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Index

Buildings Practice

Petrochemicals
Industrial Projects Onshore
An Overview

Plants Facility

Preface
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IEI Certified Professional Engineer Suraj Singh

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The objective of this work is to present to the engineering reader information about the practical aspects of Engineering involvement within Oil & Energy Industrial facilities promotion. These industries produce various types of gases in condensed form for the transportation through the pipelines for supply to the real consumer or the end user and also various petrochemical products as well as many bye products are produced. All disciplinary budding working engineers in the industry & particularly in the execution field shall be benefited by the information provided. The contents have been extracted from the practical experience earned in the field. A brief on the description of the terms used has been included. It has been noted that experiences attained are usually not recorded on documents for the benefit of the incoming young engineers to learn from the seniors experience resulting adversely on that these budding engineers depend solely on their individuals exclusive learning in the field based on the university learning which is not virtually adequate for a fast progress achievement. Therefore, to fulfill the requirement to extend the learned resources to the incoming new engineers, this small work is presented to help those who intend to know in advance about an overall perspective of building new facilities or extending the existing one to further development. The information has been given in text only. No photo or diagram could be incorporated as under the obligations of the contracts such information should not be revealed for a definite number of years from the contract commencement day to maintain the secrecy conduct clause on various contracts. This work may not provide with the in-depth specialized subjective knowledge but definitely, illumine with an idea how the procedures move in the field which knowledge cannot be drawn from the university. This book might prove beneficial for the candidates aspiring to become certified professional engineers. Of course, the contents of the book are very boring but practical. The contents vary in nature including the usual procedures of the EPC nature of contracts involving in general types of Industrial jobs carried out in the industry. Also included certain statements & reporting procedures as well as contract matters generally adopted. It is uncommon among engineers to be used to reading this type of work but practically, it is necessary. It is hoped that reader shall enjoy the work. I am grateful to Cdr Eng A K Poothia, The Secretary & Director general of The Institution of Engineers (India) for commending this work & extending most useful advise for which attempts were made to incorporate to some extent. Attempts shall continue to incorporate the readers suggestions as much as practically feasible.

Author - Professional Engineer Suraj Singh March 8, 2006 Published by Ms Sumitra, SLSM Publishers, Edited by Dr Mala Saini MBBS, 3373, Delhi Gate, New Delhi 110002

--------------------------------------Index
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IEI Certified Professional Engineer Suraj Singh

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Chapter 11 Chapter 12 Chapter 13 Chapter 14 Chapter 15 Chapter 16

Industrial development, policy, components Project Design, Contract award & Miscellaneous Engineering Construction & Controls TestingPre Commissioning, commissioning, start up, performance & maintenance Project management Detailed Engineering Requirements Building Design Concept Procurement Construction Pre-Commissioning Execution Plan Environmental clauses for plant Industrial city in Construction Contracts HSES Commercial Contracts References Sub

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Chapter 1
General Industrial development- Processing Facility formation
It is necessary in the interest of the economical development, industrial project should be efficiently promoted as Industry being backbone of a nation. Sooner the industry creation, better the prospects for the nation. Therefore, the value engineering should efficiently be applied for the product proposed to be facilitated to enable the consumer delivered with the most economic & qualitative products.

Policy decision- Authorization-Technology Promotion


The government should promptly decide relevant policy in a positive manner for the time is extremely important to be used properly to get the optimum use of the project provided adequate funds are available within the budget or finance borrowing should be made. Value engineering should be properly studied by experts to reach a conclusion that the product shall be processed imparting no adverse effect to the environment, shall be most economical in production cost, shall be easy to be transported to the end user facility, shall be most beneficial to the society from every aspect/view of cost & economy uplift as well as shall promote the technology & provide benefits to the people globally in long run.

Facility requirement
Value Engineering effective application, Effective Technology, Product end User Requirement Necessity, Approval & Financing, international competition, Cost effectiveness & environment tenability, Sustainability. Should these points be met by the proposal, the project may be given a go ahead subject to the meeting other criteria.

Facility Justification & Feasibility


Environment sustainability - Cost viability in long term Nationally beneficial to add to economic growth multi purpose approach & creation of employment casual as well as regular. Export potential of the product. Processing Technology & availability of raw material. Adequacy of availability of terrain & routes. Selection of the planning & execution mode. Availability of the expertise & experts along with all other inter related professionals.

Components Elements of any Facility - inclusions in general


Availability of the natural gas or oil fields from where the natural resources are being tapped out at offshore location Availability of the land for the required processing area onshore with acceptable terrain that may be used for the complete chemical engineering applications as well as transportation of the processed products to the outlet leading to the consumers locations Plant processing scheme & Technology with legal license for the defined period Liquefied Natural Gas tanks, cryogenic containments with spillage & other components etc for the storage purpose at minus temperature Plant processing trains elements, complete with complete descriptions of heavy & light industrial equipment
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Utilities areas element for the integration with plant equipment Off sites element for sub assistance to aforesaid Intake Piping for circulation & delivery into plant equipment for cooling Seawater basin for storage of seawater & delivery to plant Piping, pipe supports, pipe sleepers & pipe racks for the product transportation & handling Service air & Instrument air circulation piping Chlorination plant & its system for the purpose of chlorinating the water Storage & Warehousing for the physical handlings of subsidiaries Drainage infrastructure from plant to receiving basin & then to outfall structure through the discharge channels duly provided with metal lugs & channels Ditches completely lined to carry out to the final discharge the storm water from various catchments areas of the plant. Complete Package drainage system for, oily water, acid water, dusty water, sewage etc. Water line for the whole site for various purposes including loss prevention i.e. fire fighting with fresh water as well as back up sea water supply Cooling water line throughout the whole industrial area zone taking in water from the intake at sea, supplying to the industries & then through the return headers discharging to the sea directly after being supplied once as well as employing cooling water system technology to re-circulate the water & only make up water to be supplied. Pipe supports, pipe anchors, general anchors, big anchors/thrust blocks at various spacing. Pipes supports to be connected to sleepers & direct supports using structural steel connection for both direct clamping as well as achieving sliding action to make up for the expansion Electrical heat tracing system for the piping system carrying minus temperature liquid or gas to keep the pipe on required temperature not allowing freezing of the material for example Sulphur can freeze within pipe line. Administration as well as Amenities buildings elements for the operation & maintenance as well as supply that should contain various offices with access control Electrical main, sub stations, switchgears, package sub stations, Pump houses, Guard houses, Visitors areas, Ring Main Units, transformers, heavy duty armoured cables Central controlled as well as Operations building to control the whole plants from one single location Consumer receipt stations to be used by the consumer delivery control Pump houses at various locations Water retaining structures such as sumps, receiving basins, drainage channel, outfall discharge to the sea. Site security arrangements, fencing, surveillance Site telecommunications All loss prevention arrangements including internal & external fire fighting. Adequacy of plant & non- plant area of roads & paving, maintenance tracks, road crossings, utility crossings, road culverts, pipe culverts, transit manholes, Soil erosion protection for the machines & equipment Facility bye product plants as extensions & every required elements for that. All related civil engineering disciplinary structures for the buildings, sheds, equipment vessels as well as other equipment. Vessels such as cracking furnace, wash water structures, cracked gas compressor, propane compressor, ethane compressor, boilers, auxiliary boilers, various types of spheres, steel tanks, fuel towers, rotary equipment, reciprocating equipment etc. Shall be a part of the plant & necessary foundations for these be constructed according to the
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requirement. Massive concrete blocks shall be required for many of such major foundations. Civil engineering foundation structural requirement shall vary from a simple machine plinth to independent footings to combined footing to strip footing to raft & piles as well as massive block foundations. Concrete shall generally be low heat cement based produced by using micro silica or GGBS ground granulated blast furnace slag replacement up to an extent of 70% as also pulverized fly ash PFA. The bases of pipe racks may be either steel structure or RCC construction. Foundations of the pipe racks shall generally be of RCC bases or independent footings. Overhead crossing shall be required at many locations for the pipe to jump over roads. Cathodic protection requirement for the corrosion control of the reinforcement from a central control anode station shall also be necessary. Earthing for the individual structures, equipment as well as network. Coloured Covered Cable trenches RCC walled, buried directly to ground or cable ducts shall also be included in design forming a major part of the facility. These ducts shall be coordinated to various interface crossing requiring site resolutions to protect interface clashes. Heavy-duty Concrete pavement shall be required in the plant area for the purpose of the maintenance of the machines as well as movement of heavy vehicles. On the area where no pavement is included, stone aggregate shall be spread & compacted to avoid soil effect on the vessel or equipment. In addition important administration areas shall be given an attractive soft & hard landscape provision. Access security arrangement shall also be made with automatic controls using card readers etc.& installation of CCTV. Inclusion of flare towers & radio masts is also contemplated.

Components brief
LNG tanks- These components are meant to store Liquefied Natural Gas 80000cum capacity each within the steel tank. A RCC with pre-stress arrangement for the cables structure of about 80 m dia, 800 mm thick wall as we as a height of 50 m was used for the prevention spillage. Each tank was provided a spillage tank outside at finished ground level. The top of the tank was a permanent formed cupola structure raised to the level by compressed air. Cryogenic steel was used to maintain about ()60 degrees temperature of the condensed gas. The concrete of the circular walls was poured using kwickform in 5 m lifts. A cantilever operational platform was constructed on the cupola. Compressors-Compressors are to be installed as a part of trains for the Ethylene production unit. Being heavy reciprocating machines to be installed on massive foundations at elevated levels tabletops are constructed resting on massive concrete foundation. Foundation concrete for one compressor being 400 cum about 25m long, 12 m wide as well as 2 m deep. This carried thick columns above to support tabletop. Steel plate inserted between the equipment & epoxy grout. Tabletops are constructed of thick framed slabs resting on thick columns. The arrangement of the tabletop slabs are complicated in all respects about civil as well as mechanical inserts. Such type of thick & massive elements require special type of cement probably with high slag replacement which could be pulverized fly ash or ground granulated fibres or microsilica. Particular arrangements are worked for the curing solutions for such low heat generating cements to effect thermal curing methods. Cracking gas furnaces- this meant for the purpose of cracking gas from the refinery as bye product for the transmission to the compressors for the production of ethane as well
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IEI Certified Professional Engineer Suraj Singh

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as propane. These are tall heavy structures vertically oriented in group of vessels & founded on a common base. Other structures included wash water structures, auxiliary boilers within the processing train. Also included various spheres to contain gases as well as tanks for storage. Foundations for the tanks are generally constructed of RCC ring beams. Other structures are provided with independent footings stripped using grade beams. Seawater basin- A RCC open reservoir meant to collect water from sea through 2 # 84 pipes, supply to the plant various trains requirement & after cooling the system dispose water to be disposed from the industrial locations to the receiving basin & then to outfall chamber. It is a huge voluminous open structure constructed of RCC base slabs provided construction joints during construction, peripheral retaining walls up to 12 m high not more than 9 m panel as well as covered pump house area & baffles. Such structures must be water tight from all locations of the water storage portions duly tested for water tightness using BS 8007 criteria. Concrete protection is applied for both below ground as well as above ground surfaces. Many other stationary as well as vibratory equipments are included for the processing plants for which foundations are constructed accordingly either as footings bases or combined footings. These horizontal or vertical vessels are erected on these bases connected using anchor bolts & grouting done between the sitting steel plate & the top of concrete. For vibratory equipment, epoxy grouting is applied while for stationary, cementitious. Sump chambers These covered chambers are used for the collection of water from various catchment areas & constructed of RCC underground structures duly tested for water tightness using BS 8007 criteria. Concrete protection is applied for both below ground as well as above ground surfaces. Manholes, catch basins, rainwater ditches, etc are constructed using RCC. Manholes are meant for the sewerage line oily manholes for oily discharge, catch basins for rainwater. Generally, these units are in large numbers for any plant area making it preferable to produce by pre casting on site for which all working details for the yard are required to be issued to site. Open ditches are constructed for the discharge of storm water. These ditches can also be used for the purpose to give way to fire water disposal during any fire on the installation. This may also be used for the purpose of any water line maintenance discharge from any single loop. At the commencement the section is shallow but as it reached moving within various catchments, the section is considerably deepened like a big drain. Piping of carbon steel or ductile iron or Fiber reinforced plastics family GRP, ERP, GRE etc are used depending on the requirement & structural adequacy to sustain various imposable stresses. Stress analysis is carried out for various loops giving the location of various supports as well as anchoring requirement. Various types of supports are designed for varying diameter of the pipes for the on ground or underground or aboveground use. FRP (Fiber Reinforced Plastic) Pipes
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RTRP stands for reinforced thermosetting resin pipe, a composite material consisting of a thermosetting polymer, a type of polyster reinforced with glass or other fibers that provide strength & stiffness to a composite material. Different type of resins used for manufacturing GRP, GRV & GRE pipes are Isophthalic resin, Vinylester resin & Epoxy resin respectively that are selected according to the required properties like chemical resistance, temperature resistance & mechanical properties. The resins provide thermal & chemical properties such as glass transition temperature, resistance to heat, chemical resistance etc. required for finished product. The properties of GRP pipes can be varied by changing the ratio of raw materials as well as winding angle. These pipes consist of three layers adherent to each having different characteristics in relation to functional requirement. Inner Liner Veil (Glass), Resin: CSM (Glass), Resin Structural wall - Roving (Glass), Resin External liner- Veil (Glass), Resin Inner Liner Veil (Glass), Resin: CSM (Glass), Resin Inner Liner one is chemical resistant being in direct contact with fluid & therefore, responsible to resist chemical corrosion as well as permeability. The internal surface is particularly smooth to reduce the fluid head losses & also opposes the growth of minerals & algae. Lines has two monolithic sub layers. Inner in contact with fluid is reinforced with glass veil with a resin content 90 %, outer reinforced with CSM glass with resin content 70 % by weight. The standard liner thickness is about 0.5 to 1.5 mm. Structural wall - Roving (Glass), Resin Glass Reinforced layers guarantee the mechanical resistance of the whole pipe against stresses due to internal & external pressure, external loads as well as thermal loads. For GRP / GRV pipes, the layer is obtained by applying on the previous partly cured liner continuous riving of glass wetted with resin under controlled tension. For GRE pipes, the structural wall is wound directly on a wet liner. The layer can contain aggregates like silica sand if allowed by specifications while thickness depends on design conditions. External liner- Veil (Glass), Resin Topcoat or external liner is the outer layer of pipe consisting of pure resin. UV protectors may be added if so required to protect the pipe from solar exposure. In case of severe exposure condition like aggressive soils or very corrosive environment, the external liner can be reinforced with a surfing veil or added with filters or pigments. Fiberglass composites consist of glass fiber reinforcements, thermosetting resins & additives designed & processed to meet specific functional performance criteria. Amount, type & orientation of glass fibers in pipe provides mechanical strength. C Glass, E glass & ECR / Advantex glass are used commonly depending on pipe application. Various forms of glass reinforcements are surface veil, chopped strand mat (CSM), chopped roving, filament roving & woven roving (WR). Raw materials like catalyst, accelerators, inhibitors, aggregates & pigments are used together with resin & glass reinforcements to achieve desired properties of fiber glass product. Catalyst is an organic compound which when added to resin in presence of an accelerator determines the polymerization reaction at ambient temperature. Acceletor is
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a chemical compound used together with a catalyst to shorten the polymerization time. Inhibitor is added to the resin to reduce reactivity at ambient temperature. There are two manufacturing processes Dual helical filament winding process & the other being Continuous winding process (Drostholm) Pipe racks are used for the purpose of running the piping from one point to the other over ground levels. These are generally steel structures founding on RCC footings but RCC frames structures are also used. Several km of pipes are run on these racks supported & anchored to the rack structures. These are fully accessible structures for maintenance purpose. Open flooring is provided. Heat tracing is applied on the piping carrying minus degree gas which may freeze during flow & block pipes for the protection of which, the heat is continuously maintained on the piping to keep the gas in the condensed form. Various loops are provided on the piping routes for various purposes. Pipe supports / sleepers are used for the purpose of carrying the pipes at near ground levels. These are RCC units located at defined spacing. For direct support of the pipes, steel structural supports are used remaining connected or touching pipe by shoes over lengths at various spacing meant for the purpose of sliding also. For deciding the locations of the supports & the anchorage, stress analysis is conducted that dictates the spacing, dimensions & the pipe structural base design. For a pipe of dia not more than 4 m, not more than 12 m spacing is adopted. For other smaller dia pipes, the spacing depends up on the standard length of the pipes. Pipes that need sliding movement at the joints are provided such a base that allows the movement of the pipe in the direction of its run. For that, PTFE (Poly Tetra Fluro Ethylene) bearings fixed on steel plates duly designed to withstand imposed force are provided. Below the pipe support shoe steel portion, a stainless steel plate is provided so that this plate slides over the PTFE pads. Anchor sleepers, big sleepers, thrust blocks are used at various points depending on the stress analysis requirement on the en-route pipeline. These are thick & voluminous structures requiring thousand of cum of RCC for an individual sleeper connecting a group of pipes. On the pipe loops various kinds of stresses from all directions are imposed during operations or flows which are to be resisted by these sleepers. At the change in directions of the pipe routes as well as at the Tee locations etc, big sleepers or thrust blocks are provided to resist the resultant forces. These are constructed of massive blocks of RCC. Access platforms are constructed to access to an area above the pipe level for the maintenance purpose. EOT cranes are installed for the maintenance as well as lifting & placing the pipes & other items in the shops. These also meet the crossing over pipes requirement. Proper ladders, handrails & open floorings are provided for the safe access. RCC box culverts are used for the cross over of the underground pipes below roads. Pipes culverts are also used wherever required. For the accommodation of the spillage tanks, bunding is carried out around to hold oil during spillage. Pipes are connected to the base slab using steel connecting arrangements. Enough space is allowed for the maintenance purpose for free movement as well as circulation.

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Receiving basin is meant for the collection of used water purpose to further discharge into the outfall at the sea. This is also a considerable size of structure collecting water from the return piping headers discharge, letting it accumulate & the dispose into the outfall channel for further discharge into the sea. Various types of steel stop logs are installed to control the flow according to the capacity of the channel & the receiving basin keeping abreast also the maintenance function of the piping. Structure consists of RCC retaining walls in the flow direction & RCC base slab. Flare towers are required to establish a system to dispose safely into the environment the gases that cannot be used any further keeping in view that the compositions of the disposable gas does not deteriorate the environment. Height of these towers are kept considerably so that gases are burn away into the environment safely. Proper arrangements are done for the founding as well as the stability of the tall structure. Pump houses are installed as large size & highly elevated steel buildings housing a train of various pumps, electrical equipment, chlorination plant, rotary drums, intake equipment etc. The piping is routed on ground, vertically as well as horizontally on various types of supports of complex design. Various types of structural steel access platforms are built for the operational & maintenance purpose. These water is pumped into the supply manifolds located just outside where is applied the chlorination & then the pipes are routed to the main route on ground up to various industrial users. Hundreds of thousand cum of RCC structures are built for the supporting bases as well as for the anchoring arrangements depending General components for other facilities Train indicates the separate process trains. String indicates parallel process line-ups of equipment within a train Common to be used for equipment that does not exclusively belong to one train but serves the total complex. Process / Unit : Slug Catcher - Condensate Stabilisation (Column) - Flash Gas Compression - Acid Gas Removal - Dehydration, Mercaptan and - Mercury Removal Unit (Operating + Regeneration) Sulphur Recovery Unit; Sulphur Degassing - Claus Offgas Treating - Off-Gas Thermal Oxidation - NGL Extraction and Fractionation (Overall) - Refrigeration Unit - LPG and Ethane Treating Unit (LTU) - Field Condensate Treating - Plant Condensate Treating LIN & LOX Storage & Vapourisation - Air Separation Units (ASUs) - SGP Reactors Syngas Treatment - Steam Methane Reformer SMR Unit - One SMR plus one Prereformer 1x 50% One SMR plus one Pre-reformer Hydrogen Manufacturing - One High Temperature Shift (HTS) and PSA unit with compression 1 x 50% One High Temperature Shift (HTS) and PSA unit with compression - Heavy Paraffin Synthesis - Water Distillation Unit - Catalyst Activation and Regeneration - Light Ends Stripper - Light Detergent Feedstock Heavy Paraffin Conversion - Synthetic Crude Distiller - High Vacuum Unit Catalytic Dewaxing - Base Oils Re-Distillation Reliability and availability, particularly system uptime are key project drivers. A systems effectiveness model shall be developed for the complex comprising the base case configuration of the offshore facilities and GTL (Gas to liquid) plant configuration
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FEED for the project units so that the required overall system effectiveness of 335 stream days per annum is reached in a cost effective manner. The offshore development concept is based on direct transportation of the produced fluids and gas from the wells on platforms to shore without any offshore process or treatment. From each platform, there shall be multiphase carbon-steel trunk line to the common slug catcher. Chemical injection and regular pigging shall be applied for corrosion as well as hydrate formation inhibition to the carbon steel lines. The produced fluids are received into the slug catcher in the upstream onshore facilities. Onshore upstream - comprises Slug Catcher - Condensate Stabilisation - Acid Gas Removal - Sulphur Recovery (Claus Unit) and Storage - SRU Offgas Treating or SCOT Unit - Dehydration and Mercaptan Removal - NGL Extraction and Fractionation - Final treating for finished NGL products: LPG and Ethane Treating Unit Field and Plant Condensate Treating In the Onshore Upstream facilities, Condensate and water / kinetic hydrate inhibitor (KHI) & corrosion inhibitor ex the slug catcher are separated. Water is sent to a dedicated effluent treatment which caters for the KHI and possible saline components. Condensate is stabilised and treated (for sulphur removal / conversion) for export sales. Wet feed gas ex the slug catcher is routed to gas treatment followed by NGL extraction and fraction. The gas treating facilities remove sulphur components, water, CO2 and mercury from the feed gas. Treating of the ethane (ethane recovery and treating facilities shall be installed later) and LPG products to further remove residual traces of sulphur, water and CO2. The sulphur components so removed shall be converted to elemental sulphur for export as liquid sulphur. Onshore downstream: Synthesis The onshore downstream synthesis comprises Gasification Process- Air Separation Units- Heavy Paraffin Synthesis- Catalyst Activation & Regeneration - Water Distillation - Steam Methane Reformer - Hydrogen Manufacturing - The ASUs main purpose shall be to produce oxygen for use in the SGP as well as also produce HP Nitrogen for the CAR unit, LP Nitrogen and compressed air for use as site utilities. In the SGP syngas shall be produced from natural gas (NG) and oxygen by partial oxidation. The SGP produces the majority of the syngas for subsequent conversion to a synthetic heavy paraffin stream in the HPS. The SGP syngas requires treatment to remove soot and undesirable by-products. In the SMR hydrogen rich syngas shall be produced from NG and steam by a catalytic reforming process. The SMR syngas has a higher H2 content than the SGP syngas and is used to supplement the syngas feed going to the second stage of the HPS reactors. The reaction in the HPS follows the Fischer-Tropsch chemistry and produces significant quantities of process water as a by-product. The WDU shall be used to strip hydrocarbons from the process water which be subsequently sent to the effluent treatment plant for recovery. The CAR Unit shall be used to regenerate the HPS reactor catalyst. The HMU uses a High Temperature Shift (on a part of the SMR syngas) and a PSA Unit to produce an ultra pure H2 stream mainly for use as a reactant in the SMR and the Liquids Processing Unit.
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Onshore downstream: Liquids processing The onshore downstream liquids processing scope comprises Light Ends Stripper - Heavy Paraffin Conversion - Synthetic Crude Distillation & Stabilisation- Light Detergent Feedstock Units Base Oil Units: High Vacuum Unit - Catalytic De-Waxing Unit - Base Oils Re-distillation Unit The LES, LDF, HPC, SCD & Base Oil (HVU, CDW and RDU) Units shall be also collectively referred to as the Liquids Processing Unit or LPU. In the LES Unit water, CO and CO2 be removed. In the LDF Unit, components shall be recovered and after hydrogenation, rundown to storage for sale as a product. The remainder of the HPS product shall be routed to the HPC where the paraffinic molecules are cracked and isomerised into middle distillate range components, which are subsequently distilled by the SCD into LPG, Naphtha, Kerosene, Gas Oil and an SCD bottom product stream. In the Base Oil mode of operation, the SCD bottom product stream is routed to the HVU for further separation into Vacuum Gas Oil, a Waxy Raffinate fraction and a residual fraction, that is recycled to the HPC. The Waxy Raffinate fraction is shall be catalytically isomerised in the CDW and then separated into products according to boiling range and viscosity in the RDU. In the No Base Oil mode, the SCD bottom product stream shall be recycled to extinction back to the HPC. For the no Base Oil case, the throughput of the complex is limited by the capacity in the HPC (one single maximum size reactor per train). Supporting facilities: Utilities Utility systems comprise - Boiler Feed Water, Steam & Condensate Systems - Raw, Demineralised, Potable & Service Water Systems - Power Generation and Distribution Cooling Water Systems: Cooling Water System, Chilled Water and Closed - Cooling Water System - Instrument and Tool Air System - Nitrogen System - Heat Transfer Fluid System - Aqueous Ammonia System Utility systems shall be designed to allow stand-alone operation of the GTL complex. Steam and gas turbines shall be provided for shaft power and generation of electrical power. The steam shall be generated in the synthesis section thereby effectively utilising the exothermic heat of the process reactions. Auxiliary boilers and gas turbines with Heat Recovery Steam Generators (HRSGs) shall be included to facilitate black start capability, to enhance reliability of the steam and power system. Cooling shall be principally by air but cooling water may also used where appropriate. Steam is the principal heating medium but fired heaters and a heat transfer fluid system shall be provided for specific applications. Supporting facilities: Storage & off-sites - Storage and Offsite Systems comprise Relief & Blow down System, including flares - Drainage, Collection and Primary Treatment Effluent Water Treatment - Sour Water Stripper - Flushing Oil System - Storage and Loading Facilities including onsite product storage - Slops & Intermediate Storage. In general, plant condensate (blended with naphtha) and GTL products shall be stored on site and transported to the RLC harbour for shipping. Field condensate shall be stored in an on-site as well as an off-site shipping tank prior to export via the RLC harbour. LPG shall be transported directly to the RLC facilities for refrigeration, storage and export. Liquid sulphur shall be piped to common RLC facilities.
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Design Basis Mechanical Equipment Table Of Contents 1. General, 2. List Of Codes, Specifications and Standards, 3. Design Basis Mechanical Equipment, 4. Equipment Selection, 5. Spare Parts, 6. Shop Testing Design Basis Mechanical Equipment Objective The purpose of this part is to provide the design basis for all mechanical equipment (rotating equipment + static equipment) on scheme. It shall be used for verification of selection and detailing / sizing of equipment for procurement engineering (while developing EPIC documentation). The plant facility design and installation shall consider 100% equipment redundancy (where applicable), 100% availability of the plant, Equipment selection to ensure 99.7% reliability, environmental conditions. The packages and equipment shall be suitable for outdoor installation in salt laden, saliferous and highly corrosive atmosphere prevalent at open Coastal area. The Basic Engineering Data developed shall be applied for development of FEED documents. Design Life & Experience Mechanical Equipment and associated auxiliaries shall be suitable for the specified operating conditions including any upset, start up, shutdown and emergency, be designed and constructed for a minimum service life of 30 years with equipment providing at least 2 years of uninterrupted continuous service while first major over-haul requirement not before 10-years being a design criterion. Vendor experience for previous supply of at least 2 validly similar design equipment and proven track record of at least two years trouble free running history / experience (in conditions similar to this project conditions) shall be applicable. List Of Codes, Specifications and Standards The main cooling water pumps and associated auxiliaries and other mechanical equipment shall be designed and manufactured in compliance with the Requisition, documents listed in the Requisition and applicable specification / data sheets included elsewhere for the consideration as part of the FEED. Applicable Codes, Standards and Reference Documents The Equipment Specification lists the applicable International Codes and Standards. Reference to any Standards or Codes shall mean the latest edition of that Standard or Code including addenda or supplements or revisions thereto as on the effective date of contract. Project Documents, General, Project Design Basis, Technical Specification of Vibration Monitoring System, Piping Material Specification, company specifications, Lifting Equipment Technical Regulations, RA Pressure Vessel Design and Fabrication. RA Above ground Welded Storage Tanks, RA Pressure Vessels, RA Air Cooled Heat Exchanger Design and Fabrication, Plate Heat Exchangers Design and Construction RA Piping General Design, Diesel Engines, Diesel Engine Driven Generator, Equipment Identification and Tag Numbering, Standard Specification for Painting and Wrapping of Metal, Surfaces, Company standards applicable to other disciplines shall be listed in individual, Equipment specifications and data sheets included elsewhere for the consideration as part of the FEED. International Codes and Standards
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API RP 500 Recommended Practice for Classification of Location of Electrical Installation, API 610 Centrifugal Pumps for Petroleum, Heavy Duty Chemical and Gas Industry Services (relevant sections shall be applicable), API 520 Sizing Selection and Installation of Pressure Relieving Devices. API 526 Flanged Steel Pressure Relief Valve BSEN 13414 Steel Wire Rope Slings, Safety Standards, API 650 Welded Steel Tanks UBC Uniform Building Codes (Earth Quake Zones), API 2000 Venting Atmospheric and Low Pressure Tanks, API 670 Vibration, Axial Position and Bearing Temperature Monitoring, Systems. API 673 Centrifugal fans for Petroleum, Chemical and Gas Industry Service. BS 848 Fans for General Service, HI Standards (HI-2.6) Hydraulic Institute Standards on Centrifugal Pumps, NFPA20 Standard for the Installation of Stationary Centrifugal Fire Pumps for fire Protection, NFPA 24 Standard for Installation of Fire Mains, AWWA American Water Works Association, ANSI B 73.1M Horizontal Centrifugal Pumps, ANSI B73.2M Vertical Centrifugal Pumps, ISO 2858 End Suction Centrifugal Pumps, API 675 Positive Displacement Pumps Controlled Volume, ASME Sec.VIII Rules for Construction of Pressure Vessels (Div. I), ASME Sec. II Material Specifications (Part A, B, C & D), ASME Sec. V Non-Destructive Examination, ASME Sec. IX Welding and Brazing Qualifications, BSEN 10204 Types of Inspection Documents Metallic Product, BS CP3, Chapter V Basic Data for Wind loads Part2, ISO 9001 International Organisation for Standardisation, ISO:3046 Standards for Combustion Ignition Engines, ISO : 10440 (Part 2) Packaged Air Compressors (Oil Free), FEM Standards Federation of European Manufacture Standards on Drum Screens, ASME B30 Crane Safety Standards, ASME B16.5 Steel Pipe Flanges and Flanged Fittings, ASME B31.3 Petroleum Refinery Piping, ASME B16.5 Pipe Flanges and Flanged Fittings, ASME B16.47 Large diameter steel flanges (NPS 26 to NPS 60). AMCA Air Movement and Control Association, ISO 1940 Mechanical Vibration Balance Requirements of Rigid Rotors, ASTM A370 American Society for Testing and Materials Standard Test, Method for Mechanical Testing of Steel Products The principles to be adopted during the selection & specification of prime equipment and equipment within the package can be summarised as follows: Design life being 30 years, High availability, Standard / Proven Equipment Model. Safe to operate and Maintain, Typical subjects to be addressed / considered during the equipment selection and final preparation of the purchase requisitions are addressed in the following sections. The nameplates indicating major design parameters / specified parameters shall be screw attached to the equipment. Nameplates shall be in SS316 materials. Equipment Standardization The design of rotating / mechanical equipment shall ensure high equipment availability and maintainability. Effort shall be made to standardise the spares stocking by minimising the variety of makes and types of auxiliary equipment used within the package. This standardisation shall be applied so far as it does not interfere with the selection of an optimal solution for the specified operating conditions and duly considered equipment to minimize spares stocking. Noise Equipment design shall meet the noise level (85 dBA @ 1m) specified in Company standards. It is Suppliers full responsibility to ensure that noise level of supplied equipment (including drive equipment as a combined unit) shall not exceed the

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maximum allowable as specified in Project HSE Plan. Effort shall be made to select equipment with low noise level. Where it is not feasible despite the best design available, acoustic enclosures and / or acoustic insulation shall be provided. Supplier shall submit estimated noise level, consider / advise measures that would be applied when equipment noise level exceeds to noise level specified at respective specification and data sheets. Instrumentation / Controls Equipment Supplier shall include all required package / equipment / auxiliaries controls for safe operation of equipment. The instrumentation for communication with DCS shall be included to comply with requirements specified in respective Equipment Specifications, Data sheets and P&IDs. Equipment Covered This design basis covers the requirement for the following equipment : Main Cooling Water Pumps - Vertically suspended, submerged pump end, mixed flow seawater service Pumps complete with electric motor drive, VSD, Transformer, Local Control Panel (LCP) and associated auxiliaries. Centrifugal Pumps (General Service); includes hypochlorite dosing pumps / dilution pumps etc. Submersible Motor Pumps (Portable); includes sump pumps and drain water pumps. Firewater Pumps (as per NFPA 20) Instrument Air Compressor and Dryer Package Centrifugal Fan (at Hydrogen disengagement Tank of Chlorination Plant) EOT Cranes / Semi Portal Cranes (Pump house, Mechanical Plant, Receiving Basin, Workshop / Warehouse and Piping Manifold area cranes) Fixed Bar Screens cooling water common raking facility Rotating Drum Screens Stop Logs (Intake and Receiving Basin) Emergency Diesel Generator Set. Vessels and Storage Tanks Electro Chlorination Plant Equipment Equipment Selection Main Cooling Water Pump Sets The electric motor driven (through VSD), vertically suspended, submerged pump end mixed flow seawater service line shaft Pumps with right angle discharge head shall comply with Project Specification requirements, HIS Standards and in general compliance to API 610 Standards (where applicable for this service such as pump rotor dynamics, vibration levels, line shaft and thrust bearing design criteria etc). The offered vibration monitoring system for pump / motor shall be in compliance with API 670 recommendations. The pump datasheets shall address the pump drive train requirements; VSDs, Local Control Panel (LCP) and complete electrical set-up shall be provided by Pump Vendor (single point responsibility for Tender Scope). The vertical centrifugal pumps handling liquids whose vapour pressure is below atmospheric pressure, can be provided with gland packing suitable for the service. Pumps line shaft bearings shall be service fluid lubricated however, Supplier incorporate pump bearing design or operation strategy that shall take care of start-up
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scenario of stand-by pumps that would be with dried up bearings. The pumps shall be shop assembled to the maximum extent possible to consider minimum site assembly work and shipment limitations. The pump houses being in non-hazardous area while the pumps are operating in very corrosive environment i.e. salt laden sea mist, dust, wind etc. Flexible coupling shall be selected for the duty by main cooling water pump sets Vendor. Coupling guards shall be made from non-sparking material. The pumps and auxiliary items located at Pump House shall be designed for outdoor conditions as pump house is only a shelter with partially covered sides. Pumps shall be in parallel operation with head rising continuously to shutoff are required. Pumps right angle discharge head shall be with expansion-joint to tie-in with downstream flanged CCV (Combined Check Valve). In case of blocked discharge the specific unit shall be able to withstand shut off head condition for at least 5 minutes without any damage to pump and its auxiliary items. In case of CCV failure, the specific unit shall be able to withstand reverse rotation up to full speed. Pumps materials for major items / wetted parts shall be specified in Pump data sheets for Vendor review, the selection correctness i.e. compatibility to service fluid / material grades availability etc. shall be the Suppliers responsibility for providing right pump sets for the service. Pump set items shall be new and shall be selected by Pump Vendor to provide the single point responsibility of meeting specified pump duty requirements and service. Pumps selection shall consider common pump model (to the extent feasible) that provides stable continuous operating range and includes governing process flow requirements. To achieve this pump model commonality the pump driver could be of different rating and of different VSD speed range. Pump model testing is required. Complete testing requirements shall be as specified in pump specification and Data sheets elsewhere. Centrifugal Pumps (General Service) Centrifugal pumps for non-hydrocarbon service shall comply with Project Specification and ANSI Standards B 73.1 M or B 73.2 M and ISO 2858; Pump construction shall be specified on the pump datasheet elsewhere. Two-stage overhung and single stage double suction overhung pumps shall not be offered. Maximum allowable flow shall not be less than 120% of best efficiency capacity of the rated impeller. Pumps shall be selected so that it is possible to achieve 10% head rise / 5% head decrease at rated capacity by replacement with new impellers. Pumps shall have head curves rising continuously to shutoff. Shutoff head shall preferably be in the range of 110 - 120% of rated head. Pump impellers shall be closed or semi-open type open impellers are not acceptable. Use of inducers to enhance NPSH is not acceptable. The mechanical seal when specified in data sheet, shall comply with requirements of API 682. Mechanical seal design and material selection shall be suitable for the service fluid continuous operation with maximum operating temperature. Seal system piping shall be as a minimum in SS 316L or suitable to service. Material of construction of pump components shall meet the requirements as specified in equipment data sheet and compatible to service. Coupling shall be forged steel flexible type with spacer. Removable coupling guards shall be made from non sparking material suitable for very corrosive environment. As a minimum, electric motor nameplate rating shall be as below. Motor Nameplate Rating Percentage of Rated Pump Power = 18.5kW 120 20
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55kW 110 = 75kW 105. Inspection and Tests shall be carried out as per Engineering Standards and as covered in applicable specification. Sump Pumps (Portable Submersible Motor-Pumps) Portable Submersible Motor Pump shall be utilised for dewatering of pump house and receiving basins. When piping sections are to be cleaned from sediments, the pumps are required to be compatible with nature of seawater service fluid with sediments / grits. The Manufacturers Standard design shall be acceptable for sump pit installation drainage duty portable submersible motor-pumps. The pump motor shall be oil filled type and provided with two sets of mechanical seals for double security. Pump shall be fitted with cable and watertight cable connector. These drainage pumps shall be with lifting hook for portability and placed / lowered in sump pits of pump basin / receiving basin area whenever basin emptying is planned. For safe custody, these pumps shall be stored in warehouse / maintenance workshop when not in use. The tough duty submersible-motor pumps housing and impeller shall be in aluminum bronze (or alternately in super duplex stainless steel) material and all major components subjected to wear be coated with polyurethane for longer service life in fine grain abrasive application. The pump impeller shall be semi open type. The pump motor shall be water jacketed to provide cooling to motor by service fluid. Firewater Pumps Fresh water service Firewater Pumps shall be planned to provide fire protection to equipment by deluge. The horizontal centrifugal type Fire Pump sets shall be in accordance with NFPA (National Fire Protection Association) 20 design requirements. One pump set shall be with electric motor drive and other with a diesel engine driver. An electric motor driven jockey (makeup) pump shall also be installed to maintain the header pressure of fire Main Ring. The fire pump packages shall be with listed (UL / FM approved) pump set items and pump controller for fire protection service auxiliary items included in the packages comprise of circulation relief valve, water flow test devices etc. The selected pumps shall be a listed one per Firewater Pumps specifications and pump requirements in-line with NFPA 20. Pumps shall get supply from storage tank(s) of adequate capacity for the expected duration. Pump capacity selection shall be to NFPA 20 rated provisions and be specified at respective data sheets. Fire pump shall not furnish less than 150% of rated capacity at a total head of not less than 65% of the rated head and total shutoff head shall not exceed 140% of the rated head. Each pump shall have automatic relief valve listed for the fire pump service installed and set below the shutoff pressure at minimum expected suction pressure. The flexible coupling between pump and driver shall also be listed for the service. When more than one pump is installed on single suction line, the suction pipe layout at the pumps shall be arranged so that each pump receive its proportional supply. The automatically controlled Fire Pumps shall be provided with a listed float operated air release valve (when automatically controlled deluge system is planned). The Fire Pump installation shall include water flow test devices to allow test of the pump at its rated conditions as well as the maximum flow condition. Metering devices for pump tests shall be listed. Each pump shall have its own test loop. Each individual pump shall be tested at the factory to provide detailed performance data and demonstrate compliance to
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specification. Jockey / Make-up pumps shall have rated capacities not less than any normal leakage rate and discharge pressure sufficient to maintain the system pressure. Fire Pump Driver The lead fire pump and Jockey pump shall be with electric motor drive while back-up fire pump with diesel engine drive. The diesel engine and drive train components shall be listed items for the fire pump service. Controls Each pump shall have its dedicated driver and each driver its controller. The controllers for the motor and diesel engine shall comply to specification of NFPA 20 Chapter 7 (motor) / Chapter 9 (engine). Instrument Air Compressor Dryer Package The Air Compressor Dryer Package construction shall be to Vendor Standards designed for Coastal Area installations. Package units (train of compressor and dryer) shall be installed on single lift skid and compressor unit be inside its enclosure for sound attenuation. The plant facility shall be provided with two numbers of packages operating under lead lag basis. Air Compressor shall be oil-free, air cooled, electric motor driven Screw type Air Compressor unit complete with its UCP (Unit Control Panel), lube oil console and air cooler for lube oil and compressed air (inter and after cooler of compressor). Package Start / Stop and lead / lag operation shall be monitored from skid installed UCP on pressure level signals. The daily maximum average temperature shall be considered for compressor and its compressed air cooler sizing. The oil-field type air-to-air heat exchange cooler in SS316 (SS Stainless Steel) or construction with marine installation coating shall be specified to provide rugged construction in corrosive sea coast environment. The compressed air temperature down stream of air cooler shall be limited to 58C (with air cooler sized for ambient temperature of 50C). Air Dryer unit shall be heatless PSA (Pressure Swing Adsorption) type complete with twin molecular seive (aluminum silicate) desiccants towers and timer based controls for air flow switch-over. This unit shall be located downstream of Air Compressor unit and shall handle specified flow delivered by upstream air compressor unit. Compressed air shall be stored in Plants Service Air Storage Vessel and dried instrument quality air stored at Instrument Air Storage Vessel sized to cater for the Plant needs. Package instrumentation (PLC controls) for lead-lag controls shall be in Vendors local control cabinet; DCS communication as per package P&ID shall be achievable as a minimum battery limit pressure, temperature and dew point level shall be reported besides running status. A common facility delivering complete plant needs including instrument air needed for Chlorination Plant is envisaged in this Phase of project. Fans (Cf Blower) - Fans shall comply with requirements of specifications generally per API 673 and company engineering standard. Fans shall be sized to deliver the air flow & differential pressure required for the H2 disengagement duty under all operating conditions. Normally two fans (2 x 100%) shall be installed each to run and deliver the required dilution air with automatic switch over controls to other fan in case one fan trips. The power margin for electric motor drivers shall be in accordance with Specification at the rated conditions. Fans shall be provided with barrier type filter systems, filter shall be suitable for severe sandy & dusty atmosphere with rain hood and bird-screen. Fans shall be shop tested for the performance and stand by switch-over controls. Electric Overhead Travelling (EOT) Cranes / Semi Portal Cranes EOT Crane Page 18 of 491 suraj_engineer@yahoo.co.uk

