rocklands - project wide項目范圍摘要

Rocklandsproject

INSTALLATIONOVERVIEWInstallationStatusasat10-NOV-14Structural–94%Mechanical–81%Pipework–81%ForecastManHourstoComplete–28,624PrimaryIssuesDesignandFabricationIssues:ASignificantquantityofpipespoolsandpipesupportswereincorrectduetofabricationordesignerrors.SinosteelelectedtoRe-SupplyincorrectpipespoolsandinstructedWalztorectifypipesupportsonsite.PipeworkLabellingIssue:Duetopoorlabelling/managementofthepipeworkfabricationinChina,1200pipespoolsweredeliveredtositewithnolabelorlabelledincorrectly.Valves:Latesupplyresultinginextendedinstallationduration.FloatationReagentsPipework2,000m:Sinosteelinstruct/authorisedWalztoprocurefittingsandcommenceinstallationofsiteweldedDN25/15mmpipework10-NOV-14.PotableWater:Sinosteelapprovedpotablewaterlayoutsonthe11-NOV-14enablingWalztocommenceinstallationof1,200mofDN50pipework.SynthesisPipelineNetworkHold:SinosteelinstructWalztonotinstallpiperackinfour(4)locationstoenablecraneaccessatalaterdatetoinstallE-Houses(ThirdPartyContractor).CV3201AccessIssue:Walzunabletocompleteinstallationduetoongoingcivilconstructionofthere-claimtunnel(Cudeco).ExpectedhandovertoWalztoenableinstallationtocommence15-DEC-14.GrindingMillLubrication&DrainPipework:Sinosteelhaveelectedtofabricate74.407mofstainlesssteelpipeworkonsiteandadvisethefabricationdurationwillbe3-4weeks.Sinosteelhavenotcommencedfabricationasat15-NOV-14.PipelineMarkers:Sinosteelunderestimatedtherequiredquantityby500%MaterialSupplyIssue–Slip/FloatingFlangeBolts:Duetoadesignomission/error,Sinosteelsuppliedboltsforslip/floatingflangesweretooshort.CorrectlengthboltswereRe-SuppliedonCDU-028:24-OCT-14.MaterialSupplyIssue-SiteRunPipework:SignificantShortfallinsupplyofsiterunfittingsandpipe.Walzprocuredanotablequantityoffittingsandpipeworkwhichhadleadtimesofupto2-3weeks.MajorDesignConcerns:WalzholdgreatconcerninrelationtoSinosteel’sDesignofpipesupportsandpipeworkaspreviouslyadviseinNCR-0214andformalletterPipeworkDesignConcerns#1.ShipmentSummary-2014SHIPMENTSUMMARY-2014CDU-024CDU-025CDU-026CDU-027CDU-028CDU-029FirstDeliveryOnsite12-DEC-1315-APR-145-JUL-1427-AUG-1424-OCT-1430-NOV-14DeliveryDuration(Cudeco)6Weeks6Weeks8Weeks4Weeks1WeekNotDeliveredStructuralSteel(T)1,21772595550413SteelPipe/Supports(T)43330923.128.429.815PipePercentageOnsite3.1%24.1%67.4%2.1%2.2%1.1%Walznote27.2%ofthepipeworkwasdeliveredonCDU-024&CDU-025,Howeverinstallationofthispipeworkcouldnotcommenceduetoinsufficientpipesupports,pipefittingsandSynthesisPipelineNetwork(SPN)structuralsteelwhichwasdeliveredinCDU-026&CDU-027.CDU-026shipmentcontained67.6%ofthepipework,howeverthein-landdeliverywasnotcompleteduntil30-AUG-14.CDU-026shipmentcontained92.5%ofthepipesupports,howeverthein-landdeliverywasnotcompleteduntil30-AUG-14.Sinosteel’slatedeliveriespreventedWalzfromcommencinginstallationofpipeworkuntilpostdeliveryofCDU-026(AgreedConstructionBaselineSchedulestatesallpipeworkwastobeonsite28-FEB-14).DeliverydurationofallshipmentsfromTownvillePortQLDtoRocklandssitewasunacceptable.WalzadvisedSinosteelbymeansofContractorMeetings&FormalLetterssinceCDU-024andthroughout2014shipments.Tomitigatedelays,WalzprovidedSinosteelwithcomprehensiveprioritylistswhichwereprimarilyignoredandnotfollowed.RFISUMMARYREQUESTFORINFORMATION(RFI)–SUMMARYTABLEIssuesRaisedRFI’sDetailedPipework/Spool539274PipeSupport724255Total1263529Asignificantquantityoffabrication/designissueswereidentifiedwiththepipespoolsandsupport.WalzrectifiedasignificantquantityofpipesupportsonsiteasinstructedtoenableinstallationtoprogresswhilewaitingonRe-SupplyItems.PipeworkSpools

