Quality Blog

Project Blog Introduction


EPR’s project management, restructuring, and consulting experience is highly varied, often very technical, but always deeply immersive.  These formative experiences, on top of our traditional project management expertise, have resulted in a unique industry perspective.  

Poorly managed construction may exhibit problems such as safety, schedule, and escalated cost.  However, plant quality is the most significant determinant of the forward asset (plant) value.

This blog is not intended to be a deep technical reference but rather a discussion-level view.  However, our intention is to bring a real-world perspective of how construction quality impacts an owner, with enough technical content to provide context.  It is assumed the more technical reader will understand the basis for these observations.

Additionally, some posts deal with ‘case studies’ of projects EPR evaluated where poorly conceived execution strategy prior to mobilization created enormous realized construction risk and soured the asset with enduring bad quality.  EPR believes a poor execution strategy places an owner’s team at a severe disadvantage often preventing plant delivery commensurate with the contractor agreement.

All the problems identified in this Blog could have easily been avoided with skilled proactive oversight at minimal or no incremental cost.  If your project is near COD or early in construction and exhibiting some of these (or other) concerns, EPR can help.

To discuss your project needs, please contact EPR

Pumping Rocks


At a plant in the Middle East, the EPC contractor failed to appreciate the difficulty and consequences of not properly cleaning the LP Steam distribution system and Condensate system during commissioning.

The plant was a very large combined-cycle plant with back-pressure steam turbines that fed a 72" header.  That LP header in-turn fed a billion dollars in desalination equipment.  This steam network was huge.  Also given it's size, it would have been difficult in certain locations to get a sufficient steam velocity to remove scale and debris.  It is doubtful, given the evidence of fouling in the system, that anyone tried very hard to achieve a degree of cleanliness.

One snapshot of the damage in the system is the return condensate pump impeller indications.  These impellers are supposed to have a straight (square) leading edge.  Keeping in mind, these pumps were only a year old, this is not normal wear.  Also, condensate is supposed to be very clean with no debris...

A borescope was used to inspect the impellers in situ during a strainer cleaning.  Debris in the strainers is evident... Read more

Contractor Savings

Maybe some schedule time.

Repair Costs

Impeller replacement.  Probably $250k +/- depending on number of times.  54 units.

Getting Touchy


Coatings are typically shop applied and touched up in the field.  On a large power station, there is considerable touch-up and it must be done correctly.

Briefly, as mentioned elsewhere in this Blog, coatings are not "paint", they are an engineered product that requires skilled personnel to apply properly.  In this case there are three coats in the system.  A zinc primer, epoxy mid-coat, followed by a urethane topcoat.  Details... No coating will stick to steel substrate that is dirty, too smooth, or otherwise not prepared to the coating manufacturers requirements.  An epoxy mid-coat sticks well to a zinc primer but does not stick to a urethane topcoat.  If epoxy is left without a urethane topcoat, it deteriorates from UV.  Urethane in most case needs to be applied over epoxy.

So, if a repair needs to be made, the existing paint needs to be taken off down to the primer, or mid-coat, depending on the damage.  However, epoxy (mid-coat) cannot be "slapped on" as to overlap onto existing urethane.  It will not stick.  Also, coatings cannot be applied over corrosion or dirt; seems obvious... ... Read more

Contractor Savings

No savings.

Repair Costs

Varies by plant, but to re-perform is significant.  If unrepaired, O&M is constantly painting, or lets plant rust.

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