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The Pump House is provided with maintenance duty EOT Crane to handle load lifts during pump overhaul and general lifting needs. Currently PH has one 17m span crane with main hook capacity of 60T and auxiliary hook capacity of 14T. The power distribution to the long travel is by enclosed type bus bars system (with rubber lip seal) and cross travel / hoisting power distribution is through power festoon cable system. In Project, the possibility of extending the long travel of installed crane and any considerations for additional second crane shall be reviewed (as a separate study) and study recommendations shall be implemented. The crane construction as defined below shall apply for any additional crane purchase. The EOT Crane shall be top running double girder type designed for maintenance duty class 2M (FEM 9.511) and suitable for safe area outdoor location (though installed in Pump house shelter). The crane shall be with operator cabin located at one end of the crane bridge (girder) & provided with remote radio communication set-up for crane operator use. The complete crane shall be designed to provide access platform / service walk-way for servicing the equipment and flood-lights to illumine the work area. The power distribution to the long / cross travel and hoisting motion shall be Similar to Phase power distribution system, crane controls to incorporate normal and creep speed motion controls for precise adjustment. Crane load lift capacity per Phase crane and provision for auxiliary hook shall be maintained as the load lifts provision are with adequate margin. Semi Portal Crane The Mechanical Plant (Screen Yard) is provided with maintenance duty Semi-Portal Crane to handle load lifts during drum screen overhaul and general stop log lifting needs. Currently has one semi-portal 23m span crane with main hook capacity of 10T. The power distribution to the cross travel and hoisting motion is through power festoon cable system and long travel by cable reel. In Project, the possibility of extending the long travel of installed crane and any considerations for additional second crane shall be reviewed as a separate study. The crane construction as defined below shall be applied when any additional crane purchase shall be in picture. The semi portal Crane shall be top running double girder type electric overhead traveling crane with one end of the crane bridge supported at runway beam and other end resting on a portal frame. The crane shall be designed for maintenance duty class 2M (FEM 9.511) and suitable for safe area outdoor location. The crane shall be with crane operator cabin located at one end of the crane bridge (girder). Crane shall also be provided with remote radio communication set-up for crane operator use. Complete crane shall be designed to provide access platform / service walkway for servicing the equipment and floodlights shall be attached to the crane bridge for work area lighting. The power distribution to the long travel shall be through enclosed type 7-bus bar system (with rubber lip seal) and cross travel / hoist motion power supply through power festoon cable system. A suitable sun shield shall be provided for the festoon cables when in the parked position. Crane load lift capacity per Phase crane shall be maintained as the load lifts provision is with adequate margin. Other EOT Cranes The maintenance load lift facility e.g. E.O.T cranes of adequate capacity shall be installed at the following Plant Facility areas - Receiving Basin Area, Plant Workshop / Warehouse, Electro-Chlorination Plant and Piping Manifold Section.
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The equipment construction shall be similar as stated in above. The power distribution for cross travel, long travel and hoist motion shall be through power festoon cable system. The crane load lift criteria as detailed in material handling study shall be accomplished. Mechanical Plant Bar Screen and Raking Mechanism Bar screen panel consisting of fixed rectangular steel bar sections with 50 mm spacing shall be installed at pump intake basin (upstream of rotating drum screens). The screen bar panel shall be removable type and for easy cleaning these should be installed with 80 degree angle of installation. The screen panel size similar to PH installation shall be considered for this phase. The common raking machine shall be grab bucket type rake assembly with replaceable tines. The assembly shall comprise of the following main components electrically operated travelling trolley, over head monorail traverse and power supply cable festoon, hydraulically assisted grab bucket complete with associated hydraulic power pack, hoist mechanism for grab bucket lowering and hoisting complete with PLC type Local Control Panel and pendant controls, trash / debris bin (to hold and carry 0.5 T of load) for disposal of rejects etc. The hoisting mechanism and hydraulic power pack shall be attached to traveling trolley. One number of rake machine for Pump House and rake machines for Pump House (1 op. + 1 sb.) shall be installed yet to remove trash / debris / marine seaweeds / sea shells etc. arrested in bar screens. In addition one complete warehouse spare suspended grab bucket c/w hydraulic power pack shall be considered for the Phase facilities. Design Basis Mechanical Equipment Alternate trash rake machine would also be reviewed to consider efficient scraping of bars at fixed bar screen panels (availability of traversing trash rake with scrapping in ascending action for reclamation of attached sea shells and barnacles from bar screen shall be investigated). Mechanical Plant Stop Logs Plate gates type Stop Logs (stop gates) similar to Phase I installation and dimensions compatible with civil design shall be planned for pump channels. Guide frame for each stop log shall also be provided by the stop logs supplier to embed in pump house civil work. The logs are not in use. Stop log designs construction and supply shall include equalising valve and a common lifting beam (Vendor supplied) with adequately sized slings. The stop log items supply and construction specification shall include material of construction, coating/painting requirements and other corrosion protection system viz. cathodic protection as applicable. Rotating Drum Screens The double side entry and central rejects disposal type rotating Drum Screen with 3 mm (~ 6 mesh) opening wire mesh panels (removable panels) shall be installed for fine screening of intake seawater. One screen shall serve 2 nos. of pump basins. The Drum Screen shall consist of a rotating structure for drum and wire mesh panels attached to drum periphery. The screen panel backwash set-up shall be incorporated in drum screen design for efficient screening operation. The equipment shall be for sea water service as such construction in Duplex Stainless Steel (DSS) materials (of
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suitable ASTM grade) is envisaged in Phase II of the project. The sealing between the civil work and screen drum to eliminate by-pass of fed seawater shall be achieved as per the recommendation / arrangement offered by the equipment supplier. The rotating motion to drum screen shall be through rack and pinion drive, rack shall be in sectors for attachment to drum by bolting. The drum shall be shaft mounted and supported on bearing block at both the ends. The Drum Screen Supplier shall include Lubrication console for Pillow Blocks Bearing. The inner periphery of drum shall be with elevated plate buckets to lift the screenings up to debris hopper located inside the screen structure, this debris hopper shall be in two separated section to allow rotation of drum supporting structural members. The drum screen shall be provided with PLC type local control panel (LCP); interfaced with water differential level instrument and drum screen drive to monitor & control operational speed, the LCP shall also be interfaced with DCS. The installation shall be provided with service / inspection platforms and suitable structure for falling object protection to service the equipment even in operation. Vessels and Storage Tanks Pressure Vessels Pressure vessel shall be designed in accordance with ASME SEC VIII, DIV-1 Boiler and Pressure Vessels: Rules for Construction of Pressure Vessels and shall be code stamped. Pressure vessels shall also comply with requirements of COMPANY standard and specification. Vessel heads shall be 2:1 ellipsoidal. The minimum shell and head thickness for carbon steel pressure vessels, including corrosion allowance shall be 6.0 mm. The minimum internal corrosion allowance for carbon steel and low alloy steel vessels, without any internal coating, shall be 3 mm unless specified otherwise in the datasheets. The minimum corrosion allowance shall be added to both sides of nonremovable CS internals when exposed to corrosive fluid or vapour. Removable CS internal parts shall be provided with corrosion allowance equal to half the specified value on each surface exposed to corrosion fluid or vapour. All vessel nozzles connections are to be flanged connections. Vessels shall be with manholes (24 min.) / handholes (12 min.) or end flanges as specified in equipment datasheets. These shall be provided for ease of servicing and operation and complete with davit. The structural access platforms for operation / servicing shall be supplied and installed by others, however attachment clips shall be provided on the vessels. The equipment and relevant lifting accessories as tailing lugs, trunnions and lifting lugs shall be designed to withstand the equipment lifting weight considering an impact factor of 1.5, unless otherwise specified on datasheet. Wind and earthquake loadings shall be calculated in accordance with standards. Wind and earthquake loadings shall not to be considered to act simultaneously. Storage Tanks Design, material fabrication, inspection, erection (where applicable), testing and preparation for shipment (where applicable) of welded steel tanks shall be in accordance with API-650. Rectangular tanks (if applicable) shall be designed in accordance with Roarks Formulas for Stress and Strain published by author Warren C. Young or similar structural design practices. Tanks shall also comply with requirements of COMPANY standard and specification. Fixed roof tanks shall be of cone roof. Tank bottoms shall be sloped downward conically (either crown up or crown down) as specified in the data sheets. If tank is provided with drainage sumps, then sump shall be equipped with a
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drain pipe with flanged nozzle. Pressure / Vacuum relief devices shall be provided, if tank is designed for pressure/ vacuum conditions. Wind design loadings to be in accordance with BS CP3, Chapter V, Part 2. Tank shall be designed for earthquake loadings according to Uniform Building Code (UBC) with applicable Zone number as 1. Emergency Diesel Generator Set Emergency Diesel Generator (EDG) set shall comply with requirements of Company standard and specification. The EDG package shall be self contained and shall not depend on external utilities for operation. Diesel engine of package shall be 4-stroke, turbocharged type and provided with primary battery start-up and back-up start by compressed service air of plant supply. Engine shall be radiator cooled. Lubrication and cooling systems shall comply with requirements specified in ISO : 3046 and COMPANY standard. Dedicated diesel fuel system shall be provided with a day tank. Day tank capacity shall be suitable for at least 8 hours running of the package at full load without replenishment. Day tank may be part of the diesel engine generator skid or as a separate tank outside the skid. The fuel system shall include spring loaded fuel valve (actuated by fusible plug / melting fuse) that shall shut upon FIRE. EDG shall be located indoor, inside acoustically treated and ventilated building, to meet the specified noise levels. EDG Room ventilation shall be achieved by suitably over sizing the motor driven radiator fan. Generator & other electrical equipment shall comply with requirements specified in the Company Standard Electrical Specification Diesel Engine Driven Generator / Electrical Design Basis. EDG package shall be provided with a control panel which shall be located in the switchgear room away from the package. It shall be possible to start the EDG package from remote systems on failure of mains supply or manually from the package itself. Suitable synchronising hardwired interface shall be provided for the same. Spare Parts Spare parts for main equipment and auxiliaries shall be in line with requirements specified in Project Spare Parts procedure and Company standards referred therein. Generally, spare parts for pre-commissioning, commissioning & start up as well as for the defined maintenance period are provided. Shop Testing Main equipment and auxiliaries shall undergo shop and site testing. Supplier shall prepare test procedures for specified tests and submit the same for Company / Contractor review / approval. Procedures shall be in line with requirements of contract specification / applicable international standards as a minimum. Test procedures shall also identify the methodology of test, applicable international standards, acceptance criteria etc. The inspection & test plan and equipment data sheets shall identify Company / Contractor witness requirements clearly. Based on the above requirements, Supplier shall prepare project specific QA plan / Inspection & Test plan. Buildings on the plants are of two classes one being process while the other non process. Generally administrative, amenities. control, operation, main & sub stations, pump houses, gatehouses, security controls etc. are included. Also included steel buildings for the industrial support purpose namely workshops, warehouses etc. These steel buildings are provided with all mechanical furniture, heavy equipment like lathe machines, forklift, trolleys, steel furniture, tool cabinets, steel racks, lockers etc & tools.
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The buildings require equipments such as office furniture & also steel furniture such as lockers, shelving, benches, racks etc Building services require HVAC chillers, package units, air handling units, ducting, fittings such as fire dampers, volume control dampers, accessories & other controls. False ceiling, grills & diffusers. Ducts for supply & return run in the plenum between the false ceiling & the slab soffit. Also included CCTV, structured cabling, fire fighting, electrical installation of low power as well as high power, fiber optics cabling, cable cellars, switchgears transformers, telecommunications, radars controls, Information technology etc. all. Electrical supply is distributed by Main station, sub main stations, transformers etc. The area where transformers are located are constructed around by firewalls. Sub station comprises of HV & LV areas, wherein switchgears are accommodated. Proper insulation is carried out for the building envelope to reduce the thermal heat flow into the buildings to maintain the required design conditions for economical air-conditioning. Fire suppression system is used in the buildings by the name FM 200 or Inergen etc to extinguish the fire within seconds & minutes. This gas spreads in the unventilated space & extinguishes the fire immediately. Also included smoke detection systems along with fire fighting system for internal as well as for exterior use. Industries within plant area employ their individual systems for fire fighting bust preferably a sea water back up fire fighting system is also included as stand by. Fresh water system is also included for the areas locating expensive & strategic equipment for electrical supply as well as emergency controls. Cathodic protection is used to control the corrosion of the reinforcement by providing electrode at the structure centrally controlled from one location. All reinforcing bars are clipped & wired naked maintaining the continuity of the bars. Cooling towers are installed when the supplied water is required to be re-circulated for many uses for the concerned industry in which case only makeup water is supplied to maintain the balance. For once through system, the water is supplied & returned after cooling the industrial systems into the returned headers without any circulations. In some cases a combination of both could be adopted for economy.

---------------------------------Chapter 2
Project Design, Contract award & Miscellaneous
Abbreviations Some useful abbreviations generally used on the design documents for references:A / G - above ground, AFC-approved for construction, AFD-approved for design, BFDblock flow diagram, CCR-central control room, CCTV-closed circuit television system, CCWS-common cooling water system, CDR-conceptual design report, COMcommissioning, CP-cathodic protection, CT-cooling tower, CW-cooling water, DC-direct current, DCS-distributed control system, Easement- all and provided by Client to be used by Contractor for the purpose of construction, EPIC- engineering, procurement,
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installation & commissioning, ESDV-emergency shut down valve, EWS-engineering work station, FAT-factory acceptance test, FOTS-fiber optics transmission system, FEED-front end engineering design, FMEA- failure mode & effects analysis, FO-fiber optics, FRP-fiber reinforced plastic ( generic name including GRP, GRV, & GRE piping), F&G-fire & gas system, GAD-general arrangement drawing, GIS- gas insulated switchgear, GPS-geo positioning system, GRE-glass reinforced epoxy, GRP- glass reinforced polyester, GRV- glass reinforced vinyl Easter, HVAC-heat ventilation & air conditioning, HMI-human machine interface, HSSD-high sensitivity smoke detection, ICA-instrument, control & automation, IDF- intermediate distribution frame, I / O-input /output, intool- trade mark name of Intergraph software for instrumentation eng, ISTintegrated system test, ITP-inspection & test plans, IO&M-initial operating & maintenance, LAN-local area network, LBV-line break valves, LER- local equipment room, LLCC-local lot control centre, MC-mechanical completion, MCC-motor control centre, MDF-main distribution frame, MOV-motor operated valve, MTO-material take off, MWS-marine warranty surveyor, ONAF-oil natural air forced, ONON-oil natural air natural, PABX-private automated telephone exchange, PA/GA-public address / general alarm, PC-pre-commissioning, PCS-process & utility control system, PDS-power distribution control centre, PDS- plesiochronous digital hierarchy, PDS-plant design system, PMS-power management system, PEMS- power energy management system, PFD-process flow diagram. PFS-process flow scheme, PH- pump house, PIS-plant information system, PLS-programmable logical controller, P & ID- process & instrumentation diagram, PSFS-process safety flow scheme, PSS-plant safety system, PSV-pressure safety valve, PTZ-plant tilt zoom, QA/QC-quantity assurance/quality control, NCS-National construction specification, RAM-reliability, availability & maintainability, RB-receiving basin, RFC-ready for commissioning, RFQ-requisition for quotation, RMU-ring main unit, ROW-right of way, RTU-remote transmission terminal unit, SAFE- safety analysis function evaluation chart, SCADA-supervisory control & monitoring system, SDH-synchronous digital hierarchy, SPT sustained performance test, STM- synchronous time moduling, TETRA-trunked radio, TPC-Third Party Certification agency, TPI-third party inspector, TTL-transistor transistor logic, UFD-utility flow diagram, UFS-utility flow scheme, UPS-uninterrupted power system, U/Gunderground, VDRL-vendor data requisition list, VSD-variable speed drive, VSDSvariable speed drive system FEED- Front End Engineering Design Involvement of multidisciplinary teams for the required designs. Process engineers, chemical engineers, reservoir engineers, mechanical engineers, electrical engineers, IT engineers, civil engineers etc. shall be included to formulate an overall strategy of designing the plant system and supported by soil engineers, hydrographic engineers, geological engineers. After having the basic design been conceptualized, further FEED detailed works shall be undertaken by all disciplinary teams for elaborate formations of various details to be used on the project. EPIC- Engineering Procurement, Installation & Construction EPC- Engineering Procurement & Construction Contractor, SubContractor, Supplier, Vendor Sub Contractors as Engineering Consultants

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Front End Engineering Design requires complete know how about the proposed facility design, technology & construction details that is fed to the Client for inception of the whole scheme which the Client approves & based on FEED tender documents are prepared for the Engineering, Procurement & Installation contract award. This class of tendering necessitates a very competitive & competent bidders to be technically, commercially & in all respects a completely sound organization. Complete Front End Loading is to be established & provided to the design scheme. EPIC contracting requires complete design know how giving all detailed design calculations for the best & warranted performance of the facility as well as commercially competitive. EPIC contracting proposes its own SubContractors as well as vendors organization to be included as further support. Design SubContractor shall also be included as support in case the EPIC organization is not a designer or consultancy group or not having an in-house design capability. All documents based on the aforesaid abbreviations are produced schematically while preparing the FEED documents for the information purpose to the bidder about the intention of the client requirement. The FEED contractor of the client should provide as much data as possible to enable the contractor to understand the client requirement fully for the EPIC implementation contract & price according. It must again be stressed that FEED is endorsed by the EPIC contractor while submitting bid as an evidence of acceptance of FEED & its incorporation on the detailed designs based on which the works shall be executed.

Project Tender Documents


The aforesaid teams of the engineers shall prepare all required documents necessary for the invitation of the EPIC tenders from the short listed parties. These documents must cover the basic requirement & design philosophy pertaining all disciplines to enable the bidder know each & every requirement precisely. All disciplines shall be given full feed back in all respects in the form of project drawings, specifications, soil test reports, survey reports, marine survey report, bathymetric survey report, marine geological report, other studies & observations, climatic conditions, various milestones, quality standards to be adhered to, all other essential parts of the project demands. These documents should be crystal clear without any ambiguity. As far as possible, details about the equipment to be included on the project should be given within the documents. All national & international codes to be followed should be enlisted explicitly. Project design parameters should be explicitly defined. Documents shall be provided in soft as well as hard copies Production of such huge volume of design documents amounts to requirement of very experienced teams of experts for all disciplines to meet the schedule requirement

Maintenance Preparation Documents


This though applies at the end of construction i.e. mechanical completion of the project but information are required to be issued at the FEED stage for the evaluation purpose Contractor's obligations pertaining maintenance preparation General engineering and procurement
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Contractor shall take into account in the design of the FACILITY the maintainability Criteria, philosophy and spares to be defined in the FEED Design Package. In particular Contractor shall: Make permanent provisions for accessibility (without dismantling of other equipment), dismantling/tooling, lay down and handling of heavy parts. Make provisions for online monitoring of vital rotating machinery Define criticality ratings for equipment, sparing requirements for equipment, components and parts Contractor shall prepare and submit the required maintenance documentation as generally defined in the relevant Exhibits, integrate the maintenance requirements in the Vendor selection process, and obtain Vendors documentation generally defined as such. Requirements for vendors selection Pre-qualification Prior to issuing any call for tender for critical items, Contractor shall check Vendors' capabilities such as: Ability to submit tenders conforming conforming quality requirements Technical and financial long term stability. Existence and suitability of Quality Assurance procedures within Vendor's structure, covering the manufacturing process, the quality control process of raw materials, the assembly of components, the performance and conformity tests, the internal quality audits, capability to supply after sales service for maintenance, technical assistance, supply of parts, procedure for collection of product performance feed back etc.

Bid Evaluation
Contractor shall take into account at the bid evaluation stage the following Criteria for Vendors selection and accordingly advise Vendors that their bids shall be evaluated on such basis so that the vendors must include any price if so effected by such considerations: Bid price and conformity to project specification. Cost of two years or as specified in the contract recommended operating spare parts for all the machines or equipment to be installed on the project. Reliability of Components (identification of components non standardized or non tested by Vendor under conditions similar to project conditions). The components should be fully reliable to meet the intended functional requirement for the efficient performance operations. Standardization (identification of non-standard components, justifications for recommending such components, cost of spare parts needed for such components). The cost of spare parts contractually required according to the specifications shall be included within the bid correctly. Availability guarantees-Ratio optimal conditions / optimal performances- Evidences to be obtained from the prospective vendors by visiting to the factory as well as to the references works carried out on track record. The vendor shall provide with the technical brochures of the product to the contractor along with the bid all documents giving the performance evidences. The performance shall also be witnessed by visiting the location of the spare parts. Safety / Protection rating-Verification of performance evolution-Means for condition monitoring - Recommended frequency and duration of maintenance- interventions (total annual duration, maximum duration of a major intervention-Availability / Reliability / MTBF / MTTR-Availability of after sales service (rating)-Availability of spare parts lists Availability of documentation lists-Availability of documentation lists-Operational List of
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special tools maintainability-Modularity / Disassembly-Accessibility (rating)-The ratings should be obtained from some of the independent agencies published documents which should indicate that the observation & the relevant studies performed without any interference by the vendor. These third party agencies usually publish the effectiveness of these vendors product & services in parts or in totality at regular intervals or as required for some special assignment. Handling (rating)- Similar record should be confirmed from the data base of the successful projects on the vendors track record & included with the submission to the engineer as an evidence to monitor the product efficiency. Maintenance Guarantees-This guarantee is required for the contractual maintenance duration for all the machines, equipment etc. Stability of Vendor, Quality Assurance, after sales structure- Proposals for maintenance contract (rating), guaranteed reliability Contract (rating), training programme (rating)Vendor Maintenance Recommendations-Management and monitoring (rating)-First level maintenance (rating)-Diagnosis tables (rating)-Preventive and on-condition operations (rating)-Method of intervention (rating)- Identification of conformity certificatesRequirements for component testing. The provision of the aforesaid documents from the vendors records substantiate the vendors claim about the reliability & leads one-step to customer satisfaction. Vendors obligations to be enforced by Contractor Contractor shall generally carry out the procurement steps required to have the Vendors who meet maintenance requirements specifications for the supply of equipment and documentation- Contractor shall prepare and include a Vendors' maintenance requirements specification in call for tenders and purchase orders in line with the Client guidance and submit for approval. Contractor shall obtain, check, approve and issue Vendor maintenance documentation (the Maintenance Dossier) and prepare the Mechanical Catalogue. The contractor shall comply with all the manufacturers instruction in respect of the equipment or the product & evidence in this respect to be provided as quality documentation to the engineer for approval & recording. The Vendors Maintenance Dossiers shall generally include but not be limited to as the guidance is in essence. Equipment data-Equipment descriptions-Equipment inventory-Technical data sheets (reference number, serial number, tag number, purchase order number)-Connection parameters (piping, electrical, instruments)-Software documentation both in electronic format and as a hard copy-Operating documentation-Operating procedures- On-line monitoring- On-line monitoring- First level maintenance by operators- Lubrication schedule. All these documents & also any other additionally required one shall be approved by the engineer for implementation on the performance monitoring. Maintenance documentation (per type of equipment)- Scheduled inspections or interventions-Preventive, on-failure and overhaul maintenance procedures, including description of personnel, tools, spare parts, drawings required - Trouble shooting charts- Lists of consumables- List of special tools- Spare parts lists (SPL), under format attached or equivalent- Drawing- General arrangement drawings- Section drawingsSchematic and wiring drawings- Control loop diagrams- Logic diagrams, cause and effect sheets. All these documents shall be properly numbered & recorded by the document centre.

Technical Proposal
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It is unavoidable in this age of tendering particularly on the Industrial projects of international Quality Assurance nature, that the bids are submitted in two parts together or separately depending upon the Client requirement. Technical bid is always a lead submission package that is invited to fully assure whether or not, the bidder is capable to execute & prosecute the project smoothly. In case the technical bid is rejected, there shall be no need for the bidder propose commercial part of the bid. Technical bid is a voluminous document containing complete details of the bidders intentions to carry out the project execution from the commencement to the completion stage describing in details ways & methods for every part of the proposed project, how these shall be handled & whether or not, bidder is adequately resourceful, technical capable & scrutinizing all other aspects, bid is evaluated. Technical bid should contain fully descriptive & completely integrated infrastructure of the bidder in all respects about design & execution philosophies, execution plan, machinery & man power proposal, alternative proposal if so necessary contemplated by the bidder, full design criteria, materials proposed from the authentic source, acceptability of Third Party Certification, deviation from the contract & its controls, complete safety programme detailing & risk analysis, Hazard study, safety records, safety plans proposed, evidence of past safety capability records, various well designed forms to be employed for the whole duration of the project It also requires descriptive proposals from the Quality Assurance & quality control section providing all necessary formats & detailed methods of quality control maintenance including Inspection & test plans, check lists & all quality documentation procedures, method statements, proposed independent testing laboratory. All procedures pertaining company documentations shall be included involving internal documents matrix used & ensuring that documents traceability is smooth. Engineering procedures including procurement shall also be included within this proposal giving complete feed back on proposed designing system, software to be used, designers potential, complete requirement of the job related material, job temporary facilities to accommodate the manpower etc Since the Technical Proposal is based on the provided FEED documents by the client or the client appointed FEED contractor, whatever contents of the Technical Proposal be presented, should be based on the technical directives included within the FEED. The base firm proposal should not at all deviate from the FEED requirement. The bidder is required to endorse the Technical bid stating that the bid is completely based upon the FEED meeting all requirements unconditionally. The content of certification should be in accordance to the format provided. There may be an alternative proposal in addition to the firm proposal which may satisfy the requirement of FEED in addition to making cost & time saving to the client according to the Value engineering consideration that the client could accept if within the FEED. The Technical proposal is very comprehensive presentation content wise giving all information of the contract execution wise from the design to the performance & handover stage. No room is allowed for any commercial reflection within this submission. In fact the consistency & capacity of the bidder is measured from this submission.
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Many rounds of the submission are conducted to scrutinize the submission of all chapters. These chapters should be simple in the style to allow full communication of the bidder to the engineer/client to facilitate an easy understanding of the proposed execution. All sources of the materials, equipment & all other items to be used for the permanent inclusions on the project should be enlisted in a scheduled manner in line with the FEED requirement. Proposed work schedule to meet the defined milestones should be explicitly described convincing every one concerned that the bidder approach is feasible in practical terms. All workforce & staffing levels as well as management to supervise & direct the project should be clearly defined including the CVs of all key levels. These levels should meet the defined criteria according to the FEED as well as professional competencies. Design procedures should be clearly defined in a precise manner including giving all designation of Information Technology to be utilized for the project. In brief all other proposals for the proposed facilities for the temporary works as well as for the permanent works should be included explicitly. It is a long format but should be precise & to the point. The client is never interested in a voluminous documentation for show purpose but a precise content giving all true & relevant information is always welcome. It should be remembered that all these proposal documents shall be required for the actual demonstration proving the consistency as well as competency of the proposal. It is better not to propose something which is not practiced by the bidder, otherwise demonstration could detract the bidder. Many cases have been noticed when after the proposal, comments are received from the engineer asking for many clarifications which are difficult to reply positively. Be straightforward for the submission. Quality assurance as well as Execution statements constitute very important & significant role for providing value to the technical bid for which due time & devotion must be given by the bidder. The experts should be engaged for the detailed inclusions of the necessary information inclusion within the documents for the client consideration. Untoward information should preferably be avoided. Once the bidder is short listed by the engineer or client by the establishment of the bid competency, the call for the commercial presentation should be given or there is no use in case the bid fails to meet the FEED requirement.

Contract award
Within this procedure, the short listed parties shall be invited to tender for the EPIC bid who in turn calculate the demanded facility EPIC or EPC lump sum firm price for the whole or part of the job in defined fixed time based on the FEED documents, provided which submission shall be Technical in one part & Commercial on the other. Sufficiency of the Technical bid shall decide whether or not, the commercial bid should be considered. After having the Technical bid qualified by the bidder, the qualified bidders shall be notified about the opening time schedule of the commercial bids. The EPIC contract shall be awarded after complete scrutiny of the bid documents & the availability of the performance bonds & ascertaining fully the sufficiency of the quality as well as capability of the proposed Contractor. A letter of award shall be issued by the Client representative instructing the successful bidder to immediately commence the job giving the effective date of commencement. A date shall be appointed by the Client for the execution of the contract between the
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Client & the successful bidder as well as for the kick off meeting. An agenda shall be drawn for the kick off meeting defining the sequence of the points to be discussed & the officials & authorities from both parties to be present during the kick off meeting. The successful bidder shall affirmatively make available its representative to execute the formal contract documents on that day failing which, the Client enjoys the legal right to claim the tender bond amount from the surer bank. A date shall also be fixed by the Client instructing the Contractor to submit the performance bonds, insurance policies about the works as well as for the employees accidents coverage as well as all other document about these according to the General Conditions of the Contracts (GCC). Details about all deductibles, amounts covered under all policies etc shall be submitted according to the documentation procedures.

Execution Programming a contractual binding document


Contractor shall immediately prepare a detailed execution plan based on the brief level 1 plan that was included within the Technical Proposal at bid stage for the complete contract works from level 1 to level 5 or as the case may be, in the primavera or MS project software format as agreed with the engineer or defined in the contract. Programme shall cover an overall outline in Gnat format with CPM support, include all contract milestones defined, discipline & element or component wise detailed activities, detailed man power, detailed machineries, recovering delays methods, identification of problems with the resolutions, activities wise measurement of work percentage based on agreed method of man-hours evaluation or time based activities as well as cost wise breakdown applicable to (WBS) work activity breakdown structure. Progress S curves indicating various phases shall be included showing man-hours histograms, work planned progress, machines availability histograms, cash flow etc. Once the Contractors programme is approved, it shall not be altered but constitute as a base programme to monitor the whole progress progress, coordinate & recovery shall be applied, should there be any delay to the project planned progress. In addition to an overall descriptive programme, monthly 90 days look ahead monthly programme shall also be charted out regularly to monitor the progress on detailed basis. This programme shall be supported by a detailed method statement giving complete information about the phases of works & their elements arranged in an order keeping in view the priorities on the project & to accomplish aforesaid approved programme effectively. Major sequences of the operations to be covered from the home office activities including corporate management affairs, designing, procurement, documentation, selection of sub Contractor, engineering, procurement, deliveries controls, customs, material storing, quality assurance, cost control & taking down to the site relevant activities in all respects. This part shall be taken up & considered very seriously as the work progress movement rests on its actual level of performance. Organization charts shall be presented showing contract design office, contract head office, site office, sub Contractors offices & all other directly or indirectly connected parties giving full description about the corporate structures of all related contracting parties on the project.
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SLSM Publishers (CVs) curriculum vitae respecting Key Personnel to execution of the contract project shall be proposed for approval no key personnel shall be allowed to work defines its level of requirement pertaining the essential key personnel to be dedicated to it

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be involved for the complete approval by the Client. Without on the contract. Every project qualification & expertise for the

Format for Execution Programme only for guidance Scope, Work breakdown structure, Contractors organization including details of its organization, sub Contractors organization, job positions & descriptions of key personnel down up to supervisory level, Contracting strategy-direct hire-direct control or management, Home office activities, other Contractors Interface coordination, Operations, Mobilization-break down of manpower by trade including manpower histograms-major equipment utilization schedule, Construction sequence-temporary facilities-including utilities & camp accommodationssite preparations-underground piping-underground electrical & instrumentation-civil foundations & concrete work-structural steel-equipment erection-pipe fabrication-pipe erection-electrical-instrumentation control systems-telecommunication-paintinginsulation-pipeline, Quality management systems, Material management system-customs formalities-port storage-& transportation to site-warehousing-storage-material handling-general responsibilities of field materials personnel-material receiving & inspections requirements-maintenance procedures-protection & preservation procedures, Health safely & environment-responsibility of safety personnel-HSE process & execution plan-HSE orientation-HSE site programs-construction environment control procedures-permitting-medical facilities, Site security, Heavy lift & transport, Personal transport, Manpower (direct & indirect), Field non manuals, Construction automation plan, document control, acceptance, Mechanical completion incorporating pre-commissioning, Pre-commissioning & commissioning organization-job descriptions, Close out, AttachmentSite organization charts, Field non manual staffing plan, Sub contract plan-number, name & scope of each subcontract, Level 2 construction schedule, manpower loadinghistogram by trade including both directs & indirects, Equipment utilization plan, Temporary facilities & camp accommodation plan.

Stages of Execution-EPIC / EPC-Construction Contractor


Safety, Health & Environment- Safety plans-Training-Induction-Regular courses-Special courses- Site Walks-Tool Box Talks-Risks Analysis-Corrective ProgrammesInspections-Awards-Audits Quality Assurance QA / QC- Quality plans-Training-Induction-Regular courses-Special courses- Audits- laboratory- dossiers Engineering Design detailed philosophy, Design, Detailing, Shop drawings- Working drawings-Schedules-Technical Queries, Site works queries, Proposals for technical resolutions, Documentation appraisals, Construction ability checks, inference of technical documents, Engineering meetings, Construction Method statements
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Construction & Controls - Mobilization-materials-manpower- equipment-procurementphysical construction-contract management construction project management. Testing - Pre Commissioning, commissioning, performance & maintenance Operations & maintenance Third Party Certifications Project records - Issued for Construction documents-Red Lines Mark ups-As builtOperation & maintenance Manuals Punch List / Snags - Visual defects-Technical defects- minor non-conformance-snagsrectification- remedial measures-investigations Mechanical Completion- Pre commissioning & commissioning-site acceptance testperformance - plant performance Final Completion - maintenance & successful performance Hand Over-Recording the learning of lessons-suggestions-about the sub Contractorsabout the Client engineers-Close Out-discharge Warranty liability - relevant guarantees for the required periods.

--------------------------------------Industrial Safety Briefs


Safety, Health & EnvironmentFirst & foremost is the safety for any project. Slogan SAFETY FIRST is very common among the safety promoting projects. Without safety no work is allowed. Safety is the responsibility of every one. Every person working on the project must use personnel protective equipment PPE & all necessary special precautions must be taken whenever directed by the safety official responsible for the project. All activities must be conducted in a safe manner to the best possible minimum cost incurred on safety. In case no proper arrangements are made to keep safety intact, the execution of the activity should be suspended. On important works, safety team must be present & support the construction team for smooth safety management. Site engineers should abide by the instruction & direction given by the safety personnel. Proper care must be taken during deep excavation works as well as overhead works.

Safety plansDiscipline activity based safety plans should be prepared in conjunction with construction in-charge, approved & issued by the safety department for the guidance of the construction personnel. Training- Various classes of training are necessary to be imparted to the site personnel for onsite implementation. Induction- Immediate on the joining, all personnel should be given safety induction course duly recorded on proper register for the training. The course must include all precautionary instructions required on the site generally to be prosecuted onsite.
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House keeping- Training should be given to all personnel to keep the working & other areas tidy during & on the end of the day. Tools should be properly kept on site. Material should not lie here & there. Working environment should be felt comfortable by all concerned personnel. Supervising safety Every supervisor should be trained for the understanding of managing safe supervision over the site operations. How to handle the ground works & how to handle the overhead works. How to make the workers understand all procedures of safe handling the operations so as no operation should effect the workerss health badly causing no overstress physically. Heat stroke On constriction sites particularly in hot & arid regions, the effects of heatstroke are imminent to workers. They should be taught the methods of how to prevent such incidents by gradually inducting the worker to the hot working conditions & over timings adjustments. Fire watch Every workers should be clearly taught the ways of possible fire incident & if occurs, how to handle to extinguish. Toolbox talks In general, prior to begin any activity, tool box talk should be given to the group working on the activity involving any or all calling. How minor or major injury may occur during carelessly using the tools & how to act if injured. Liquid consumption & food Every worker should consume water or available drinks after a period of work to protect one from the adverse effect of dehydration & should be allowed the intermittent rest pauses. Dust prevention Dust accumulation causes environment degradation & affects working on site. During such inclement weather conditions, ample means of water should be available to spread on site so that the dust does not lift into air. Sanitary Adequate arrangements must be made on site for the workers & staff to use sanitary facilities throughout the currency of the project to maintain the working area healthy & hygienic. Regular coursesIn groups workers should be given feed back on the site safety as well as gas inhale prevention, during fire how & where to assemble, how the fire alarm works etc. How to construct for temporary platforms at high levels to be used for various purposes to meet the site instant requirement. Special coursesHow to take precaution to avoid electric shocks or some other hazard.
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Incentive should be given to the leading workers who keep proper safety as well as check & advise coworkers & colleagues to take due measures. Accessibility to site horizontally as well as vertically should be explicitly explained to every one. Positioning of the ladders in the trenches, which location shall not be more than 8 m. Provision of the platform guardrail of suitable height. For example use of wooden or Aluminum ladder in excavation areas or to the higher working areas. Platform construction, supports, toe board etc. Fire extinguishers use. First aids use. How to access emergency phones for hospitals. Site Safety WalksWhenever necessary, site walk should be conducted by the safety engineer with the site in-charge to pin point the deficiency on safety & on site correction applied. Tool Box TalksEvery skilled worker, semi skilled or unskilled should know about proper use of the tools & maintenance of these. They should be explained about all types of dangers if the tools are not properly used during work Risks AnalysisKeeping in view all types of operations on site, what risk are imminent, should be studied by the safety engineer & in cooperation with the construction people & expected causes of risk & their relevant solutions be explained to the team for implementation on site as well as properly documented. Safety of heavy equipmentCrane operation, shovel operation, concrete pump operation or any other equipment operation requires a complete safe operation system. How to operate these machines safely on site. License of operators as well as banks man instruction manual. Third Party Certification for the crane particularly. Only licensed operator should be allowed to carry out the lifting operations. ProgrammesRegular & frequently, safety programmes should be conducted on site from every aspects to make all aware of overall safety to avoid accidents Practical training should be conducted for the equipment operators to let them understand the effects of not conforming to the safety practice. InspectionsSafety engineer should inspect working areas frequently to examine that the arrangements adopted on site for the running operation meet the necessary criteria of the safety rules & if observed certain deficiency, the site engineer should be intimated for the corrective measures. AwardsTo motivate the workers on site to take due safety measures during working hours & thereafter as well, awarding system should be adopted for the workers who work on full safety on site. AuditsCorporate safety team should check casually & as programmed, the safety records physically on site & due observation circulated along with the proposed corrective measures.
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A healthy worker on site works many times better than a sick & unsafe worker. It is better to spend reasonable amount on safety rather than spending on loss of work causing inefficiency on site. SAFOP-Safe Operation- It is the key to the success of the project in all respects. SAFAN- Safety Analysis- Prior to an application of the safety, complete analysis is a must to know & select the best safety methods SYSOP- System Security & Operability Analysis-It is very significant from safety engineering viewpoint. Until complete problems are listed, applicable procedures may not be known. Systems generally involve safety against fire, gas explosion & electric default. Therefore, these import application of all precautionary measures selection of which depend on the detailed requirement as obtained from the risk analysis & details of equipment operations. OPTAN- Operator task Analysis-Control & field Operator-This part also involves detailed study as well as precise applications. No slackening should be allowed. Attempts should be made to take due measure to prevent accident in hot work as well as cold work areas & also in restricted & confined entry areas. Permit to Work PTW must be applied to work in such areas of the facility.

--------------------------------------Quality Assurance, QA / QC Briefs


Quality plans-Training-Induction-Regular courses-Special courses- Audits- laboratorydossiers The term Quality Assurance which includes quality control being significantly important form the customer satisfaction viewpoint, must be clearly understood by all participants on the project. Many have the unclear concept of these terms. For information, QA is a principle term applies to overall quality system management means, Total quality management, while quality control applies to particular quality control procedure, for example laboratory testing of material, site checks, inspection & test plans & so many other technical involvement during construction operations. Follow up of the whole procedures as included within the quality plan from project inception to the handover & discharge successfully to the customer full satisfaction is termed Quality Assurance. QA involves major policy & competency of the company. Based on the successful completion of various projects conforming to QA, past track records confirms the competent standing of the company on QA. Company mean not the company management but all members of the company at all levels of corporate & home office, middle management, lower management, workers. These include working of all departments of the company in both home office, branch office, field offices 7 in field, market contribution, market collaboration & so many other aspects which cannot be covered in brief explanation.

Quality plans
This term includes company quality manual & project quality plan.

Company quality manual


A primary document of the company announcing companys quality basic policies in full. It provides the details of the corporate management, companys organization, directors responsibilities, management of its various departments, documentation system, policy decisions, incorporations & accounting, companys goals, instructions & job descriptions
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of its middle & lower level officers, full operational descriptions, procurement & material handlings, human resources management, accounting management, transportation but not the least. Companys planned approach in business & how to satisfy a prospective customer. Manual is a permanent document amendable from time to depending on the advancement & progress of the organization. Virtually it is like a constitution of the company telling every thing about the company management. All sections are included as completely descriptive giving elaborate information to the concerned person. Based on the contents of this document, further documents for presentation & approval are prepared for the upcoming projects or tenders submission. The major policies included within this document shall guide the contents formation within the project quality plans. This documents main chapters include company policy, companys potential, companys objectives in national as well as international market, companys organization approach & basis, companys various sections or divisions, corporate structure, constitution of the governing board, staffing level, job description of the corporate & senior staff, companys strength comprehensively giving machinery as well as manpower, companys know how potential all but not limited to these.

