Inspection Team, Customer saved a lot of of time and money preventing excessive expenses per back charges for Re-works at field site per unacceptable issues on Wrong Materials used and Not Compliance to Project Specifications, if Not Corrected/Repaired in timely manner at Vendor Shop.
Project Detail
Project: RTL 63 – Phase 5
Equipments: Air Inlet Filter.
Date: December 2009
Vendor Location: Fabricator of Air Inlet Filter Equipments in Coahuila, Mexico.
Visual Inspection per ITP-3156-07 Item 12, Drawing 7112-03 Rev 3 and Customer Specification TR-2188-09 Rev 5.
Item Inspected: Filter Module.
Findings: Per Drawing 7112-03 Rev 3 and Vendor Bill of Materials, a Gasket Item 25, described as STH type 3154-PVC-White Finish is specified to be installed in connection interfaces of Filter Housing, however Vendor has installed a gasket in black neoprene material.
Re-Inspection: Per Fraza Team observation,Vendor has removed the neoprene gaskets and installed the right gaskets in accordance with Referenced Project Requirements. See Photo on Described Issue.
Visual Inspection on Welds per ITP-3156-07 Item 4, Drawing 8245-02 Rev 4 and Customer Specification TR-2188-09 Rev 5.
Item Inspected: Inlet Silencer.
Findings: Silencer Panel Weldments observed with stitch welds applied on external stiffeners, Not Acceptable since per Customer Specification TR-2188-09 Rev 5, Section 8.3-(b), ¨All external seams shall be full seams, No external stitch or tack welds shall be permitted”.
Re-Inspection: Vendor has conducted the needed repairs to complete on seal welding of external stiffeners to get Compliance to Referenced Project Requirements. See Photo on described issue as originally found.
Benefits to Our Customer: By using Fraza Inspection Team, Customer saved a lot of of time and money preventing excessive expenses per back charges for Reworks at field site per unacceptable issues on welding and gasketing if Not Repaired in timely manner at Vendor Shop.
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