Project Detail
Project: South Mountain Unit 03
Equipments: Expansion Joints
Date: March 2009 to June 2009
Vendor Location: Fabricator of Expansion Joints in Nuevo Leon, Mexico.
Visual Inspection per Inspection Plan ITP-EJ-5938-01 Rev 2, Item 3.1 and Drawing 5938-002-01 Rev 1.
Item Inspected: PO-ER-54100 Item 20, Expansion Joint Tag-EJ5938-04.
Findings: Observed Internal Liner almost in contact with inside of end spool due to an excessive ovality of the Liner with serious risk to be both parts in touch when the expansion joint be in operation.
Re-Inspection: Defective Internal Liner has been removed and other one showing aceptable ovality condition has been installed and welded. See Photos as illustration on Referenced Issue.
Inspection on Preparation for Shipping per Inspection Plan ITP-EJ-5938-01 Rev 2, Item 16.2 and Shipping Notes of Drawing 5938-003-02 Rev 1.
Items Inspected: All Expansion Joints per PO-ER-54100.
Findings: All Expansion Joints are being prepared for Shipping placing them over a wood skid and tied with bandings, which is not in accordance with Shipping Notes per referenced Drawing which specifies ¨All Expansion Joints shall be shipped in individual crates.
Re-Inspection: Vendor has conducted the needed corrections to prepare all Expansion Joints for shipping in accordance with Project Requirements referenced above. See Photos on described Issue as originally found.
Visual and DFT Inspection on Carbon Steel Items per Inspection Plan ITP-EJ-5938-01 Rev 2, Item 14.3 and Painting Notes per Drawing 5938-006-01 Rev 3.
Items Inspected: Expansion Joints per PO ER-54100 Items 20, 40, 170,180 and 330.
Findings: Carbon Steel End Spools and Covers, Specified DFT Range for Inorganic Zinc Primer CZ-11, 2-0 to 3.0 mils. All DFT Measurements found bellow 1.5 mils, which is Not Acceptable to specified DFT Range and Standard SSPC-SPA-2.
Re-Inspection: Per Customer Direction, all referenced Carbon Steel Parts have been blasted and primer coated again in accordance with referenced Project Requirements. See Photos on DFT as measured after Rework.
Review on Project Requirements per Inspection Plan ITP-EJ-5938-01 Rev 2, Item 1.2 and Drawing GA-5938-TY1-01 Rev 0.
Item Inspected: PO-ER-54100 Item 40, Expansion Joint Tag-EJ5938-03.
Findings: Fraza Team has detected on omission by Vendor for test per Referenced Drawing and Customer Spec 5938-R-NH-058 Rev 3, Section 5, which specifies ¨ All cases of corrosion protection used (Including applicable CZ-11 Coating) shall comply with a 500 hour test of salt fog exposure in accordance with ASTM B-117 and shall be certified by an independent laboratory. Vendor has had serious problems finding an independent laboratory with the ability to perform the referenced test.
Re-Inspection: As a support to Vendor, Customer has confirmed the referenced test will be supported and documented per Carboline Data Sheet for CZ-11 Primer Coating, which reflects on compliance to referenced test requirements per ASTM B117 Standard.
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 Omitted Corrosion Tests, Dimensions, Packaging and Painting, if Not Corrected/Repaired in timely manner at Vendor Shop.
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