Companys project quality manual


For the purpose of including within the technical package submission for the tender bid as well as for the contract documentation submission for approval purpose, a document containing specific project details in conformance with the company manual giving full & elaborate explanation of the ways of executing the relevant project from the award to the handover & final completion stage is entitled Companys project quality

manual.
Project Quality Plan This document is specifically constituted for the management control of the relevant project & gives all information applicable to the project, which cannot be generalized. The contents of the information depend on the specific requirement of the project & may differ from one project to another as well as from one discipline to another. Contents of this document should be like sub headings given below for guidance. Description & magnitude of the project & companys general policy towards this.-Brief details of the project & contract-Project execution programme-Corporate office involvement-Joint venture involvement-Sub Contractors involvement-Specialist vendor/s involvement-Corporate management & Co ordination-Corporate Safety, health & environment-Corporate Engineering Corporate Quality assurance-Corporate Procurement-Corporate supports for all disciplines-Project site/field management & Co ordination-Project site/field Safety, health & environment-Project site/field Engineering-Project site/field Quality assuranceProject site/field Procurement-Project site/field supports for all disciplines Aforesaid chapters or parts of the documents should be designed in conformance to specific requirements meeting the contract criteria, company manual, international, conventional practical standards & the ultimate objective customer satisfaction. The document should be prepared by the quality manager/engineer in conjunction with corporate as well as project manager/construction manager/project engineer after
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studying all details & specification relevant to the contract, General Conditions of contract. The draft should be approved by the management & then by the Client. It should be distributed as controlled copy & not to be altered. In case any alteration is required, another approval should be obtained. All relevant supervisory staff must know about the contents & interpretation of the documents to their respective discipline & fully explained to all how the implementation shall be effected.

--------------------------------------Chapter 3
Engineering
Introduction
Company / Client believes from its vast experience that one of the key foundation blocks for successful, efficient and cost-effective end product FACILITY is the quality of detailed engineering and design. Therefore, Company / Client places a very high importance on the Contractors selection of an internationally recognised Detail Engineering and Design Sub-Contractor or in-house organisation with a proven track record of undertaking and successfully delivering similar projects in a single location under one roof. Accordingly, the Engineering and Design Subcontractor shall mobilise their team for the Project. Company / Client shall verify this at the time of review of CVs and interviews of Key Personnel. This shall be one of the key bid evaluation criteria for the selection of the Contractor. The CVs shall be reviewed from an overall qualification viewpoint which means only academic qualification shall be not exclusively a basis but practical specific experience on interdisciplinary sphere to be considered for the acceptance of the proposed key personnel along with general capabilities such as communication skills, efficiency to carry out jobs in the field & in office environment & effective response the client personnel to prosecute the project coordination activities. Contractor shall carry out site surveys to familiarise himself with the existing installations if any, pipelines, infrastructures, pipelines corridors and tie-ins locations. Site survey is also required to verify the proposed pipelines routes and confirm the tie-ins location and configuration etc. and to retrieve necessary information (data, drawings etc.) All survey records & database shall be verified by conducting full survey of the site to the requirement of the contractors scope of works. These actual surveys shall form the basis of the actual design to be approved by the engineer or the client. The survey provided with the FEED or the tender document shall be treated only for guidance. It shall be Contractors responsibility to ensure that all relevant documentation and drawings available with Company / Client (at various locations) are retrieved in a timely manner, so as not to impede the progress of the detailed Design. All the records or as built drawings required for the purpose of coordination shall be required for practical interfaces & coordination criteria which should be requested to be issued by the relevant authority according to the planned requirements. Engineering shall include endorsement and upgrade of FEED including design optimisations, detailed engineering, process engineering, procurement, installation, commissioning and any other engineering work that Contractor shall need to develop for
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the required design, detailed definition, procurement, supply, construction, Installation, Testing, Pre-Commissioning, Commissioning, Start-Up, Initial Operation and Maintenance and hand-over of the FACILITY. The contractor shall certify while submitting the tender that every criteria mentioned within the FEED documents have been considered while designing the project & included in price. Any deviation should be explicitly detailed. Any alternative proposal should also be elaborately detailed for the engineers or the client consideration. At the design stage, the contractor shall be bound to apply all the FEED requirement & if possible upgrade during the design. Contractor shall start from the engineering documentation supplied by Company / Client contained in the FEED Design Package and shall further develop the design to achieve the Contract objectives and requirement. However, Contractor acknowledges that the FEED Design Package does not define the Work in full detail. The contractor shall consider the FEED only as a guidance for clients requirement & therefore, fully develop the project from conceptualisation to the completion accordingly, so that the project specifications are satisfactorily met at the end of the project execution. Contractor shall ensure the maintainability criteria, maintenance philosophy and spare parts philosophy, are fully considered in the development of the detailed design from the FEED. In undertaking the detailed design, the Contractor shall undertake all necessary geotechnical and geophysical surveys to ensure connections to the existing Phase Installations are correct. Contractor shall carry out any and all engineering required for provision of his construction Accommodation Camp, any construction facilities needed at Construction Site within Plant Industrial City, as well as any construction engineering required for the Work. Contractor shall carry out engineering as per Contract Specifications. However, incase of conflict or contradiction with Company / Client Corporate Standards and the latest edition / revision of the recognised international standards, codes and practices, Company / Client shall be consulted for taking the appropriate joint decision. Company / Clients decision shall be binding and shall have no cost and / or schedule impact to Company / Client. Contractor shall undertake the detail design of the FACILITY utilizing the typical details pertaining to the project. The Company / Client Engineering Standards, which Company / Client is in possession, shall be made available to Contractor. However, Contractor shall have to arrange for the referenced Standards not available from Company / Client. Engineering and design of all tie-ins and tie-outs to existing Phase installations shall be undertaken in such a manner that do not cause interruption of water supply or shutdown to the existing End-Users. Contractor shall work closely with Company / Client to achieve this task.

General Engineering Requirements


Contractor shall prepare all engineering documentation required for the Work, the documents listed and produce all or any other documents required for the successful completion of the Work. These documents should provide comprehensive engineering design information for all disciplines involved on the project such that all details are self
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explanatory requiring as minimum as possible further issues to produce works executive details in the form of shop & working drawings, though which may not be unavoidable from an working engineering viewpoint. The design should be explicitly clear in its basics theoretical calculative form giving adequate details to be well understood & coordinate properly all sequential activities for the team engineers to co-relate at various stages & at various offices. Clear details save the time & provide efficiency on the performance of execution. Contractor engineering group in charge of detailed engineering shall provide all details necessary to be produced for carrying out the job satisfactorily & conveniently without any break of understanding the project details smoothly by the engineers involved, but not limited to the following engineering services: Develop and update / upgrade drawings, drawings lists, document index, Deliverable Review and Approval Matrix, Deliverable Register, Data Sheets, Specifications etc. Review & update documents for safety, Operability, maintainability, reliability and ensure its concurrence with environmental regulations and requirements. Review / update FEED specification and data sheets (as required, and prepare additional document when required), engineering drawings, PFDs (Process flow diagrams), P&Ids (Piping & instrumentation diagrams), calculation sheets, engineering material requisitions, Vendor drawing requirements list & schedule (VDRLS) and purchase requisitions (PR) and amendments as necessary up to 'As built' status. Prepare Scope of Work and Specification of Sub-Contracts. Evaluate received from Vendors and Subcontractors. technical bids

Review and approval of Vendors data, drawings, other documentation and include / update Project design drawings (core drawings / specification to be submitted to Company / Client prior to approval by Contractor. Provide detailed material take-off and continuous monitoring of material changes for all engineering disciplines. Develop and update equipment lists, drawings, specifications, Basis of Design Philosophies, Procedures, requisition schedules and all other necessary engineering deliverables. Develop testing procedures including SAT (Site acceptance test) for individual facilities and Performance Test Procedure for the FACILITY. Witness and report FAT (Factory Acceptance Tests) at Vendors Premises. Provide engineering support for procurement, construction, installation, testing procedure, Commissioning, Start-up and Initial Operation and Maintenance including assistance to Subcontractors / Vendors in the interpretation of specifications and drawings. Incorporate process requirements in detailed design and engineering. Prepare Final Documentation specified
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Where there is a conflict in specifications, codes or standards, Contractor shall immediately bring such conflict to the notice of Company / Client on a Technical Query form. The decision on all technical queries shall be made by Company / Client in writing which shall be final and binding without any cost or schedule impact. 3DCad Model Company / Client requires a 3-D CAD (PDS) model to be developed for the project. FEED 3D model may be utilized by EPIC Contractor for further development. The final 3-D CAD model shall include sufficient detail to allow plot plans and layout drawings to be produced from the model. The model shall include modeling of the following as a minimum All Piping / pipeline Pipe supports / saddles for piping larger or equal to DN50 Fresh Water Distribution System (Firewater storage and distribution) Electrical and Instrumentation items including cable trays, ladders or ducts (300 mm width and larger) All civil / structural works Intake area upstream of Seawater Pumps. All existing facilities (to the extent required) at locations such as tie-ins, crossover on existing piping / new pipelines, in existing culverts, etc. All piping within package units such as Electro chlorination plant. Vents, drains, manholes and vacuum breakers. Contractor shall provide the entire model to Company / Client as part of final documentation. Contractor shall not employ any proprietary techniques or add-in programmes while developing the 3-D CAD model that may prevent Company / Client from fully maintaining the model after takeover. Contractor shall provide a user manual to aid future update of 3-D CAD model by Company / Client. Contractor shall provide view-only access to the 3-D CAD model for Company / Clients nominated personnel whether they are located on Contractors premises [Office or site] or if they are accessing the system remotely during the course of detail engineering. A copy of (review model) updated regularly during Construction and engineering stages shall be available at Company / Clients Offices at site. In addition, Contractor shall provide documentation, training and support for Company / Clients nominated personnel so that their use of the system is unencumbered and effective. Plastic Model Contractor shall design, fabricate and assemble a plastic model for all facilities which include all pipeline / piping, all structures, buildings, etc. to be included on the Plant facility whatsoever, for making it operational. The models shall be produced to an acceptable size so that every part of the project is clearly identifiable by the user personnel. As far as possible, all essential design details shall be included for the exhibition purposes. These models should be fabricated in different modes like drawings that means birds eye view, sections within that & many different views for clarity.

Engineering DesignFor EPIC or EPC, the design part is a major contribution to the successful execution of the contract. Design of the whole project components / constituents are demanded to be
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produced one by one meeting the timely requirement to the project plan. The designing team should understand explicitly the contract philosophy & the FEED documents prior to commencing the design work. Complete Project Design Systems should be produced based on the FEED & the best possible design alternatives for a minimum cost. The project target to be achieved should be clearly understood. First & the foremost significant part of the design process is the selection of the processing machine / equipment to be installed as a part of the processing trains, which machines may include horizontal & vertical vessels, vibratory & rotating machines, pumps, oil tanks, gas tanks, all related control instruments, electrical installations, gas installations, safety installations, all equipment necessary for the complete facility safety & controls, fire fighting controls. Equipment selections may take time & delay the whole facility construction therefore, prompt decisions should be made. It should be kept in view that the foundation designs pertaining the equipment depend on the parameters of the equipment. Initial foundations designs may be amended based on the final selection for the inclusion of the equipment. Related drawings about equipment based on the feed back available from the FEED should be schematically produced for the considerations of the structural design engineers for initial use which shall vary may be to an extent of 10 to 15 % during final stage of the designs issue. All designs should be correlated in sequence so as not to miss any part of ant machine in the train. All designs of the equipment to be included other than the trains should also be similarly produced in a timely manner. All constituent parts or elements of the project regarding all engineering disciplines should be enlisted & a programme charted out to show the start & issue dates pertaining various design drawings for review & approval by the Clients. The discipline wise engineering design work should then be entrusted to the charge of a disciplinary design engineer. All design discipline engineers should report to the engineering project engineer or Manager as the case may be. Initial drawings after complete checking & review of the design calculations should be properly recorded, approved & issued for Client review & approval. The Client should promptly review these drawings & issue consent to facilitate the design team to proceed further for detailed design work. Design drawings in general may be classified to the following categories Facilities Key plan showing all sections or zones Plan showing process & non process area indicating trains, utilities, offsites, circulation, control as well administrative areas. Plan showing existing facility if any, proposed location of sea intake as well as discharge into sea. Plan showing out plan to facilitate construction of temporary structures for the use by the Contractor. Plan showing located areas for warehousing, storage, equipment maintenance, access to site & all other necessary information the Contractor or bidder shall require to take into consideration the impact of cost on price. Facilities drawings should be classified into the lay out of the trains with location of all equipment & piping scheme.
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Facilities drawing showing all line plans & isometrics of the processing technology & piping giving capacities. Plan showing hazards & non-hazard areas based on HAZOP studies conducted by a specialist agency. Plan showing complete & comprehensive philosophy adopted for the proposed plant system. Plan showing location of all buildings process as well as non-process. Plan showing location of all utilities buildings & electrical infrastructure buildings. Plan showing all major & minor buildings & other structures required for the complete control & administration of the plant operation. Plan showing philosophy of the communication, satellite control, security fencing, roads, maintenance access, landscape areas, environment related issues. All equipment major & minor foundation layouts All underground utilities & services including drainage, sewerage, chemical disposal etc. & shall include catch basins, manholes, chemical manholes, oily manholes, open ditches, closed drains, pipe culverts, cable trench, covered trenches, buried trenches, duct banks, street lighting infrastructure, interconnecting cable infrastructures, proposed road crossings, proposed interfaces, services to be coordinated with the existing services requiring work permits from operating authorities in the form of hot & cold works etc, cathodic protection philosophy for the whole plant, Architectural plans for buildings including elevation & sections Structural plans for buildings including elevations & sections Bar bending schedules for all members of the structures building wise Discipline wise plans for services such as electrical, HVAC, mechanical, drainage, sanitary, loss prevention, fire fighting, water supply, telecommunication, CCTV closed circuit television, security access, card readers, building management, Roads layouts, maintenance roads layouts including types, & sections Plant Piping layouts & pipe racks around including overhead crossings Interconnection layouts Structural plans for the pipe racks giving all design details Structural plans for the steel buildings giving all design details External roads interconnection & access to plants Landscaping giving all soft & hard landscape layouts

Engineering DetailingPage 42 of 491 suraj_engineer@yahoo.co.uk

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After having received the preliminary drawings approved by the Client, the design team should concentrate to produce all necessary drawings, which should then be submitted along with the building permit application to the relevant municipality if so required. The design engineers should also commence with the detailing of all structural & architectural elements of the included parts of the project. All other disciplinary details should also be taken up simultaneously. This part always consumes much time & therefore adequate staffing should be allowed for details production. These detailing should include sections, various details on plans, details of all elements necessary for execution or for the transmission of the information to equip the shop floor drawing engineers for working drawing production. There shall definitely hundreds of such details discipline wise. Crosscheck must be applied to all these details prior to giving a final approval. Working out of the details shall require multiple considerations of thought to be given for the end results of the design so as to make it convenient for the ease of construction execution with the application of minimum efforts with keeping cost to a minimum as far as practically feasible. Concept of the detailing is a cumbersome job requiring competent skill on the part of the design engineer who coordinates mentally all possible operations related to the designing & construction by these details. The details dictate on many outcome on site & help the construction engineers a lot if well thought of in advance. Sometimes, the good-looking details are difficult for execution. Details should be as easy as possible to save the procurement as well as execution duration to minimize the cost. It is suggestible that as far as practicable, standard items should be included in the designs for easy procurement. Also these items are well known to the experience supervisors involved with the construction operations. Typical details production shall give good results for the production purpose. Unnecessary details should be avoided. Details should be explicit to make the engineering coordination easy for easy references. It has been experience that multiplicity of documents coordination creates unnecessary difficulties for the execution team while clashes & absence of necessary details as well as so many other factors result in the raising of engineering & site technical queries ETQ & STQ respectively. These queries further augment the recording & execution complicity. Generally it happens due to the involvement of many hands as well as change of heads on the same job. Some competent engineer should concentrate on one activity to reach it to the conclusive decision so as to be finally sent to drafting section. Also cross-references on the drawings should be properly reflected for there are chances of missing these. It is also suggested that what details are required should be planned in advance of commencing the detailing work in the form of a working schedule to keep a control on the quantity of detailing work.

Design SchedulesMajor items schedules respecting all disciplines should also be included within the detailed designs to guide the construction team for placing various Material Take Off MTO after due verification. After producing all necessary detailed documents, a guiding bill of quantity BOQ should be prepared for the whole project to assist the construction
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team to place various order after due verification of the quantities as well as the applicable specifications & codes. No limit governs the quantification of the production of schedules for it depends on the discipline as well as the size of the project. There may be hundreds of such schedules for some project while some only a few. But quality schedules help the placement of the procurement orders. Scheduling is no easy job. It requires complete know how of item under consideration. It also requires complete coordination within all relevant drawings & technical documents to reach final take off the quantities & the applicability of the specifications & drawings as well as specialist specifications produced by the manufacturers. Scheduler has to go through all these procedures immersing fully for all related items. SubmissionsAll aforesaid project documents which may include all design drawings, detailed drawings, schedules, project specifications designed by the specialist engineers should be registered properly according to the agreed system of documentation & thereafter be submitted under cover of a transmission sheet to the approving authority engineer for technical approval in the form of IFC Issue for Construction. It is not essential that the documents should be approved in first submission. Comments received back from the engineer should be incorporated on the revised documents & resubmitted keeping the process continued until the documents are approved for construction. After the approval for construction status, the document should be copied in required numbers as agreed within the documentation procedures duly sealed on the document & circulated to the concerned parties. Copies should also be transmitted to the engineer for site use. Shop drawings All details as explained above cannot be practically produced within these documents. Depending upon various factors related to available material, details provided on the approved drawings & the trade practice & further minute technicalities involved for the production operations, it shall be essential to produce some more documents to be used by the shop floor engineer. These documents shall be worked out from the coordination among all such gathered information solving probable clashes & giving a final shape for production or execution on site. These documents should also be passed through the approval procedures & IFC document should be issued to site for construction. There shall be hundreds & may be thousands such documents necessary to be produced from time to time of site requirement. These can be entitled shop drawings. Working drawingsEven after the availability of all approved documents, there shall be required some more drawings to be used by the supervisors on site as well as in the workshop. These drawings should support with further details of the sequence of works in the form of real fabrication & execution at shop floor or on site. These drawings should be well drawn clearly so that supervisors do not require further assistance to get the job done without further details. These drawings should also be approved but all drawings do not require approval. In some case based on the contract drawings & shop drawings further details are worked out which are consistent with approved drawings, may be used directly virtually off record.

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Otherwise these drawings should also be approved by the engineer in which case proper documentation is necessary followed by the issuing procedures as explained earlier. Technical QueriesA technical query is raised when some discrepancy is discovered pertaining any design item not correlating or corresponding between architectural & structural or any other discipline drawing details. For the resolution of the correct detail, discrepancies are raised in the form of a technical questions format giving full details regarding the discrepancy & if possible, a solution be proposed or clarification sought or understanding for confirmation made. This document is originated by the relevant engineer, checked by the technical or engineering section & authorized by the site management for transmission to the engineer for response. Engineer scrutinizes the questions & writes back the answers for execution on site & recorded as red line mark up. There may be engineering queries ETQ or site technical queries STQ or SC site clarification depending on the mode of the format adopted on the project. ETQ is generally used by the Engineering team only whilst the STQ is used for the site execution purpose. Site works queriesDuring carrying out works on site, dictated by the site conditions & to comply with the specifications & design criteria, it usually happens that suitable adjustments have to be made to the design details on the safer consideration. Such situation requires an agreement between the Contractor & the engineer on site, which should be recorded on the STQ for confirmation. Proposals for technical resolutionsOther than aforesaid queries, there shall be many instances when alternative detailed proposal are to be worked out for site requirement to meet the design criteria & practicalities, proposals for such problems are made for the engineers approval. Full details in the form of sketches are prepared & put in the form of STQs or directly as sketches as working drawing as convenient. All virtual clashes on site due to unforeseen conditions may be resolved on site & recorded as technical resolution in the same manner. Documentation appraisalsAt time of the contract execution as well as during the whole currency of the contract, the Contractor shall from time to time receive thousands of documents in the form of contract documents, post contract documents etc which should be appraised properly & competently. All such documents should be registered in such a way that traceability functions efficiently without wasting time of the engineers unnecessarily. The document controller should have on his tips on the database any required document located immediately. Arrangements should be such that documents for a particular element on the job should be proficiently filtered out for better control. Project in-charge should ensure that all required documents according to the register as well as fulfilling practical needs of the project for construction have been issued by the designers. Construction ability checksIssued / approved for construction documents pertaining all disciplines must be checked sequence wise as well as discipline wise to make sure that these contain wellPage 45 of 491 suraj_engineer@yahoo.co.uk

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coordinated information necessary for the 100 % construction of the relevant portion or element. Project engineer should immediately notify any missing information to be provided proficiently. Any clashes observed should be recorded any ETQ or RTQ raised for a possible resolution without any delay to the execution. The approval about the queries procedure should be perused personally in some urgent cases & the resolution communicated to the supervisor concerned for on site implementation prior to the mistaken work is carried out. Inference of technical documentsInference of the technical documents is no easier an activity. Only a competent project engineer or an experienced discipline engineer should be entrusted the job to explore any missing information as well as to know whether or not the issued documents are giving adequate information for the purpose of full construction or yet, the technical queries are necessary to be raised. This activity requires total concentration to study the contents of the design & their coordination & mutual interfaces. It depends on the volume of the documents what duration is required for complete understanding of the technicalities involved on the design. Study & review should not be confined to design drawings only but detailed specifications should also be included so that complete project requirement is properly integrated for physical execution. Engineering meetings Meetings for the engineering discipline form extremely significant portion of the contract. Actually this activity commences at the tender negotiation time when technical proposal is submitted. Hundreds of clarification questions are raised by the Client on the contents of technicalities offered by the Contractor as well as those at pre bid stage as replied by the Client based on the Contractor queries. For a collection of important queries, meeting is conducted to resolve the issues in hand directly between the two parties. During contract stage, when the design is submitted meetings are conducted for every discipline for a satisfactory response on the design questions, clarifications & software related issues or formal presentation of PDS project document system. During this stage, meetings shall be very long but impart efficiency for the decision-making & save time for the approvals. During construction stage, regularly programmed meetings are conducted for the engineering difficulties or other matter related therewith which require urgent attention. These meetings more or less form part of the regular progress meetings until lot of queries have been accumulated necessitating separate meeting. Day to day meetings are conducted on site between the area engineers of two parties to resolve the matters subject to the approval of the field engineering manager of the Client. Engineering meetings cannot be confined to the aforesaid instances but according to the job requirement, these have to be conducted at any level of supervision to expedite the site works progress. These meetings also involve the contribution from the quality assurance & control engineering section on site for urgent decisions & acceptable to the construction department. Construction Method statements During the construction phases, activity wise construction method statements are required to be issued to the supervisors on site to adhere to the statements for the smooth carrying out of the activity concerned.
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These statements should be approved by the Client prior to the commencement of the relevant activity. Method statement should be prepared by the project or discipline engineer or quality engineer or office engineer depending on the availability on site. This documents should contain full information about the activity under consideration giving how the sequence & technicalities shall be carried out & how the inspection should be conducted based on the requirement of the Inspection & Test Plans & quality check list as well as conduction of the necessary testing & laboratory involvement from time to time. All disciplines require method statement. These should therefore, be prepared in advance, checked & approved by the site manager for further transmission to the Client for the final approval as IFC or AFC & circulated to the site as a document. No limit governs method statements numbers. Agreement has to be made between the Client & the Contractor on the requirement. For the reference to the reader, a number of method statements have been appended only for knowledge exchange. These are based on the practical experience & are used on projects. Please use them for guidance only & create your own statements for particular requirement. But basics of the methods writing can be advised herein. Just think of what is the solution of particular construction operation. Contemplate on what the involved minor activities are. What are the sequences & materials to be used for temporary as well as permanent inclusions what are the other requirement for the accomplishment of the operation from the inception of the activity to the final outcome. After having considered all these, make a sequence thinking that you are available on works & carrying out the activity. How the activity should be sequenced one after the other & write the statement lines & then recompile to a comprehensive statement. There shall be a long list of method statement or procedures from different engineering disciplines. For example site preparation, camp construction, temporary facilities establishments, earthworks, excavations, blinding concrete, formworks, reinforcement fabrication, reinforcement assembly or placement, concreting, finishes activities, complete HVAC system, electrical system, loss prevention system, specialist gas fire suppression system, aluminum works, cladding works, structural steel erection at low as well as high levels, road works, paving, piping both below & above ground, pre-commissioning, commissioning, performance, maintenance, quality testing & many more. It is not practically possible to produce all methods in one go but quiet in advance of the relevant activity allowing time for approval; the statement should be prepared & submitted for approval. The basics of the activity should be conferred with the relevant supervisors & quality personnel & then finalized to the specification & design requirement. The document should form an integrated approach for the job as professional.

--------------------------------------Chapter 4
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Construction & Controls Construction & controls are very interrelated sections for successful completion of any project. Design may be over safe or optimum but real construction involves actual expenses, contract time & reputation. It should be the motto of any organization to apply good controls on the project to keep on line with the programme or planning an actual part of controls. Control includes, progress, cost, time, budget, quality assurance & engineering & safety. These are all integrated divisions, which should move in unison to achieve project target. A well-designed project could be jeopardized during construction phase from budget viewpoint should it not be given due controls application properly.

Schedules- Programming
Programming schedules indicating by GNAT bars or by CPM or PERT various graphical representations respecting the overall & detailed plans for the time, activities, milestones, manpower requirement, machinery requirement, cost flow & all other requirement & running reviews of all these during the whole currency of the project from real progress, lost time recoveries as well as look ahead projections. These documents are produced involving all sections working for the project & reports are inter considered by all departments. Planning engineers or the project control engineers work for such activities dedicated on the project & report from day to day & time to time basis. The planning activities commence from the day of commencement to the final completion & documents are produced from level 1 to may be level 5 depending on the project or the contract specification requirement. Generally primavera or MS project software are used for the professional documentation for planning purpose. During tender stage also programming documentation giving complete details & milestones, manpower, machines, cash flow etc are given for the inclusion with the Technical Proposal, which is considered as one of the competencies of the proposal. In case the details do not give full information about the proposed methods of execution for which it forms a part, the proposal may be liable for rejection.

MobilizationThe very first step to get into the stage of physical establishment for construction. The site is taken over & all transfer stations are established using available satellite records. Surveying department commences its works for the establishment objectives. Approvals are obtained from the authorities concerned & from the engineer or Client. Applications are made for the record drawings from the statutory services authorities if so required. Applications are also made to the operating authorities for the issue of all record drawings if so required for the permits. Permit to work PTW is required prior to the commencement of any excavation in hot & cold work areas. No excavation is allowed in projects until these permits are obtained. For the application of the work to start permit, documentation is carried out giving details about the applied work, official award letter, availability of the safety officers, full time supervisor, method statement etc & then application is considered for sanction. Fencing is erected & the establishment of the temporary camp & offices is effected according to the engineer approved plans & method statement.
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All arrangements for the accommodation for the personnel, sanitary facilities, water supply for drinking as well as for washing purpose, electrical & air conditioning, fire fighting, access to the camp, security, messing, sewage treatment plant, leisure areas, common rooms, sports courts, parking, swimming pool, local shops, etc as required by the contract & the temporary facilities that Contractor or the engineer deem necessary should be provided. Similarly, site offices establishment should also be constructed according to the site establishment approved plans & Permit to Work obtained before commencing for the site establishment offices. All provisions of the utilities should be made according to the contract, engineer & Contractor requirement. The site offices should start functioning on or before the appointed date according to programme of mobilization. It should be kept in view that some agreed percentage of payment should be released when the mobilization is completed & work can be commenced with. Mobilization also includes deployment of required manpower, machinery & the supervisory, construction, safety, planning & engineering as well as administration staff without any loss of time. This deployment shall accelerate the procedure on the commencement of job in the beginning & time may be gained to keep in line with the programmes. Smart & efficient project managers & engineers understand this aspect very well & keep very proficient at this stage as additional efforts are required to commence with the project. Running project may not be that difficult to push but starting & streamlining all departments operations demand efficiency & hard work. Site offices require full fledged modern computerized facilities for fast interaction & communication, intranet, internet, telecommunication, conferencing, sanitary, water supply, drinking water dispensers, refreshments, electrical supply, standby generator, heat, ventilation & air conditioning, first aid, ambulance, doctor for immediate attention with nurse, assistants & a well established site clinic. Site offices require full fledged stores, warehousing, mechanical & auto maintenance & repair workshops, vehicular & equipment parking areas, labour temporary shelters for lunch & tea etc as well as for rest pauses necessary under safety management for the prevention of heat stroke & environment attack during hot working hours.

MaterialsWithout materials no project can be completed in time. This is the only item that may delay the completion of the project due to possible non-delivery in time. Material constitutes more than 60 t0 70 % budget for the contract & every prudent Contractor should intend to make as much saving as is possible out from this element of expenditure simultaneously keeping in line with the quality assurance & control procedures. Every purchase department manager & the owner of company tries their best to procure acceptable material within reasonable & minimum cost, making trial & again from a number of interested vendors both before & after the award of a contract. There may be
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some delay to decide from which vendor or supplier the materials are to be procured. This is also expected in a similar fashion from the prospective sub Contractors. But the relevant purchase managers should not endeavor to spend unnecessary redundant time on this activity but make a decision in time to get to the site materials in planned time including all FAT as well as SAT & performance tests. Material approvals is a tedious & time consuming exercise which must be given due consideration & optimum time management for a possible successful completion of the contract. It has to be remembered that missing the approval, no purchase order can be released by the procurement manager or project engineer/manager. It should also be taken note of that there are hundreds of permanent inclusion materials respecting which approvals are to be obtained. Every submission required full manufacturers information, engineers specifications as well as conventional practice demand & updated standards & these should also be covered within budget cost other wise escalation shall take place should delay is allowed resulting in the delay on completion leading to imposition of liquidated damages on the contract. Actually it is suggested that major homework should have been carried out at the tendering time itself to avoid such delays, of course market may fluctuate but there shall remain room for negotiations with the vendors or suppliers.

Manpower- Workforce
Significant is this element in the absence of which nothing is feasible. Difficulty is to be faced when well-trained workforce is not available in time from the expected source. Contractor shall try to deploy manpower costing within the job budget. There shall be so many problems for deploying them & providing demanded facilities on the contract. Human resources department should be efficient to deal with this matter so that particular delay is avoided due to non-availability of the required planned manpower. Workforce shall be time wise required respecting all disciplines & be kept on mobilizing in & demobilizing according to project requirement. Similarly staff shall also be mobilized & demobilized according to contract requirement. On considerable big size projects, mobilization & demobilization programmes are prepared & approved by the engineer or the Client to ascertain that the job commence in time & after the demobilization, the progress is not effected adversely. In fact only after the approval from the Client is obtained, any demobilization can be effected though the approval shall not be withheld unreasonably. Control of manpower constitutes in itself a separate mini discipline involving complete procedures from making requirement, forming recruitment strategy, approving the strategy, using agencies, & then interviews, short listing of selections & appointment on contract followed by mobilization to the job site. This is a long process, which must be preplanned to avoid any conflict with the site requirement.

EquipmentEquipment necessary for the inclusion on the project permanently requires considerable input from the Authorization, FEED stages to the performance stage. Technology decision for the project dictates the model & types of the equipment to be installed for the facility. Elaborate & descriptive detailing is extremely necessary during designing, approval & procurement stages. The equipment installed must satisfy the design requirement failing which the facility shall be jeopardized of performance giving any
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possible halt to the processing & the Client or the operation authority shall make the designer or EPIC Contractor liable to compensate all damages incurred to it by the faulty commissioned equipment. Equipment are too expensive requiring making competent decisions for the inclusion as well as for the election of the vendor. Decision pertaining the model dictates the foundation designs. This need should also be kept in view while working on the designs to avoid delay on account of providing input to the civil design team. Frequent amendments/modifications have been experienced on the major projects during the day of concreting or one or two days before. This type of bad practice should preferably be avoided. If possible, certain decisions could be taken at the FEED stage & the EPIC Contractor be directed to comply with the vendor of the equipment based on novation of the item.

ProcurementProcurement means to supply to the site all materials & equipment & the process commences from the requirement scheduling, vendor selection, quotation invitations, short listing quotations, specification matches, financial viability, approvability, warranties applications & then the final decisions based on the quotation that fits within the budget & items be the best for the optimum performance according to the requirement of the contract. Every company has established its own procedures meeting the guidelines of the international quality procedures ISO 9001 according to which full corporate management is involved for the procurement management practically effected by the procurement manager or engineer of the corporate part of the company management. This department involves itself for the complete operations front the estimations of the items quantities through the delivery to site & taking up the issues to the insurances in case of transportation damage. During tender stage itself, the expected items are invited for quotations for specialized & important disciplines with negotiations done. Later on subject to the condition that the work is awarded to the tender, further procedure continues & final & confirmed quantities are worked out based on the engineers approval of the proposed material or the machine which is separately applied prior to the placement of the procurement order. This is very time consuming process as submission, comments, rejection, incorporation of the comments, re approval etc all are involved. The process involved initially complete package submission meeting defined documentation procedures. A competent & experienced engineer should be involved to carry out all these procedures for technicalities are to be resolved during the whole exercise. Study pertaining each & every requirement should be conducted by the relevant disciplinary engineer & quotations accordingly invited. Based on the quotations, & financial factors, further scrutiny of the quotations regarding conformance to the specification & the project design criteria are done. Then a comparative statement is prepared giving full technical as well as financial with feasibility of timely manufacture & delivery & financial matters such as demand of the letter of credits or other financial support etc. All are reflected to be examined by the management for making a decision promptly.

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Once the decision is made in favour of one of the suppliers, further submission procedures should be started to obtain engineer & Client approval since procurement order cannot be placed without the Client or the engineers approval. After having obtained engineers approval, the requirement is processed for a procurement order by the management & all accounting procedures effected & delivery schedule confirmed. That schedule should also be agreed by the engineer & adherence to the agreed dates have to be adhered until unforeseen circumstances irrelevant to the general circumstances play any role. The delivery should be made smoothly all in good condition to the site & the site manager should arrange complete examination by his team as well as approval of the delivery by the engineer concerned so that the delivered material or the equipment is including for the part percentage payment as agreed on the planning schedule.

Physical Construction-Contract management Construction Project Management Physical construction


After having the mobilization been completed, time comes for the commencement of the permanent works for which the actual contract is meant for. It is definite that the civil construction takes the lead generally on all the projects. This requires the availability of all the approved for construction drawings circulated under control to the relevant supervisors/engineers for the purpose to correctly prosecute the works according to the contract requirement. Sooner the commencement, better the prospective to save the time and money. Every site manager or the project manager should endeavour his plans with the support of the schedule engineer to keep at least in line with the approved programme if not advanced. For this attainment, all necessary resources availability should be properly coordinated. For EPIC case all design matters should also be properly coordinated to keep in line to facilitate the easy construction. There may be a case when due to some unavoidable circumstances, some portion of the contract cannot be prosecuted, the project manager should immediately find an alternative portion to replace the prosecution so as to keep an equivalent proportion of the progress intact. Civil engineering part of the contract is not that easy for it requires basic works on site involving trades persons & semi & unskilled workforce along with the materials in site. Relevant engineers supporting on site should be well experienced & proactive to take up the responsibility for the results orientation. A well coordinated approach is necessary for there could be many instances requiring on site decision to resolve technicalities that must be immediately effected meeting the requirement & properly recorded as a part of field office engineering. Physical construction requires a concentrated as well as diverse attention of the quality assurance & control section or department on site. There should be no delay on this account for the approvals & constant inspection attendance should be ensured whenever necessary on a fast track project. Every activity is inspected according to the Inspection & Test Plans based on a checklist & percentage witness etc. Hold points should be released when the activity is on that status. Most of the jobs are based on the concreting constituting very important element of the contract & quality assurance should take proper attention for this onsite operation.
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It should also be noted that whilst the civil engineering activities are prosecuted on site, simultaneously, on a foreign station or in a foreign land, other discipline activities for example production of equipment, the pre engineered parts of the structure & other procurable items might be under manufacture demanding factory testing according to the procedures approved. QA & QC should take into consideration proper inspection attendance there as well under the supervision or surveillance or witness of the engineer or the experts for the acceptance of the factory products as level I & completion of the parts in factory or manufacturing place as level II inspection prior to the equipment is shipped to the site location. It is no use should the equipment be rejected after delivery on site.

Contract management
It is very wide term on the Industrial contracts. Basically it is the main contract that requires well-established professional management but also covers various sub contracts as well as services contracts. Requirement of complete knowledge of the relevant laws, procedures & coordination correspondence are extremely significant for the performance of Contract management. It is not just one discipline, but from the beginning of the project & until post completion, Contract management shall be required to be applied & represented on site as well as in home office for the resolutions of many complexities. This term also covers a wide part of the documentations to be prepared for forming future arbitration basis as well as proceeding. It may involve costing effects, claims, extras, extension of time claims, additional contractual obligations, contractual correspondences & many more legal affairs requiring resolutions on the contract or the sub contracts as well as services part of the low tier vendors. This term is very complex as its proper implementation necessitates the contracts manager to know & properly understand the engineering, construction, coordinations & relevant contractual & general laws applications on the contracts. Construction project management. Project site manager or the construction manager or if project engineer be authorized for this responsibility, got very leading & significant obligation to dispose off on a daily & hourly basis. What is going on site is direct responsibility for accountability. Daily, weekly, monthly programmes as well as all discipline coordination is a must for the speeding of the operations. Then also comes the duty to arrange & coordinate the materials as well as the other resources to be utilized on the project. Attendance on the engineering, construction, safety & other meeting is a must. The outcome of the construction depends on the efforts of the construction team. Coordination with all team members as well as the team members of the engineer Client is a must. Co-ordinations with all sections of the site teams & home office teams as well as procurement are very significant. Authorizations of the letters & correspondences produced by the contract as well as other departments for the project is also one of the duties. Reporting all functions to the Client as well as to the home office & resolutions of all possible solutions is also one of the responsibilities. Authority has been invested with him to allow resources promotions & imparting training for the personnel of all categories as on job training. Job requires very dynamic & passionate person who commands all & gets respect from all sections & keeps good working relations with the Client as well as with home office.

