The State's hi-tech passport system cost twice as much as its original price tag, the Dail's public spending watchdog heard today.
The automated production facility in Balbriggan was estimated by consultants to cost €13.5 million but it had doubled to €27 million before it was completed in 2004.
The Department of Foreign Affairs today told the Public Accounts Committee (PAC) in Leinster House that computer software to provide additional security features in a post 9/11 climate incurred the extra expense.
Secretary general Dermot Gallagher said: "There was no off-the-shelf model. It was uncharted territory for all of us but we now have one of the most enhanced security passport systems in the world."
Department officials told PAC members that the new system issued a record 670,000 passports in 2005 and can produce an emergency passport in 20 minutes to an Irish citizen stranded abroad.
Mr Gallagher said staff costs were reduced due to the high level of automation process but extra workers are employed to vet each passport application.
"More people are now involved in the human evaluation and judgement of criteria because of the incidence of fraud," he said.
PAC members were discussing the Comptroller & Auditor General's 2004 report on the Department, which also focused on a tendering process for chauffeur services for dignitaries during the EU presidency in 2004, which didn't comply with EU procurement procedures.
Under close questioning from PAC members, Mr Gallagher said the EU presidency presented enormous challenges to the Department, which had begun preparing three years previously. Up to 140 extra staff were recruited and some officials worked 18 hours a day, seven days a week for six months.
"We ran out of time to conduct open EU recruitment procedures," Mr Gallagher told the committee. "I was told there was minimal risk. Sometimes the public services can be too risk averse but the time comes when you have to bite the bullet over public services."
Mr Gallagher said the Department had learned valuable lessons from the issues highlighted by the C&AG John Purcell.
He explained that a dedicated procurement unit set up and the department's legal advisor had established new procedures with the Chief State Solicitor's Office.
A new Financial & Budget Control Committee, chaired by Mr Gallagher, now meets fortnightly to review all spending within the department.
PA