LESSONS LEARNED

RLNG-II Compressors

S.No

Issues

Tendering to award time for Turbo-Compressors was very long

(around 10 months). This could have been reduced through proper
planning. One of the bidder went to court against its technical
disqualification.

Site development work was started late which made the overall
completion of the Civil works very difficult.

As per established execution sequence, construction of main

Piperack was dependant on timely site delivery of Process Gas
Coolers which were part of BOP to be shipped from China. Delivery
of BOP items was delayed, hence entire sequence of construction
was disturbed. Close monitoring of delivery of Process Gas Coolers
should have been done & matter could have been resolved through
part shipments of coolers. Even when the coolers reached Karachi
Port & dispatches to site started, the dispatch of base structure was
delayed by around a week resulting in delayed start of construction
work on these items.

Delay in procurement and Installation of plant lighting system.

Delay in Installation of Gas Gensets.

Delay in delivery & Installation of Instrument Air compressors

Accomodation arrangements were not adequate at site. Proper

accomodation with all basic facilities should have been made
available for staff posted at site & the visitors.

Warehousing arrangements were not planned timely.

Although scrubbers & filter separators were available well in time,

their installation was elayed till the end.

10

Cable trench design was not aligned with tight schedule of the
project. This aspect was in the knowledge since May 2016 yet no
actions were takentill October. A timely action could have provided
better solution & assisted in timely flooring of area around the
compressors.

11

During execution phase, a few changes were made e.g on header of

scrubbers & filter separator & on installing temporary vent stack
which could have been avoided.

12

Although various milestone data was missing, there was no way to

identify how, how much in the delay and what are the remedial
actions.

Note:

For the lesson learned the target dates are taken from the original project schedule according to which 4 Turbo-Compressors were to b
commissioned by 31 Dec, 2016 & remaining two were to be commissioned in first week of Jan, 2017.

NS LEARNED
Compressors

Lesson Learned

Area of
Improvement

The scope of work document, Tender terms &

proceddings of the bidding & award stage
Scope Documentation/
need to be reviewed & actions to shorten
Planning
the tender to award time to around 8
months.
Due attention should be paid on extent of
civil works at FEED stage, during bidding
stage. This would help in starting the civil
Planning/ Prioritization
works at site at early stage. Normally, within
two months of award of contract, site
development work must start.

Need of greater vigilance on items falling on

the critical path of the project.

Planning/ Monitoring/
Vigilance on
sensitivity

A RACI matrix needs to be developed (&

updated as needed) to establish roles &
responsibilities of each function for the
execution of the project. The support
functions need to be given scope of work well Team Work /
in time. Regular coordination meetings on
Co-ordination/ System
specific items need to be held with stake
& Procedures
holders & minutes issued regularly.
There is a need to
develop/ improve team work, establishing
formal communication & feedback system.

Utility needs should be defined during

bidding stage & orders for utility items must
be placed well in time to avoid any delay in
execution of work.
Lessons learned for S.No 4 above is also
applicable here.

Team Work /
Co-ordination/ System
Procedures

Lessons Learned for S.No 4 & 5 above are

also applicable here.

Planning /
Tendering /
Monitoring/ System
Procedures

Proper manpower deployement schedule

should be prepared & accomodation
arrangements should be made at site
accordingly.

Planning

Proper arrangements of warehousing needs

should be made & warehouse should be
constructed before arrival of the equipments
at site.
Such matters could be resolved through
improved team work, RACI matrix, good
planning & effective monitoring
Proper sensitivity analysis on items which
can delay the project or can cause difficulty
in completion of construction is required.
There is a need for improved planning, team
work & co-ordination.
For such jobs, greater teamwork,
co-ordination & consultation is required.
A proposal made plan with S-curve should be
prepared to realistically monitor the progra.

Planning

RACI matrix/
Planning / Monitoring/
Team Work

Planning/
Co-ordination/ Team
Work

Team work/ Coordination/

Consultation
Planning/ S-curve/
Monitoring

ect schedule according to which 4 Turbo-Compressors were to be

oned in first week of Jan, 2017.

LESSONS LEARN
RLNG-II Pipeline P
S.No

Title

Issue

Selected contractor for Segment I defaulted on

safety, quality & schedule adherence throughout the
Low caliber
project. It was evident that the contractor had
Contractor of
deficient experience & in-adequate tools & plant,
Segment 1
deficient manpower, lacking planning abilities. This
has lead to delays in completion of the Project.

Land
Acquisition
Problems

Land acquisition issues were repeatidly arising

throughout the Project Life Cycle causing delay in
pace of work. In some cases ROW was handed over
to contractor but was re-possessed by the land
owners i.e. continuity of land possession was not
maintained.