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Chapter 5
Testing- Pre Commissioning, commissioning, start up, performance & maintenance
The testing is carried out at various stages of given levels. It is conducted in the factory during processing as well as after the finishing of the production. It is then conducted on delivery, prior to the installation & commissioning & during performance & operation. Factory Acceptance Test, Pre commissioning test, Commissioning Test, Site Acceptance test, Integrated system test, Sustained Performance Test Factory Acceptance Test FAT Verify quality & quantity visually according to documents Demonstration of all system & diagnostic functions Demonstration of technical parameters Functional test for all components Power consumption Module, communication failure & recovery Mechanical checks Pre Commissioning Test PCT Upon completion of system installation, align, adjust & balance the system for pre commissioning performance in order to ensure the conformance of the system to the requirements of the drawings & specifications. Deficiencies to be observed, corrected & if so required, replacement of the malfunctioning of the damaged items with new ones & re-testing until satisfactory performance conditions are achieved. Prepare forms for systematic recording of acceptance test results. After pre commissioning is complete, provide a letter certifying the installation is complete & fully operable, including the names & titles of the witness to the preliminary tests. Commissioning Test CT It shall base on FAT & performed on site after the completion of installation & pre commissioning test. Where systems interface between each other, all necessary systems & interfaces shall be operational prior to starting the test. Verify quality & quantity visually according to documents Demonstration of all system & diagnostic functions Demonstration of technical parameters Functional test for all components Power consumption Module, communication failure & recovery Mechanical checks Site Acceptance test SAT SAT shall be based on selected tests from the commissioning tests & witnessed by Client & Authority. SAT shall be performed at site after completion of commissioning tests. Integrated System Test IST
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To be performed of all sub systems or infrastructure used at physical, network & application level. Equipment meets the technical & functional specifications Specified equipment does not interfere with all other systems implemented & all operate without interference from each other in full operation or under fault conditions. Sustained performance test SPT Long-term stability & reliability of the system under normal operating conditions as well as its ability of automatic diagnosis of defects & alarming any problem in a timely manner. It is done after IST for 30 days or longer A failure is defined as any occurrence preventing full or partial utilization of the system. Availability shall not be affected & SPT shall be temporarily suspended in case of any failure caused supplied equipment or services. EPIC Contractor shall design for approval by authority Design of sustained performance test Reliability of central equipment Field equipment reliability External interface input or output failure System sustainability as identified by frequency of false alarms Operations & maintenance O & M Every contract defines a particular duration of post practical or mechanical completion initial operation & maintenance to make sure & evidently prove efficient performance by the equipment / deliveries. During this period training is also imparted to the Client personnel according to the provisions / requirement of the contract so that these personnel get used efficiently for the proper control about operation of new technologies. During initial operation, the contractor shall operate the systems according to the functional requirement complying strictly to the equipment manufacturers instructions. Contractor shall deploy his operators for the purpose of initial operation duration & after successful completion of the initial operation, the control of the equipment then shall be taken over by the client. In case during the period of equipment performance as well as initial operation & maintenance, certain defects are discovered on the deliveries, these are identified, analysed & if so required, replaced or repaired as agreed with the Engineer or Client. The operation & maintenance period recommences until it is evident that no further defects exist on the deliveries. There could be included within the contract modalities any condition of damage compensation to the client applicable because of equipment performance test failure, which case requires the EPIC contractor to make compensation to the Client of the calculated claimable amount for the failure of the required deliveries performance of the technology. This is very significant condition in the sense that compensation may amount to many times the cost of the works. The contractor should be careful during initial operation & maintenance by keeping controlling eyes on all systems & discover any minor or major defects appearing on the operation & if detected any defect, must be brought to the knowledge of the engineer & client for the agreement of the corrective
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steps to be taken & after correction, re-operation commenced for the successful initial operation completion duration. Third Party Certifications TPC On many specialists deliveries a clause is included that the product should be certified by a third party independently which shall be approved by the Client or the engineer prior to the commencement of its scope of the works. The third party shall, according to the provisions of the quality systems adopted or approved, inspect the deliverables in the factory as well as on site during procurement; pre-commissioning & commissioning & also during performance & maintenance. No payment shall be made to the Contractor until the third party certifies that the delivered product is according to the project specification requirement as well as meets all defined acceptable requirements. The Contractor shall have to arrange for all proceedings in all respects according to the requirement of the Third party certifying authority, how to effect the item inspection in the factory as well as on site in the presence of the engineer or engineers representative. All provisions to be extended to the third party inspector shall be made available in due time so that the inspection be conducted smoothly. Instruction given by the third party shall immediately be implemented to accomplish the job. After having the certification over, the document received shall be processed for presentation & examination by the engineer & the Client for this certificate/s has/have to be included as part of the mechanical completion certification. Third Party Certification services Contractor is to appoint a Third Party Certification Agency (TPC). The list of approved TPC is to be provided within the FEED documents. The Third Party Certification (TPC) services shall be in accordance with DIN 50049, 3.1C and the certificate to be provided by Third Party Certification Agency shall include the following as a minimum: Proof of identification of the material Tests report duly signed by Inspector Identification symbol of Agency or Inspector Certificate number and date of issue The different levels at which involvement of TPC are required shall include, but not be limited to, the following: Material Traceability Level Any material under the following categories (Traceability Levels) shall require specific certification or documentation as given below: Level 1 - Full Material Traceability The TPC shall review the data books of manufacturers and witness all the tests in accordance with DIN 50049 3.1C or equivalent. These items shall be fully traceable. Level 1 includes Critical System, structures and components where failure could result in: A significant hazard to personnel. A significant loss of production. A significant environmental hazard. For example certification of Level I may include: ANSI/ASME B31.3, Generators, Switchgear, Transformer, Craneage and supports Level 2 - Material Traceability
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The TPC shall ensure that the materials supplied to the Project can be traced back to Manufacturers Certificates (DIN 50049 3.1B or equivalent), which shall be compiled in a data book and delivered with the equipment package. It is to be ensured that the marked up drawings are supplied to Client for reference and traceability purposes. Level 2 certification is applicable to: Critical system, structures, components where failure could result in: A limited loss of production, A limited environmental hazard. Level 3 - Material Traceability The material shall have a Certificate of Compliance (DIN 50049 3.1A or 3) Level 3 is applicable to material that is not in level 1 & 2. Example of system / unit to be included in level 2, Any process system non-process wetted or non-pressure parts which are not in level 1 or 2. Materials not in levels 1 & 2 e.g. hand rails, floor plate, cable tray. Minor items e.g. sacrificial spool pieces of low value and non-hydrocarbon duty, etc, Produced water, Lube oil, Instrument air. Packages The traceability level for an equipment package can be found by using level 1. The component parts of an equipment package do not warrant the same level of traceability. The certification type should always be considered consistent with the high criticality and type of equipment / material being designed, procured or fabricated. Consideration needs to be given to the applicable international codes and standards to which the particular equipment is being built. Project records All documents in whatever format produced, shall be controlled by master record copy in both hard as well as soft mode. These documents shall be duly numbered for the purpose of efficient traceability. Well established document centre of the Contractor as well as of the Engineer shall affect this requirement for all relevant incoming as well as outgoing documents. All records shall be well maintained & made accessible to the relevant authorities under the direct control of the document controller. All contractual documents, schematic drawings, design drawings, approved for construction documents, specifications, red line mark ups, deliveries, inspections, procedures & others, shall be kept in the centre for an easy reference / review for the authorized personnel. Only controlled copy shall be issued to the designated personnel for reference as well as official use. Issued for Construction documentsThese documents are meant for the construction purpose having due approval by the engineer & the Client. Without an availability of these documents, no work shall be allowed on site. The site personnel should ensure that the documents under use are approved for construction by making an enquiry from the document control centre. Document control shall immediately affix the superseded seal on the documents not to be used any further. These documents are also given various sequence of revision depending on the changes effected thereto. The document control shall regularly update the register of the documents showing these changes & revision references & circulate to the designated personnel. Red Lines Mark ups- basis for As Built documents
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Every operation on site should go smoothly when all details are available. There shall be instances due to the site requirement of actual conditions, which possibly might not have been included during the original design, that need immediate attention & effects to a certain extent the site for adjustments on the practical execution of the design after the approval by the engineer is granted. These changes on the site shall be recorded on the drawings or the specifications temporarily as red line markings/markups to be used as records for producing as built records. Every red line mark up shall be intimated to the engineer for the purpose of obtaining an approval for as built production. These shall be recorded in the document control as regular documents. As builtEvery project requires documentation for the works done on site for the final handover dossiers. Those changes recorded as redline markups shall be properly studied by the discipline or the project engineers one by one to decided whether or not these changes should be reflected on the approved for construction documents. All redline mark ups shall be incorporated on to the as built title drawings before the submission to the engineer as project dossiers. Separate documents references shall be used for the se documents for an easy reference as well as traceability. Operation & maintenance Manuals All equipment belonging to every discipline procured from any vendor shall be used on operation of the facility permanently under proper maintenance. The responsible facility operators should know explicitly how these machines or the equipment to be used. The respective vendors should provide all operation & maintenance manuals for the reference of the user describing fully to meet all normal as well as emergency requirement. The Contractor shall submit these manuals after processing formally as documents for approval by the engineer. These shall also form part of the handing over dossiers. Punch List / SnagsBefore the mechanical completion as a part of the pre commissioning stage, joint inspections are carried out to enlist the minor defects as snags for all items one by one according to the approved checklists. These leads are given by the quality assurance & control department jointly with the construction & engineering. These notes of snags are recorded & a time frame agreed to incorporate the correction to items that are correctable. The items that need replacement because of defects shall have to be replaced immediately without any delay so as not to adversely affect the project handover. After conducting the correction to these snags, inspections are made & final list is prepared for minor defects that may not effect the commissioning or the performance of the facility which may be taken up to be repaired during maintenance stage to the agreement of the parties concerned. Visual defectsIt shall be easier to some extent for which prosecuted items may allow visual inspections for the purpose of full or part acceptance admissible within the quality assurance procedures. Item should then be closely inspected from inside & outside according to the procedures specified on the Inspection & test check list. Whatever observation made, should be recorded & final interpretation punched for further action which shall decide the level of acceptance & suggest the further remedial action applicable. These types of repairs should be immediately carried out to avoid unnecessary inclusion on the punch list.
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Technical defectsWhere technical defects have been noted on records pertaining items, amounting to severe nature, that case invites items to be replaced immediately to avoid any delay on the start up. In case defects amount to very minute nature which do not necessarily invite replacement action, touch up repair may be agreed with the engineer & after agreement, according to the procedures the repair be effected for re inspection & acceptance. Minor non-conformanceWhere a non-conformance has been recorded to repair minor defects, should these defects be repairable, after agreement of the proposal with the engineer, the repair be conducted & approved by re examination. SnagsSnags have been covered in aforesaid explanation but should be dealt with all according to site requirement & the item concerned. Some snags may require replacement of the item in full that should immediately be effected to avoiding any delay on the performance of the system. Investigations / rectification / remedial measuresDuring the inspection many categories of the snags for punch list shall be observed & pointed out. All these should be recorded & some important snags noted which amount to sloppy quality assurance for which investigation must be resorted immediately to establish the responsibility of neglect during supervision. Based on these reports of investigation & punch list reference, Non conformance reports should be constituted, thereafter resolution recorded on these for acceptance & implementation following which, the execution of the resolution, re-inspection & approval process repeated. Precautionary measures as revealed by the investigation of the responsibility as established should also be included within the reports & on the close out report for future lessons & references. Mechanical Completion- Pre commissioning & commissioning-site acceptance testperformance- plant performance-Final documentation Final Project Dossiers shall be produced as per Engineering Standard compilation of Project Dossiers (Latest revision as on Effective Date Of Contract) and as described below: Mechanical catalogueGeneral Contractor shall prepare the Mechanical Catalogue & make available 3 (three) months prior to being Ready for commissioning for the system / sub system / unit stage as a compilation of engineering and vendor drawings and data for use during installation, commissioning, start-up, performance testing, operation and maintenance & include all documents as builts up & others as necessary for installation & operation of the relevant system or sub system or unit . Contractor shall organise all the Mechanical Catalogue by unit and equipment category, which consist of several volumes depending upon from case to case & be submitted in the approved format.
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Mechanical Catalogue should be bound in hard, durable, binders, with the Job Title and Project Number embossed on the cover. The Table of Contents of each Volume is to appear in all volumes. Contents should be sectionalized and separated by properly labeled dividers. Volume thickness of each book shall not exceed eight (8) centimeters. Book pages are to be A4 size. Drawings should be reduced to A3 size and may be accordion-folded to A4 size. All indices, labels, contents, etc. stated should be in the English language along with electronic media format Data Books. All drawings and data shall be "as-built" Mechanical Catalogue Contents The Mechanical Catalogues shall include items such as given herein: Lists for items for example - engineering documents, requisitions, general and particular specifications, Development Plan and Design Basis, Design criteria, Specifications and data sheets, PFDs (process flow diagrams), P&Ids (piping & instrumentation diagrams), line lists, Isometrics, ESD (electrical/electronic system diagrams), One line diagrams, Utilities summaries, Plot plans and layout drawings-Approved For Construction (AFC) drawings in all major disciplines (civil, structural, piping, electrical, instrumentation and others), Equipment lists, Load lists, Instrument lists-Major calculation notes for all disciplines, Instrument loop diagrams, Electrical short circuit and load flow diagrams, Electrical trouble shooting diagrams, Electrical relay co-ordination diagrams, Vendor drawings and documents for all equipment and materials, Un-priced purchase orders

Quality assurance record book


General
Contractor shall prepare Quality Assurance Record Books consisting of a compilation of quality assurance / quality control documentation representative of the material, manufacturer, fabrication, erection and test history of the equipment ordered and materials installed as appropriate. Contractor to note that some of the requirement stated herein may not be applicable to the Project. The purpose of the Quality Assurance Record Book shall be to ensure that quality assurance and quality control documents originating at the engineering, procurement, fabrication, erection and commissioning stages from multiple sources (Contractor, Subcontractors, Vendors, and their respective sub Contractors and vendors) shall be easily retrievable in order to provide evidence that equipment and materials used and assembled in the FACILITY comply with the Contract requirements at each step of the Work. The content of the Quality Assurance Record Book shall vary depending upon the type, size and complexity of the equipment. Each book shall contain all documentation referenced in the inspection data sheet and all records of testing required. In view of the requirement for full traceability of materials and dimensional control, Contractor shall include drawings such as vessels, tanks and piping shop drawings marked up with welding identification and material certificate numbers. The documents for the quality assurance dossier shall be kept in specific quality assurance files as soon as these are issued, remain easily retrievable and available for consultation at all times during the course of the work.
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Contractor shall organise the Quality Assurance Record Book by Unit and equipment category. There shall be several Quality Assurance Record Books each consisting of several volumes. The final Quality Assurance Record Book shall be issued together with the other documents to be included in the Final Documentation in required number of copies. Contractor shall submit the details of the format and contents of the Quality Assurance Record Book for approval prior to starting preparation. The Quality Assurance Records Book shall be bound in hard, durable, binders with the Job Title and Project Number embossed on the cover. The Table of Contents of each Volume is to appear in all volumes. Contents should be sectionalized and separated by properly labeled dividers. Volume thickness of each Volume shall not exceed eight (8) centimetres. Book pages are to be A4 size. Drawings should be reduced to A3 size and may be accordion-folded to A4 size. Contractor shall have all indices, labels, contents etc. stated in the English language. The Project Manager / Engineer shall be consulted as to what arrangement shall be most suitable. Also, Contractor shall prepare electronic media format Data Books. All drawings and data shall be "as-built" Contents of Quality Assurance Record Book The Quality Assurance Record Book shall include but not be limited to the following items: Approved dossier index-Signed off copy of quality plan-Technical Certificates of compliance as well as non-conformance technical certificates for the record if any. Where NACE compliance is a requirement, NACE certificates-Typical material certificates-Fully traceable material mill certificates-Weld procedures and qualificationsWeld repair procedures-Welders qualifications-NDE procedures- NDE reports for examination of welds including X-ray films UT test sheets-NDE operative qualifications-Visual examination certificates-Dimensional check report-Heat treatment Procedure-Heat treatment ChartsAs built drawings-Vessel nameplate details-Weight and centre of gravity details-Hydro test certificates-Pneumatic test certificates-Balancing reports-Over speed test reportsString test reports-Hazardous area test reports / certificates-Functional tests, either mechanical, electrical, control system and others as required by national standard or Client specifications, whether witnessed or not (as applicable)-Crane SWL certificateElectrical continuity / insulation resistance test-Instrument calibration certificatesGeneral electrical / instrument/control/telecommunication-testing. The Pre-commissioning and Commissioning dossiers shall also be included in the Quality Assurance Record Book.

Manuals and data book Introduction


Contractor shall prepare the Operating, Maintenance and Other Manuals for the Client to use for operator training as well as for preparing the detailed operating procedures. Contractor shall organize the Operating, Maintenance, Safety, other manuals and Data Books by unit, System or Sub-System. For that purpose, a number of manuals shall need to be produced to allow the commissioning team to produce detailed procedures and instruction for operating and
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maintaining the FACILITY. The manuals are listed here in order that the Contractor may identify any information of an appropriate nature, which should be compiled and handed over to Client. Client shall specify procedure for the coding, format and final completion of documentation, drawing and certification to achieve a smooth hand-over from the Client project task force to the operating staff. It is important that all stages of the Work are properly recorded. The records and documents generated during the Work shall be included in Manuals by Unit, System or Sub-System to be handed over to Client during the transfer of responsibilities from construction to commissioning to operation. Complete document packages for each Unit, System or Sub-System shall be available before transfer of responsibilities for Unit, System or Sub-System takes place. Computerized records shall be utilized where appropriate. PFDs, P& IDs and single line diagrams prepared by Contractor shall be in a format for direct input in Client CAD (Computer Aided Design) system. Also all such documents from Vendors shall be computable to Client CAD format specified in TDMS specification. Manuals shall be written with regard to the overall construction and commissioning program, quality control, operations and maintenance so that they are available at the right time for their proper utilisation. Each Manual shall consist of several volumes. Client might have identified the following manuals to be generated as a minimum: Each Operating, Maintenance, Safety, Other Manuals shall be available in preliminary form three months prior to ready for commissioning for the relevant system or unit and be issued in the final form together with the other documents to be included in the Final Documentation at the time of applying for Certificate of Completion. The required number of copies of the Operating, Maintenance, Safety and Other Manuals as well as the format is defined somewhere in the documents. Contractor shall submit the details of the format and contents of the Operating, Maintenance and Safety Manuals for Approval prior to starting preparation. The Manuals and Data Books shall be bound in hard, durable, binders, with the Job Title and Project Number embossed on the cover. The Table of Contents of each Volume is to appear in all volumes. Contents should be sectionalized and separated by properly labeled dividers. Volume thickness of each Volume shall not exceed eight (8) centimeters. Book pages are to be A4 size. Drawings should be reduced to A3 size and may be accordion-folded to A4 size, stated in the English language. The Project Manager / Engineer shall be consulted as to what arrangement shall be most suitable. Also, Contractor shall prepare electronic media format Data Books. All drawings and data shall be "as-built" Facilities Manual It shall describe the overall FACILITY and contain the basic data which determines the methods of protecting, operating and maintaining the FACILITY. It shall contain the operating parameters including safe working limits for all vessels and pipes. It shall contain plot plans, area classification plans, together with escape routes and other items to be approved by Client. Access Manual This manual shall show access and lay-down for maintenance of all items of equipment and be developed by the EPIC Contractor for further review and approval by Client.
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Operating Procedures Manual This shall be the collection of detailed operating procedures relating to each FACILITY or system. Operating manual shall be categorized into Process Units, Utility Units, Auxiliary Facilities, Safety, Control systems, Pipelines, Communications. The manual shall describe the FACILITY in sufficient detail to the level of a competent operator including but not limited to the following:FACILITY description, Unit capacities and limitations, start-up and shutdown procedures, emergency shut down procedures, equipment list, PFD, P&ID, operating parameters, cause & effect charts. The draft operating procedure manuals shall be produced well in advance of Equipment and FACILITY commissioning. Emergency Procedure ManualThis shall contain all the actions that need be taken in the response to an emergency incident on the site or in its vicinity such as acid spillage, pipe bursting, fire, accidents, etc. It shall describe the organisational response required to deal satisfactorily with such incident, the required liaison with outside authorities & include any special procedures or instruction relating to process / utilities equipment with normal operating procedures. Engineering Manuals These are record dossiers of all items of FACILITY and equipment to be supplied by the Contractor. The manual should include Equipment data sheets / vendor documentation, specification, spare part lists, drawings, repair procedures and QA procedures etc. Maintenance Manuals These shall provide sufficient information to the Client Maintenance Department and be produced in a form which shall facilitate the setting up of a Maintenance Management System. The final formal and content shall be decided by Client to reflect site policies. The manuals should contain the appropriate data to allow Client Maintenance to perform their function effectively as well as include vendors equipment description, detailed drawings, spare lists, references, re-ordering procedures, maintenance and vendor manuals. Training Manual This manual shall be produced by Contractor for approval by Client. It shall give a brief description of systems and the associated subsystems. It is intended to be used for training purposes only for which, it shall form the basic of a detailed programme for the operation and maintenance activities of the facility, system and subsystem where appropriate.

Maintenance procedures
Maintenance procedures are to be split per main equipment or main equipment category. General-Detailed description of the equipment and auxiliaries-Detailed instructions for use-Detailed trouble shooting Section and details of self-diagnostic routine-Detailed dismantling instructions-Itemized spare parts lists with reference drawings-Recommended list of consumable-Maintenance schedule Data book Data Books are intended to provide the information necessary for Clients resident Technical Department or an outside Contractor or consultant to understand the processes involved, calculate performance capacities, efficiencies and design modifications.Data Book(s) shall in general conform to the following:
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Basic Engineering Data: General Information. Utility Information, Meteorological Data, Summary report on Soil conditions, Site conditions, Operating and design parameters. Elevations and Coordinate References and government requirements. Drawing Index of all Client, Contractor and Vendor drawings This index shall include: (a) One column wherein all drawings included in the Data Book are clearly indicated and, b) one column wherein all drawings for which electronic format (CAD). Tape / diskette) supplied to the Client are clearly indicated. Also, those included in the Equipment Reference File should be so marked. Refer TDMS specification requirement . Contractor with Client approval, shall provide a database for recording of the index. Equipment ScheduleOf all equipment by item number, description and specification number. Group equipment by category, i.e. tower, exchangers, vessels, etc. Also Manufacturer's name. Process Units Include Process flows (show oil and utility quantities for specified charge rates), P& IDs by Unit, Block flow diagrams, Process plot plan, Heat and material balances, Process calculations index and Battery limit line Tables for Process and Utility lines, Licensors documentation. Water Systems Including sources, treating facilities, cooling water, etc., distribution and balances for normal and maximum design conditions; fire water systems design pumps, hydrants, hose and hose reels, fixed spray systems, monitors, etc. systems plot plans, P&IDs, and water treating data sheets. Air Systems FACILITY and instrument: Include design basis (quantities, pressure, dew point). Also, systems plot plans, flow sheets and tie-ins when provided. Air Quality Control Include design basis for air quality dispersal rates; setting stack heights, and major equipment used in control. Also, flare stack height data related to smoking / nonsmoking capabilities; maximum emission allowances for C02, S02, etc. as required by local and other governmental regulations. NoiseInclude in-plant and community design noise level limit criteria, specifications, where required the local and other governmental noise limit regulation for in-plant and community noise. Electrical Systems Including all distribution facilities, design basis abnormal load and peak demand tabulation of significant operating conditions. Systems plot plan (including substation locations), single-line diagrams of generating and main distribution system. Design data for switchgear and motor controllers. System description and data on telesignalling system Communications Include system description, special requirements (radio, walkie-talkie, etc.) and equipment layouts.Page 64 of 491 suraj_engineer@yahoo.co.uk

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BuildingsInclude brief description, type of construction, plans, elevations and plot plans. Safety Special requirements as related to operating units and equipment.-

Equipment Data
Pump information to include pump list data sheets. performance curves, outline and dimensional drawings (including driver), mechanical seal arrangement drawings and auxiliary (vents, drains, lube oil systems) piping drawings. All power System Studies to be submitted as a stand-alone dossier complete with drawings, data, CDs etc. Centrifugal & Reciprocating Compressors and Drivers information to include data sheets, performance curves, general arrangement (outline) and cross-sectional drawings, steam gland and sealing diagrams (when required), lube and seal oil diagrams indicating instrumentation and control and outline drawings, specifications of lube oil and seal oil consoles. Special Equipment such as mixers, filters, etc. to include data sheets, drawings, piping arrangement, electrical. Instrument information to include schedule, listing data by category (temperature. pressure flow, etc.); process information and pertinent mechanical description Maintenance Facilities information to include list (type, size) of permanently mounted shop tools, special portable tools and special inspection equipment; plan and arrangement drawings of simple buildings used for maintenance and bulk materials storage. Also, major platform arrangements, including access for operations and maintenance. Line list information shall be provided as per specification. Back up of the control / DCS system configuration made for the plant or package shall be provided in CDs or DVDs in 4 (four) numbers. Technical Data Management System (TDMS) Contractor shall develop and provide Final Documentation in accordance with TDMS specifications.

Maintenance, Engineering Data Acquisition, Management and Maintenance Strategies for SAP System
The supply of the software is not included in the Scope of Work of this Contract. Client shall install the SAP system software. Contractor shall compile the data in accordance with the SAP structure as per the Scope of Work. Contractors Scope of Work is to input / entry data into the SAP system in conformance with the Scope of Work and structure as indicated in the SAP document. The operation of SAP is included in the Scope of Work of Contractor. However, the Contractor shall provide hardware and Software interface between SAP System and the DCS. Between the SAP system consisting of SAP modules and the DCS equipment, an Open access module is required. The SAP Open Access module shall extend the functionality of SQL plus to provide direct access to SAP modules from the APIs of DCS equipment. The Open Access module shall be both a Client and server to SAP, so data exchange may be initiated by either SAP or any application program on DCS (like Setcim and Infoplus of Aspentech etc.). This dual functionality shall allow bi-directional event driven information links to be developed between API (setcim) of DCS and SAP applications. This module at a most basic level shall allow standard SAP PP-IP messages to be received and transmitted by SQL Plus. Additionally, in order to accommodate customised SAP systems, the SAP Open Access Module shall also allow user defined messages to be transmitted and
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received from SAP Advanced Business Application Program (ABAP) which be developed by the Contractor as per the Scope of Work defined. The registration and definition of these messages shall be handled by this module allowing applications to be developed without any changes to any of the already existing SAP configurations.

Final Completion- maintenance & successful performance


Hand OverHanding over the site refers to mechanical or physical handover to the client at practical completion. The works should have been completed in all respects so that these can be used for the intended purpose & production commences according to the plant designs & technology involved. All documents as explained in the foregoing are compiled according to the QA system to constitute a bunch of documents contractually for an approval by the engineer & the client for permanent use by the client. Immediately after the handover, performance start up, the operations work & the maintenance period commences which continues up to an agreed period or duration according to the provisions within the contract. A list of minor snags not effecting the performance should be prepared for repair in the maintenance period as agreed by the client & the engineer. All punch list items as included within snags should be properly & efficiently attended to so that it does not take much of the maintenance period for the reinstatement conditions. All personnel meant for training the operative of the client should be engaged for imparting to them formal training courses according to the agreed conditions for explaining complete systems demonstrated properly so that no mistake may occur during operations. Recording the lessons learntIt should be the endeavour of a professional contractor to record all incidents during the contract execution which obstructed the progress on the contract & all instances evidencing the cooperation by the engineer & his staff. All problems faced or experienced by the contractor should also be recorded on documents giving base for incorporation solutions for future contracts. Contractor should also describe his mistakes or how otherwise the problems could have otherwise be tackled to minimize the loss of time & expenditures. Also a record should be made for the performance of the engineer or the client personnel & any required improvement. These documents are termed as close out report part. The client & the engineer should go through these records to amend its style of working on the future projects. Suggestions-about the sub Contractors- These should also be recorded based on the regular records during the various progress stages. About the Client engineers-These records should also be based on the regular comments noted on the progress achievement during the contract period giving necessary suggestions about enhancing the client or engineers efficiencies & dealings in the interest of the future projects. Close Out-The close out reporting is very significant in essence as it is a final document speaking all history summary of the project which may be used to learn various lessons for future use by all parties involved & can form an operational research database for supervision analysis Discharge-After obtaining the final completion & maintaining certification, discharge certification should be given by the client & the engineer relieving the contractor of the construction responsibilities provided the contractual warranties as well as liabilities remain in force as secured for the coverage of certain guaranteed items on the scope of work.
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Technical safety, operation review & technical audit


Contractor shall arrange for technical safety, operability and maintainability reviews which are required to be carried out by Company / Client at specific stages of Engineering, Procurement and Construction during the Project development to check for safety, reliability, operability and maintainability of the FACILITY. In addition, Company / Client at its sole discretion may appoint a third party to carry out such quality / HSE audits of the Work. Contractor shall make available all records and all aspects of the Work at all times and at all places where Work is performed for detailed auditing by Company / Client or any third party appointed by Company / Client. In particular, Contractor shall make available for reference and Company / Client use at all places where the Work is performed, a good quality copy of the latest issue of all applicable codes, norms, standards, drawings, specifications and qualified Contractor Personnel to assist Company / Client. Contractor shall also provide a suitable venue for such reviews. Additionally, Contractor shall carry out Hazards Analysis, Safety Analysis and Project Health, Safety and Environment Review (PHSER). Contractor shall also prepare Safety Audit and Inspection Manual to submit to Company / Client for approval. Additionally, Contractor shall carry out safety, operability and maintainability reviews and provide copies of Contractors findings to Company / Client. Company / Client shall have the right to attend such reviews. Contractor shall implement the review findings into his Scope of Work. Contractor shall also submit Safety Requirement Specification.

-------------------------------------Chapter 6
Project management
Various facilities at Construction Site
Contractor shall be responsible to arrange to acquire all the service logistics required at Plant Industrial City for the performance of the Works. The costs of such services shall be included in the Lump Sum Portion of the Contract Price. Examples of the required services are: Land rental for Accommodation / office camp and lay down area. Gate pass of personnel and vehicles, equipment, plant H2S, BA Certificate courses. Fresh water etc All these facilities shall be managed by the contractor sufficient in advance so as to meet the schedule requirement. It should be noted that the procedure for the lease of the planned land for the camping consumes considerable time by the municipality or the industrial city authorities as well as other authorities. Also, the application procedures for the security gate passes based on its own regulation take certain hours for the issues. All these points should be kept in notice to initiate the application quiet in advance to meet the schedule requirement.
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Construction Accommodation Camp and Other Construction Facilities Contractor shall choose from option 1 or 2 (below) for its accommodation camp. Option 1 - Accommodation facilities Inside the Fence of Plant Area. Contractor may utilize accommodation facilities provided by Plant inside the fence of Plant area. Charges and fees to be paid by Contractor to Plant for such accommodation if so preferred & available. Contractor notes that Plant accommodation facilities shall be subject to availability at the time of request and be provided to Contractor or other parties on the basis of first come first served. In the event that the Plant accommodation facilities are not available, Contractor shall utilize an approved Plant designated area and construct, operate and maintain his own accommodation facilities. Option 2 - Accommodation facilities Outside the Fence of Plant Area. Notwithstanding the above, Contractor may elect to have his accommodation facilities outside the Plant area fence. In such case Contractor shall obtain necessary approval from local authorities as mentioned in the foregoing. Other Construction Temporary Facilities Contractor shall provide, maintain and operate a suitable lay-down area, fabrication area and office camps and obtain permit from Company / Client Plant and / or Government Agencies to build these temporary facilities at Plant Industrial City including permits for all utilities such as power, water, telecommunication, etc. In accordance with the latest Health, Environment and Safety standards for which Company / Client shall assist Contractor by issuing an introductory letter to the Authorities. Contractor shall submit office Accommodation and lay-down area requirements for Company / Client approval after Contract award. Contractor shall utilise these Temporary Facilities for the purpose of the Project only. The approved temporary office camp and lay down areas shall be at no cost to Contractor, provided that these space requirements are considered as reasonable and justified by Company / Client / Plant.

General
Contractor shall take over construction preparation for the Temporary Facilities after obtaining approval from local authorities, Plant and / or Company / Client. Contractor shall build, operate and maintain up to Completion the accommodation camp for Contractor Personnel and other related facilities. The camp design and construction is to conform to the design requirements to be developed by Contractor and approved by Company / Client during the engineering phase. Contractor shall provide accommodation, catering and servicing (including safety, medical aid, housing, cleaning, recreational facilities, laundry) in the camp and generally cater to all personnel (no accommodation to be provided to Company / Client personnel) assigned to Construction Site. Contractor shall be responsible for operation, maintenance and housekeeping of the Accommodation Camps and other facilities. Contractor Personnel are to be accommodated in camp facilities in accordance with the latest Health, Environment and Safety standards. After Completion, Contractor shall close down and re-instate the Accommodation camp to its original state (as a minimum) and other facilities including all facilities provided to Company / Client. Office Buildings and Other Facilities
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Contractor shall build, operate and maintain throughout the duration of the Work all other required Construction Site facilities including but not limited to the following: Office buildings for Contractor and Company / Client Personnel. Reprography and communications (including phone, fax, radio, etc.) Pipe fabrication shop. Warehouses and lay-down area Warehousing facilities shall include covered storage, air-conditioned storage and outdoor storage as appropriate. Piping must be protected with pipe caps. Radiography examination room. Toilets, washing facilities, showers and change rooms. Testing laboratories, both civil, mechanical and E &I Concrete batching facility. Roads, paths and car parking for construction requirements. Guard houses, entrance control and fencing. Craft work areas, Fuelling stations for equipment, trucks, buses, adequate storage and handling facilities, Rigging loft, First aid medical stations (minimum three (3) stations), Equipment maintenance facilities, Labour canteen facilities, Explosives storage if required, Lining storage area and work area. Steel fabrication area, Civil prefabrication work areas, Grit blasting, painting shop, Utilities such as power, water, air etc. For the phases of Work up to Completion, any other facilities required for the Work, Contractor shall prepare details and obtain relevant approval of the facilities proposed. The temporary construction facilities provided by Contractor for the Camp, Offices, lay down areas fabrication shops, etc. shall be subjected to the inspection of the State Environmental Supreme Council such as sewage disposal, earth renewal and disposal, dirt transportation disposal, spills, etc. In case, Contractor is not compliant with the minimum requirements, Contractor shall take all necessary remedial actions for proper compliance. Utilities For Accommodation Camp, Office Buildings and Other facilities at Construction Site Power- accommodation camp Contractor shall arrange for power to be provided from Electrical Department through Plant or alternatively to arrange for his own power generation system, Office buildings and other facilities The office buildings and other facilities are to be located close to the Facility to be constructed. Company / Client shall not allow Contractor to utilise existing Company / Client facilities / utilities and Contractor arrange for its own power generation system. Contractor shall arrange for temporary power and lighting arrangement in all work areas at Construction Site. Fresh Water - Accommodation Camp Fresh water at camps at Plant Industrial City shall be provided by Contractor, including what is required for the Work. Office buildings and other facilities Contractor shall provide for the collection, storage, transfer and distribution of all water required for office buildings as well as other facilities at Construction Site. Requirements shall also include items such as concrete production, aggregate materials washing, testing of piping, vessels, tanks, drinking water, personnel waste flushing and for compaction of Construction Site fill. Contractor shall provide for adequate water storage facilities for this purpose. Wastes from accommodation camps, offices and other facilities at construction site
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Effluents Contractor shall provide for the collection of all sewage and wastewater from both the accommodation camp and other facilities at the Construction Site to storage tanks and provide for the contents to be treated at the existing Plant Sewage Treatment Plant. Construction debris Construction debris may be disposed as follows: Clean construction rubble and excavated materials hauled elsewhere within Nation to a site approved by Company / Client and / or relevant body. Garbage and construction unclassified rubbish to be hauled to a Site within Nation approved by Company / Client and / or relevant body. Scrap steel to be disposed of through local organisations. Untreated sanitary waste and solid waste to be hauled to a treatment plant located to a site within Nation approved by Company / Client and / or relevant body. Contractor shall adhere to Environmental Guidelines and Company / Client Environmental Protection Standards and apply to the relevant National public authorities for disposal of such construction debris. Company / Client shall provide a letter of introduction for such application. Contractor shall adhere to Regulation for Disposal of dredging material given in Contract documents. Waste disposal All wastes generated from the Contractors Temporary Facilities shall be disposed off by Contractor at disposal sites within the Plant Area as approved by Company / Client. Contractor shall utilize the Plant sewage treatment plant for its domestic waste / sewage treatment for which Contractor shall be charged at the rate of . per cubic meter. Contractor to arrange for transportation of the sewage from his camp to the Plant sewage plant. Communication Systems during Construction, Telecommunications (TEL), a governmental agency has total jurisdiction on communications for this Project. During Construction Work on the FACILITIES, communications services shall be required for Accommodation Camps, Office buildings and other facilities at Construction site. Construction communications should be considered as a separate stand-alone part of the Project including power supply arrangements. Contractor shall determine the exact requirements. A temporary exchange with sufficient capacity to meet the anticipated heavy demand for telephone and facsimile circuits during this phase shall be provided. Telephone extensions and facsimile machines shall be required throughout duration of the Project for offices of Company / Client, Contractor and Sub-Contractors. Contractor shall seek TEL advice on their requirements to supply telecommunication equipment upon request. For the use of individual groups working at Construction Site with no requirement for access to external circuits, separate hand-portable radio systems with base station repeaters shall be provided. More channels and hand-portable / mobile units are anticipated during the construction phase than during normal operation. The base station repeaters should be installed in the construction office and coverage of the work areas obtained by the use of directional antenna systems. Alternatively, base equipment can be installed in suitable containers and located to provide optimum coverage. Contractor shall co-ordinate Construction Site communication system requirements through Tel. Company / Client may provide a letter of introduction for such applications.
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All communications / correspondence with the local tele-communications company (Tel) shall be in coordination with Company / Client. The Communication requirement for Company / Client Personnel is specified. Import of equipment and materials All materials for the Work shall be subject to customs regulations and inspection. Contractor shall review and understand these regulations. Contractor to note that the Certificate of Origin must be certified by a Chamber of Commerce and ratified (legalised) by a National Embassy / Consulate. National customs shall reject any of these documents not ratified by a National Embassy / Consulate. Contractor to arrange authentication / legalisation of such documents. Contractor shall carry out co-ordination of movement of ships, offloading and handling of equipment and materials delivered to the Construction Site, in accordance with the local regulations and following the requirements in the relevant section of the FEED Design Package. Contractor shall give preference to Plant Port while importing materials. Plant Port is a modern port and has necessary facilities like exclusive heavy load berth, cargo berths etc. To facilitate Project import Material. Alternatively, other Ports can also be considered if necessary. Airfreight shall be through international airport at all stages. Contractor shall clear all materials through National Customs for use at the Construction Site. Contractor shall be responsible for payment of legalisation fees, Custom duty, customs clearance etc. Disposal of temporary facilities and construction surplus The Temporary Facilities installed, the equipment and tools used and the vehicles are either to be re-exported or disposed of as the case may be, and as directed by the National authorities. Contractor shall be responsible to co-ordinate these activities with National Authorities. Company / Client shall provide a letter of introduction for such applications. Contractor shall be responsible for the disposal of all construction surplus (overbuy) immediately after completion of the Work subject to Company / Client approval. Guarantee Period The Guarantee Period for the Work shall be 24 months from the Completion Date. System Reliability and Water Availability Contractor shall ensure that the Facility is designed, specified, constructed and commissioned to achieve an overall system reliability of not less than 99.7%. Contractor shall ensure that water availability is maintained at 100% at all time to all consumers. Contractor shall perform Reliability Study based on OREDA Reliability Data and statistical data from Plant which shall be requested by Contractor. Contractor shall ensure that the system reliability of 99.7% shall be maintained and proven to Company / Client with the manifold design arrangement. Contractor shall implement in the detailed design the recommendations (e.g: Mean Time Between Failure [MTBF] requirements etc.) Made in the reliability report given in documents
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It is a part of Contractors Scope of Work to monitor and establish design reliability and availability by data collection and analysis for a period of one year from performance test within the contract closure date. Maintenance, Engineering Data Acquisition, Management and Maintenance Strategies for SAP System Contractor shall compile input and entry data into the SAP system in conformance with the Scope of Work and structure as indicated in the SAP document.

