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Skid Fabrication at ABJ |
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ABJ Workshops has recently been developing additional value-added services for its clients by applying new technologies to deliver services that are sorely needed in the construction markets in the Gulf. George Lahoud explains.
One new service that has been developed successfully is the design, fabrication and assembly of skids. Skids are bases with racks and supports that are custom-designed to hold and unite the different components of a process on a single platform. For example, skids for pressure vessels will hold the vessels, as well as all the piping, stairs, gangways, and controls required to operate the unit, on a single purpose-built base with a supporting super-structure.
Process skids are usually needed in most production plants. Manufacturing these units requires close co-operation between many engineering disciplines. The structure of the skids base frame, pipe racks, supports, etc needs to be able to carry the loads of the various components, such as pressure vessels and ancillary equipment. The pressure vessels in turn need to be designed to meet quality codes and operational needs, while the electrical and instrumentation engineering must support the working of the entire system. Last, but not least, the entire system needs to be kept free of rust through corrosion protection which, in order to be effective over the useful life of the asset, must be applied during the preliminary stages of assembly. |
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Quality Control at All Times |
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ABJ is committed to delivering services to its customers that comply with international quality and safety standards. The Quality Control Department plays a crucial role in helping to accomplish this goal.
Quality Control is defined as the observation techniques and activities used to fulfill requirements for quality. This means that QC is a system for maintaining an acceptable standard in a product by inspecting samples against specifications.
Thus the main objective of ABJ’s QC department is to help operations control the quality of their end product. This is achieved in four main ways: |
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by providing support during tendering; |
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by sourcing and developing QC staff; |
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by providing support during execution; and. |
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by providing support after execution. |
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During tendering the QC department helps in developing project quality plans which will be developed further during the execution stage. QC also helps identify special requirements which would affect costs, such as the use of exotic materials (e.g. low alloy steels) or special testing needs (e.g. non-destructive testing) so that the tendering department can add the costs of these to their estimates.
Once a contract has been awarded the QC department sources the quality control staff required to execute the project efficiently. The strength of ABJ’s QC department is amongst
the best in the region. All members of the QC department, welding engineers and inspectors, are carefully selected for their knowledge and experience and they make up a team of high caliber, spirited employees who have a proactive approach to the work. The department develops its staff through coaching and by sharing their concerns relating to their work at monthly meetings attended by all staff. |
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During project execution the QC department provides constant support by: |
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developing and implementing project quality plans: |
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developing and applying technical procedures for activities such as civil, piping, pipelines, painting, and equipment; |
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developing inspection and test plans (ITPs for each activity requiring inspection; |
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carrying out inspections of work based on approved ITPs; |
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establishing welding procedures and monitoring welders’ performance; |
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providing orientation to the technical staff on a project to ensure compliance with the specific quality control requirements of the project; |
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highlighting any issues concerning compliance with quality control requirements that may arise during execution, as well as any client requests that exceed the quality specification in the contract; and |
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helping with the completion of tasks Right First Time to eliminate rework and avoid any additional costs on the projects. |
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The QC department supports the quality control staff on site by following up with them on a weekly basis and sharing information related to the project.
Once a project has been completed, the QC department helps to document lessons learned during execution to avoid the repetition of costly mistakes on future projects.
Some projects worry that the cost of quality control staff is high and has a negative impact on project returns. But the truth is that implementing quality control properly can reduce reworking and save costs. For example, if the current rework rate is averaging 2% then on a project worth KD1 million the estimated rework value would be KD20,000. This rework value could easily be much higher without a proper quality control system in place.
Besides supporting projects in the achievement of their quality targets, the QC department has other roles within ABJ relating to qualifications and certifications.
Welding is the main activity for our operations and the current boom in development projects in the Middle East has created a shortage of skilled and committed welders. The QC department includes The Welders Training & Certification Unit (WTCU), which was established to develop an in-house team of highly-qualified welders. The WTCU is responsible for all welders in ABJ. The WTCU maintains a comprehensive database of welders, along with details of their qualifications and skills.
ABJ Fabrication Services is accredited to ASME (the American Society for Mechanical Engineers) for the fabrication of pressure vessels and piping; ABJ’s facilities at both Shuaiba and Mina Abdullah are certified by ASME. This could not be possible without an effective quality control system implemented in accordance with the requirements of the ASME code. These ASME code stamp certifications must be renewed every three years through an assessment audit by the ASME committee and the QC department works closely with ABJ to ensure compliance with the code’s requirements.
Quality is never an accident; it is always the result of high intention, sincere effort, intelligent direction and skillful execution; it represents the wise choice of many alternatives |
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