Re-Supplied/LateDeliveryTOTALNUMBEROFPIPELINES>DN50=EIGHTHUNDRED&NINETYTWO(892)Shipment

CDU-028CDU-029DeliveryDateOnsite24-OCT-1430-NOV-14-ExpectedRe-Supplied/LatePipeSpools27277PercentageofPipelinesEffected30.5%8.6%SinosteelelectedtoRe-Supplythelargemajorityofincorrectspools.TheRe-Suppliedpipespoolsarrivedonsite24-OCT-14(CDU-028)howeverthisshipmentonlyaccountedfor68%oftherequiredRe-SupplyItems.PipeSupports

Re-Supplied/SiteModificationTOTALNUMBEROFPIPESUPPORTS=1,182Shipment

CDU-028CDU-029DeliveryDateOnsite24-OCT-1430-NOV-14-ExpectedRe-SuppliedPipeSupports777No.SupportsModifiedOnsite724PercentageofPipelinesEffected67.77%Walznote67.77%ofthepipesupportsontheprojectrequiredmodificationduetofabricationanddesignerrors.Lostproductivityandflow-oneffectstosubsequentpipeworkinstallationactivitiesweresignificant.UniqueValveSupplySummaryTOTALNUMBEROFUNIQUEVALVEFORPIPEWORK=637Shipment

CDU-027CDU-028CDU-029CDU-030?DeliveryDateOnsite27-AUG-1424-OCT-1430-NOV-14(Expected)?QtyUniqueValves23439234130RunningPercentage38%44%81%100%Asat13-NOV-14thepercentageofoutstandingUniqueValvesis56%.Supplyissuepreventscompletionofthelargemajorityofpipework.Walzarerequiredtore-accessallvalvelocationsuponsupplyofvalvesforinstallation.TomitigatedelaysWalzhaveinstalledspacersinpipeworktoallowinstallationtoprogressintheabsenceofthevalves.Non-UniqueValveSupplySummaryTOTALNUMBEROFNON-UNIQUEVALVEFORPIPEWORK=1365Shipment

CDU-027CDU-028CDU-029CDU-030?DeliveryDateOnsite27-AUG-1424-OCT-1430-NOV-14QtyNon-UniqueValves24117862276RunningPercentage2%88%93%100%Asat13-NOV-14thepercentageofoutstandingNon-UniqueValvesis12%Supplyissuepreventscompletionofsiterunpipework<DN50andinstallationofvalvesinpipework>DN50WalzhavehighlightedtoSinosteelasignificantshortfallinsupplyhasbeenidentifiedfollowingacomparisonofPackingListsVsP&IDMTO.PipeworkLabellingIssueWalzadvisedSinosteelinRFI-0612toRFI-0641datedthe23-JUN-14thatonethousandtwohundred(1200)pipeworkspoolscouldnotbelocatedonthepackinglistsofCDU-026.SinosteeladvisedintheWeeklyContractorMeetingonthe5-JUL-14thattheonethousandtwohundred(1200)pipeworkspoolswereinfactpresentontheshipmenthowevertheyarenotlabelledorlabelledincorrectly.AsadirectresultWalzwererequiredtomeasureandcheckeverypipespool(Approximately8,000)againsteveryisometricdrawing.Lostproductivityandflow-oneffectstosubsequentpipeworkinstallationactivitiesweresignificant.PipeworkLabellingIssue