Project management, control and administration Project Management


Contractor shall ensure that all parties involved in the Work properly co-ordinate on all interfaces dealing promptly. Accordingly, Contractor shall initiate and implement appropriate project management, control and administration procedures. Provision and implementation of Project control procedures for the Work shall be following the guidelines provided in Contract. In particular, Contractor shall give proper attention to the following: Project Control Contractor responsibility includes the following as a minimum: Undertaking project management of the design, Engineering, Procurement, Construction, Installation, Testing, Pre-Commissioning, Commissioning start-up, Initial Operation and Maintenance of the FACILITY including the management and supervision of all Subcontractors, Vendors and ancillary or temporary services that are necessary for the expeditious completion of the Work in accordance with the Contract. Preparation and submission of organisation charts for Engineering, Procurement, Construction, Installation, Testing, Pre-Commissioning and Commissioning (separately for each phase and location of the Work). Provision of a project management team/s to manage the implementation of the Work. Provision of Contractor Personnel to fulfill contractual requirement for timely completion of the Work. Co-ordination and control of work of each work group e.g. Design, engineering, procurement services, project control, contracting, construction, Installation, Testing pre-commissioning and commissioning to ensure the Work is completed within Scheduled Completion Date according to the specifications and drawings Implementation of a safety program throughout the execution of the work. Implementation of a Quality Assurance Program throughout the execution of the Work and submission of periodic reports to Company / Client. Carrying out periodic quality, safety, technical and schedule audits with Company / Client attendance and advising Company / Client of the results of such audits together with the appropriate action taken on any recommendation/s. The said audits shall be carried out at 30%, 60% and 90% of the Engineering, Procurement and Construction progress. Preparation of a complete set of Project Administration Instructions / Manual for the Work to obtain approval in line with the requirements of Contract. Contractor shall prepare, finalise and obtain Company / Clients approval of the project Document Distribution and Approval Matrices which be produced for each work phase i.e. Engineering, Procurement, Construction, Pre-commissioning, Commissioning and Initial Operation and Maintenance. The matrices shall include Contractors internal distribution as well as Company / Clients involved parties, management and discipline engineers.
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Contractor shall prepare, finalise and obtain Company / Clients approval of the project Deliverable Register (s) which be produced separately for each work phase i.e. Engineering, Procurement, Construction, Pre-commissioning, Commissioning and Initial Operation and Maintenance. Management and co-ordination of all external interfaces associated with the Work. These interfaces cover Engineering, Procurement Services (including supply), Construction, Pre-Commissioning, Commissioning, Initial Operations & Maintenance activities. Attending all management meetings with Company / Client at Contractors Design Office, Construction Site and Company / Client offices in Nation in accordance with Contract. Reporting to Company / Client in accordance with guideline provided in Contract. Construction Pre-Commissioning / Commissioning / Start-up and Initial Operation and Maintenance Management Contractor shall provide all Construction Management, supervision and support services including but not limited to the following: Construction Management and Interface Management Construction supervision Safety Management Quality Control / Quality Assurance Construction engineering and technical control services Material control and warehousing Management of Subcontractor and Vendors TPC and TPI Services Disposal of construction surplus materials Dismantling and disposal of construction aids and Temporary Facility except otherwise directed by Company / Client. Commissioning, start-up, Initial Operation & Maintenance management. Co-ordination with Vendors and sub-contractors Contractor shall ensure the following: Timely supply of AFC drawings and information to be issued to SubContractors. Timely supply of Engineering documents and information to be issued to Vendors. Adequate expediting of Vendors drawings / data for incorporation in detailed engineering and timely return of engineering comments and approvals of Vendors drawings /data. Adequate expediting and inspection of Vendors equipment and materials. Timely supply of Pre-Commissioning, Commissioning, Testing, Start up and Initial Operations and Maintenance spare parts to the Construction Site. Expediting Vendors for providing completed SPIR forms within the stipulated period i.e. Within three (3) months of placement of purchase orders. Adequate provision of Vendors assistance for equipment during Construction, Pre-Commissioning, Commissioning, Start-Up, Initial Operation and Maintenance and Performance Test. Timely supply of equipment and materials to be issued to Subcontractors for installation and Construction. Timely supply of One Year Operational Spare Parts, Capital Spares and Laboratory Equipment when required to do so by Company / Client. Centralised Document Control
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Contractor shall provide and maintain the Master Document Control Centre for Contract for documents issued by or to the Contractor at Contractors Design Office, Construction Site offices and other operational centres through the life of the Contract. Contractors primary responsibility shall include but not limited to the following provisions: Centralised Document control facilities, document control staff, relevant hardware and systems at the above mentioned offices / centres Up to date PC based register of all documents issued by and to the Contractor. Read / Sort / Print access of Contractors Master Document Control Database to Company / Client. Issuing / obtaining Company / Client acceptance to proceed on all Document Transmittals in advance of distribution in accordance with the approved Document Distribution Matrix. Distribution of all Contractor generated documents duly sorted by function and classification to Company / Client advising due dates for Company / Client comments. Co-ordination, expediting and collection of Company / Client comments in accordance with due date schedule. Provide dedicated staff to carry out the necessary document control function pertaining to Company / Client specific requirements. Provide additional staff viz. Document clerks as required by Company / Client Project Manager to supplement / support the deputed document control staff. Project Administration Contractor shall develop detailed Project Administration Instruction Manual applicable for Engineering, Procurement, Construction, Pre-Commissioning, Commissioning, Testing, Start-up, Initial Operation and Maintenance covering all aspects of planning, scheduling, progress reporting, cost control and project administration. An effective system shall be implemented for planning, scheduling and reporting of progress. Project Administration Instruction Manual shall be submitted for approval within 30 (thirty) calendar days from the Effective Date. Contractor shall develop all Project Administration Instruction Manuals following the guidelines and any other requirement stipulated under the Contract in accordance with good professional practices. Final Project Documentation Contractor shall prepare and Handover to Company / Client the Final Project Documentations as per the Guidelines provided in relevant documents. The Final Project Documentations including the following as a minimum shall be approved by Company / Client. Mechanical Completion Manuals, Quality Assurance Record Manual(s), Close-out Report, Project Dossiers Closeout Report Contractor shall prepare Closeout Report in accordance with requirements and guidelines provided. Contractors Closeout Report development and update shall be done on monthly basis from the Contract Effective Date to ensure authenticity of the report. Services and facilities to be provided by company / client / contractor Facilities provided by Company / Client to Contractor Contractor Personnel shall be required to work at or visit Company / Client facilities at Plant and elsewhere whilst performing the WorK. For this purpose each Contractor Personnel must posses a valid gate pass.
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Application for gate passes can be submitted to Company / Client for approval once the person has a valid entry visa stamp of Nation. Contractor shall submit the application for gate passes for Company / Client approval when all requisite formalities are completed in all respects satisfying the requirements of the security authorities and deposit with the concerned department / security office to obtain the passes. Contractor Personnel shall carry the pass at all times when on Worksite. Contractor shall be responsible for all costs relating to Contractor Personnel in obtaining passes, certificates and attending any kind of training training. Services and Facilities by Contractor to Company / Client Contractor shall accept the presence of Company / Clients representatives as well as any third party nominated by Company / Client at Worksite, in his facilities and at Subcontractors / Vendors premises for such purpose as Project co-ordination, monitoring, review of drawings, specifications and schedule, inspections, testing etc. all other aspects of the Work. Services and facilities at Contractor Design Office Contractor shall provide and maintain the following services and facilities for Company / Client personnel at Design Office where Engineering or Procurement Services are performed for their entire service duration: Contractor shall ensure that Company / Client offices within Contractors Design Office shall be available for Company / Client access at all times i.e. Company / Client staff have uninterrupted and unhindered access 24 hours a day, seven (7) days a week for the full duration of their stay at Contractors Design Office. Contractor to record that Company / Client staff shall not call his security staff to open the doors to Company / Client offices outside normal working hours. Contractor shall ensure that Air Conditioning and heating to Company / Client offices during the hot and cold seasons shall be working efficiently at all times. Offices and Related Services and Facilities (Indicative) One managerial office of not less than twenty (20) square meters. Three managerial offices of not less than sixteen (16) square meters. Fifteen single occupancy offices of not less than twelve (12) square meters. Common working area would not be acceptable. Secretarial / clerical, administration pool area adequate for at least four persons and locked Document Control Area. One fully furnished and equipped conference room for the exclusive use of Company / Client of not less than forty (40) square meters with conference table for a minimum of twenty (20) persons with all presentation equipment such as overhead projector, writing boards, etc. Contractor shall make available to Company / Client the use of other conference rooms and use of items of equipment such as television, computer projector, video (VCR) and the like for meetings and / or presentation purposes, as required. One fully equipped archive office of not less than twenty-five (25) square meters with filing cabinets, filing drawers, etc. One Prayer Room of not less than thirty (30) square meters. Shaded car parking for twenty (20) cars within the basement of the office building which Company / Client staff shall be accommodated in.
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One high-speed multi-copy photocopying machine (A4 and A3 plain paper sizes) for the exclusive use of Company/Client. Photocopying machines specification shall include, but not limited to, user friendly console, sorting and stapling facilities with at least twenty (20) trays, dual side copying, enlarging and reducing capabilities, minimum fifty (50) pages feeder, A4 and A3 volume paper trays and speed of not less than sixty (60) pages per minute. One colour photocopier machine for exclusive use of Company/Client. Two (2) paper shredding machines Office scanner suitable for electronic transfer of documentation. The office accommodation shall be supplied with all utilities and services (24 hours a day) such as, but not limited to, electricity, lighting, ventilation, heating and/or air conditioning, fully stocked and maintained dedicated kitchen with hot and cold refreshments, toilet / washing facilities, to the satisfaction of Company / Client. Maintenance and daily cleaning of the offices and common areas shall also be provided. Pantry with a person to serve tea / coffee, etc. Shall be for the exclusive use of Company / Client Toilets with ablution for the exclusive use of Company / Client Muslim staff shall be maintained at EPIC Contractors Home Office. Keys shall be provided so that Company / Client office can be accessed at all times. The offices furnishing supplied shall be of good quality and should be sufficient and include, but not limited to, carpeting, lockable desks, chairs, reference tables, meeting tables, lockable filing cabinets, stick files, wall mounted notice boards, white marker boards, drafting boards and telecommunications as described hereinafter. Provision of coat hangers, waste-paper bins and normal office stationery such as, but not limited to, stapling machines, hole punchers, A4 size writing pads, note books. Diaries, Lever arch files, scientific hand calculators, pencils, markers, erasers, scissors, staple extractors, pens, drawing pins, paper clips, stackable paper trays, etc. Are to be provided as required to all Company / Client staff. Stationery and consumables to be used for equipment specified shall be supplied, as required. This shall include, but not be limited to, stationery and consumables for photocopier, facsimile, computer workstations, printers, paper guillotine etc. Offices provided by Contractor for Company / Client shall be in the same building, which Contractor intends to use for the execution of the Work, and shall be segregated from Subcontractors, and other Contractors Clients. All managerial and Company / Client staff offices including document control and archive office shall be lockable. Secretarial and Document Controller offices to be of an open space style. Contractor shall be responsible for the security and safety of the office accommodation. Secretarial/Clerical Assistance Two (2) secretaries / clerks fluent in English, complete with office space and furniture, as per the specification of those for Company / Client, and equipped and familiar with the telecommunications and computer equipment. Shall be provided. All clerks shall be provided with their own computer workstations, printers, etc. (in addition to those provided to Company / Client elsewhere in the Contract, as per the specification of Company / Client. All Secretaries/clerks shall be subject to Company / Client approval. Contractor shall provide all resumes and arrange for interviews by Company / Client of all secretaries / clerks.
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Telecommunication Facilities All offices, administration pool, archive office and conference rooms listed above shall be supplied with telecommunication facilities comprising telephones with speakers and microphones for conference calls with access to domestic and international networks through Contractors central switchboard. Two laser facsimile machines with A4 size paper and with at least 100 pages memory connected with two direct lines external to Contractors switchboard and with access to domestic and international network. Charges for telephone and, facsimile calls including connection and rental charges shall be to the account of Contractor. Company / Client shall make use of the international calls only for business purpose. Computing Facilities Contractor shall provide and install the following equipment and shall ensure proper maintenance support (hardware and software) through Contractors own computer support group: Fifteen Computer Workstations with minimum 3.0 GHZ processor, 256 MB RAM memory, eighty (80) GB Hard Disk, 512 KB cache memory, 3.5 floppy drive, DVD/ CD ROM drive, 15 SVGA monitor (17 for engineers involved in design review), Windows 98 key board (US Standard), Windows mouse and mouse pad. All Computer Workstations shall be supplied network and Internet ready. Two Notepad Computers with minimum 2.0 GHZ Centrino Processor 3.0 GHZ processor, five hundred twelve (512) MB RAM memory, eighty (80) GB Hard Disk, 512 KB cache memory, DVD / CD ROM drive, 3.5 floppy drive, 15 TFT screen, built-in Windows XP key board (US standard) and built-in-mouse and external mouse, integrated headphone/speakers and microphone jacks, rechargeable battery with average of 3 hours life time plus a carrying case and universal power adapter. All Notebook Computers shall be supplied network and Internet ready. One computer workstation for direct access to Company/Client intranet through the Internet complete with printer. Common Facilities Common facilities to be shared between as many workstations as listed in (a) & (b) above connected by a local area network and consist of: Two A4 laser printers, 12 pages per minute. One A4 and A3 laser printer, 12 pages per minute One A4 / A3 scanner. Use of A4 / A3 color laser printer and A3 color plotter, as required. Software Back-up facilities. All computer systems should be supplied ready to use. Software, latest English versions for the above Computers (each), as specified here below: Windows and Winzip, Antivirus, Microsoft Professional Office. Adobe Acrobat Writer, Network Software and card , E-mail Software Lotus Notes Planning Software CONTRACTOR intends to use for the WORK. Scanning Software, Any software related to all engineering disciplines that Contractor intends to use for the WORK through Contractors Network. Flash Memory Sticks of at least 2 GB, Contractor shall install all cables, connections, junction boxes and software for the installation of a local area network to service all the above computers (including secretary / clerks and Company / Client Assistant Engineers workstations) and common facilities.
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Contractor shall connect all computers to E-mail and Internet networks to enable communication between Company / Client personnel and Contractor personnel and communication with Company / Client management in National through the Internet Network or telephone modems. Contractor shall endeavour to use the same software applications as shall be used by Company / Client (defined above) for ease of data/reports between Contractor and Company / Client. Contractor shall ensure unlimited e-mail access for Company / Client staff at his Home and Site Offices. Company / Client shall not accept limitation on the size of the Inbox. There shall be unlimited megabyte size of the Inbox. Contractor shall ensure that remote access by Contractor, of workstations used by Company / Client shall be blocked. However, access may be permitted for short periods following approval by Company / Client. Messing Facilities Contractor shall provide access to its home office canteen of senior personnel for Company / Client Personnel and nominated third parties at costs equivalent to those for Contractors employees. Administrative Assistance Contractor shall provide assistance for obtaining (in the country of Contractor Design office where Work is performed) necessary permits, Governmental or administrative authorization visas, residence visas, car rental, domestic and international travel booking services and any other similar administrative matters for Company / Client personnel and their families and any third parties nominated by Company / Client. Contractor shall provide administrative assistance to Company / Client personnel, their family and any third party nominated by Company / Client in relation to, but not limited to the following: Arranging with removal firms for transport of personnels belongings. Assisting personnel and their families to find leisure facilities, schools, hospitals, accommodation for leasing and any similar matters. Contractor shall provide the requisite guarantee if required. Cost of the above-referred administrative assistance to Company / Client is included in lump sum Contract Price. In case of the following items, Company / Client representative would issue specific instruction to Contractor authorizing permission and Contractor shall have to bear the cost upfront. Company / Client would reimburse the approved documented cost at actual for all such expenditure through Variation to Contract. However, all costs related to Contractors overhead expenses for arranging and assisting with the above would be at Contractors account and deemed to be included under the Lump Sum Contract Price. Payments of hospitalization costs (or guaranteeing payment if acceptable to hospital authority) for Company / Client personnel (in the country of Contractor Design office where Work is performed) in case of an emergency hospital admittance and until such time payment is made directly by Company / Client to the hospital. Company / Client would furnish Contractor with a copy of such payment remittance for his record. All fees, charges and costs for visas, permits, residence formalities, etc. Full and Shot-down Copies of Contract Document Contractor shall provide thirty (10) shot-down copies of the Contract documents in A5 size for Company / Client use (drawing to be on A4 size folded to A5 size). The shotdown Contract document copies shall be bound with good quality hard covers and shall be subject to Company / Client approval. Shot-down copies of Contract Document
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exclude the Technical Information Volumes. Additionally, Contractor shall provide (10) full size copies of the Contract documents including Appendix F documents. Mail and Courier Services Contractor shall provide to Company / Client mail and courier services through Contractors mail office. Training of Company / Client Personnel Training of Company / Client Assistant Engineers at Contractors Home office. Contractor shall provide cost for on-the-job-Training for five (5) Company / Client Assistant Engineers at his Design Office as provisional sum. Contractor shall assign a Lead Engineer as Contractors focal point concerning the training of Company / Client Assistant Engineers. The focal point shall provide and be responsible for the following: Preparation and submission of training programs in accordance with the PCP for Company / Client review and approval. Co-ordination of all training activities and matters. Keeping track of training progress for all Company / Client Assistant Engineers. Ensuring that training progress assessment reports are submitted in a timely manner. Liaison with Company / Clientrepresentative or his delegate in all matters regarding the training of Company / Client Assistant Engineers. Providing seminars and classroom courses for Company / Client Assistant Engineers. Arranging vendor factory/shop visits as necessary. Contractor shall assign a Senior Engineer as a mentor for each Company / Client Assistant Engineer in accordance to their specific engineering discipline during the entire Engineering / Procurement phase. The mentors shall be responsible for the following: Familiarization of Company / Client Assistant Engineers with Contractors working systems and facilities. Assigning project related activities to Company / Client Assistant Engineers and providing sufficient guidance for them to be able to complete the assigned work at the expected level of competency. Reviewing and evaluations of the activities performed by Company / Client Assistant Engineers. Reviewing the monthly reports prepared by the trainees and forwarding them to Company / Client Representative with their recommendations. Submitting schedule of activities planned for assignment in advance to Company / Client Representative or his delegates. Preparing quarterly progress reports in accordance with the format to be provided by Company / Client. The training of Company / Client Assistant Engineers shall be planned in a way to enable their full appreciation of the overall engineering consideration with respect to their discipline areas during the evolution of the Detailed Engineering and Procurement Services works. This shall include, but not limited to, the following: Applicable engineering standards, codes and practices Engineering design calculations, operating philosophy, process simulations, equipment selection and specifications. Preparation of specifications, data sheets, engineering drawing and engineering document management. Supplier evaluation and selection Quality, safety and environmental Familiarization with applicable computer software
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Services and Facilities at SUBCONTRACTORS / Vendors Premises Contractor shall provide the following at Subcontractors & Vendors premises: Contractor shall provide through Subcontractors and Vendors the following services and facilities for Company / Client personnel assigned permanently and / or temporarily at Subcontractors/ Vendors premises where any part of the Work is performed and/or manufactured: Use of private offices similar in specification to as mentioned above. Use of Subcontractors / Vendors telecommunication facilities (telephone, fax, and the like) for all WORK related matters including international line access. Use of Subcontractors / Vendors Computer workstations and printers. Use of Subcontractors / Vendors photocopying machines. Access to Subcontractors / Vendors messing facilities. Contractor shall provide training for Company/Client personnel through Vendors of the following equipment: DCS Equipment, Electrical Switchgear, Main Cooling Pumps including VSDS drives, GRP Piping / Pipelines F&G System, CCTV System (at site), Analysers (at site), Package Control (at site), Laboratory Instruments (at site) The training shall be conducted at Vendors Premises for five (5) Company / Client personnel. Over and above Contractor shall provide training for ten (10) Company / Client Operation staff at Construction Site. The Training At Vendors Premises Shall Cover All Areas of design, manufacturing, operating, inspection and testing, QA / QC regulation and packing while the team at the Construction Site shall cover all operation and maintenance of the equipment. Duration of training shall be for a minimum period of three (3) weeks in Vendors premises and four (4) weeks for Construction Site. Course venues, equipment, stationery and documents shall be provided by Vendors at Vendors premises and Contractor at Construction Site. Services and Facilities at Construction Site Contractor shall provide and maintain the following services and facilities for Company / Client personnel and any third party nominated by Company / Client at Construction Site where Construction, Pre-Commissioning, Commissioning and start-up parts of the Work are performed up to the Contract Completion Date. Offices and Related Services and Facilities Contractor shall provide temporary office building at Construction Site for the sole use of Company / Client, which shall accommodate the services and facilities detailed hereunder. Company / Clients Construction Site office building shall be close to Contractors Construction Site office building. The services and facilities shall include the following: One managerial office of not less than twenty (20) square meters. Three managerial offices of not less than sixteen (16) square meters. Thirty five single occupancy offices of not less than twelve (12) square meters. Secretarial / clerical, administration and document control pool area adequate for at least four persons and their furniture and equipment.
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Two fully furnished and equipped conference rooms for the exclusive use of Company / Client of not less than forty (40) square meters with conference table for a minimum of twenty (20) persons with all presentation equipment such as overhead projector, writing boards, etc. Contractor shall make available to Company / Client the use of items of equipment such as television, computer projector, video tape player (VHS) and the like for meetings and / or presentation purposes, as required. One fully equipped archive office of not less than forty (40) square meters with filing cabinets, filing drawers, etc. One Prayer Room of not less then forty (40) square meters.h) Shaded car parking for thirty five (35) cars. Two high-speed multi-copy photocopying machine (A4 and A3 plain paper sizes) for the exclusive use of Company / Client. Photocopying machines specification shall include, but not limited to, user friendly console, sorting and stapling facilities with at least twenty (20) trays, dual side copying, enlarging and reducing capabilities, minimum fifty (50) pages feeder, A4 and A3 volume paper trays and speed of not less than sixty (60) pages per minute. Use of Contractors colour photocopier machines, as required. Two paper shredding machines One office scanner suitable for the electronic transfer of documents. The office accommodation shall be supplied with all utilities and services such as, but not limited to, electricity, lighting, ventilation, heating and / or air conditioning, fully stocked and maintained kitchen with hot and cold refreshments with a person to serve tea and coffee (full time), toilet / washing facilities (prayer washing facilities shall be provided close to the prayer room), to the satisfaction of Company / Client. Maintenance and daily cleaning of the offices and common areas shall also be provided. The offices furnishing supplied shall be of good quality and should be sufficient and include, but not limited to, carpeting or vinyl tiles, lockable desks, chairs, reference tables, meeting tables, lockable filing cabinets, stick files, wall mounted notice boards and white marker boards, drafting boards, scientific hand calculators and telecommunications as described hereinafter. Provision of coat hangers, waste-paper bins and normal office stationery such as, but not limited to, stapling machines, hole punchers, A4 size writing pads, note books, diaries, Lever arch files, pencils, markers, rubbers, scissors, staple extractors, pens, drawing pins, paper clips, etc. Are to be provided as required. Diaries, Lever arch files, scientific hand calculators, pencils, markers, erasers, scissors, staple extractors, pens, drawing pins, paper clips, stackable paper trays, etc. Are to be provided as required to all Company / Client staff. Stationery and consumables to be used for equipment specified shall be supplied, as required. This shall include but not limited to stationery and consumables for photocopier, facsimile, computer workstations, printers, paper guillotine, etc. All offices and archive office shall be lockable. Contractor shall be responsible for the security and safety of the office accommodation.

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Roads to Company / Client Site offices shall be paved with asphalt concrete. Construction traffic, trailers and trucks shall not use these paved roads to Company/Client offices Secretarial/Clerical assistance Two Secretaries / Clerks fluent in English, complete with office space and furniture, as per the specification of those for Company / Client, and equipped and familiar with the telecommunications and computer equipment. All clerks shall be provided with their own computer workstations, printers, etc. (in addition to those provided to Company / Client elsewhere in the Contract), as per the specification of Company / Client. All Secretaries / clerks shall be subject to Company / Client approval. Contractor shall provide all resumes and arrange for interviews by Company / Client of all secretaries / clerks. Contractor shall provide one General Helper person for general office routine. Telecommunication Facilities All offices, administration pool, archive offices and conference rooms listed above shall be supplied with telecommunication facilities comprising telephones with speakers and microphones for conference calls with access to domestic and international networks through Contractors central switchboard. Two laser facsimile machines with A4 size paper and with at least 100 pages memory connected with two (2) direct lines external to Contractors switchboard and with access to domestic and international network. One office scanner suitable for the electronic transfer of documents. Charges for telephone and facsimile calls including connection and rental charges shall be to the account of Contractor. Computing Facilities Contractor shall provide and install the following equipment at the temporary Construction Site office buildings and shall ensure proper maintenance support (hardware and software) through Contractors own computer support group: Twenty-five Computer Workstations with minimum 3.0 GHZ processor, two hundred fifty six (256 MB) RAM memory, eighty (80) GB Hard Disk, 512 KB cache memory, 3.5 floppy drive, DVD / CD ROM drive, 15 SVGA monitor (17 for engineers involved in design review), Windows 98 key board (US Standard), Windows mouse and mouse pad. All computer workstations shall be supplied network and Internet ready. One Notepad Computer with minimum 3.0 GHZ processor, five hundred twelve (512) MB RAM memory, eighty (80) GB Hard Disk, 512 KB cache memory, DVD/ CD ROM drive, 3.5 floppy drive, 15 Active matrix colour SVGA, built-in windows 98 key board (US standard) and built-in-mouse and external mouse, integrated headphone / speakers and microphone jacks, rechargeable battery with average of 3 hours life time plus a carrying case and universal power adapter. All Notebook Computers shall be supplied network and Internet ready. Contractor shall ensure that remote access by Contractor, of workstations used by Company / Client hall be blocked. However, access may be permitted for short periods following approval by Company / Client. Common facilities Common facilities to be shared between as many workstations as listed above connected by a local area network and consist of :
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Three A4 laser printers, 12 pages per minute. One A4 colour laser printer, 12 colour pages per minute. One A4 / A3 scanner. Use of Contractors A3 colour laser printer, A1 and A3 color plotters, as required. Software Back-up facilities 6 Software, latest English versions in all cases; for the above Computer Workstations and Notebook Computers, as specified here below: Windows XP or the latest (one (1) copy per computer). Microsoft Professional Office (one (1) copy per computer). Network Software and card (one (1) copy per computer). E-mail Software (one (1) copy per computer). Planning Software Contractor intends to use for the Work (two (2) copies). Use of any software related to all engineering disciplines that Contractor intends to use for the Work through Contractors Network. Latest English / Arabic software version of Windows and Microsoft Professional Office with a full set of manuals each (2 copies). A full set of manuals for each software application. Anti-virus (One copy per workstation or one multi-user server based copy) All computer systems shall be supplied ready to use. Contractor shall install all cables, connections, junction boxes and software for the installation of a local area network to service all the above computers (including secretary/clerks workstations) and common facilities. Contractor shall connect all computers to E-mail and Internet networks to enable communication between Company / Client personnel and Contractor personnel and communication with Company / Client management in National through the Internet Network or telephone modems. Contractor shall endeavour to use the same software applications as shall be used by Company / Client (defined above) for ease of data/reports between Contractor And Company / Client. Messing facilities Contractor shall provide all messing facilities (including food) for Company / Client personnel and Company / Client nominated third parties at the Construction Site as provided for Contractors management personnel. The food shall be of good quality and from a variety of international cuisines such as Mediterranean, European, Oriental, vegetarian etc. It is a specific requirement that all meals shall generally be low in oils and fats. Contractor shall allow for a minimum of thirty (30) Company / Client personnel. The menu shall be agreed with Company / Client. Training of COMPANY / CLIENT Personnel Contractor shall provide On-The-Job-Training for five (5) Company / Client Assistant Engineers. Contractor shall provide all services and facilities to Company / Client Assistant Engineers as per the specification of those for Company / Client. Contractor shall provide offices, computing and telecommunication facilities for each Assistant Engineer. The services provided to Company / Clients Assistant Engineers shall be in addition to those listed elsewhere for Company / Client.

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IEI Certified Professional Engineer Suraj Singh

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Contractor shall assign a Lead Engineer as Contractors focal point concerning the training of Company / Client Assistant Engineers. The focal point shall provide and be responsible for the following. Preparation and submission of training programs for Company / Client review and approval Co-ordination of all training activities and matters. Keeping track of training progress for all Company / Client Assistant Engineers. Ensuring that training progress assessment reports are submitted in a timely manner. Liaison with Company / Client representative or his delegate in all matters regarding the training of Company / Client Assistant Engineers. Contractor Shall Assign A Senior Engineer As A Mentor For Each Company/Client Assistant Engineer in accordance to his specific engineering discipline during the entire Contract duration. The mentors shall be responsible for the following Familiarisation of Company / Client Assistant Engineers with Contractors working systems and facilities Assigning project related activities to Company/Client Assistant Engineers and providing sufficient guidance for them to be able to complete the assigned work at the expected level of competency. Reviewing the monthly reports prepared by the trainees and forward them to Company / Client Representative with their recommendations Submitting a schedule of activities planned for assignment in advance to Company / Client Representative or his delegates. Preparing quarterly progress reports in accordance with the format provided by Company / Client. The training of Company / Client Assistant Engineers shall be planned in a way to enable their full appreciation of the overall engineering, construction, precommissioning, and commissioning work consideration with respect to their discipline area. This shall include, but not limited to, the following: Applicable Construction, Pre-Commissioning and Commissioning standards, codes and practices Construction Quality, Safety and Environment Control Familiarisation with applicable computer software Equipment Factory Acceptance Test (Travel, lodging - including meal and transportation costs shall be provided by Company / Client) Conducting technical meetings, presentation and courses Welding, Civil and Painting Inspection Material control and traceability Construction and Commissioning operating and safety technical reviews Construction and Pre-Commissioning work Commissioning and start-up preparation work Contractor shall provide On-The-Job-Training for ten (10) Company / Client operating personnel during the Pre-Commissioning and Commissioning, Initial Operation and Maintenance phases of the Work. Contractor shall provide a pool area with adequate furniture (in addition to what is specified for Company / Client elsewhere) to accommodate Company / Client operating personnel for the entire duration of PreCommissioning and Commissioning phases. Contractor shall assign a focal point to administer the training of Company / Client operating personnel. Contractor shall submit
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a detailed training program for Company / Client review and approval three (3) months prior to start of Pre-Commissioning work. Tax Consultancy Services Option Price C calls for a Tax Consultancy Call off Service Detailed below is the Scope of Work for this service: The Engineering and/or Design part of various major projects undertaken by Company / Client in the State of National are carried out by Contractors in different countries. Company / Client intends to second its personnel to the offices of the Contractor and these personnel stay overseas for a period that makes them liable to tax in that country. The tax on the individual employees shall be paid by Company / Client. Company / Client wishes to engage the services of a Tax Consultant, managed by Contractor, who has world wide office infrastructure to advise Company / Client on all tax matters related to personal income tax and complete the necessary documentation. The Scope of Work for the Contractors tax consultancy work includes, but is not limited, to the following: Pre-assignment/Pre-Departure Tax Services leading to information on preassignment tax planning opportunities and procedures that the assignees should be aware of while on assignment. On Assignment Tax Services in host countries. Company / Client shall advise Contractors Tax Consultant as soon as Company / Client personnel reach the foreign country for Project development and intend to stay for a duration long enough to attract tax liability with details like names of the employee, their Staff Number and the likely period of stay. Upon receipt of above information supplied by Company / Client, the Contractors Tax Consultant is required to provide: Current relevant provisions of Personal tax laws of the country. Liabilities of Company / Client towards compliance of tax laws. Further details required, if any, by the Contractors Tax Consultant from Company / Client. Based on input / feedback from the Contractors Tax Consultant, Company / Client shall issue an Instruction to Proceed detailing the Work required from the Contractors Tax Consultant. Within 14 days of receipt of an Instruction to Proceed the Contractors Tax Consultant shall provide to Company / Client: Execution Programme detailing the arrangements and methods which the Contractors Tax Consultant proposes to adopt for the execution of the Work including tax planning required, time required, manpower and man-hours required, estimated cost and necessary scheduling. Execution Programme when approved by Company / Client shall become part of the Contract and Contractors Tax Consultant shall execute the Work strictly in accordance with the Execution Programme. Contractors Tax Consultant shall: Keep Company / Client fully informed of the progress made in the Work. Maintain liaison with local tax authorities. Have regular contact with Company / Client employees in those foreign countries. Scrutinise the requirement of advance tax payments and estimated tax determination thereof and advise Company / Client accordingly.
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IEI Certified Professional Engineer Suraj Singh

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The Contractors Tax Consultant shall provide necessary tax returns, ensuring full compliance of tax laws of the country and file the returns with appropriate tax authorities within the specified time. Arrive at the total tax payable and advise Company / Client. Complete the tax assessments within the specified time and endeavour to get: Clean Assessment Orders.Income Tax Clearance certificates for all the employees. The Contractors Tax Consultant shall put its best efforts to obtain for the benefit of Company / Client all lawful discounts, tax credits, allowances and refunds from the tax authorities. Repatriation Tax Services involving execution of all tax related matters that are required to be complied with by Company / Client employees while making exit from the host country and re-enter the country of origin. Post Assessment Tax Services Eliminate / minimize the possibilities of post assessment proceedings like appeals, reassessment, litigation, etc. Keep Company / Client informed from time to time of the potentialities and possibilities of Post Assessment Proceedings and recommend suitable preventive and / or corrective actions that may be required to be taken by Company / Client / its employees in host country. Contractors Tax Consultant is required to make every effort to avoid / mitigate such proceedings. Any or all of the Work as mentioned above may be called upon for a particular country or a number of countries either simultaneously or at different points of time through issuance of an Instruction to Proceed. Payment of tax amount to tax authorities shall be based upon duly receipted acknowledgement of tax authorities in the host country. Payment to Contractor shall be made on a flat rate per person per fiscal year basis against completion / progress made in the tax consultancy work. The flat rate quoted by the Contractor shall include for partners, lead consultants, senior managers, senior consultants, managers/ consultants & support staff. Flat rate quoted is fully inclusive of all associated costs for employment of personnel and all overheads and profit. Project Soft wares Contractor shall use the following application software in preparation of the project deliverables: Word processing Microsoft Word 2000, Spreadsheet Micro soft excel 2000, Presentation Mocrosoft powerpoint 2000, Database Microsoft access 2000 or equivalent, Project planning Primavera Latest Revision, Piping Stress Analysis Caesar II, Finite Element Analysis ANSYS, ABAQUS, COSMO or equivqlent, Draughting AUTOCAD 2004, Reliability Study RAMP (Ver 3.4 or latest) or equivalent 3D Modeling, (if chosen by Contractor) PDS / PDMS Pipeline simulation (dynamic / surge analysis) pipenet or internationally validated software, which shall be approved by Company / Client Electrical System Studies CYME software Structural Design STAAD PRO & STAAD -III Company / Client shall not provide any software to the Contractor. The Contractor shall provide pipenet Simulation Programme for Company / Clients permanent use at the end of the project. Company / Client personnel shall have access to Contractors pipenet Programme at any time. Contractor shall specify the software used for sizing Control Valves, Relief Valves, Orifice Plates, Processor Loading etc. If the software used is of proprietary nature and
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not standard ones, a copy shall be provided to Company / Client for use in future Maintenance, or design modification.

--------------------------------------Chapter 7
Detailed Engineering Requirements Process Engineering
The Contractor shall during bid stage verify the process engineering work performed by FEED consultant and provided in the bid documents and satisfy himself that it is a workable design. Contractor shall bid on the design and provide all process guarantee. Should there be any technical deficiencies to prevent Contractor from providing the process guarantees, then these perceived technical deficiencies along with the proposed remedies or solutions should be clearly stated in the Contractors bid. In the event Contractor accepts the process design as proposed by Company / Client, but fails to address it as such in his bid, it shall constitute acceptance of the process design by the Contractor as well as to provide all process guarantees. After contract award and during detailed engineering, Contractor shall not reduce sizes of equipment items or lines nor shall he delete instrumentation or valves from the proposed process design without written approval from Company / Client. Any modifications / revisions to the P& IDs, equipment data sheets, piping lay out and any Company / Client developed drawing / document shall be subject to review and approval by Company / Client. Any proposed reduction or deletion of equipment items, lines or instrumentation and valves shall be submitted for Company / Client review and approval. Contractor shall be solely responsible for any increase in the size of equipment items, lines, instrumentation and valves and any necessary process modifications after contract award and during the detailed engineering phase. It is therefore, in the Contractor interest to ensure that the Bid Documents comprising the basic process design package is well evaluated and accepted by him. The detail design and engineering shall be based on the design developed during the FEED. However Contractor shall be responsible for confirmation, verification, and validation, update of all process and process related documents and endorsement of all FEED findings. These shall be reviewed, checked, verified and updated by the Contractor as per design criteria, guidelines, codes and standards and acceptable practices. The new system design shall meet 99.7% reliability and 100% availability. Contractor shall start from the Engineering documentation supplied by Company / Client as a result of FEED work or otherwise, and contained in the FEED package. However, the Contractor acknowledges that the FEED package does not define the plant in full detail and needs further development in order to achieve the desired objectives. Contractor as part of the detail design shall optimise all the systems and update as necessary. The relevant process documents included in this tender shall be updated, completed and amended by the Contractor to reflect further design detailing, design development and actual equipment data, performances and characteristics.
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IEI Certified Professional Engineer Suraj Singh

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Any changes to the PFD, heat and material balance, equipment / instrument data sheet, P&IDs or FEED package in general, as the result of the optimisation, must be approved by Company / Client before implementation by the Contractor. The Contractor shall perform, as a minimum the following process engineering activities as part of scope of services: Process basis of design and Process Design Philosophy Contractor shall review and update the process basis of design and Process Design Philosophy to include any other additional data considered for detailed engineering. Contractor shall reconfirm Sea Water Demand figures and other design data with Company / Client before proceeding with the detailed design. Steady state hydraulic study Contractor shall carry out hydraulic modeling and study based on the final cooling water network for the whole project using latest PIPENET simulation software. Contractor shall demonstrate the routings used in simulations are in agreement with the latest available pipeline / piping layout documents and drawings. In case there are marked differences between routings used in simulations and actual layout during detailed engineering to an extent that they shall invalidate the hydraulic results and conclusions, then Contractor shall carry out new updated simulation. Based on the flow rate defined by Company / Client for individual consumers, Contractor shall optimize pipeline sizing that satisfies all the operating and maintenance scenarios. The soft copy of the model shall be provided to Company / Client during the course of detailed engineering. The Contractor shall provide access to Pipenet Simulation program for the Company / Client process engineers and hand over to Company / Client soft copies of the simulation. Contractor shall determine the allowable minimum water flow in the network and propose engineering and operation solutions to maintain higher flow in the network piping system. Contractor has to highlight consequences of not adhering to this requirement. Transient Analysis For the selected and approved cases only, Contractor shall carry out thorough and detailed hydraulic surge analysis of the entire cooling water system to determine any adverse effects on the system, e.g. Water hammer, undue stresses on connected equipment and on pipeline supports etc. Based on the hydraulic transient analysis, Contractor shall determine and provide the required protection measures such as vacuum breakers and specify the required valves closure time. Contractor to note that during FEED, transient analysis of the return cooling water network related to recirculation system has not been done due to non-availability of data for the cooling water pumps of cooling towers. Contractor shall obtain all the necessary data of the pumps and carryout detailed hydraulic surge analysis for the return cooling water network of recirculation system during EPIC phase. If data is not available, same shall be assumed in consultation with Company / Client. Dynamic simulation studies shall be conducted by Contractor for the following objectives: Verify operability and controllability of the pumps under various transient conditions, such as start up, coast down, emergencies and operational transients. Confirm the Start-Up procedures. Confirm the shutdown procedures. Confirm the design requirement for vacuum breakers. Confirm the closure time for the valves.
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The soft copy of the model shall be provided to Company / Client during the course of detailed engineering. The Contractor shall provide access to pipe net simulation program (transient state) for two (2) Company / Client process engineers. If the Contractor intends to carry out the transient analysis by its own in-house expertise, this must be approved by Company / Client prior to start of work. Electro Chlorination system Contractor shall carry out a detailed hydraulic analysis and design for the chlorination system including the distribution systems and generate / update all necessary drawings / documents. Contractor shall carry out the aforementioned scope of work suitable for continuous operation and shock dosing modes. The Contractor shall also design for chlorine discharge monitoring system. Utility System Contractor shall verify the design and capacity of the utility systems such as instrument air, plant air and service water. Process Flow Diagrams (PFDs) Contractor shall perform all work necessary to verify, correct or revise Process Flow Diagrams and heat and material balances to reflect any changes in the design made as a result of Contractor's work. Utility Flow Diagrams (ufds) Contractor shall perform all work necessary to verify, correct or revise the Utility Flow Diagrams and heat and material balances to reflect the requirements of the process and utility design which shall be approved by Company / Client. Piping and Instrument Diagrams (P&IDs) Contractor shall review, fully update and develop the Process, utilities and electro chlorination P & IDs, provided in the FEED Design Package, during detailed engineering. All the FEED Holds on the P & IDs shall be investigated appropriately & reviewed by the Contractor. Further development of the diagrams shall include, but not limited to, finalising all line sizes, including details of control valves / vacuum breakers etc., adding or correcting mechanical, electrical and instrument details resulting from the detailed engineering and adding vendor details. The Contractor shall implement and action the items identified in FEED HAZOP as a part of Contractor responsibility. Further, the Contractor shall ensure that all HAZOP actions have been closed out. Any auxiliary P& IDs required, like for the pumps protection or Cooling of the Thyristors of Variable Speed Drives (utilising De-ionised water) etc. Shall be developed by the Contractor or obtained through the equipment supplier / vendor. All valves including manual / gear operated Valves shall be tagged. The Contractor shall fully develop the detailed P & IDs for Phase and ultimate Phase and update these drawings during the course of EPIC, as required. Any proposed additions / modifications to the P & IDs, by the Contractor that may jeopardize or compromise the currently built in operating reliability and or flexibility shall be rejected. Contractor shall then rectify / modify the design and the P& IDs to Company / Clients satisfaction and at no cost to Company / Client. Should there be a conflict between the P &IDs as developed and Company / Client specifications, the
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former shall prevail. It is understood and accepted that P & IDs may see many revisions during the detailed engineering stage and even during network construction. Every revision shall require Company / Client review and approval. The Contractor shall carry out all changes / revisions requested by Company / Client as part of the contract. Upon successful network commissioning, a full set of as built P & I Ds shall be prepared and submitted to Company / Client for review and final approval and acceptance. Line List Contractor shall review and fully update the Line List based on the results of detailed engineering. Contractor shall develop and complete basic line designation tables (LDTs) in their entirety during the detailed engineering phase. Contractor shall verify all line sizes as depicted on the P & IDs during the bid stage. No reduction in any line sizes shall be permitted after contract award. Any increase in line size, required as a result of oversight on the part of the Contractor to check and verify during the bid stage, shall be to the Contractors account. Process Data Sheets Contractor shall perform the sizing of all the equipment and instruments and update / generate the process datasheets for all items including but not limited to the packages, equipment and instruments. Contractor shall provide process guarantees for the satisfactory performance of each equipment item provided in FEED package. Should the Contractor find that certain equipment items need to be modified and/or the size / capacity / duty needs to be increased; he shall clearly state this in the bid and provide the desired design. Failure to do so shall imply that the Contractor accepts the equipment sizes / capacities / duties as depicted by Company / Client on all process data sheets forming part of the bid document and shall provide all process guarantees. Philosophies Contractor shall review and update the following philosophy documents as necessary to incorporate the updates during detailed engineering. Process design philosophy Operating and control philosophy The philosophies shall cover as a minimum the valving / isolation, maintenance, operations, blow down, design temperature / pressure and chlorine distribution. Cause and Effect charts / PSFS Contractor shall be responsible for modifying / creating all Cause and Effect Charts and PSFS diagrams to include all the new facilities during the detailed design. Utility / chemical summaries Contractor shall review and update the utility / chemical summaries and alarm / trip settings documents. RAM study Contractor shall carry out a reliability and availability study to confirm that the new system can meet 99.7% reliability and 100% availability. The study shall be carried out on the full system utilizing recognized international standards and practices. Pre-commissioning, commissioning and start-up manuals Contractor shall prepare detailed pre-commissioning, commissioning start-up manuals based on the pre-commissioning / commissioning philosophy defined in FEED package.
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Operating manual Contractor shall prepare detailed operation and maintenance manual covering operation procedures, startup, shutdown, maintenance procedures. The format and content of the operating manual shall be discussed and agreed with Company / Client. Performance test run Contractor shall produce a detailed performance test run procedure and shall be approved by Company / Client. The objective is to demonstrate that the FACILITY is satisfactorily operating in accordance with the design parameters and achieves the product specification and quantity and other performance warranties as specified under the Contract. The performance test shall be carried out within an agreed period between Contractor and Company / Client from the date of hand over of the network to Company / Client. The performance test shall be carried out in accordance with the approved procedure in order to determine whether the network performs in accordance with the design, the performance test shall be carried out by Company / Client. The duration of the test shall be a continuous 72 hrs. Contractor may be present to witness the performance test. Samples of water for chlorine content shall be taken by Company / Client operating personnel and analyzed in Company / Client laboratory. Contractor may choose to carry out his own analysis. In this case, Company / Client shall take another set of samples for the Contractor. The results of the analysis obtained by Company / Client shall then be compared with the analysis results obtained by Company / Client shall then be analyzed once more. Should the difference still remain, then another two sets of samples shall be taken and the procedure repeated again. If at the end the differences still remain and in the event no agreement could be reached then a third party laboratory technician shall be brought to the site to carry out the analysis. This third party technician shall be acceptable to both Company / Client and the Contractor. Other Requirements Contractor to note that all equipment, instruments and lines have been provided with temporary tag nos. Specific for FEED phase. Contractor shall update all the necessary documents with new identification in line with Company / Client Standard after obtaining the correct sequence numbers from Company / Client. Contractor shall undertake HAZOP using an Independent Third Party Chairman approved by Company / Client. The date (s) for the HAZOP shall be agreed with Company / Client. Contractor shall incorporate the findings of the HAZOP into the detailed design without any cost and / or schedule impact to Company / Client. As part of Phase, Contractor has to provide cooling water supply connection to Power, which is defined in various FEED documents. But in order to meet the immediate requirements of Power, a temporary cooling water supply is being provided by others until such time the permanent supply from Phase development becomes available. This is to highlight to the Contractor the existence of a temporary connection for Power, and Contractor has to note this information before preparation of detailed drawings and to liaise with Company / Client in this regard for any further details. Contractor shall provide the following: A DN200 tapping with manual operated Butterfly Valve on the line A DN200 manual operated Butterfly valve on the same line Upstream of tapping. Tapping and valves shall be near the Pump House area.
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The above requirement is as per Company / Client requirement to have interconnection with Phase. The interconnection shall be used in case of emergency and start up of Phase if Chlorination package of Phase is delayed. As the above requirement is specific and not part of the FEED design, this is not reflected at any of other FEED documents / drawings. Process Deliverables List The following documents shall be developed by the Contractor as a minimum. The Contractor shall provide a list of deliverables showing the documents and drawings that shall be produced under this Contract. It is the Contractors responsibility to develop any other documents that are required to complete the detailed design to Company / Clients satisfaction. Updated Process Basis of Design Steady state Hydraulic calculation report for cooling water system reflecting all updates and amendments made by the Contractor Transient analysis report for cooling water system reflecting all updates and amendments made by the Contractor Steady state Hydraulic calculation report for chlorine system reflecting all updating and amendments made by the Contractor Process flow diagrams with heat and material balance diagrams Utility flow diagrams with heat and material balances, Process System Description, Utilities System Description, Hydrochlorination System Description, P&ids for process, utility and auxiliary systems, PSFS diagrams, Cause and Effects Charts, Process equipment data sheets, Process instruments data sheets, Line list, Operating and control philosophy, Process design philosophy, Alarm and trip settings, Utility and chemical summary, Performance test run procedure, Pre-commissioning and commissioning manuals, Operating manual and the Start-up / Shut-down procedures. Safety Integrity Level Mechanical Engineering Contractor shall be responsible for but not limited to the following Contractor shall review / update / upgrade and validate FEED specifications and data sheets for equipment and prepare material requisition documents including Vendor data requirement list & schedule (VDRL) for the equipment in accordance with the Contract equipment list. Contractor shall prepare detail engineering documents for specified modification works of Phase (e.g. Sun shelter at PH for Semi- Portal Cranes current collector and replacement of existing cable reel power line of said crane, etc. As specified in study; Existing Phase crane use as a common crane), and when required prepare specification, data sheets etc. For the equipment not covered specifically in FEED documents. Contractor shall include for RAM Study to confirm requirement of additional EOT Cranes at Pump-house and Semi-portal Crane at Screen-Yard. Contractor shall witness and approve all documents necessary during major testing such as mechanical run tests and Performance Tests. Also, Company/Client shall witness inspections and tests when required. Contractor shall review and Validate Mechanical Handling Study Report (accessibility and maintainability) of all Project FACILITIES and relevant data sheets shall be updated for procurement.