Procurement
The delivery of Heavy Wall Thickness Pipe (HWT)
of Heavy Wall
delayed the overall Project Execution plan.
Thickness Pipe

Payment
Terms of
Contract

Release of payment against the progress acheived

by the contractor was not rationalized. The
contractor kept making progress in BOQ item which
were easy to tackle such as stringing, ditching etc. &
received major portion of payment from the
Company. BST paid very little attention to lowering,
pigging & hydro-testing. This resulted in
unacceptable delay in the completion of the work.

Trench
Collapse

Trench collpase is one of the most serious incidents

and has therefore been addressed first. The design
and the construction of the trench at tie in position/
valve assemblies were not as per safety requirement
(shoring, widening etc.) leading to trench collapse
resulting in injuries to the workers in the trench.

Indus River
Crossing

Ditching
(Rocky Soil)

This single item has the potential to jeopradize the

entire project. The award for Indus river crossing was
delayed which delayed the execution of the work
and therefore resulted in delay in completion of the
work. Risk analysis on this job was not done
properly. Delay in start of work badly affected the
schedule of the project.

Ditching in rocky areas was the main reason for

delay in completion of pipeline by BST.

11

Safety

Health, Safety & Environmental procedures were not

properly followed resulting in injuries to workforce.

Project
Improper Communication Protocol leading to lack of
Management correspondence

Incentive
Program

Non-availbility of any incentive or award mechanism

LESSONS LEARNED
NG-II Pipeline Project
Lesson Learned

Pre-Qualification of contractors should be carried out paying due

attention to their past track record, adherence to safety & Quality
procedure, availibility of required tools and Plant etc.

Area of
Improvement

Pre-Qualification/
Tendering

Land issues should be resolved prior to occurance and procedures must

be developed by the land department focusing on timely acquisition of
land and assuring no further hindrances while the work is being carried
out. Possession should be maintained through deployement of land
walkers and security guards. Also, Good relationships with the local
communities including local councils, government departments and
Land Acquisition/
affected landowners must be maintained and establish liason with local
Planning/
law enforcement agencies. In case a segment of ROW is handed over
Monitoring
to the selected contractor, responsibility of continuity of possession of
the segment should be the responsibility of the contractor. The
Company should develop a system documenting handover of a
segment of ROW on which all lanowners should sign. The contractor
should also sign this document, accepting the takeover.

It is stressed that the project pivots on an effective supply chain

operation. It is imperative that the deliveries of the materials are
regular and timely, otherwise, the entire project progress will be
severely hampered. Heavy wall thickness pipe should have been
procured timley on top priority to assist in timely execution of crossings
in the agreed weather window & on receiving statuary approvals etc.

Planning/
Tendering/
Monitoring

Weightage of payments should have been rationalized in such a way

that payment on activities except lowering, pigging and hydrotesting
remains capped at 70%. Major chunk should be paid to contractor on
completing a minimum stretch of 10-15 km segment in all respects.
This will assist in generating greater focus of the contractor on critical
activities like pigging, hydro-testing etc resulting in timely execution
and completion of the work.

Planning/ Contract
Management

The Company should prepare an elaborative job method details for

pipeline construction work extracted from various codes & standards
and from its own experience covering all activities of the construction
Safety Awareness
work i.e. ROW preparation, ditching, stringing, welding, lowering,
& Implementation/
backfilling, pigging, hydro-testing etc. This document should also
Job Method Details
highlight safety & quality requirements in detail. The document should
also highlight sequence in which the Company wants the contractor to
execute the work.

In case HDD is necessary in view of security reasons, two pipes of 30

dia. 500 meter apart should be laid as equivalent of 42 dia. pipe, so
that if any problem is faced on one pipe, at least the other line would
be available for transmitting 50% volume. It has been noticed that no
problem was faced in drilling & reaming up to 48 dia. All this needs to
be discussed with experts on this typical HDD crossing of Indus River.
The concept of two pipes may have additional cost but will increase
reliability of the system. Alternatively, a standby pipe line should be
constructed using pile footing to cross Indus River.

Planning

This issue could have been avoided if the Rocky areas were discovered
through boring at each 500 meter length at an early stage and team
deployed from the very onset using ripper machine to carry out
ditching in rocky areas. This will provide reasonable data for the biddrs
to assess the extent of rocky areas.

Planning

Safe Work Practice Awareness should be created in the workforce &

regular follow-up and continuation should be maintained in this regard.
Site Supervisor must ensure that all precautions are taken before the
Safety Awareness/
commencement of work. Also, the Contractor should be allowed to
Site Supervision
deploy safety trained work force only. No new induction without safety
training should be made.

Develop a formal communication system where the Project manager

should be the focal point of all activities and communication of the
project. The Project manager should establish proper monitoring and
Communication
review system for the project. Contractor must issue its weekly plan &
Protocol/
a weekly review meeting should be held with the contractor. The
Team Work/ Project
minutes should be issued within 24 hr. of the meeting. Contractor
Organization
should address all its correspondence to the Project manager with copy
to another nominated members of management team.

Award & incentive mechanism should be implemented to promote safe Safety Awareness
work practices and improve the moral of the workers.
& Implementation