SitePhotographExampleRedundantPipeworkFloatationReagentsPipework

2,000mofSiteRunPipeRFI-1429dated29-SEP-14,identifiedtheSCH40pipematerialwassuppliedwhichwasunsuitableforpress-fitconnectionsasperdesign.Sinosteelinvestigatedalternativeoptions.Re-SupplyofSCH10material.ChangeDesigntoscrewedfittings,thiswouldenabletheuseofSCH40pipe.DesignwaschangedtobuttweldandWalzwererequestedtosubmitaquotefortheonsitewelding.SinosteelinstructedWalzonthe10-NOV-14toprocurefittingsandcommenceinstallationofsiteweldedDN25/15mmpipework.Scheduleddurationissix(6)weeksaspreviouslyadvisedinnumerousWeeklyContractorMeetingsonsite.PotableWaterPipeworkSinosteelinstructedWalzonthe18-JUL-14toholdinstallationofallpotablewaterpipingtotalling1,200mtotwentysix(26)safetyshowersontheproject.InstallationhadnotcommencedatthistimeastherequiredfittingswereonCDU-026,howeverthesafetyshowershadbeeninstalledatthistime.Sinosteeladviseonthe11-NOV-14thepotablewaterholdisremovedandWalzcancommenceinstallation.Walziscurrentlyconductingareviewofthequantityofsuppliedfittingsandpipe.SynthesisPipelineNetwork(SPN)

HoldonInstallationSinosteelinstructedWalzonthe29-SEP-14toholdinstallationofpiperackinfour(4)locationstoallowcraneaccesstoinstalltwenty(20)E-Houses.Theholdeffectscompletionofthefollowingareas;GrindingMillAreaFloatation&MagneticSeparationAreaTableSeparationAreaSpiralSeparationAreaCu&PyriteConcentrateDewateringShedAreaMagnetiteConcentrateDewateringShedAreaCompressedAirStationFloatationReagentsAreaLimeStorageArea

ExpecteddeliveryofE-HousesMID-JAN-15.SPN–SitePhotographs

SinosteelHold–Section#1SPN–SitePhotographs

SinosteelHold–Section#2SPN–SitePhotographs

SinosteelHold–Section#3SPN–SitePhotographs

SinosteelHold–Section#4CV3201

RECLAIMTUNNELACCESSCivilHandoverofCV3201isstilloutstanding.Cudecocompletingexcavationactivities15-NOV-14.CivilWorkbythirdpartycontractorhavenotyetcommencedasat15-NOV-14.ForecastedhandoverforthemechanicalinstallationiscurrentlymidDEC-14.(AgreedConstructionBaselineScheduleis9-MAR-14)Walzhavecompletedandinstalledbeltsonallotherconveyorswiththeexceptionoffinalalignmentactivities.CV3201–RECLAIMTUNNELGrindingMillArea

Lubrication&DrainPipeworkAllGrindingMilllubricationanddrainpipeworkwastobedeliveredtositefullyfabricated.Thelubricationanddrainpipeworkwasdeliveredtositeonthe27-AUG-14onCDU-027,howeverwassuppliedasloosestainlesssteelflanges,fittingsandstandardlengthsofpipe.Walzwasrequestedtoprovideaquotationforweldingandfabricationofpipework.Sinosteelprovideisometricdrawingsoffive(5)pipelines.SinosteeladvisedWalz10-NOV-14Sinosteelwouldperformtheonsitefabricationandweldingofthepipework.SinosteelrequestedWalztoprovidetherequiredweldingequipmentandconsumablesforthiswork.SinosteeladviseduringContractorMeetingonthe10-NOV-14thefabricationprocesswilltake3-4Weeks.Sinosteelhavenotcommencedfabricationasat15-NOV-14.GrindingMillArea

Lubrication&DrainPipework

SitePhotographPipelineMarkers–ProjectWideRFI-1721MediumLabel(DN63andlarger)SmallLabel(UptoDN63mm)QtySupplied1,536147CDU-028QtyRequired

6,0003000Shortfall4,4642,8537,317QtyRequiredisbasedontheCudecoSpecificationforLineMarkersWalzrequestedpipelinemarkersonthe17-MAY-14inRFI-0466.PipelineMarkersweredeliveredtositeonthe24-OCT-14onCDU-028:WalzadvisedSinosteelonthe9-NOV-14inRFI-1721,thequantitysuppliedhasbeengrosslyunderestimated.AccessrequirementfortheinstallationoflinemarkerspreventsWalzfrominstallingwallgirtstothefollowingareas;Floatation&MagneticSeparationAreaTableSeparationAreaCu&PyriteConcentrateDewateringShedAreaMagnetiteConcentrateDewateringShedAreaMaterialSupplyIssue