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Contractor shall design, supply and install all necessary facilities as recommended in the mechanical handling report such as A-Frame, manual chain Hoist etc. That are not covered in the FEED documents. Equipment List Contractor shall complete / further develop the equipment list included in FEED. Equipment Data Sheets FEED document includes data sheets developed in accordance with process design criteria for all major equipment items. Prepared equipment data sheets identify the minimum design requirements. Contractor is responsible for review and update as required and preparing final detailed equipment data sheets for all equipment. Civil / Structural Engineering Contractor shall be responsible for but not limited to the following: Applicable for all Facilities A preliminary site preparation drawing, along with soil survey report on borehole samples has been included. In addition, rough grades have been established along with a perimeter fence drawing, preliminary grading and drainage drawings, preliminary roadway drawings, road and utility crossing drawings, pipeline drawings, foundation drawings, structural steel drawings and other miscellaneous drawings showing lines only but no details. These drawings / documents are issued for information only. The Contractor has to remove existing pavement in order to place new foundations. Contractor's work includes, but not limited to, the review and verification of Plot Plans to include any development resulting from supplier information, piping stress analysis, requirements for constructability, plant safety, operation and maintenance to suit completion of the FACILITY. Surveys A Geo-technical report Geo-technical Site Investigation has been provided for Building Area, Outfall Area and on Pipe Corridor's. The purpose of the report is to provide preliminary information on foundation recommendations. Contractor shall be responsible to plan and carry out any supplemental soil survey, to verify the data and to collect additional data at the area(s) where soil data is neither sufficient nor available. At the completion of the site preparation work, Contractor shall carry out site survey for setting out his work and to verify that the Construction Site preparation is done as per Project requirement in terms of extent and elevation of the developed area for all FACILITY. Contractor shall ensure that all existing survey monuments are preserved and properly protected. Survey monuments damaged by Contractor during the performance of the Work shall be repaired or replaced, by the Contractor at his cost. Contractor shall locate and install new permanent monuments at each corner of the facilities Construction Sites and other locations as needed for the Work to mark boundaries and establish additional horizontal and vertical controls for the construction work. Contractor shall record the locations of these monuments and benchmarks on the Contractor's topographical survey drawings together with their National National Grid references and National Height Datum (NHD) elevations.

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Contractor shall reference the FACILITY grid system for all new co-ordinates, and the National Height Datum for all elevations used for the Work. As a minimum, the accuracy of horizontal measurements shall meet the requirements of relevant Company / Client standards. The accuracy of running levels for the purpose of establishing grade elevations is expressed as: Maximum permissible error in mm = 8 times the square root of the distance of level run in kilometres or as specified in Company / Client standards. Topographical Survey Information and details pertaining to existing roads, storm drainage, etc. Shall be coordinated with Company / Client during the execution of the Project. However, Contractor shall survey the existing infrastructure to acquire the actual information and ensure consistency in design and construction. Contractor shall carryout a complete topographical survey of the work site and submit report with drawings to Company / Client. Contractor shall contact the GIS Department for information pertaining to the transformation parameters from grid. Bathymetric Survey Bathymetric Survey shall be carried out by the Contractor for the sea bed profiles for the design of the Outfall Structure. Civil, Structural and Building Contractor shall carry out the following civil design and engineering for the Work included but not limited to the following: Construction Site preparation, final grading, paving. Excavation including de-watering. Foundation works and carrying out soil improvement, soil replacement and / or piling, as required. In the reclaimed land area, soil improvement or piling shall be considered for large equipment foundations, heavily loaded pipe sleepers and / or foundations sensitive to settlement. Roads, paving, culverts, footpaths, road markings, signs, safety barriers and guard posts in compliance with Company / Client and other local Authority Standards, CS and National Traffic Manual, Design guidelines for road pavement and road crossings in Plant Industrial City. Flush kerb stones shall be installed at change of road construction and road direction while crash barriers (guard rails) shall be installed at culverts, ramps and change of road direction as a minimum. Company / Client shall not supply copies of CS standards. Contractor shall have to obtain his own copies from the Ministry of Municipal Affairs and Agriculture. Underground services, such as, sewers, drains, cable trenches, duct banks, pipe trenches, and other civil works associated with underground service installations including underground piping, cathodic protection, electrical cables and grounding, instrument cables, and heating systems. Seawater pipes shall be installed above and under ground. Design, cut and fill shall be for the full width of the pipe corridors, plus the two side maintenance tracks which are part of other corridors adjacent to the Cooling Water Corridors i.e. For Phases while the construction of pipe supports shall be for Phase only.
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Earth embankment / dikes and related concrete works, if required during construction to be executed by Contractor. Structures in concrete, steel and masonry block, including but not limited to equipment and pipe supporting structures and foundations, culverts and bridges, pits, manholes, basins, ponds, receiving basin, discharge channel, outfall structure, earth retaining structures, piping anchors and thrust blocks, etc. Conformance to local law, regulations and practices. Contractor shall design, supply, install and commission impressed current cathodic protection system to protect the reinforcing steel re-bar of the Pump house pit (above and below ground), Receiving Basin, Discharge Channel, Outfall structures and for all structure and foundations within water table or/and below 0.0m NHD. Extent and type of the structure of wing wall to PH for the future phases shall be finalised by Contractor during detail design and subject to Company / Client approval. Contractor shall refer to PH walls. Actual dimensions including buttress walls of Receiving Basin shall be detailed by Contractor and finalised during detail design subject to Company / Client approval. Physical modeling of the Pump pits, Receiving Basin, Discharge Channel and Outfall Structures are to be carried out by the Contractor. Specialist recommends that the developed design for the intake pumping station be the subject of a physical model test by the Contractor in order to: Investigate detailed internal flow conditions Investigate potential vortex action at the pump chambers Investigate potential pre-swirl at the pump suctions Optimise required vortex suppression devices. Investigate performance in the vicinity of the pumps and to confirm pump chamber geometry etc. The proposed overall layout and dimensions for the screen chambers is considered satisfactory for FEED. However, that the required width of each screen chamber element should be subject to further review by Contractor- following identification of the actual screen vendor and actual screen dimensions. Landscaping Contractor shall carryout design for free bare land beautification including required irrigation pipeline at Common Seawater Facility. Soft landscaping The soft landscaping is to be installed around the Building, comprising of grass area, planting beds, plants, trees (palm trees for Operation Building only), shrubs and the like. This landscaping shall cover the following area: Operation Building - Tag No.. Workshop / Warehouse Building - Tag No. Workshop Building - Tag No. The required irrigation pipeline is also to be specified for watering of landscaping. The source of water supply is available from connection to PLANT Landscaping Water Network at CSF Main Road, which is presently under implementation. Hard landscaping The area between the buildings and roadways should be kerbed and filled with 100mm depth of 20mm crushed and washed stone (i.e. Pebbles) to the available space between the buildings and road. Earthing pits and cable markers shall be minimum
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50mm above the finished levels or shall be reinstalled appropriately. This landscaping shall cover, but not limited to, the following area: Control Building (Extension) - Tag No. Electro-chlorination Building - Tag No Electrical Switch gear building for Chlorination -Tag No. 33kv Switchgear Building - Tag No. VSDS Substation for PH - Tag No VSDS Substation for PH - Tag No. 220kv Switch Gear Building -Tag No. Contractor to follow project specifications and Company / Client amendments while designing all Civil Works in addition to the Civil and Structural Design Basis and applicable codes and standards. Underground Facilities These shall include all civil work associated with electrical, instrument, telecommunication, fire fighting system and cathodic protection, including cable trenches of all types (concrete wall type, direct buried type, etc.) And duct banks and associated civil work for underground piping, and cables including the required pipe trenches, drainage systems including sewers, drains, catch basins, manholes for various purposes. Contractor shall follow project specifications and Company / Client amendments while designing Underground facilities in addition to applicable codes and standards. Steel Structure While designing the steel structure, Contractor to follow the Project specifications, Civil and Structural Design Basis, codes and standards Contractor shall be responsible for providing all steel structures. Strict quality control, supervision, inspection and testing during fabrication and erection shall be implemented for the production of steel structures. Only new material certified to the Project Specifications shall be used. Materials conforming to code equivalent to latest ASTM Standards, such as BS or JIS are acceptable for structural materials with prior Company/Client approval. The quality control including material, fabrication, welding, protective coating, transportation, handling and storage is outlined in Project Specifications and shall be strictly followed. With regard to the use of hot-dip galvanised steel structures, Company / Client is concerned with zinc embrittlement of stainless steel and high nickel alloys. Steel structure with a potential to be in contact with equipment containing stainless steel piping or equipment shall not be galvanised but be painted in accordance with Company / Client Painting Spec. In addition, Contractor's design shall make provisions to prevent contamination of these equipment and piping due to dripping of molten zinc from galvanised structural steel due to fire. Thus, wherever there is a potential for contamination due to molten zinc, Contractor shall either paint the overhead structure in-lieu of hot-dip galvanising, provide adequate protection shields or insulate/fireproof the structure. Operating stages and access on pipe racks, equipment supporting structures, shelters and equipment as well as stages and walkways on ground necessary to facilitate FACILITY operation and maintenance including structural platform shall be provided by Contractor, for Company / Client's approval. Contractor shall be responsible for determining the requirement, developing detail design, and providing small shelters such as those required for local panels and instrumentation, etc. These small shelters are not listed in the Building List. Contractor shall seek Company / Client approval for the scope of small shelters.
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Miscellaneous pipe racks and pipe supports which shall be required in process, and utility areas are not shown on the plot plans nor in the Building List. Contractor shall be responsible for developing layouts, detail design and providing these pipe racks and supports.

--------------------------------------Chapter 8
Building Design Concept
Design General Specification
Structural Design Basis Buildings, Process Structures, Pipe Racks, Miscellaneous Plant Structures, Vessels, Exchangers and General Introduction This specification gives the minimum criteria for structural engineering and design purpose necessary for structural engineering and design for the framework and foundations of all buildings, process structures, pipe racks and for the foundations for vertical vessels, horizontal vessels, heat exchangers, storage tanks, vibrating equipment, grade and elevated slabs and masonry structures. Miscellaneous plant structures such as pits, sumps and retaining walls etc. Codes And Standards The following Codes, Standards and Specifications form part of this specification. Only the latest codes shall apply to all requirements. Alternate Codes, Standards and Specifications meeting the requirements of the these Codes, Standards and Specifications may be used with approval by the Company. Steel grade material S 275 JR to BS EN 10025 and bolts to BS 4190 and BS 4395 may be used upon the Company approval. Steel grade 43A to BS 4360 may be used for small access platforms without valves, small pipe supports, handrail and ladders, subject to Company approval. American National Standards Institute (ANSI) ANSI A12.1 Safety Requirements for Floor and Wall Openings, Railings and Toeboards. ANSI A14.3 Safety Requirement for Fixed Ladders. ANSI A64.1 Requirements for Fixed Industrial Stairs American Society Of Civil Engineers (ASCE) ASCE 7 Minimum Design Loads for Buildings and other Structures American Institute of Steel Construction (AISC) AISC Specification for Structural Steel Buildings AISC Manual of Steel Construction AISC Code of Standard Practice for Steel Buildings and Bridges AISC Specification for Structural Joints Using ASTM A 325 or A 490 Bolts American Concrete Institute (ACI) ACI 301 Specifications for Structural Concrete for Buildings ACI 302.1R Guide for Concrete Floor and Slab Construction ACI 318M Building Code Requirements for Reinforced Concrete Commentary on Building Code Requirements for Reinforced Concrete ACI 325.3R Guide for Design of Foundations and Shoulders for Concrete Pavements
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ACI 336.2R Suggested Analysis and Design Procedures for Combined Footings and Mats ACI 350R Environmental Engineering Concrete Structures ACI 530 Building Code Requirements for Concrete Masonry Structures American Welding Society (AWS) AWS D1.1 Structural Welding Code - Steel AWS D1.4 Structural Welding Reinforcing Steel American Petroleum Institute (API) API 650 Appendix E American Society For Non-Destructive Testing (ASNT) ASNT-TC-IA Recommended Practice Portland Cement Association (PCA) PCA IS 003D Rectangular Concrete Tanks PCA IS 072D Circular Concrete Tanks without Pre-stressing National Concrete Masonry Association (NCMA) NCMA TEK 59 Reinforced Concrete Masonry Construction. Occupational Safety and Health Administration (OSHA) OSHA - CR29 American Association Of State Highways And Transportation Official (AASHTO) Standard Specifications for Highway Bridges American Society For Testing And Materials (ASTM) ASTM A6 Specification for General Requirements for Rolled Steel Plates, Shapes, Sheet Piling and Bars for Structural Use ASTM A36 Specification for Structural Steel ASTM A53 Specification for Pipe, Steel, Blank and Hot-Dipped Zinc-Coated Welded and Seamless. ASTM A123 Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products ASTM A143 Recommended Practice for Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedures for Detecting Embrittlement ASTM A185 Specification for Steel Welded Wire Fabric Plain for Concrete Reinforcement ASTM A193 Specification for Alloy-Steel Bolting Material for High Temperature Service ASTM A307 Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength ASTM A325 Specification for High Strength Bolts for Structural Steel Joints (Including Suitable Nuts and Plain Hardened Washers) ASTM A490 Specification for High-Strength Steel Bolts Classes 10.9 and 10.93 for Structural Steel Joints (Metric) ASTM A500 Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes ASTM A569M Specification for Steel with Carbon (0.15 Maximum Percent) Hot-RolledSheet and Strip Commercial Quality ASTM A786 Specification for Rolled Steel Floor Plates ASTM A830 Specification for Plates Carbon Steel Structural Quality Furnished to Chemical Composition Requirements ASTM C90 Specification for Load-Bearing Concrete Masonry Units ASTM C270 Specification for Mortar for Unit Masonry ASTM F436 Specification for Hardened Steel Washers ASTM F959 Specification for Compressible-Washer-Type Direct Tension Indicator for use with Structural Fasteners
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UBC Latest Edition BRITISH STANDARDS (BS) BS 4 Structural Steel Sections Part 1 Specification for Hot Rolled Sections BS 4190 Black hexagon bolts BS 4360 Weldable structural steels BS 4395 High Strength Friction Bolts and Associated Nuts and Washers for Structural Engineering BS 4449 Carbon Steel Bars for the Reinforcement of Concrete BS 4483 Steel Fabric for the Reinforcement of Concrete BS 4592 Grating BS 4848 Hot-Rolled Structural Steel Sections Part 2: Specification for Hot-Finished Hollow Sections BS 5950 Structural Use of Steelwork in Buildings BS 7419 Holding Down Bolts BS 8004 Foundations BS 8007 Design of Concrete Structures for Retaining Aqueous Liquids BS 8110 Structural Use of Concrete BS EN 20898 Mechanical Properties of Fasteners Part 1: Bolts, Screws and Studs BS EN 10025 Hot rolled products of now-alloy structural steels and their technical delivery conditions British Publications U.K. Concrete Society Technical Report No. 34: Concrete Industrial Ground Floors Cement and Concrete Association Technical Report 550: Design of Floors on Ground British Cement Association Interim Note 11: The Design of Ground Supported Concrete Industrial Ground Floors CIRIA Special Publication 31: The CIRIA Guide to Concrete Construction in the Gulf Region CIRIA Report No. 91 Early Age Thermal Crack Control in Concrete Quality Assurance / Quality Control Contractors proposed quality system shall fully satisfy all the elements of ISO 9001 Quality Systems - Model for Quality Assurance in Design / Development, Production, Installation and Servicing and ISO 9004-1987, Quality Management and Quality System Elements - Guidelines. The quality system shall provide for the planned and systematic control of all quality related activities performed during design. Implementation of the system shall be carried out in accordance with the Project Contract Agreement, Contractors Quality Manual and Project Specific Quality plan. Quality manual as well as project specific quality plan shall be submitted to Company for review, comment and approval. Design Requirements Reference codes and standards All structural engineering design shall be within the parameters of the documents listed above and shall constitute part of this design basis.

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Measurement All dimensions, quantities and units of measurement shown on drawings or used in specifications and calculations shall be in metric units while pipe size may be in inches. Site Survey and Soils Report Company accepts no liability for the information contained in the Site Survey and the Soils Report (if any). Site survey All design shall be in accordance with the horizontal and vertical controls contained in the survey report prepared by the survey consultant. Soils report All design shall be in accordance with the recommendations contained in the soils report prepared by the geotechnical consultant. Basic Design and Drawing Concepts Design and calculations Prior to starting detailed design, a basic design shall be made consisting of: Basic sketch Loading Derivation Calculation Stability check Main Structural members Basic Sketch The sketch shall show the proposed structure (in perspective and / or a series of cross sections). Structural members may be shown as single lines. The sketch shall include the foundations & all other parts of structures in structural steel or in structural concrete. All applied loads shall be shown on the skethch excluding the dead loads. Calculations The calculations shall give the design philosophy and all loads including the dead loads of the relevant structural components. The calculation shall state the loads in the main structural members (axial loads, bending moments, shear and possibly torsion, reactions, deflections) and shall include the upward reaction loads on the foundation (load per unit of area). The calculation shall take into account the soil investigation report. If any computer programs are to be used for the detailed design, these shall be identified during the basic design stage with all required documentation provided to demonstrate their adequacy & sufficiency. Stability Check The stability of the structure shall be checked for both factored and non-factored load combinations. Main Structural Members In the assessment of the sizes and dimensions of the main structural members the most critical load combination shall be considered. Structural details, such as connections of
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steel beams and columns or details of reinforcing steel over the full length of a reinforced concrete beam shall be designed and detailed by the Designer. Standard steel connection details may be designed by the Supplier but must checked by the Designer duly certified by a Professional Engineer. Or equivalent duly registered complying with international standards of EMF. Detailed Design The detailed design shall be based on the basic criteria as well as FEED. The calculation shall clearly indicate: 1. The table of contents 2. Design philosophy employed on engineering assumptions 3. Applicable codes, formulas, graphs / tables 4. References to literature etc. for subjects not covered by applicable codes 5. Loading tables with loads location diagrams 6. If computer programs are used, the following information shall be supplied: a. Logic and theory used b. Analytical model of the structure used for computer analysis c. Users manual d. A hand calculation to prove the validity of the computer analysis except if validated by QA / QC system. e. Loads and load combinations Drawings and related documents Drawings shall be of the standard metric sizes, i.e. A0, A1, A2, A3, A4. The preferred computer aided design system is the software used internationally as well as designers in house developed or other software approved by Company. These shall be suitably prepared to facilitate microfilming and incorporate a numbering and indication of revision system. Dimensions on the drawings shall be in the SI system unless otherwise specified. Levels shall be indicated in metres & all other dimensions in millimeters. Layout drawings shall show the highest point of grade as El. 100.00 and the reference of this level to the local datum level for Process Units, in offsites the actual level shall be indicated. All headings and notes shall be in English. Each drawing shall bear the following information in the title block. Order number of the Company, Name of plant , Name of unit , Name of part of the unit , Example: Order number , Catalytic cracking unit , Compressor building Portal frames Only drawings marked "Released for Construction (RFC)" or Approved for Construction (AFC) shall be used for execution of works every where. This mark "Released for Construction" can be given only by the Designer responsible for design and engineering. Drawings shall be submitted together with the relevant calculations including those required for submission to local authorities. Revisions to drawings shall be identified with symbols adjacent to the alterations, a brief description in tabular form of each revision shall be given and if applicable, the authority and date of the revision shall be listed. The term Latest Revision shall not be used. Claim to all drawings prepared by the Contractor under any order placed by the Company shall be vested in the Company and the later shall have the right to use these drawings for any purpose for this project without any obligation to the Contractor. The Contractor shall not disclose or issue to any third parties without obtaining written consent of the Company any documents, drawings, etc. provided at his disposal by the Company or
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any documents prepared by him in connection with inquiries and orders for purposes other than the preparation of a quotation or carrying out these orders. Structural concrete Plan drawing On this drawing, the general information / data shall be shown as General Notes on the right-hand side or any other suitable location of the drawing. The general notes shall state that: a. Levels are expressed in meters with reference to the highest point of grade b. Dimensions are expressed in millimeters c. Bar diameters are expressed in millimeters Furthermore, the general notes shall list: d. The quality (or qualities) of concrete e. The quality (or qualities) of steel reinforcing bars f. The quality (or qualities) of cement to be used g. Concrete blinding (location, quality and thickness) h. Polyethylene sheeting, if applicable (location and quality) i. The concrete cover on bars (type of construction, location and thickness) j. The list of reference drawings and related documents stating their title and number k. The legend of the Contractors reinforcing bar call out Including an indication for which part(s) each quality is to be used. Detail drawings On each of the detail drawings, the following information / data shall be listed: a. For general notes, see Drawing No. ...... b. This detail drawing refers to Drawing No. ...... c. For bar bending list(s), see No. ......, sheet 1 to ....... d. For weight list(s), see No. ........, sheet 1 to ........ e. Quantity of concrete (for each quality of concrete separately) Bending and weight lists These lists shall always be made by the Designer unless explicitly stated otherwise. The lists shall be prepared on the detailed drawings or on separate sheets. Scale of drawings Plan drawings shall be made to a scale of 1:50 and detail drawings to a scale of 1:20. Structural steel Part of the information / data supplied by the Company may be in the form of one or more instruction drawings. If instruction drawings are provided, all the dimensions shown on these drawings shall also appear on the Contractors drawings. General arrangement drawings These drawing shall show the complete structure to be supplied. All main dimensions and the section to be used shall be included. All members to be fireproofed shall be marked with an appropriate symbol or FP designation. A fireproofing legend shall clearly identify the symbols and designations with the work to be performed. For the preparation of the general arrangement drawing, the Contractor may use a reproducible of the instruction drawing(s). For small and simple structures, this drawing may be combined with the base plate drawing.

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Baseplate drawing This drawing shall show all dimensions and details of the base plate including anchor bolts which be taken into account in the design of the (concrete) foundation. When the need for a slight adjustment of the anchor bolts during erection is expected, this shall be indicated on the drawing. The scale for details shall be at least 1:10. For small and simple structures, this drawing may be combined with the general arrangement drawing. Construction drawings These drawings shall clearly show all constructional details of the structure to be supplied. The location of the various parts in the structure shall be indicated. Scale of drawings Drawings shall be made to an appropriate scale. Bills of material Bills of material shall show the weights of all large members from the viewpont of transportation and erection at site as well as the total weight of the structure. Steel structures Structural steel design shall be carried out in accordance with the relevant project, general specifications and international codes. The plastic design method in the AISC Manual shall not be used in steel design. Steel structures shall be designed for the loads and load combinations allowed In this specification. Normally, only pinned column bases shall be used in the design of steel structures. Use of fixed base plates for certain type of pipe racks and buildings may be necessary because of deflection considerations. Where headroom, access or equipment arrangement permit, wind and other lateral loads on a steel structure shall preferably be transferred to the foundations through vertical X-bracing or K-bracing included on the transverse and longitudinal column lines of the structure. As a second choice, wind and other lateral loads on a structure should be transferred to the foundations through moment resistant frames in one direction and vertical X-braced or K-braced frames in the other direction. Structures that resist lateral load with rigid frame systems in two directions should be avoided. The method of bracing selected for a structure should generally be used throughout the structure. Compression bracing for steel structures shall normally be designed with wide flange and structural tee shapes. For tension bracing, single angle or structural tees may be used. Double angle bracing because of maintenance difficulties shall not permitted for either compression or tension locations. When using structural tees in compression, the design shall include bending induced by eccentrically loaded connections. Braces for structures subject to vibration from equipment shall be designed as compression members. Horizontal bracing shall be provided in the plane of a floor, platform or walkway when necessary to resist lateral loads or to increase the lateral stiffness of the unit. Floor grating shall not be allowed to resist lateral loads in diaphragm action without investigated. In a floor system, beam compression flanges should be considered to be fully braced when a concrete slab is cast to match the bottom face of the compression flanges on both sides or when chequered plate is bolted or welded to the compression flanges or when grating or metal deck is welded to the compression flanges. Grating shall normally be clipped or bolted and therefore, shall not be considered as adequate compression flange bracing. In such cases, additional vertical and / or horizontal bracing in the floor system shall be provided. Bar joist floor and roof systems are generally considered to be too light for heavy industrial plant work. However, when approved by the Designer, bar joist systems may be used on a project.
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Steel Structures shall be designed so that the surfaces of all parts be readily accessible for inspection, cleaning and painting. Pockets for depressions which would hold water shall be provided drain holes or otherwise protected. Connections for steel structures shall conform to the following requirements: Shop connections may be bolted or welded. Field connections shall normally be bolted however, when approved by the Designer, welded field connections may be used. Bolted connections for primary members shall utilize high-strength bolts conforming to ASTM A325 or A490. A minimum of 2 M20 bolts shall be used for all connections. These connections shall be designed as bearing type. Those connections subject to vibration or stress reversal shall be bearing type. Loads for bearing type connections shall be based on threads excluded from shear plane. Turn of the nut method or loadindicator washers shall be used for tightening all connections. Bolted connections for secondary members (e.g. purlins, girts, stair framing. etc.) shall be made with A307 bolts with the appropriate finish. Connections will normally be designed by the Supplier and checked by the Designer in accordance with the project construction specifications and loads shown on the drawings. Moment connections and special connections, however, shall be worked by the Designer duly shown on the engineering drawings. Moment connections can be bolted or welded type depending on the type of structure and situation. The Designer will determine the type of connection to be used for each structure. All shear connections shall be designed and detailed by the Supplier and checked by the Designer. Reactions shall be shown on the engineering drawings or as per the calculation note provided by Designer. Plant area shall have the primary structural connections continuously seal welded except high strength bolted field connections. Primary structural connections include horizontal and vertical vessel supports, beams and columns on major pipe racks, inaccessible maintenance areas, etc. The forces in truss members and all main bracing shall be shown on the engineering drawings with plus signs indicating tension and minus signs indicating compression or as per the calculation note provided by Designer. The minimum thickness of any structural steel plate or bar shall be 10 mm. Gusset plates shall not be thinner than the members to be connected and shall have a thickness of at least 10 mm. Welded steel grating for platform covering shall be 30 mm x 6 mm bearing bars at 30 mm on center. Cross bars shall be twisted square 6 mm on each side and spaced not over 100 mm center to center, hot-dip galvanized in accordance with ASTM A123 and A143 for corrosive environment. E70xx welding electrodes shall be specified for all shop and field welding of structural steel. All welds shall be continuous. All bracing shall be arranged to minimize torsion and where practicable, be arranged concentrically about the resultant line of force. The connections wherever possible, shall be arranged so that their centroid lies on the resultant of the forces those members intended to resist. When the condition cannot be achieved, the members and connections shall be designed to resist any local bending due to the eccentricity of the force. In practice, it is noticed that corroded steel plates and bolts limit the expected movement which may result in additional stresses. The Designer should consider this point to include sequential additional stresses in their design consideration. Steel structures supporting equipment shall be fireproofed where required by risk & safety analysis. Reinforced concrete structures and foundations Cast-in-place or situ concrete structures shall be designed in accordance with ACI 318 except as indicated otherwise in this specification. Cast-in-place or situ concrete structures shall be designed for the loads and load combinations required according to codes & description elsewhere in project
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documents. The working strength or limit state of serviceability design methods shall be used for the structural design of concrete members unless otherwise indicated. Load combinations and load factors for all concrete design shall be adopted in accordance with ACI 318. The design and details of cast-in-place concrete structures shall consider the monolithic nature of hardened concrete. Construction joints in a concrete structure shall be located so as to least impair the integrity and unity of the structure. Construction joints in beams at column or pedestal faces should be avoided. The Designer / Contractor Site Management shall approve the location of all construction joints on site agreement. Moving concentrated loads on elevated concrete beams and slabs shall be treated in accordance with applicable recommendations of the referenced AASHTO specifications. Slabs at grade for buildings and process areas shall be designed in accordance with the publications Concrete pavements for heavy storage areas Underground structures such as basements, rectangular tanks, sumps, and pits shall be designed in accordance with the latest referenced PCA bulletins and / or BS8007. The design of such structures shall include the effects of ground water pressures and buoyancy. A minimum factor of safety of 1.1 for buoyancy shall be used ignoring soil cohesion. Concrete process treatment structures shall be designed in accordance with ACI 350 R. For all liquid retaining structures, special precautions shall be taken for water tightness. All joints shall be fully detailed by Designer. A corrosion allowance of 3 mm shall be required for all anchor bolts. Bolts shall be hot-dip galvanized in accordance with ASTM A123 and A143. Foundation design in addition to the above applicable criteria shall meet the following requirements: Foundations shall be designed in accordance with the project geotechnical (soils) report. Foundations for structures shall be sized and stability determinations made using service loads only. Load factors shall not be included in these design operations. Unless there is a conflict with the project soils report, individual foundations shall normally be used for major equipment. If combined foundations are appropriate, the centroid of the bearing area should coincide with the resultant of the applied operating load (excluding live load). All foundations shall be placed on sealed blinding concrete on firm, undisturbed soil. Some seal slabs, however, may be placed on well-compacted earth fill, if approved by the Designer. In such cases, the engineering drawings shall specify the kind of fill material and the degree of compaction required for the fill material. Spread footings, combined footings and mats should be designed assuming linear soil pressure distribution. Where the rigidity of the foundation is questionable, an analysis considering the interaction between flexibility of the foundation and the subgrade soil reaction should be considered. For mats particularly, this method of analysis may be in order. ACI 336.2 R contains suggested design procedures. Foundations shall be proportioned so as to minimize general and differential settlements. In order to reduce the overturning moment on individual footings of buildings and process structures, the transfer of column base shears into the concrete grade slab should be considered. The frictional resistance provided by the grade slab shall equal at least 1.15 times the applied column base shears. For design purposes, a coefficient of friction of 0.2 may be assumed between the concrete slab and the membrane. If this design approach is used, the grade slab thickness and joint details shall be properly designed. Where seasonal changes in soil moisture content occur extremely, special details may be required to minimize foundation movements. Control of foundation movements is especially critical for masonry structures. The Designer shall determine design parameters to control such movements. The stability ratio (SR) based on service loads for isolated spread footings shall not be less than 1.5 when determined as follows:
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SR = D (P) / 2M = D / 2e Where: D = Diameter or width of footing, P = Minimum gravity load at bottom of footing (exclude equipment and live loads, include buoyancy), M = Maximum overturning moment at bottom of footing, e = Eccentricity = M / P The uplift factor of safety based on service loads shall not be less than 1.25. This factor of safety must be maintained when 70 percent of dead load is combined with no reduction of wind load for uplift. The stability ratio (SR) based on service loads for buildings, process structures and other framed structures shall not be less than 1.5 when determined as follows. SR = Resisting Moment / Overturning Moment Where Resisting Moment = Moment due to dead load of foundation and structure (include buoyancy), Overturning Moment = Moment due to lateral loads The overturning and resisting moments shall be computed about the most critical axis of rotation of the foundation block at the soil / concrete interface. There may be more than one axis of rotation. The stability ratio (SR) of retaining walls based on service loads shall not be less than the following. a. For sustained loading: SR = Resisting Moment / Overturning Moment = 3.5 for cohesive soils = 2.0 for cohesionless material b. For sustained loading combined with temporary loading: SR = Resisting Moment / Overturning Moment = 2.0 for cohesive soils = 1.5 for cohesionless material Where: Resisting Moment = Moment due to dead load of wall and soil overburden (include buoyancy) Overturning Moment= Moment due to lateral loads Resisting moment and overturning moment shall be taken about the toe of the retaining wall and bottom of footing. For all service load conditions, the sliding resistance of foundations especially retaining walls, shall at least be equal to 1.5 times the applied lateral loads. Sliding resistance shall be developed by either friction between the footing and membrane or by passive resistance of shear keys extending below the bottom of the footing in the case of retaining walls. In cases where sliding resistance is developed by a combination of friction and passive resistance, it is recommended that a minimum factor of safety of 2.0 shall be provided. Stability calculations shall include the weight of the foundation concrete and the soil immediately above the footing(s). The effects of buoyancy on the concrete and soil weights shall be considered. Passive earth pressures shall not be included in stability calculations except in the design of retaining walls with keys. In this case, only that pressure acting on the key face shall be considered. Foundation bottom level shall be defined taking into consideration geotechnical (soil) report and other factors to be clearly noted on the drawings. Keep standard bottom of footing elevations where possible. Consideration shall be given to interferences with underground soil systems. General The Region has been defined as being in an Ultra Hot Climate t together with the extremely heavy concentration of chlorides in both the ground and atmosphere together with high humidity that result in the rapid degradation of Reinforced Concrete structures. The degradation of the concrete is principally caused by reinforcement corrosion due to the ingress of chlorides and other aggressive salts, the consequential increased volume of rust produced commonly breaks off the cover on the reinforcement. Failure of the R.C
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member then becomes imminent. The degradation of concrete arises also from the use of salt contaminated materials. The durability and quality of the concrete itself is of paramount importance. Factors to increase durability while designing shall be considered in concrete such as thermal insulation coating measures as recommended in the CIRIA Guide to Concrete in The Gulf Region. Quality of concrete is achieved by good engineering and detailing proper materials and proportioning good construction techniques and concrete curing. One of the main characteristics influencing the durability of concrete is its permeability to the ingress of chlorides, water, oxygen, carbon dioxide, wind blown chloride contaminated dust and other deleterious substances. Coatings shall be applied to all buried and exposed concrete surfaces as an essential protection against attack from chlorides, other harmful elements and to provide the concrete to develop a refined pore structure enhancing impermeability. Coatings shall have crack bridging properties on flexural members. Steel plates shall not be embedded in concrete. The Contractor shall develop a detail that allows attachment of the plates to inserts embedded in the concrete. A detail shall also be developed to ensure an effective seal from exterior moisture is achieved around the perimeter of the plates at the point of intersection between concrete and plate. Crack prevention Crack widths shall be controlled by an expeditious use of combinations of reinforcement sizes, spacing and cover. Crack widths shall be calculated using the applicable formula in BS 8007. The calculation shall be based on the long term, steady state loading. For durability it is not necessary to consider peak loadings although this may affect coating selection for the requirement for crack bridging and flexural performance. Crack widths apply at the surface of the concrete i.e. the full depth of cover shall be utilized in the calculation. Calculation of crack widths shall consider both load (flexural) and restraint (due to thermal and shrinkage effects) induced cracking. In order to reduce flexural cracking to acceptance limits, it will be necessary to use reduced allowable stresses in the reinforcement. Calculation of crack widths shall not use deemed to satisfy options of BS 8007, i.e. do not calculate crack widths on PC and minimum reinforcement ratios. The minimum external restraint factor (R) shall be 0.5. Methods of calculating crack widths in relation to temperature and moisture effects are given in Appendix A - BS 8007. The minimum fall in temperature between hydration peak and ambient (T1) shall not be less than 31 C for walls and 21 C for ground slabs. Seasonal temperature fall (T2) shall be considered where continuous construction is used - BS 8007 - Table 5.1 - Option 1. This shall be not less than 30 C. Crack widths shall be limited as follows. Crack width shall be = 0.15 mm for all buried, submerged and exposed concrete. Crack width shall be = 0.30 mm for all concrete located in an air conditioned and sealed environment. Crack widths shall be = 0.10 for all liquid retaining structures. Reinforcement Use smaller diameter re-bar at closer centers. For sections = 500 mm thick and for the outside 300 mm of large sections, reinforcement shall not be less than 0.35% of the applicable gross cross-sectional area of the concrete section.
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Maximum spacing of reinforcement shall be 150 mm in any direction. Use fabric reinforcement where possible (nested where necessary) as this gives better crack control. Do not bunch reinforcement or use in vertical or horizontal pairs. Reinforcement shall be adequately detailed to eliminate congested areas i.e. laps to be staggered. Place reinforcement nearest to the surface where it is the greatest restrained length which means horizontal wall reinforcement will be on the outside of the vertical reinforcement. Ensure additional diagonal reinforcement is placed at each re-entrant opening to prevent cracks emanating from corners. All reinforcement shall be fully detailed by the Designer on bar bending schedules BBS for fabrication. All concrete sections with a thickness of 250 mm or more, reinforcing bars shall be placed on both faces over the full section. In addition, minimum reinforcement shall be placed in the other two faces. Concrete Cover Adequate cover to the outside of all reinforcement is essential for resistance to corrosion for all types of sections & situations whatsoever.. Minimum Concrete Cover (mm) Concrete cast against or permanently exposed to earth (all below grade structures) and all marine facilities over or in contact with water 75 Concrete exposed to weather (all above grade structures not enclosed by a temperature and humidity controlled building) 60 Concrete not exposed to weather and located within a temperature and humidity controlled building 50 Where any individual structural element falls within two or more categories then the most stringent criteria shall apply for the entire element. Horizontal re-bar in walls and faces of large elements shall be on the outside of the vertical reinforcement for more effective crack control. All concrete cover shall conform strictly with values given above unless noted otherwise on design documents or in the applicable standards. Required covers shall not be reduced by provision of protective coatings, membranes or by membrane protective screed. If fire resistance of more than 2 hours is required, cover shall be as determined in Table 3.5 in BS 8110 Part 1 for the particular element under consideration. Concrete Grades Concrete shall have a minimum compressive strength as given in Specification for Concrete Externals Features Features which collect sand and dust that can form with rain or dew into a corrosive pollutant shall be avoided i.e. decorative patterns with holes and pockets, gutters, ledges and exposed aggregate finishes. Top surfaces shall be designed with falls to encourage run-off drainage. Tops of all pedestal heads shall be sloped 1:20 away from the base plate grout. Top of pedestal shall project a minimum of 100 mm from the edge of the column base plate grout. Dimensions of the concrete columns or foundations are designed taking into account loads applied to & not by reference to geometric dimensions of base plate.
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Minimum pedestal heights excluding grout above top of adjacent paving shall be as follows: Structural Steel columns: 150 mm to 200 mm Equipment (general): 100 mm to 300 mm Equipment (pumps): 100 mm to 300 mm Grout is to be sloped 1:1 away from the bottom outside corner of the column base plate grout. Shear keys shall not be used on pedestals / plinths. Stress Raisers Complicated plan shapes which produce stress shall be avoided. Large and sudden changes of cross-section i.e. wall junctions and counterforts in the middle of bay lengths shall be avoided. Locate joints adjacent to these stress producers or cast in two separate sections. Provide appropriate extra reinforcement where stress producers are unavoidable. Casting-in pipes, box-outs, notches in the middle of bay lengths shall be avoided, Locate joints adjacent to these stress producers if possible. Anchor Bolts For small diameters, Chemical type anchors or cast-in anchors are preferred. Where chemical anchors are used, the hole must be properly cleaned according to Manufacturers instructions. Anchor bolts shall be designed for combined tension and shear as per BS5950. Minimum edge distance measured to outside of tube shall be 100 mm or 4 times the bolt diameter whichever is greater. Shear Keys For standard conventional structures, shear keys shall not be used. For situations where shear keys are required, back up design calculations and justification shall be given for approval. Pits and Tanks As a minimum requirement, the recommendations of BS 8007 - Section 5 Design, Detailing and Workmanship of Joints shall be adhered to regardless whether or not, the structure is liquid retaining. All construction joints shall be designed, detailed and shown on the drawings by the Designer or Subcontractor for Construction with approval of Contractor. Where continuous construction is necessary, the method of Temporary Open Sections as specified in BS 8007 C1.5.5 shall be used. Such open sections shall not be more than 1.0 m containing the Lapped section of reinforcement. The use of sequential bay wall construction shall not be permitted. Unless roofs are insulated, these sections are subject to extremely high daytime temperatures and lower night temperatures. Consideration shall be given to the use of insulation or reflective coatings (e.g. aluminum). All such structures (other than blast resistant structures) shall have an isolated roof slab on a sliding bearing (slip strip or equal approved). Monolithic construction with the supporting wall shall not be considered in such design. Paving For ground slab paving construction, the method used for design and construction shall be by the alternate long strip method using a combination of transverse contraction
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joints (induced or formed). Adjacent longitudinal strips shall be cast with longitudinal tied joints between each strip. The recommendations for slab design and construction shall be complied with the provisions in the following publications:Design of Floors on Ground by Cement and Concrete Assoc. Tech. Report 550. Concrete Industrial Ground Floors by U.K. Concrete Society Technical Report #34. The Design of Ground Supported Concrete Industrial Ground Floors by British Cement Assoc. Interim Note 11. Guide for Concrete Floor and Slab Construction by ACI 302.1R. The location of all joints shall be shown on the drawings with accompanying details of each joint type. Isolation joints are to be provided around all equipment foundations and pedestals. Concrete Masonry Structures The design of concrete masonry structures shall conform to ACI 530 and the UBC. Concrete masonry structures shall be designed for the loads and load combinations specified Grouting All grout materials and application procedures shall be approved by the Designer and the Manufacturer. Sand-cement grout shall not be used for any project. All grouting shall be in accordance with the defined project specifications as well as proprietary standards. Epoxy-based non-shrink grout shall be evaluated by Contractor and the Manufacturer for each application for temperature creep as well as strength and applied in accordance with Manufacturer's specification. Grout material used below base plates for machinery, pipe racks, pumps, pipe supports, etc. shall not be placed higher than the bottom of plate level and sloped outward at a 1:1 slope away from the bottom of the base plate to prevent water accumulation near the base plate as well as to prevent cracking of the grout as a result of corrosion around base plate edge. Contractor shall develop a detail to ensure an effective seal from exterior moisture is achieved around the perimeter of the base plates at the point of intersection between grout and base plates. Fireproofing Fireproofing zones Only specific structures and equipment located within a Fire Proofing Zone (FPZ) shall be fireproofed as described in Specification for Fireproofing Loads Buildings, Process Structures, Pipe Racks, Miscellaneous Plant Structures, Vessels, Exchangers and Tanks The following loads shall be considered: Dead Load a. Soil Load (Include as part of Dead Load) Operating (Product) Load Test Load Live Load a. Sand Load (Include as part of Live Load) b. Surge Load (Include as part of Live Load) Truck Load
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Wind Load Earthquake Load Crane / Impact Load Dynamic Load Thermal Load Erection Dead Load Maintenance Load Miscellaneous / Differential Settlement Load Earth / Hydrostatic Load and Buoyancy Blast Load Future Load The above loads are defined as follows. Dead Load Dead load is defined as the weight of all permanent construction including walls, foundations, floors, roofs, ceilings, partitions, stairways and fixed service equipment. For heavy industrial work, this would include equipment, vessels & internals, pipes, valves, accessories; electrical and lighting conduits, switchgear; instrumentation, fireproofing; insulation; ladders; platforms; and all other similar items. Weight of equipment shall be extracted from the Manufacturers data sheets and include auxiliary machinery, piping. Equipment and piping should be considered empty of product load when calculating dead load. The gravity weight of soil overburden shall be considered as dead load a. Soil Load (Dead Load) Soil loads shall consist of lateral earth pressures. Active and passive coefficients for lateral pressures shall be obtained from the project soils report. Operating (Product) Load (Live Load) The load shall be defined as the gravity load imposed by liquid, solid or viscous materials in vessels, tanks, equipment or piping during operation. Unusual loading that occurs during regeneration or upset conditions shall also be considered. Test Load (Live Load) The test load shall be defined as the gravity load imposed by any method necessary to test vessels, tanks, equipment or piping. When more than one vessel etc. is supported by one structure, the structure need only be designed on the basis that one vessel will be tested at any one time and that the others will either be empty or still in operation. Live Load Live load is defined as the weight superimposed by the use and occupancy of the building or other structure but not permanently attached to it. For industrial design, live load can be defined as the load produced by personnel, moveable equipment, tools and other items placed on the structure but not permanently attached to it. Unless specified otherwise, use the minimum live load values given in the table below. Uniform loads and concentrated loads do not occur simultaneously. Types of Structures Load (kN/m2) Walkways (not used as operating) 2.0 (or 3.0 kN point load) Operating platforms (other than compressor and generator platforms 5.0 (or 5.0 kN point load) Trench covers (non vehicular) 5.0 Roof (min) 1.0 (or 3.0 kN point load)
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Sand on roof (min.) 0.75 Light Storage 6.25 Heavy Storage 12.5 Compressor and generator platforms; Floor framing (Determine from use but never less than) 5.0 Floor Grating and Slabs 10.0* For floor grating and slabs being subjected to a concentrated load from either the installation or removal of equipment Office first aid buildings, guards houses, control room, computer room, electrical equipment room, laboratory room locker room 3.0 Canteens, Lunchrooms, Stairs, Halls 4.0 Library 5.0 Battery rooms 10.0 Mechanical, electrical, instrument workshop building 20.0 Bulk storage 40.0 Stairs and Ramps 2.0 (or 3.0 kN point load) Handrailing ** ** 0.75 kN per linear meter applied horizontally at the top of railing, or a horizontal force of 0.9 kN at any one point. a. Sand Load (Live Load) Sand load shall be additive to live loads only when the area under consideration is used as a work area. A 0.75 kN/m2 load shall be used in the design of flat roofs. The effect of sand accumulating behind walls and upstands shall be considered in the design of the walls and roof (treat similar to snow loading). b. Surge Load (Live Load) Surge loads may occur in some vessels or equipment such as fluid cokers, hydroformers, crackers etc. In such cases, the magnitude and direction of the load will be given in the equipment specification. The project process engineer shall furnish a list of equipment having surge loads and the designer make allowance for such loadings in relevant calculations. Truck Load (Live Load) Structures accessible to trucks shall be designed to withstand the gravity, lateral and impact effects of truck loading. Truck loading shall be HS20 or HS20-44 wheel loading as defined by the AASHTO specifications. It shall be checked where applicable whether maintenance and / or construction equipment loads are governing over HS20 wheel loading. At least one road leading to the main process area(s) shall be designated as a heavy equipment route. Bridges, culverts and other underground facilities shall be designed for the maximum expected loading condition caused by transportation of heavy equipment Wind Load (Live Load) The design wind loads shall be calculated based on a basic wind speed of 145 km per hour at a height of 10 m above the ground for terrain exposure C and a mean recurrence interval of 50 year. For this exposure and recurrence, the value of the importance factor of (I)=1.1. The Designer shall develop specific wind load calculation criteria and procedures using ASCE 7 for various types of structures and equipment for the project. For overhead pipe tracks 4m wide or less, the wind load on the three largest pipes shall be taken into account. For overhead pipe tracks of over 4m wide, the wind load on the four largest pipes shall be taken into account.

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The following tabulated velocity pressures shall be used for calculating design wind forces for the design of all structures, buildings and equipment and their parts, portions and appurtenances for the project. Pressure coefficient Cf = 0.8. Pipe racks 4 m wide or less: Wp = 0.8 qh (D1+D2+D3) or pipe racks wider than 4 m: Wp = 0.8 qh (D1+D2+D3+D4) Where Wp = Unit design wind load on piping qh = Velocity pressure determined at piping elevation h Dn = Diameter of pipe Reference ASCE 7-1993 V - 145 km / hr 50 year mean recurrence, I = 1.1, Exposure C Height Zone Above Grade (m) Z Velocity Pressure in Kg/m2 qz Gust Response Factors Gh and Gz 0-6 107 1.29 6-9 114 1.26 9-12 125 1.25 12-15 134 1.22 15-18 142 1.21 18-24 151 1.18 24-30 164 1.17 30-36 173 1.15 36-45 183 1.14 45-60 198 1.12 60-90 219 1.10 90-120 241 1.08 Increase factors may be used to modify the projected areas of vertical and horizontal vessels (including insulation if any) to allow for attachments such as manholes, nozzles, piping, ladders and platforms. The shape increase factors may be used to modify the projected areas of vertical and horizontal vessels (including insulation if any) to allow for attachments such as manholes, nozzles, piping, ladders and platforms. Use Cf = 0.8. Wind loads shall be separately computed for all supported equipment, ladders, and stairs except for vessels where projected area increase factors have already been accounted for these items. Gust response factors G for main wind resisting systems of flexible buildings, structures and vertical vessels having a height exceeding five times the least horizontal dimension or a fundamental natural frequency less than 1.0 hertz shall be calculated. Calculations shall be based on a rational analysis that incorporates the dynamic properties of the main wind force resisting system. One such procedure for determining gust response factor is described in ASCE No reduction shall be made for the shielding effect of vessels or structures adjacent to the structure being designed. For main wind force resisting systems and walls, use Gh evaluated at the height h (top) of the structure. An exception is in the various structural specifications for equipment, the variable gust response factor Gz is used. For components and cladding, use Gz evaluated at centroid height z above ground. Earthquake Load (Live Load) Earthquake load shall be applicable according to project Location & in conformance to Uniform Building Code (U.B.C.) 1997-Division III-Seimic zone Tabulation Section 1653.
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Crane / Impact Load (Live Load) For structures carrying live loads that induce impact, the live load shall be increased sufficiently. If not otherwise specified, the live load increase shall be following: Category Vertical Load Horizontal Load For supports of elevators (dead and live load) 100% Cab operated traveling crane support girders & and their connections 25% 20% 1 10%2 Pendant operated traveling crane support girders & and their connections 10% Monorails, trolley beams, davits 50% Light machinery, shaft or motor driven 20% Reciprocating machinery or power driven units 50% Hangers supporting floors and balconies 33% 1. Increase the sum of the weights of the rated capacity of hoist, crane trolley, cab and hooks. Apply one-half of the load at the top of each rail acting in either direction normal to the runway rails. 2. The longitudinal force shall if not otherwise specified be taken as 10% of the maximum wheel loads of the crane applied at the top of the rail. 3. Live load on crane support girders shall be taken as the maximum wheel loads. Dynamic Loads (Live Load) Each structure shall be designed to withstand the effects of vibration and impact to which it may be subjected. Each structure and foundation supporting a compressor, turbine, pump or other machinery having significant dynamic unbalance shall be designed to resist the peak loads specified by the manufacturer. Vibration amplitudes of the supporting structure or foundation shall be kept within acceptable limits for dynamic forces that occur during normal machine operation. In the case of a tall and slender structure, there may be a need to investigate the dynamic effects of wind gusts. Centrifugal pump foundations for pumps less than 750 kW do not require a dynamic analysis. However, the foundation to pump assembly weight ratio shall not be less than 3 to 1. Foundations for reciprocating machinery, centrifugal machinery and centrifugal pumps over 750 kW require a three dimensional dynamic analysis. Thermal Load (Live Load) ASCE 7 mentions thermal loads however, the ASCE thermal comments are not geared to heavy industrial work. Thermal loads shall be defined as forces caused by changes in temperature. The primary source of thermal loads in an industrial plant is the expansion or contraction of vessels and piping. Another source of thermal loads in a redundant structure is the expansion or contraction of the entire structure or individual structural components. Provisions shall be made for thermal forces arising from assumed differential settlements of foundations and from restrained dimensional changes due to temperature changes. Thermal loads and displacements caused by operating conditions shall be based on the design temperature of the item of equipment rather than the operating temperature. Design atmospheric temperature ranges from a minimum of 5 deg C to a maximum of 58 deg C. Low friction slide plates (Fluorogold, Teflon / PTFE or an approved equal) shall be used if the vessel operating condition weight is greater than 45 kN at the sliding end. For preliminary design, the temperature drop of 1.9 deg C / mm from the bottom of shell to bottom of saddle may be assumed.
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The following friction coefficients shall be used for calculating frictional restraint due to temperature change or lateral loading on sliding surfaces: Surface Friction Coefficient Steel-to-steel (corroded) 0.35 Steel-to-concrete 0.50 Teflon-to-teflon A straight line variation of 0.17 to 0.08 for bearing Stresses from 0.0 N/mm2 to 0.7 N/mm2, respectively Bearing stress greater than 0.7 N/mm2 0.17 to 0.08 0.08 Graphite-to-graphite 0.15 For computing friction loads due to the effects of pipe expansion in pipe racks, use the following friction coefficients: Number of Lines on Support Friction Coefficient 1 3 0.3 4 - 6 0.2 7 or more 0.1 For a given support, if considering only larger lines and ignoring smaller lines results in greater loads. These forces and associated friction coefficients shall be used instead of considering all the lines. A concrete pipe rack beam shall be designed for an arbitrary horizontal pipe anchor force of 15 kN acting at midspan unless design calculations dictate a higher force and more locations. The pipe anchor force shall not be distributed to the foundations. For pipe anchor forces transferred by longitudinal girders to structural anchors (bracing) an arbitrary force of 5% of the total pipe load per layer shall be taken into account unless design calculations dictate a higher force. These forces shall be distributed to the foundations. Foundations and structures which are subject to temperature effects shall be designed for the various loading conditions and also for any temperature difference which may occur in parts of structural members. a. Anchor and guide forces shall be obtained from the Designers Piping Engineering Department. b. Structural Steel Pipe Supports shall be designed in accordance with Industry Standard Structural Design Methods. Erection Dead Load The erection dead load is the weight of the equipment at time of erection plus the weight of the foundation. The foundation weight is the combined weight of the footing, pedestal, and overburden soil. All possible loading conditions during erection shall be considered and for any member of a structure, the most unfavorable be considered. Heavy equipment lowered onto a supporting structure can introduce extreme point loads on structural members exceeding any operating or test load. After placing of equipment, the exact positioning (lining out and leveling) can also introduce extreme point loads. The above should be interpreted on the basis of contractors practical experience, manufacturers information and allowed for in the design calculations accordingly.
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Beams and floor slabs in multistory structures e.g. fire decks shall be designed to carry the full construction loads imposed by the props supporting the structure immediately above. A note shall be added on the relevant construction drawings to inform the field engineer of the adopted design philosophy. Maintenance Loads (Live Load) Maintenance loads are temporary forces caused by the dismantling, repair or painting of equipment. The force required to remove the tube bundle from a shell and tube heat exchanger shall be assumed to act along the horizontal centerline of the exchanger with a value of 2 times the weight of the bundle but not less than 10 kN. Miscellaneous Loads (Live Load) Miscellaneous loads shall be defined as loads that do not fit into the categories listed in this section. Earth / Hydrostatic Load and Buoyancy (Live Load) Earth and hydrostatic water pressures on retaining walls and underground structures shall be determined. Outward pressures on liquid retaining structures shall also be considered. The buoyancy load is equal to the weight of the volume of displaced water. Blast Load (Live Load) Negligible Blast Buildings located more than 610 m away from the potential explosive sources do not require special provisions with regard to explosion resistance. Blast Resilient Buildings within the 200 m to 610 m distance from potential explosive sources shall be designed to the same loading conditions as specified for buildings beyond the 610 m zone and in accordance with the following design concepts: The building structural frame, roof, walls, bracing and connections shall be designed in such a manner that large plastic deformations of the major frame members as well as external wall panels will be allowed to occur without causing partial or total building collapse. Blast resilient buildings shall be designed and detailed in accordance with ACI 318, Chapter 21, Special Provisions for Seismic Design. The building frame shall comprise of reinforced concrete or structural steel. The building walls shall be constructed as reinforced concrete, reinforced masonry with concrete filled cells or properly designed carbon steel cladding system. Walls for these buildings shall not be used as mainframe members or to provide structural stability and / or structural strength. The building roofs shall be constructed of monolithic reinforced concrete or a properly designed carbon steel roofing system. Loose lightweight concrete roof slabs or asbestos cement sheeting shall not be used. Gravel as a protection of roofing finish or loose tiles for walkways on top of the roof finish shall not be used. For steel structures, structural steel bracing in roof and walls shall be provided. Materials with a brittle behavior such as masonry shall not be used in such a way that provides strength. For additional architectural construction requirements, refer to Specification for Architectural Design Basis (Not included)

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Blast Resistant Buildings within 200 m distance from the potential explosive sources may be designed to withstand the anticipated blast effect. The blast loads or pressures to be used for the design of various structural elements shall be calculated in accordance with an acceptable method taking into account the dynamic response. The calculated blast loads shall not be less than the following equivalent static loads acting inward or outward perpendicular to the surface: External Walls 100 kN/m2 except loads on doors and windows which may be assumed to be 30 kN/m2. Blast loads on the roof slab is dependent on the span between supports. 50 kN/m2 for span of 3m 45 kN/m2 for span of 4m 40 N/m2 for span of 5m 35 kN/m2 for span of 6m 30 kN/m2 for span of 7m 25 kN/m2 for span of 8m and over It is to be assumed that the blast loads will act simultaneously on and over one wall and the roof. These loads act with applicable dead loads. Suction on walls and roof shall be 50% of the above-mentioned static loads and it is to be assumed that these loads will act simultaneously on one wall, the roof and not in combination with above-mentioned loads. Structures shall be detailed in accordance to ACI 318, Chapter 21 Special Provisions for Seismic Design. Pre-stressed concrete shall not be used. In general, special attention shall be paid to ensure continuity and a minimum of local stress concentration. Adequate lapping of reinforcement is required. The following provisions shall supersede ACI 318, Chapter 21 for Blast Resistant structures: The concrete walls and slabs shall be reinforced each side in the main direction with a minimum of 0.6% in the case of steel bars with a yield strength of 410 N/mm2 and a minimum elongation of 14%. In the other direction on both sides, a distribution reinforcement of at least 20% of that in the main direction shall be applied. Maximum spacing of bars shall be 150 mm center to center. It is preferable for the wall and roof thicknesses to be between the limits of 250 and 400 mm in order to facilitate the placing of the required reinforcing bars. Shear reinforcement shall be applied in beams only being a combination of stirrups and horizontal sidebars: web reinforcement. When the actual shear stress (V) is less than 1.3 N/mm 2 (Vc1): no web reinforcement is required. When the actual shear stress (V) is more than 1.3 N/mm 2 (Vc1) but less than 4.5 N/mm2 (Vc2): web reinforcement shall be required for (V-Vc1) N/mm 2. Where: V = Actual shear stress Vc1 = Concrete shear stress lower limit Vc2 = Concrete shear stress upper limit At least 50% of the bottom main reinforcement shall extend over the face of the support providing a good anchorage between the supports. Wind or earthquake loads shall not be combined with blast loads. Future Load (Dead or Live Loads) Future loads including pipe rack extensions and building expansions shall be considered when so directed by the Company.
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Load Combinations Piles, structures and members of structures as well as their support and fixing points shall be designed for various loading combinations given in the following tables: Load Description Abbr. Weight of Structure DL Empty Weight of Vessels and Equipment DLempty Operating Load LLop Hydrostatic Test Load Test Live Load LL Moving / Truck Load LLmove Wind Load WL Earthquake Load EQ N/A Crane / Impact Load CR Dynamic Load DY Thermal Load TL Erection Load ER Maintenance Load ML Differential Settlement DS Earth / Water Pressure HY Blast Load BL Loads shall be combined as specified below. Concrete bund walls shall be designed for accidental load condition when the bund is completely filled with water to the crest. Only the hydrostatic fluid acting in the outward direction and gravity loading need to be considered. The factor of safety shall not be less than 1.3 for this loading condition. Load Combinations A through G: Primary Operation Test Erection Earthquake Maintenance Blast Loads without wind with wind ABCDEFG DL x x x x x X x DLempty x x1 x x x X x Test x LL x x x x x X Crane x x x X LLop x x 1 x LLmove x x x X WL x x 3,4 x 4 EQ N/A DY x x x2 X TL x x X ER x ML x DS x x x X x HY x x x x X x BL x 1. The most unfavorable load combination shall be taken into account. 2. Only if the structure supports rotating equipment that will be in operation while a vessel is being tested with water. 3. Only 50% wind load shall be taken into account.
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4. The effect of wind forces acting on temporary scaffolding erected during construction or later for maintenance which will be transferred to the vessel or column shall be considered. When considering these effects, the actual projected area of the scaffold members together with the correct shape factor and drag coefficient should be used. As an initial approximation, the overall width of the scaffolding itself can be taken as 1.5 m on each side of the vessel or column with 50% closed surface and shape factor 1.0. 5. Blast condition shall be taken into account for the blast resistant design of buildings where applicable. 6. In the ultimate limit state design, due regard shall be given to the different load factors for the various load combinations and the adverse or beneficial effects of the basic load cases. Where imposed loads (live loads) have a beneficial effect, they shall be zero. Structural Materials The general types of material to be used are defined below : Structural Steel The furnishing, fabricating and erecting structural steel and miscellaneous steel shall be in accordance with Design General Specifications. Structural steel shapes and plates shall conform to ASTM A36 or to BS 4 or BS 4848 or BS EN 10025. Cast-in-Place or situ Concrete Cast-in-Place or situ Concrete shall have a minimum compressive strength in accordance with Specification for Concrete Supply. Upon the approval of Company, higher strength concrete may be used. Precast concrete shall be carried out only with approval of Company. Reinforcing Steel Requirement to prevent stray current corrosion of steel in concrete (due to implementation of impressed current Cathodic Protection to the nearby underground installation) is to be in accordance with Specification Material Selection and Corrosion Monitoring Philosophy Reinforcing steel shall conform to BS 4449 Grade 460. Epoxy coating shall not be applicable where Cathodic Protection CP is provided. Welded wire fabric shall conform to BS 4848. Epoxy coatings shall not be used. Reinforcing is not required to be electrically continuous for any future cathodic protection of concrete structures. Concrete Masonry Mortar shall be Type M mortar (fc = 17.3 N / mm2) conforming to ASTM C270. When determining allowable mortar stress, assume no inspection. Concrete blocks shall be Grade A, hollow-unit concrete blocks (fc = 9.3 N/mm2) conforming to ASTM C9O. Reinforcing steel shall conform to BS 4449 Grade 460. Anchor Bolts Anchor bolts shall conform to ASTM A36. Minimum size bolts for structural columns and typical equipment shall be 20 mm, 16 mm bolts may be used for small pumps and handrails. Anchor bolts shall be galvanized in accordance with ASTM A123 and ASTM 143. In special cases where A36 anchor bolts are not sufficient, ASTM A193 Grade B-7 shall be used. Paint (only) for these high strength bolts may be used upon approval of the Designer.
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Handrail All handrail shall conform to ASTM A36. Welding shall conform to the AWS D1.1. All welding electrodes shall meet filler metal requirements given in AWS D1.1. The electrode material shall be E70XX. Grating Grating shall conform to ASTM A569 or BS 4592. The grating size and method of attachment shall be indicated in the project specifications. Grating and fixing material (clips) shall be hot-dip galvanized in accordance with ASTM A123 and A143. Floor Plate Chequered floor plate shall be four-way raised pattern steel plate with a thickness of 10 mm. Plate material shall conform to ASTM A36. Bolts The following bolts shall be used for all connections unless higher strength bolts are required and noted on the drawings: Bolts 20 mm and larger shall be high strength ASTM A325M or A490M; Bolts 16 mm and smaller shall be in accordance with ASTM A307. Anchorage of low temperature equipment (-50C) on steel structures shall use ASTM A320.L7 bolts. Unless noted otherwise on the drawing, bolt size shall be as follows: For main members: 20 mm (min) For railings and ladders: 16 mm (refer to applicable standards) For ladder cages: 12 mm (refer to applicable standards) For stair treads: 8 mm (refer to applicable standards) High strength bolts shall be installed in accordance with AISC. Grouting All grout materials and application procedures shall be used in accordance with Specification for Grouting. Embedded Items All embedded items shall be ASTM A36 material and be hot-dip galvanized. Contractor is to develop a detail which effectively seals the junction of embedded items and concrete for Company approval. Allowable Stresses Structural Steel Allowable stresses specified in AISC specifications shall be used for the design of structural steel. Cast-in-Place Concrete The allowable stresses specified in ACI 318M shall be used in the design of concrete. Masonry The allowable stresses specified in ACI 530 and UBC shall be used for masonry design. Anchor Bolts and Base Plate Bearing 1. The allowable stress for anchor bolt shall conform to AISC and ACI Specifications. Neither probability factors nor allowable stress increases shall be used for anchor bolt design. The calculated bolt diameter required to resist specified design loads shall be increased 3 mm to provide an allowance for corrosion. 2. Permissible bearing stress under base plates shall be as given in ACI 318 Code. Stress Increase The allowable stresses specified in the applicable codes given above for structural steel, concrete and masonry shall apply for all design with the following exceptions: The increase in allowable stresses for all structural elements and their connections: 20% - Test without Wind Load 33% - Including Wind
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Test Load Factor for Concrete Design Deflection and Vibration Allowable Deflections The following sections give normally permissible deflection limits for steel and concrete structures. The functional requirements of the structure may impose stricter limits. Systems should be reviewed for possible incompatible deflection behavior in piping, equipment or building components and support deflections. Beam Deflections (Based on Live Loads Only) Maximum allowable deflection for beams supporting floor systems and equipment shall be as follows: Max deflection = L / 500 L = Span Maximum allowable deflection for beams supporting brittle finishes such as plaster ceilings shall be as follows: Max deflection = L / 360 L = Span Maximum allowable deflection for purlins supporting roof system shall be as follows Max deflection = L / 400 L = Span Maximum allowable deflection for cantilever beams shall be as follows: Max deflection = L / 400 L = Overhang Length Maximum allowable deflection for beams supporting steel platforms, staircases, pipe racks, etc. Max deflection = L / 300 L = Span Crane Runways Max deflection = L / 300 L = Span Overhead Traveling Max deflection = L / 600 L = Span Monorails Max deflection = L / 400 L = Span Lateral Sway Maximum allowable sway of buildings or structures shall be as follows: Max deflection = H / 300 H = Height - if equipment supported H / 200 H = Height - If equipment not supported Maximum allowable sway for pipe racks shall be as follows: Max deflection = H / 200 H = Height Maximum allowable deflection for wall stanchions shall be as follows: Max deflection = H / 300 H = Height h = height of story or height of structure These limits apply to sway between stories and to the structure as a whole. Grating = L / 250 (Maximum span 1.6 meter) Vibration Superstructure Vibration The primary source of vibration in superstructures is harmonic unbalanced forces generated by rotating or reciprocating equipment. The final design should be such that vibrations will be neither intolerable nor troublesome to personnel and not cause damage to the machine or structure or adjacent foundations, structures or services. As a general rule, none of the natural frequencies of the structure should be within a band of the operating frequency of the supported machinery. The band recommended to be avoided is 1.414 above operating frequency and 0.707 below operating frequency. To find structural natural frequencies, a computer analysis shall be required.
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All natural frequencies below 2 times the operating frequency for reciprocating equipment and below 1.5 times the operating frequency for rotating equipment shall be calculated. It shall be demonstrated that the amplitudes at the natural frequencies between 0.35 and 1.5 times the operating frequency are within the allowable values even assuming that, due to differences between the actual structure and the assumed model, resonance does occur. In this case a reasonable amount of damping should be estimated. Resonance condition requires a detailed three dimensional dynamic analysis. Once a model analysis has been conducted, a harmonic response analysis shall be performed. The response analysis will indicate anticipated amplitudes of vibration, velocity, and acceleration as well as magnitudes of forces in structural members. From the above information, the adequacy of the design can be evaluated and if necessary, modifications may be made. The maximum vibration amplitude of the equipment shall not exceed the lower of the following values: a. The maximum allowable values stated by the manufacturer of the equipment. b. The amplitude (single amplitude) which causes the effective velocity of vibration to exceed: 2 mm / s at the location of the machine bearing housings 2.5 mm / s at any location of the structure c. The dynamic amplitude of any part of the foundation including any reciprocating compressor shall be less than 80 m single amplitude (80 x 10^-3mm). The effective velocity is defined as the square root of the average of the square of the velocity, velocity being a function of time. In the case of a pure sinusoidal function the effective velocity is 0.71 times the peak value of the velocity. The depth of a steel beam supporting large open floor areas free of partitions or other sources of damping should not be less than 1/20 of the span to minimize perceptible transient vibration due to pedestrian traffic. Foundation Vibration The Designer shall determine which vibrating equipment is to be analyzed by dynamic analysis. Dynamic Analysis For foundations for reciprocating machinery, centrifugal machinery and centrifugal pumps 750 kW or over, a three dimensional dynamic analysis must be performed. Foundation vibration generally involves a grade foundation designed to support one or more reciprocating or rotating machines. Generally the same considerations for superstructure vibration also apply to foundation vibration. The primary differences are that these foundations are often rigid blocks and that soil behavior must be considered. Rigid foundations supporting only one major machine can readily be analyzed using hand calculations and the concept of elastic half-space theory. For flexible foundations or foundations with many machines, a computer analysis should be utilized along with the concept of elastic half-space theory. The Designer shall prepare an instruction for foundation vibration analysis which contains current state-of-the-art approaches, soil information, machine information, dynamic analysis aids, published response criteria, example solutions, and a comprehensive list of references. The dynamic amplitudes of any part of the foundation including any reciprocating compressor shall be less than 80 m (80 x 10^-3 mm) single amplitude.
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For the dynamic analysis, the exciting forces shall be taken as the maximum values that according to the Manufacturer of the equipment will occur during the lifetime of the equipment. When the exciting force is not given by the Manufacturer, it shall be determined from Q(kN) = [Rotor Speed (rpm)/6000] x Rotor Weight (kN) The dynamic calculations shall be based on a mechanical model wherein the weights and elasticity of both structure as well as foundation and the weight of the equipment to be represented in an appropriate way. All natural frequencies below 2 times the operating frequency for reciprocating equipment and below 1.5 times the operating frequency for rotating equipment shall be calculated. It shall be demonstrated that the amplitude of the natural frequencies between 0.35 and 1.5 times the operating frequency are within the allowable values even assuming that, due to differences between the actual structure and the assumed model, resonance does occur. In this case, a reasonable amount of damping should be estimated. The natural frequency of the supporting structure shall not coincide with any resonant frequency of the equipment. The static deformation for rotating equipment foundations shall be calculated and shown to be within the limits stated by the Manufacturer of the equipment. The calculations shall include but not be limited to the following causes of deformation. Shrinkage and creep of concrete. Temperature effects caused by radiation and convection of heat or cold generated by machinery, piping, and ducting. Elastic deformation caused by changing vapor pressure in condensers. Elastic deformation caused by soil settlement. Non-Dynamic Analysis For installations that do not warrant a dynamic analysis, (equipment weight less than 5000 kN), the mass ratio concept is commonly used. In the design of equipment foundations subject to vibratory loading where dynamic analysis is not performed, foundations shall be proportioned as indicated below: Rotating equipment mass ratio = weight of concrete / weight of machine > 3 Reciprocating equipment mass ratio = weight of concrete / weight of machine > 6 Miscellaneous Design Data Clearances and accessibility Minimum clearances for Equipment, Structures, Platforms and Supports shall be in a accordance with the table in Specification for Design, Layout and Drawing Coefficients of Static Friction Coefficients of static friction for various material combinations are listed as follows: Steel to steel Smooth, dry surfaced 0.3 Oxidizing steel 0.5 Steel to concrete or grout 0.5 Fluorogold, Teflon / PTFE and other similar materials as per Manufacturer's recommendations Concrete to foundation materials Clean sound rock 0.7 Clean gravel, gravel-sand mixtures, coarse sand 0.55
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Clean fine to medium sand, silty medium to coarse sand, silty or clay gravel 0.45 Clean fine sand, silty or clayey, fine to medium sand 0.35 Fine sandy silt, nonplastic silt 0.30 Very stiff and hard residual or pre-consolidated clay 0.40 Medium stiff and stiff clay and silty clay 0.30 Membrane sheet 0.20 Engineering Maintenance Manual The Designer shall prepare a detailed maintenance manual for use by the operators. The manual shall contain the following information: Design Basis A brief description of the basis of design of all foundations, structures and buildings, including reference to the detailed calculations for each to enable them to be retrieved if necessary. Inspection Recommendations for the routine inspection of works to enable the early detection of potentially dangerous deterioration including guidelines regarding the symptoms to be looked for such as locations and types of cracking which could be found in reinforced concrete structures etc. Routine forms for inspection are to be established. Materials A detailed listing of all materials used (both generic types and Manufacturers' details) in the works including concrete mix constituents, concrete surface coatings, steel grades, painting details etc. to enable the Company to obtain compatible materials for future maintenance. Maintenance and Repair Procedures Details of recommended repair procedures for common types of failure such as breakdown or mechanical damage to concrete surface coatings, cracking of small foundations plinths due to reinforcement corrosion etc. Finishing Material Manual Additional list of all finishing materials used in the project buildings including material catalogs and sources to enable the Company to obtain such material or equal for future maintenance. Operational Requirements Concrete asset management system (CAMS) In view of the continuous deterioration of reinforced concrete structures in plants, a computerized database system shall be developed by the Company to carry out periodical inspections and monitor the evaluation of disorder, if any. Data related to new structures / foundations is required to be entered by the Contractor in the system in accordance with the existing procedure. Existing settlement check survey program An existing computerized monitoring system for tanks and critical foundations carrying large loads, rotating equipment foundations etc, shall be developed by the Company. As a result of this ongoing program, new tanks and critical foundations shall be required to be monitored for future maintenance.
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The Contractor is required to provide the following: 1. Permanent bench marks to allow for future check surveys. 2. List of tanks and critical foundations / structures proposed for monitoring. 3. Monitoring devices (non-corrosive material) embedded in the concrete foundations and fixed on the tanks as required. 4. Plot plans showing locations of the monitoring points and the permanent bench marks. 5. A computerized form filled with the first readings of the monitoring points surveyed at the completion of the Project. Corrosion monitoring system for critical concrete structures Some critical concrete structures due to operational requirements cannot be shut down for inspection. A new technology exists which allows for installation of metal sensors into concrete structures in order to monitor the corrosion risk at regular intervals. In this way protective measures can be taken before excessive damage occurs and without the need of a shutdown for inspection. The following structures are given as an example of the types of structures to consider for installation of the sensors: 1. Below ground culverts 2. Outfall structures 3. Brine tanks 4. Below ground tanks such as sulfur pits 5. Reinforced concrete or pre-stressed pipes Contractor is required to propose to Company the corrosion monitoring system to be used and to propose to Company the critical structures which should be equipped with the system. Contractor then is responsible to install the agreed system to structures. Units Of Measurement All dimensions, quantities and units of measurement shown on drawings or used in specifications and calculation sketches shall be given in metric units except pipe size which shall be given in the English units of inches. Refer to Basic Engineering Design Data. Contractor shall design all buildings to adequate dimensions (lengths, widths and heights) to accommodate the necessary requirements inside. However the following minimum criteria shall be followed. The corridors connecting the rooms within the buildings shall be wide enough to allow possible movement of equipment. The clear height of room from finished floor level to finished ceiling levels shall be minimum 3500mm. The space between equipment and walls shall be wide enough for a technician to walk around with tools, instruments, etc. (Refer to Company / Client Electrical Specification) and carry out the necessary inspection/maintenance works. The external doors of the building shall be minimum 2400mm wide x 3000mm high plus a 300mm transom. The internal doors shall be 1100mm wide x 2100mm high. The HVAC system shall be Direct Expansion (DX) Split System ducted and adequately sized for the heat load inside the buildings. Contractor shall follow the requirement of space between equipment and walls as per Company / Client Electrical Specification All Civil/Buildings works shall be of construction type as indicated below; Pump Pits (Sub-Structure) shall be of reinforced concrete complete with impressed current cathodic protection
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Receiving Basin shall be of reinforced concrete complete with impressed current cathodic protection Outfall Structure shall be of reinforced concrete complete with impressed current cathodic protection Discharge Channel shall be of reinforced concrete complete with impressed current cathodic protection. Bottom slab of discharge channel shall be constructed with reinforced concrete. Pump Houses -steel frames with profiled metal sheet cladding with hot rolled steel section for all structural members. Metal sheeting shall be protected with lightning protection rods to avoid puncturing. Electro-chlorination and Electrical Switchgear Building - Reinforced concrete with block work panel and storage area shall be structural steel framing and metallic roofing and siding complete with protection against lightning. Electro chlorination building shall be fully covered structure steel building with metal sheeting and provided with transulent sheet for lighting. 33kv Electrical Switch Gear Building for PH- Reinforced concrete frames with block work panels. VSDS Substation for PH- Reinforced concrete frame with block work panels. VSDS Substation for PH- Reinforced concrete frame with block work panels. Operation Building - Reinforced concrete frame with block work panels. Local Lot Control Buildings - Reinforced concrete frame with block work panels. Contractor to design all LLCCs for Phases and to construct only Phase LLCCs. Gate Houses - Reinforced concrete frame with block work panels. Workshop Building - Structural framing with metallic roofing, complete with translucent sheets and lightning protection. Contractor shall allow for 3m high perimeter block wall and panels for offices and other rooms. Warehouse/Workshop Building - Structural framing with metallic roofing complete with translucent sheets and lightning protection. Contractor shall allow for 3m high perimeter block wall and panels for offices and other rooms. Control Building (Extension) - Reinforced concrete frame with block work panels. 220 kv GIS Building Reinforced concrete frame with block work panels. Transformer Pens Transformers shall be supported on reinforced concrete foundations in a room having two sides as a minimum covered with firewalls and front side with fence provided with gates. Top of transformer pen has to be covered with metal sheeting. Foundation for Analyser houses. All concrete exposed to seawater or saline ground water shall be provided with additional protection as appropriate, including cathodic protection to the reinforcement, water proofing system, extra cover to the reinforcement, use of admixtures in the concrete and protective paint on the surface of the concrete. Corrosion Inhibitor shall be added to the structural concrete mix at the minimum rate of 10 lt / m3 for Pump Pits, Receiving Basins, discharge channel, outfall structure and to all structure foundations within water table or and below 0.0m NHD. The list of required buildings and their conceptual drawings with finishing material schedule are provided. These building drawings are conceptual and have been developed based on preliminary building requirements and equipment sizing developed during the Front End Engineering Design. Contractor shall examine the drawings in detail and shall modify the drawings as necessary to accommodate final equipment selection and operational requirement. Material Specifications
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The selection of material is based on Project Specifications and any deviations shall be subject to Company / Client's approval. Contractor shall import rock for outfall structure. The quarry shall be subject to Company / Client approval. Concrete as Specified in project specification shall have fly ash, microsilica, corrosion inhibitor and the course aggregate shall be of Gabro type. HVAC and Plumbing HVAC HVAC system design and sizing shall be by Contractor in accordance with Project Specifications and all auxiliary systems and equipment shall be provided by Contractor. Operation building HVAC System The operation building shall be air conditioned by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on operation building roof. The specification for DX Condensing Units / AHU's shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with back draft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHUs. Twin duty / standby auto changeover fans shall be used for toilets, pantry and Battery room exhaust. Battery room twin fans shall be eexcl IIC, T6, non sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries. All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver.VSDS Substation building PH, PH and 33 Kv switchgear Building HVAC system. The VSDS Substation Building PH, VSDS Substation Building PH and 33 kv Electrical Switchgear building shall be air conditioned by independent HVAC system for each building. Each building shall be air conditioned by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on respective building roof. The specification for DX Condensing Units / AHUs shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with back draft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHUs. Twin duty / standby auto-change over fans shall be used for Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries. All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver. Electro Chlorination Building HVAC System. The chlorination cells building and electrical substation building within Electro Chlorination Building shall be air conditioned by independent HVAC systems. Each sub building shall be air conditioned by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall
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be supplied by 100 % capacity duty / standby air handling units mixing fresh air and recirculating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on electro chlorination building roof. The specification for DX Condensing Units / AHUSs shall be as per the Company/Client specification and other standards. Each AHU shall have a centrifugal fan chamber with back draft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHUs. Twin duty / standby auto-change over fans shall be used for Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries. All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver. Control building (extension) HVAC System. The control building (extension) shall be air conditioned independently by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and recirculating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on control building (extension) roof. The specification for DX Condensing Units / AHUs shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with back draft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHUs. Twin duty / standby autochange over fans shall be used for toilets, pantry and Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries. All fresh air intakes shall have sand trap louvers / Pre-filters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver. The conversion of existing two rooms in to Laboratory in existing control room is foreseen during the FEED design. Contractor shall re-balance the complete Existing HVAC system for Ground Floor to accommodate the ventilation and cooling requirement of laboratories. For Construction of the Control Room Extension, the existing HVAC condensing units shall be either relocated and connected to Ground floor existing AHUs or secured to allow the construction of First floor works without any disturbance to the function of ground floor HVAC system. Upon completion of first floor construction the new condensing units for existing ground floor along with first floor shall be installed on the first floor roof and connected to the respective AHUs. Local Lot Control centres HVAC System. The Local Lot Control Centres Buildings shall be air conditioned independently by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on respective building roof. The specification for DX Condensing Units / AHUs shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with
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backdraft and volume control / shut off dampers. The AHU fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHUs. Twin duty / standby auto-change over fan shall be used for Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries. All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver. Workshop / Warehouse building HVAC System All Offices and Electrical room in workshop / warehouse building shall be treated with wall mounted split units. Air-cooled condensing units shall be located on external walls. Vendors standard Indoor units shall be suitable for wall mounting. Chemical / sensitive materials store (s) within warehouse shall be air conditioned independently by duty / standby Direct Expansion (DX) Package units to ensure 100% redundancy. Total 100 % treated fresh air shall be supplied by 100 % capacity duty / standby Package units. The duty / standby Package units shall be located outside workshop / warehouse building on ground. The specification for Package Units / AHUs shall be as per the Company / Client specification and other standards. Each Package unit shall have a centrifugal fan chamber with backdraft and volume control / shut off dampers. The Package unit supply air fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the Package unit. Electric heating coils and steam humidification sections shall be provided in the Package units air handling section. Twin duty / standby auto-change over fans shall be used for Chemical / sensitive materials store (s) Pantry and Toilets room exhaust. Chemical / sensitive materials store (s) twin fans shall be eexd IIC, T6, non-sparking type. Warehouse storage area for Mechanical items and Electrical Cables shall be ventilated by 100 % capacity duty / standby exhaust fans installed on roof and air intake through wall opening at low levels. Wall opening at low level shall be with sand trap louvers and G4 pre filters. Workshop area shall be ventilated by 100 % capacity duty / standby exhaust fans installed on roof and air intake through wall opening at low levels. Wall opening at low level shall be with sand trap louvers and G4 pre filters. Workshop building HVAC System Offices area within workshop building including electrical room, electrical workshop, instrument workshop, tool room, spares parts room, HVAC room and corridor shall be air conditioned independently by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located outside workshop building on ground. The specification for DX Condensing Units / AHUs shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with backdraft and volume control / shut off dampers. The AHU fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each.