Slip/FloatingFlangeBoltsSinosteeladviseonthe5-JUL-14thatallsuppliedslip/floatingflangeboltsareincorrectastheyaretooshortandwillbeRe-Supplied.Walz‘pinned’allslip/floatingflangestoenablepipeworkinstallationtoproceedaheadasperSinosteelinstruction.Re-Suppliedboltsarriveonsiteonthe27-AUG-14onCDU-027.Walzwererequiredtore-access358‘pinned’connectionstoinstalltheRe-Suppliedbolts.Lostproductivityandeffectsonsubsequentpump/pipeworkfinalalignmentactivitiesweresignificant.DesignConcern#1

PipeSupportsWalzissueNCR-0214onthe29-OCT-14outliningWalzconcerninrelationtothepipesupportsontheproject.ThetypicalpipesupportdesignbySinosteeldetails16mmholesinthebaseplateforM12x50mmGr4.6Boltstomaketheconnectiontostructuralsteel.Theholesinthestructuralsteelcolumnsare14mm.Walzalsonotedthattheactualbaseplateholes/slottedholesareupto17/18mmduetofabricationerrors/techniquesusedbySinosteelsupplierinChina.Thisissuecausesthewasherandnuttohaveinsufficientbearingcontactareatothebaseplate,andcan/hasresultedinsomeofthewashers/nutspassingthroughor‘folding’intotheholeovertime.Pipesupportsontheprojectarenowfailingundertheselfweightofthepipewithoutcarryinganyservices.DesignConcern#1

PipeSupportsDesignConcern#2

PipeworkConnectionsWalzissueSinosteelformalletterJ03429-LTR-0337-00onthe12-NOV-14outliningWalzconcernrelatingtoSinosteel’sPipeworkDesign.PipeworkisprimarilysupportedbytheVictaulicCouplingconnectionsbetweenpipespools.Thisdesigncausesasignificantamountofunduestressoneachcouplingwhichmaycauseleaksorevenfailureoftheconnection.ItiscommonthroughSinosteel’sdesigntoencounterupto5-10connectionsbetweensupports.WalznoteinVictaulicDesignData26.01,TheVictaulicCouplingManufacturer’smendationsstatethat“Nopipelengthshouldbeleftunsupportedbetweenanytwocouplings”.DesignConcern#2

PipeworkConnections

DesignConcern#3

PumpCasingsWalzissueSinosteelformalletterJ03429-LTR-0337-00onthe12-NOV-14outliningWalzconcernrelatingtoSinosteel’sPipeworkDesign.Walznotedallslurrypipeworkconnectingtopumpsuctionsanddischargesareprimarilysupportedbythepumpcasings.Thisdesignissuemaycausedamagetothepumpcasingsduringoperation.DesignConcern#3

PumpCasings

DesignConcern#4

ConveyorWalkwaysWalznotethatnomid-railhasbeendetailedontheconveyorsideofallwalkways.WalzbelievethisdoesnotcomplywithIndustry,andpossibly,AustralianStandards.ReferAS1657-2013:Fixedplatforms,walkways,stairwaysandladders–Design,constructionandinstallation.DesignConcern#4

ConveyorWalkwaysDesignConcern#4

ConveyorWalkwaysWalzholdconcernswithregardstotheminimalamountofsupportoftheconveyorgridmeshpanels.Allconveyorwalkwaygridmeshissupportedonlybychannelsteeloneithersideofthewalkwayswithoverlapaslittleas20mm.Walzbelievethisincreasesthechanceofapanelfallingiftheclipsshouldcomeloose.DesignConcern#4

ConveyorWalkwaysDesignConcern#4

ConveyorWalkwaysWalznotethatatallinterfacesbetweenconveyorwalkwaysand‘workshop’floorlevelsdonotmeetAustralianStandardsduetothedifferenceinheightsbetweengridmeshpanel