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Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHUs. Twin duty / standby auto-change over fan shall be used for Toilets, Pantry rooms and Locker rooms exhaust. All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver. Workshop area shall be ventilated by 100 % capacity duty / standby exhaust fans (i.e Four 50 % capacity fans) installed on roof and air intake through wall opening at low levels. Wall opening at low level shall be with sand trap louvers and G4 pre filters. Gate house HVAC System Gate House Building (s) offices shall be air conditioned with cassette type ceiling mounted split units. Air-cooled condensing units shall be located on external walls or on gate house roof. Vendors standard Indoor units shall be suitable for wall mounting. Twin duty / standby auto-change over fans shall be used for Toilet exhaust. 220 kv switchgear and control buildings HVAC System The 220 kv Switchgear and Control building shall be air conditioned by independent HVAC system for each building. Each building shall be air conditioned by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and recirculating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on respective building roof. The specification for DX Condensing Units / AHUs shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with backdraft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHUs. Twin duty / standby auto-change over fans shall be used for Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries. All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver. Plumbing For all Buildings Contractor shall design, furnish, install and place in satisfactory operation a chemical waste sewer system with utilities for wash down of the Battery room. The Battery room chemical waste sewer shall be provided with floor drain and be piped to a local storage system for truck removal. Plumbing facilities including number of equipment and fixtures, and their capacities shall be developed by Contractor in accordance with Project Specification. Contractor shall allow for the design, supply and installation of eyewash, complete with plumbing and drainage works for all Battery rooms and electro-chlorination area. The list of required buildings and their conceptual drawings with plumbing arrangement are provided. These plumbing drawings are conceptual and have been developed based on preliminary building requirements and sizing developed during the Front End Engineering Design. Contractor shall examine the drawings in detail and modify the
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drawings as necessary to accommodate final sanitary equipment selection and operational requirement. Roads In principle no road cutting is allowed in the State. However, cutting for road / utility crossings for cooling water pipe work, identified within the Scope of Work, is acceptable to Company / Client. For these crossings, Contractor to design, procure and construct approved road diversions, so as not to disrupt traffic at any time. Contractor shall reinstate roads / tracks / ground to its original specification / condition. For all other crossings, Contractor shall design and construct road crossings by way of horizontal drilling without cutting the main asphalted road and without disturbing the traffic. All pipe crossings for existing roads and corridors shall be made through micro tunneling or cut & cover method depending on the availability of the micro tunneling equipment. Road design and construction shall be according to National Highway Design. Road markings / road signs to be provided in both local language and English. Crash barriers along culvert, bridges, change of road direction and along embankments such as ramps. Overhead steel pipe to be painted with sign warning and clearance. Marking road edges. Flush kerb-stones shall be allowed for at change of road construction and change of road direction. Considerations for final grading and surface drainage shall allow excess water to flow into open drainage and shall include the following: The open ditch system should be connected to the storm water basin. The water can be re-routed to the sea. Roads, other areas as necessary to be paved. In case of heavy rainfall, all building and equipment areas should be accessible. Road levels shall be higher than the adjacent graded level (as a minimum 500mm above FGL) Detailed engineering should be developed by the Contractor for the following: Construction lay down; including temporary facilities; warehouse area; construction camp; site offices for Company / Client and Contractor. Access road to Company/Client site offices shall be asphalted. Parking, road marking, traffic signs & information in both local language and English Handling Devices Structures. Rising pipes should be installed on structural steel pipe racks. Road and utility crossing by indicated approximate sizes and elevation to NHD shall be prepared by Contractor. Minimum requirement of clearance between walls, bottom slab and sofit of top slab and pipe shall be 600mm. Also note that 5.5m minimum clearance is required between roads whether existing or / and new and bottom of structures supporting pipes in utility crossings. For consumer utility crossing involving any combination shall be designed and built by Contractor. Contractor shall design all the pipe bridges and utility crossings required for Phase and construct only Phase bridges. Minimum clearance shall be as indicated on FEED drawings (6m). Pipe Bridge Crossing Over Existing and New Discharge Channel Contractor shall design and construct series of concrete support frames to support pipelines over the new and existing discharge channels. The corridor crossing occurs
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just up stream of the road bridge. Contractor to construct the foundation for the Pipe Bridges, each end user shall construct their own steel truss bridges for carrying pipes. The required conceptual drawings Pipe Bridge are provided. These drawings are conceptual and have been developed based on preliminary requirements and sizing developed during the Front End Engineering Design. Contractor shall examine the drawings in detail and shall modify the drawings as necessary to accommodate final pipe sizes and routing. Oil Spill Control Equipment Contractor to design and construct Oil Spill Control Equipment based on the SOW (Scope of work) provided, however the SOW provided is based on the preliminary requirement of Company / Client, and the same to be modified based on the one constructed at Phase for Pump House Electrical Engineering The Phase of the project shall derive power at 220kv from a new 220kv substation, as further detailed below. Power Supply for Local Lot Control Centers located at the Consumer premises receive and distribute Power at 415V. At intermediate locations, power supplies for Local Lot Control Centers shall be derived from the existing 11kv network, by providing 11kv RMU units and 11kv / 433V Package substations and distributed at 415V. At Receiving basin and Outfall areas, the existing 11kv network shall be augmented by providing 11kv RMU units and 11kv / 433V Package substations and power supplies to llccs shall be distributed at 415V. The Contractor shall provide the following systems / facilities as a minimum. 220 kv System Two 220kv / 34.5kv, 165/220 MVA transformers (located near the new 33kv switchgear building) shall be provided. A 220kv Substation consisting of double bus switchgear shall be provided. Existing two circuits of 220kv cables shall be cut and terminated to the 220kv switchgear as incoming cables. New 220kv cables shall be provided from the 220kv switchgear to feed the two existing 220 / 33kv transformers. Also, new 220kv cables shall be provided for the two new 220 / 34.5kv transformers. The GIS shall have provision for additional two 220kv feeder bays to receive power from a future Electrical department substation. 33kv System New 33kv double bus switchgear with Gas Insulated bus bars and vacuum circuit breakers shall be provided and located in 33kv Switchgear building. This shall include 33kv gas insulated bus ducts connecting the transformers to the 33kv switchgear. Expansion of existing double bus Siemens make 33kv switchgear (gas insulated) located in existing 33kv Electrical Switchgear building-1 to cater to Phase loads located in Phase area. One 33kv, 1250A rated tie feeder connecting existing 33 kv switchgear (feeder allotted from the expansion portion) to the new 33kv switchgear. Two 33kv / 6.9kv Transformers (located near VSDS Substation for PH area. Two 33kv / 6.9kv Transformers (located near Electro Chlorination building). Replacement of two existing 33kv / 6.9kv Transformers with higher MVA capacity transformers (located near existing 33kv Electrical Switchgear building-2).
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33kv XLPE Cables along with termination kits and associated items for feeding vsds transformers and various other loads. Harmonic filters connected to new 33kv switchgear and to existing 33kv switchgear. 11kv System 11kv / 433V Package substations (consisting of RMUs, 11kv / 433V transformers, LV Switchboard, etc.) For deriving Power supply for llccs in MOV corridor area, Receiving basin and Outfall area. 11kv XLPE Cables with their termination kits and associated items for modifications / additions in the 11KV network. 6.6kv System New 6.6kv metal clad draw-out type switchgear with insulated (solid insulation) bus bars and vacuum circuit breakers shall be provided and located in VSDS Substation for PH building. This shall include 6.6 kv bus ducts connecting the transformers to the 6.6kv switchgear. New 6.6kv metal clad draw-out type switchgear with insulated (solid insulation) bus bars and vacuum circuit breakers shall be provided and located in new Electro Chlorination building. This shall include 6.6 kv bus ducts connecting the transformers to the 6.6kv switchgear. Expansion of existing 6.6kv switchgear (Schneider make) located in existing 33kv Electrical Switchgear building-2 to cater to Phase loads located in Phase area. Four 6.6kv / 433V Transformers (located near VSDS Substation for PH building). Two 6.6kv / 433V Transformers (located near 220kv GIS Building) Two 6.6kv / 433V Transformers (located near new Electro-Chlorination building). Two 6.6kv / 433V Transformers (located at operation building). Two 6.6kv / 433V Transformers (located near VSDS Substation for PH building). 6.6kv XLPE Cables with their termination kits and associated items for feeding various loads. 415 V System New 415V SwitchgearMCC assembly located in VSDS Substation for PH building. This shall consist of an emergency section fed from an emergency diesel generator and shall also include 415V bus ducts connecting the transformers to the 415V switchgear. New 415V SwitchgearMCC assembly located in VSDS Substation for PH building. This shall also include 415V bus ducts connecting the transformers to the 415V switchgear. New 415V SwitchgearMCC located in new Electro Chlorination building. This shall consist of an emergency section for feeding emergency loads and shall include 415V bus ducts connecting the transformers to the 415V switchgear. New 415V SwitchgearMCC located in vsds building for PH. This shall consist of an emergency section fed from an emergency diesel generator and shall include 415V bus ducts connecting the transformers to the 415V switchgear. New 415V SwitchgearMCC assembly located in 220kv GIS Building. This shall consist of an emergency section for feeding emergency loads and shall include 415V bus ducts connecting the transformers to the 415V switchgear. New 415V SwitchgearMCC assembly located in Operation Building. This shall consist of an emergency section for feeding emergency loads and shall include 415 bus ducts connecting transformers to 415 V switchgear.

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Modifications to existing 415V SwitchgearMCC located in 33kv Electrical Switchgear building No-2 to add manual synchronizing for Load testing of the existing emergency generator. New 415V SwitchgearMCC assembly located at existing Electro chlorination building to feed the loads of Power consumer. This shall consist of an emergency section feeding emergency loads. Modifications to existing 415V SwitchgearMCC located in Electro chlorination building to provide power feeders to Power MCC indicated above. New 415V Power distribution centres for sub-distribution of 415V Power supply (Normal and emergency as applicable) at various load centres. New 415V SwitchgearMCC located in each. 230V AC UPS System New 230V, 50Hz, UPS system shall be provided at the following locations: UPS with battery banks for Phase equipment located in Phase-I area and located at extension portion of Control Building. UPS with battery banks for Phase located in VSDS Substation for PH building. UPS with battery banks for each LLCC building located in End-User premises, MOV Corridor, Receiving basin and Outfall area. UPS with battery banks for 220kv GIS located in 220kv GIS building. 110V DC System New 110V DC UPS system shall be provided at the following locations: UPS with battery banks for Phase located in VSDS Substation for PH building. UPS with battery banks for Phase located in 33kv switchgear building. UPS with battery banks for Phase located in Electro Chlorination building. UPS with battery banks for 220kv GIS located in 220kv GIS building. Control, Protection and Alarm Systems The Contractor shall provide control, protection, interlocking and alarm systems for Phase-II equipment as detailed below: 220kv System Separate Relay panels, Control and annunciator panels shall be provided and located in 220kv GIS building. 33kv System Separate Relay, Control and annunciator panels shall be provided for new switchgear and located in new 33kv Electrical Switchgear building. Separate Relay, Control and annunciator panels for extension of existing 33kv switchgear shall be provided and located in existing 33kv Electrical Switchgear building. 6.6kv System Relays control and annunciation system shall be mounted on the 6.6kv switchgear LV Compartment for new and modified switchgear. 11kv / 433V Package substations Relays, control and annunciation system shall be mounted on the 11kv rmus LV Compartment / 415V switchgear compartment as applicable. 415V System Relays, control and annunciation system shall be mounted on the 415V switchgear LV Compartment as applicable.

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Substation Control and Monitoring Systems (SCMS) and Power Management Systems (PMS) The Contractor shall provide the following: SCMS System FOR 220kv System Separate SCMS system shall be provided for 220kv GIS. This shall include all necessary Control, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis. One Human machine interface (HMI) with necessary software and graphical interface shall be provided for the 220kv GIS. This shall have necessary gateways for Electrical department, 33kv SCMS and Power Management system (PMS). SCMS System FOR NEW 33kv System Separate SCMS system shall be provided for the new 33kv GIS. This shall include all necessary Control, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis. One Human machine interface (HMI) with necessary software and graphical interface shall be provided for the 33kv GIS. This shall have necessary gateways for Electrical department and PMS. Transformer Monitoring System Separate transformer monitoring system (equivalent to GE Faraday TMCS) shall be provided. This shall log all transformer signals from transformer monitoring devices. PMS System PMS shall be provided for overall control and monitoring of the Phase electrical system The PMS shall be linked to Gateways of the SCMS of 220kv and 33kv systems. The PMS shall be linked to the data acquisition and control system of the new VSDS and all control, signals shall be enabled in the PMS. The PMS shall be linked to the data acquisition and control system of the existing VSDS and all control, signals shall be enabled in the PMS. The PMS shall be linked to the existing PMS and all control signals shall be enabled in the new PMS. The PMS shall be linked to the Transformer monitoring system and all signals and data shall be available at the PMS. For 6.6kv, all necessary Control, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis, shall be provided. For 415V system, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis, shall be provided. Control shall be provided for Incomers, bus ties and feeders ties. One (1) Human machine interface (HMI) with necessary software and graphical interface shall be provided for the PMS. This shall be located in the Control building. This shall have a gateway facility to DCS. Tariff Metering Systems Tariff metering system shall be provided on the Incoming feeders of new 33kv switchgear. The metering scheme shall be subject to approval by Electrical department. Existing as well as new metering signals are to be transmitted to NCC Lighting Systems The Contractor shall provide lighting systems as detailed below: Indoor lighting systems for all buildings in Phase. Building external lighting (Photo-cell controlled) shall also be provided. Outdoor Areas Lighting systems (Photo-cell controlled) for the intake area of Phase.
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Stilling basin. Additional lighting to be provided to enhance the lighting (Photo cell controlled) to 150 lux at the Outer edge of Stilling basin. Security Lighting (Photo cell controlled) system shall be provided for the intake plant overall perimeter fence. This shall consist of pole-mounted floodlights. The poles shall be located inside the perimeter fence. The floodlights shall be with high pressure (HPSV) lamps. The lighting level at the fence shall be 150 lux. Earthing Systems The Contractor shall provide earthing system for all installations in Phase. This shall consist of insulated earthing cables and stainless steel earth rods. Earthing studies and calculations shall be carried out to establish the parameters of the earthing system design. Contractor shall perform the studies using CYME software to plot ground potential contours for 33kv and 220kv GIS installations to substantiate that the touch and step voltages are within tolerable limits. Both electronic and hard copies shall be submitted to Company / Client as a part of final documentation. Lightning Protection System Lightning protection shall be provided for all the buildings and tanks associated with Phase. This shall also include the Control building extension. The Contractor shall provide calculations to establish the design of the system. Both electronic and hard copies shall be submitted to Company / Client a part of the final documentation. Power System Studies Following studies covering the entire plant network shall be conducted. The studies shall be conducted in accordance to Company / Client specification and harmonic requirements. The studies shall be contracted to a Company / Client approved study Consultant. All the studies shall be carried out on Windows based CYME package except Insulation coordination study, which shall be on PSCD EMTP software. The VSDS vendor documentation shall also the CYME software package for analysis and reporting. Other Specialized software may be used for insulation co-ordination studies but this shall be subject to prior approval of Company / Client. Load flow studies Load Flow studies shall be performed to validate the chosen equipment ratings (continuous). This shall include motor starting studies. Short circuit studies Short circuit studies shall be performed to validate the chosen equipment (short time) ratings. The actual fault levels at the 220kv + PLANT substation shall be made available during detail design. Fault level details shall be co-ordinated with Company / Client during detail design. Harmonic studies As harmonic levels are in excess of the stipulation mentioned in the specifications, the Contractor shall install necessary filters to mitigate the harmonic levels to the specified limits. Following successful plant completion, Contractor shall perform extensive site verification tests to prove that limits imposed have not been exceeded. Protection co-ordination studies. Establish the relay settings for all protection relays. These shall include protection settings at all llccs. Insulation co-ordination studies

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The studies shall establish that the insulation levels of equipment are adequate for probable surges in the system with a safety margin. The studies shall also establish the location, number and rating of surge arresters/surge suppressors in the system. Both electronic and hard copies shall be submitted to Company / Client as part of the final documentation. Motor Starting Substation Earthing LV Power and Control Cables XLPE insulated Copper Cables shall be provided as required to distribute LV Power, and for Control, protection and annunciation requirements. The Contractor shall route the cables in concrete troughs, trays, conduits, raceways, under ground trenches, etc. As detailed in the cable layout drawings. Emergency Diesel Generator An emergency diesel engine driven generator with a minimum rating of 630kva shall be provided to cater to the loads of Phase emergency loads and located in VSDS Substation for PH. The Contractor shall size and verify the rating based on various loads connected to the emergency bus. An emergency diesel engine driven generator with a minimum rating of 350kva shall be provided to cater to the loads of Phase-II emergency loads located in Phase area. This shall be located in VSDS Sub-station for PH. The Contractor shall size and verify the rating based on various loads connected to the emergency bus. Bulk Materials The Contractor shall provide as required Push button stations, receptacles (415V and 230V), local control panels, junction boxes, etc. As required for each system. Scope at Remote PLANT Substation and NCC The Contractor shall provide the necessary facilities at the remote end for telesignalling. Co-Ordination with PLANT and Electrical Department The design, installation and commissioning of all 220kv equipment (including control and signalling to PLANT substation) shall require co-ordination/approval of Company / Client, PLANT and Electrical department. Contractor shall take the responsibility / lead in obtaining approval for the interface facilities with PLANT and Electrical department. Company / Client shall facilitate the coordination and interface by a letter of introduction. Contractor shall engineer, connect and configure the signals for monitoring and controlling the FACILITY pertaining to this Project only. Twenty percent (20%) of the spares shall be connected and configured as spares as detailed in the specification provided. Provision for expansion shall be made for connecting any additional signals (future). Harmonic Filters Harmonic filters shall be provided based on the power system study requirements. This shall consist of : One set to cater to the requirements of existing 33kv network and connected to the existing 33kv switchgear (in the modified portion). This shall be further split into two groups. Each group shall be connected to individual bus-section. One set to cater to the requirements of new 33kv network and connected to the new 33kv switchgear. This shall be further split into two groups. Each group shall be connected to individual bus-section. The filters shall require a minimum of manual intervention and shall be designed for minimum energy losses. The harmonic filter package shall be for the Phase (existing).
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Tele-protection System and RTU The existing tele-protection system (SWT-3000), in the existing 33 kv switchgear room, shall be expanded to be made dual redundant. The existing tele-protection system in PLANT shall be expanded to be made dual redundant. A new dual redundant tele-protection system shall be provided for the new incoming cables in the new 33 kv switchgear room and the new 220 kv switchgear room. The existing RTU and existing C30 Controller located in existing 33kv switchgear room shall be expanded to cater for additional feeders. The tele-protection systems at PLANT, existing 33kv, new 33 kv and the new 220kv are to be integrated into a network via redundant, dedicated optical fibre cables. The network shall be configured such that the functions of any one redundant tele-protection unit that has failed shall by automatically assumed by another tele-protection unit within the network. Tele-signal Transfer The existing communications system shall be extended and expanded in order to provide voice and data links from the new 220 kv substation to the NCC. A new SDH node, PDH and PCM multiplex and supervisory system at the new 220 kv substation connected to PLANT via redundant optical fiber cables shall be provided. Telephone and hotline telephone facility at the new 220 kv substation shall be provided. The existing SDH and associated equipment at PLANT and NCC shall be expanded, including software upgrades, to cater for the new and expansion of the tele-signaling and telecommunication requirements or a new SDH equipment shall be provided. Necessary software and hardware modifications, including map work, network display, etc., and additions shall be provided at NCC for the new substation. Miscellaneous Requirements Reactive Power compensation equipment shall be provided if necessary based on the power system study requirements. The design shall be based on a design life of 30 years for all equipment. Fibre Optic cables for all networked equipment. In order to coordinate with others, Contractor shall provide the following: Estimated annual load build-up for the Project based on available data on flow requirements and utilities. This estimate shall be in tabular as well as graphical format. The first submission shall be within four months of award date and tabulation shall be regularly revised every six months with the development of the Project. Priority shall be given to finalising the load Schedules / load Data for all end-user llccs so that early coordination of LV power supplies can be undertaken with the respective end users. Where new roads or maintenance tracks cross-buried cables, Contractor shall install duct banks to safeguard the buried assets. The design of duct banks shall be suitable for a 30-Ton axle load. Pipelines and Distribution Contractor to note that the terminology Piping or Pipelines anywhere in this document refers to complete piping systems (both on plot and off-plot) including Pumping Station piping, Manifolds, package piping, fire water piping, utility piping, cooling water supply and return headers, piping from / to end users battery limits, etc. General Requirements Contractor shall check, validate and endorse all FEED documents, drawings and data during detail engineering as a part of his scope of work. Contractor shall bring to the notice of Company / Client in writing any contradictions / conflicts in the FEED documentation provided.
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All detail engineering deliverables shall fully comply with the requirements of all relevant Company / Client standards / specifications and FEED documents. Survey Requirements Topographic and Geotechnical Survey for all cooling water corridors have been performed as part of FEED engineering and the survey report is included. Contractor shall perform additional survey as required for detailed engineering to confirm the pipeline routings, tie-ins, fouling/interface with other facilities, collection of data for detailed engineering, installation of piping, road and utility crossings and pipe supports. Detailed Engineering Contractor shall perform detailed engineering for piping including but not limited to the following activities: Basis of Design The FEED Basis of Design for Piping shall be expanded as required for detailed engineering. Any change in the Basis of Design shall be specifically highlighted and shall be subject to Company / Client approval. Specifications All FEED specifications shall be developed to detailed engineering status. Any modifications from the FEED specification shall be specifically highlighted and shall be subject to Company / Client approval. Additional specifications, as required during detail engineering, shall be prepared by the Contractor. These shall be stand alone, self contained and Project specific. Drawings Review the piping drawings included in APPENDIX and produce complete piping General Arrangement Drawings (GADs), Equipment Layouts / Plot Plans, Sections, Piping standards, etc. For engineering and construction covering all pipe work. Verify that pipe routings indicated in FEED documentation have not been compromised or fouling with by on going works / projects. Prepare Key Plans, which shall show the facilities subdivided into geographic construction areas and sectors and their corresponding documentation. Develop piping general arrangement drawings for the entire facilities. All drawings shall be produced from 3D CAD model and in AUTOCAD electronic format and shall conform to Company / Client draughting standard requirements. Plot Plans, Key & Area Plot plans. Overall Pipe Routing Plans. Fire Water / Fresh Water Routing & gads. Prepare a list and drawings on special supports. Prepare Piping Isometrics for all piping having the following information as a minimum: Complete line from start to end with all components with full dimensions. Complete Bill of Materials. Information on type and thickness of insulation. Information on Process conditions and parameters. Information on whether line is stress analysed, stress relieved, etc. Information on pipe supports. Pipe supports to be shown on the Isometric drawings only for DN 50 and above piping. Information on reference drawing Studies, Perform Mechanical Handling studies and prepare a report for Company / Client review. Incorporate any changes required as a result of maintainability and operability study. Calculations. Contractor shall reconfirm selected material and wall thickness for all piping as part of detailed engineering activities. Review and update all existing piping engineering calculations that have impact on the Project as appropriate and carry out new calculations wherever required. Contractor shall perform detailed flexibility analysis of all relevant piping based on final pipe routing and design conditions. CAESAR-II latest version shall be used for flexibility analysis. Stress analysis of FRP piping shall be carried out by the FRP pipe supplier utilizing specific properties of the supplied pipes. Contractor shall perform detailed support design and develop new project specific
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support standard / drawings and lists based on detailed engineering for all piping. Carryout Surge Analysis for the Fire Water (Fresh Water) System GRE Piping. Finite Element analysis for Critical Components, supports, and manifold Tees, reducers etc. Using COSMO, ABAQUS or ANSYS Soft wares. 3-D Model Prepare a 3D PDS model for the entire facilities. Piping of all sizes shall be modeled. The 3D model shall further include modeling of pipe supports for DN 50 and above piping, electrical and instrumentation items / cable trays, civil and structural information, all equipment, etc. Intelligent model to be submitted to Company / Client, updated to include as-built status of installed facilities. This shall be used by Company / Client for further engineering during ultimate phase or future phase Vendor Data Review. Review, check and comment on all applicable Vendor calculations, drawings and data and incorporate requirements in design and engineering. Construction. Prepare all documentation for fabrication, erection, installation, inspection and testing of piping. Tie-ins, Prepare Piping Tie-in schedule and details as per P& I Ds and other Project documents. MTO and Requisitions. Perform and prepare Material Take-offs and summaries for piping and support materials including bulk material. Prepare material / purchase requisitions (RFQs) for all piping and support materials. Prepare Technical Evaluation Summary reports for all piping items. GRP Piping. Coordinate between different GRP Vendors. As Built Documentation Prepare and submit final As-Built documentation. Piping / Pipeline Deliverables Electronic copies in native format (generic) and hard copies shall be supplied in final documentation for all disciplines. Piping Basis of Design. Piping Material Specification (Piping Classes). Piping Wall Thickness calculations Reports. Technical Specifications for Pipes, Flanges, Fittings, Valves, Rubber Expansion Joints, Bolts & Nuts, gaskets, etc. Process / Piping specialties specifications and data sheets. Valve Data sheets. Valve Schedule. Specification for flexibility/stress analysis. Specification for Pipe Supports. Specification for Fabrication, Erection, Installation, Inspection and Testing of Piping. Specification for Hydrostatic Pressure Testing of Piping. MTO for piping and support materials. Requisitions for all piping bulk items, valves, specialities, etc. Technical Bid Evaluation Reports. Mechanical Handling study report. Surge Analysis report for the Fire Water (Fresh Water) System GRE Piping. (Plot Plans / gads / Pipe Routings) Key Plans. Plot Plans (Overall & Unit). Piping General Arrangement Drawings (key Plan & Plans & Sections / details). Piping Isometrics (AFC). Tie-in schedule and details. Critical Line List for Piping Stress analysis. Piping Stress Analysis calculation reports. Standard Pipe Support drawings. Special Pipe Support Drawings. Support Schedule. 3D PDS Model (Generic and Intelligent). Overall Pipe Routings Reports / Calculations notes etc. As listed. As-built drawings (for all above referenced drawings / documents) Specific Requirements Design, Fabrication and Installation of FRP Piping. Detailed design and supply for FRP (GRE / GRP / GRV) Piping are of specialist nature and hence shall be subcontracted to the Specialist GRP and FRP pipe manufacturer respectively. Detailed Design shall include, but not limited to the following: All thickness calculations for pipes and piping components. Update and issue of design and installation drawings.
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Flow / Surge calculations for the system as may be appropriate. Static and Dynamic stress calculations and analysis. Design of jointing system based on the design. Design and location of supports, anchors, and design data for anchor blocks. Review of all proposed field design changes, which may affect FRP pipework or support throughout construction. Supply of FRP Piping and spool fabrication. Supply of piping components such as pipes, fittings, flanges, etc. For FRP piping system. Supply of pipe supports such as saddles etc. Supply of fabricated spools. Further, the FRP vendor shall furnish Installation, inspection and testing procedures for FRP piping and shall supervise the site installation activities in order to ensure single point responsibility of design, supply and installation. Instrumentation & Controls Contractor shall be responsible for but not limited to the following: General Contractor shall be fully responsible for the design and provision of instrumentation, and associated control systems for the Project. Responsibility extends to all required detailed design, material supply, engineering, factory inspection and testing, packaging, logistics, calibration at site, installation, hook-up and field verification. All systems shall be supplied, configured and tested in accordance with the relevant Project Specifications. Refer Instrumentation & Control Basis of Design, General Instrumentation Specification, Specification for package Instrument Installation Contractor shall make a detailed site visit to study and familiarize the existing Instrumentation & Control system already implemented for Phase Site visit report shall be submitted to Company / Client. The Instrumentation and Control system to be implemented for Phase shall only be considered for the Project. Phase related items would be a separate project in future. Instrument scope shall include, but not be limited to the items listed below: Instrumentation Data base Contractor shall develop a Master database of Instruments in intools. This database shall cover the details of all the tagged instruments and their signals as per the Company / Client Drafting & Numbering system. The basis for this list shall be P&ID. This database shall be dynamic until the As built stage of the project. All the features of the intools e.g. Index module, Data sheet module, Calculations, wiring, Instrument Loop diagrams, hook-ups etc. Shall be utilized. As a minimum, one license of INTOOLS shall be made available for Company / Client use during project stage and the same license, complete database with associated information shall be handed over to Company / Client at the end of the project. Instrument specifications & Data sheets Contractor shall generate a stand-alone specification and / or data sheet for every Instrument and Control system. These documents shall be regularly updated until the As built stage. The Specification shall cover minimum requirements such as the selection of type, Material, requirements pertaining to Manufacturing, QA / QC, Inspection, Painting, Storage, Handling, Transportation and Maintenance & Operations etc. The data sheets shall cover complete details of individual instruments. Installation drawings and Documents
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Contractor shall develop detailed instrumentation installation related drawings to facilitate the easy construction of the Instrument & Control System. These drawings shall include but not limited to the instrument equipment layout in building, location layouts, cable block diagrams, cable routing layouts, cable schedule, Hook-up Diagrams, Bill of Materials, MCT schedules, Air supply distribution, Termination diagrams, Loop diagrams etc. Contractor shall develop a detailed Specification for the Installation of Instrumentation & Control System. Input to various disciplines / participation in various studies Instrumentation shall provide inputs to the various disciplines associated with the Project. Proper co-ordination among all the Project team members is expected. Instrumentation shall participate in various studies (e.g. Hazop, Constructability review etc.) During course of the detail engineering. Procurement Contractor shall prepare detailed Scope of supply (which includes Documentation requirement etc.), Material Requisitions for each type of Instrument and Control system. The enquiries shall be floated to the Company / Client approved Suppliers only. A detailed Technical evaluation shall be carried out and the Technical Bid Analysis shall be submitted to Company / Client. All the relevant documents shall be updated to reflect the make, model number of the individual instrument and submitted along with the technical section of the Purchase Order. Vendor Drawing approval Contractor shall carry out detailed review and approval of all the Vendor drawings and documents. Vendor Data Books shall be submitted in format explained in the relevant Project specification. Inspection & Testing Inspection and testing shall be conducted as defined in the relevant Project specification. Distributed Control System (DCS) The Control system for Phase is EMERSON make Delta V system. There are two options for Phase. Either this system can be extended to cater for the expansions including phase or an independent third party Distributed Control System integrated with the existing DCS through OPC open system connectivity. It is intended that the Operator stations implemented for Phase shall be continued to be in use for Phase and all the future phases of the Project including Phase. Presently only one additional operator station is planned to be added. Contractor shall develop Control philosophy and all relevant documents for the System Supplier like Functional Design Specification, Control / Logic Narratives, I / O lists (Hardwired & softwired), Loop typicals, Graphic specification, Layout of individual Graphic pages, Logic Diagrams etc. Contractor shall finalize the hardware required for the Project and ensure smooth integration. It should be noted that the plant would continue to run during implementation of this Project. Contractor shall submit detailed Method statement for proper and uninterrupted transition of the new system. A separate method statement shall be prepared for the pre-commissioning of the Control system. Depending on the final architecture and the routing of the Fiber Optic cable, a sequential start-up is expected. Due care shall be taken to define and implement the communication links to various subsystems like HVAC, Machine Monitoring systems, VSDS, Switchgears, F&G
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Systems, End users systems, and various packages etc. The DCS shall have redundant F.O. network. Refer Specification for Control system, Specification for Machine Monitoring system, Control System architecture and various equipment layouts of the buildings. Fire & Gas System The Fire and Gas System to be used for Phase shall work on a F.O. redundant network of single mode fibres. Also the fire panel at each location shall communicate serially to the DCS over redundant link. The Master Fire panel shall be located in the CCR. Repeat signals shall be connected to the panels in PLANT Control at existing main gate house and Fire station within the PLANT . The Phase seawater pumping & distribution project has a Cerberus make Fire & Gas system having one operator station in CCR and one in PLANT control in existing main gate house. The system has hardwired contacts to the respective DCS subcontrollers. Also this system is communicating over multi-mode fibers and not on Single mode fibers. In order to integrate Phase systems, following two options are envisaged: 1. Communicate all the Phase alarms and signals to the existing F&G Operator stations located in CCR and PLANT control at main Gate House. 2. Replace the Phase system completely and bring Phase and Phase systems on to a single platform. In this option, for the F&G panels in Phase building, either existing telecommunication F.O. network (single mode) shall be used or new connections shall be made to the F&G panels at nearest building that is being built in Phase of the project. Every unmanned Building shall have HSSD System. The manned building shall have smoke detection and other associated detection system specified in the relevant Project specification. The Fire & Gas detection and alarm systems for each building shall have a F&G panel. All such F&G panels shall be connected to a new Master F&G control panel to be located in the existing Control room, the PLANT Control located at the Main Gate House (known in Phase as Fire / Incident Control Room) and Fire Station, which shall communicate with the Operator station. Two new Gatehouses are planned in the Project, which shall also have alarm panels as defined in the relevant specification. The Fire and Gas system shall provide a fast, comprehensive and automatic means of detecting, alarming and indicating the presence of fire and combustible gas hazards. The system shall also be connected to activate deluge of 220 kv / 33 kv transformers on detection of fire. The system shall close the inlet dampers in the control room and other buildings when toxic gas is detected. Refer Specification for F&G System and F&G System block diagram Instrumentation on Package Equipment. Contractor shall develop Control strategy for individual packages where instrumentation and Control system shall be involved. All the interfaces between the various systems shall be properly defined. Refer Specification for Package Equipment Instrumentation. Flowmeters Contractor shall implement water Metering System at discharge main header and each consumers intake. Dual beam multi-path ultrasonic flow meters shall be used in line and shall have accuracy equal to or less than 0.5%. The ultra-sonic meters shall be clamp-on type. The mounting arrangement shall be such that there shall not be any loss of signals. Analyzers
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Analysers installed in Analyser House / shelter shall be utilised for environmental monitoring at the intake, outfall and at every consumer. Control and On-Off Valves All the Control and On-Off valves for the Project shall have Motorized actuators (with the exception of any pneumatic valves having independent Instrument Air system for Electro chlorination package). The actuators shall be intelligent type and shall communicate on single pair cable forming a network. A master station shall be located in the CCR / LLCC for certain number of movs based on Manufacturers recommendation. The output signal from DCS to the Control valves (fvs and ccvs) shall be hardwired. The Combined Check Valves (ccvs) shall have electro-hydraulic actuators. Each CCV shall have an independent hydraulic system and control panel. Contractor shall develop the network and implement for the Project. Other Field Instrumentation Contractor shall ensure that all the field instruments are procured from the Suppliers listed in Company / Client suppliers list. Also all the Instruments shall completely comply with all the Project documents. There is a special requirement to measure the seawater temperature one meter below the surface at outfall. The temperature points shall be distributed in a semi-circular fashion at a distance of 100 meter from the discharge point. A sensor attached to a floating buoy is a preferred arrangement. Contractor may suggest any other alternatives for consideration by Company / Client. The cables for these temperature sensors shall be sleeved with a pipe and precast concrete blocks. Alternatively, remote wireless sensors and transmitters can be considered. Access shall be provided for sensors inspection / replacement. Laboratory Contractor shall design a laboratory, design, supply, install, test and commission the laboratory instruments as per the specification for Laboratory Instrumentation Doc. and Laboratory Layout Drg. The laboratory layout shows only indicative minimum requirements and Contractor shall suggest any requirement of additional equipment, space, etc. Instrument air required for the laboratory shall be tapped and arranged from the existing Instrument Air compressor located near Electro chlorination package of Phase F. O. Network It is intended that a complete redundant Fiber Optic Network shall be utilised for the following: DCS;-F&G;-MOV;-Telecommunication; The F.O. Cables shall run on either side of the Cooling Water Pipelines. The cable shall be supported over the cable trays laid over the Pipe sleepers on the above ground portion. The cables shall be buried where the Pipeline is also buried. In case, all the pipes are not laid in the defined Pipeline corridor and second route of the F.O. cable is not available due to this, Contractor shall be allowed to commission the system on non-redundant F.O. network temporarily as a special case. However Company / Client approval shall be taken in advance and shall be properly reflected in all the documents. Once the second route is available, the redundancy shall be implemented. Instrumentation Deliverables All documents and drawings shall be continuously updated until as-built revisions. Following is a minimum list of Instrumentation documents to be generated by Contractor or enhance the FEED documents where applicable for the implementation of Phase
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Site Visit report, -Instrumentation and Control Basis of Design.-Specification of Individual Instrument;-Data sheet of Every Instrument;-Material Requisitions;-Technical Bid Evaluation and Recommendation;-Vendor Data Manual;-System Specifications (DCS, F&G, etc);-Functional Design Specification / Control Narrative;-Loop diagrams showing terminal numbers and all elements of the loop.-Logic Description;-Flow chart derived from the Cause and Effect Matrix (developed under Process discipline) or the narratives for trip, shutdown or operation of equipment.-Instrumentation Index (Database);-I / O Lists;-System Architecture Diagrams;-Logic Diagrams and sequence charts;-Instrument Cable Block Diagrams;-Cable Routing Layouts;-Instrument Location Layouts;-F&G Detector Layout,-Laboratory Layout,-Instrument Junction Box wiring diagrams;-Instrument Hook-ups;-Installation MTO;-Instrument Cable Schedule;-MCT Layouts for CCR and llccs;-MCT Schedule,-Interface wiring diagrams;-Equipment Layouts in the Buildings;-Instrument Loop Diagrams;-MODBUS address mapping details;-Instrument Grounding Layout;-Calculation of Instrument Air Consumption, wherever applicable;-Power Requirement Calculations and distribution drawings; -I/O allocations, Controller allocations;-Sizing Calculations for Valves, Orifice Plates, Power supplies, Instrument Air consumption;-Noise Calculations;-Following documents shall be generated by individual suppliers. These shall be duly approved by Contractor and submitted to Company / Client.-Panel GA Drawings;-Panel Dimensional Drawings;Panel Wiring Diagrams;-Calibration Procedure;-Calibration reports;-Operation Manual;Maintenance Manual;-Spare Part Manual (The manual shall include the complete Bill of Materials. All the parts that have individual part numbers shall be listed in the manual);FAT and SAT procedures and completed dossier where applicable, for systems and packages.-Contractor shall detail the FAT and SAT already included in the Instrument Specification documents. Instrumentation softwares required Contractor shall specify all the proposed software to be used for the Project. Following is the list of preferred software: Database intools; Flow Orifice Sizing instrucalc / intools; Control Valve / Safety Relief Valve Sizing instucalc / conval / intools; Drawings autocad. Telecommunication System The Contractor shall be responsible for the complete design and provision of telecommunication facilities for the project. The responsibility extends to all required detailed design, material supply, engineering, factory inspection and testing, packaging, logistics, installation, hook-up, Integration and field verification. All systems shall be supplied, configured and tested in accordance with all the relevant Project Documents. General The Contractor shall provide telecommunication facilities for the existing Central Control Room (CCR), other new buildings in the Intake Area and Local Lot Control Centres (llccs) being covered in Phase of the Project. Refer: Telecommunication Basis of Design, Document No., System Diagram - Overall Telecommunication System, Drawing No., Block Diagram Overall Telecommunication System, Drawing No and Equipment List Telecommunication System, Document No. The Contractor shall interface with existing telecommunication facilities in the existing buildings as stated in the relevant documents. The Contractor is required to make himself fully aware of all relevant standards and regulations, such as the following, on which the design and installation of the Telecommunication System shall be based: Tel Publications.
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IEEE wire regulations for Electrical Installations, ITU International Telecommunication Union, C Electromagnetic Radiations Compatibility, Company / Client Standards, Project Documentation. The Contractor shall note that the Company / Client Standard, SD-ITN-001, Cable Infrastructure Standards of the IT Department is vendor limited, in some cases, and therefore shall not be issued to vendors. The Contractor shall ensure that the entire Telecommunication Works shall be carried out through a qualified Telecommunication Systems Integrator. The Contractor and Systems Integrator shall attend liaison, review and progress meetings, in National, on a monthly basis during the design phase and weekly site meetings during the construction phase. The monthly meetings during the design phase to be for a period of 3 days and shall include site visits. Company / Client, at its discretion, may choose to conduct certain monthly meetings via teleconference. The weekly meeting during the construction phase to be for a limited period, as required, and shall include a joint inspection of the work taking place at that time. The Contractor shall study and revalidate the FEED both as a desktop exercise and via a number of site visits to be conducted during the initial stage of the Project to familiarize and study the Telecommunication System implemented, as well as the changes being implemented, within PLANT. The Contractor shall make four (4) site visits for a period of two (2) full days each visit. The Contractor shall suggest any enhancements, with rational, to the FEED following the FEED verification, in the form of a report, for the approval of company / client. The Contractor shall submit, for the approval of Company / Client, Site Visit Reports for each site visit. The Contractor shall provide load analysis on any of the existing power supplies that shall be directly utilised as a part of this project and provide a report with rational and recommendations, having considered all alternatives. All systems shall be provided fully assembled, supplied, configured and tested in accordance with the relevant project specifications. Also, the Contractor shall be responsible for interfacing the new systems with existing telecommunication systems; any upgrade work required on the hardware / software of the existing system for this purpose shall be carried out by the Contractor. The Contractor shall obtain prior approval from Company / Client of his detailed design before proceeding with any purchase of equipment and any installation work. The Contractor shall participate in a formal design review, in National, six (6) weeks prior to purchase of equipment and include appropriate Company / Client comments in the design. The Contractor shall obtain Tel Type approval as required. The Contractor shall ensure adequate co-ordination between the Telecommunications System Integrator and all other disciplines / activities on site takes place in order to ensure an efficient installation.

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The Contractor shall make provision and ensure common infrastructure like the routing of the Fiber Optic cables shall include the llccs / Buildings planned to be implemented in the future phases e.g. By provisioning a coiled FOC length near Phase llccs. The Contractor shall be aware that there is telecommunications effort associated with the new and existing electrical sub-stations and the existing Electrical department network by virtue of tele-signalling transferring systems and tele-protection systems and that this effort is detailed in Clause Electrical Engineering. The Contractor shall be aware that at the present time the Optical Transmission System in the Plant Industrial City Telecommunication network comprises redundant SDH nodes at STM-1 (Alcatel SDH 1650 SMC) configured in a single ring on main and standby cables and that other interfacing contracts, being performed by others, shall initially retain the single ring, identified as PAB, POB, NTB, MGH, E2, RB, LNG 2, Fire Station # 3, IPP, W6, CB and PAB and then reconfigure the single ring into three (3) rings of STM-1 namely Port Ring, Eastern Ring and Western Ring. The Scope of Work in Phase is to implement a spur link from Fire Station # to LLCC MOV Corridor H and integrate with the Western Ring and also provide telecommunication system facilities and connectivity to various llccs as stated in the Telecommunication Facility Requirements and Connectivity Table Document No The Contractor shall make him self aware of the status of the various concurrent interfacing contracts and establish any impact to the Scope of Work. The following interfacing contracts are identified at this time: (i) add a SDH/PDH node at the Fire Station # 3. This new node shall be connected to the network via 2 x 24 core Single Mode Fibre Optic cable routed to the existing LNG 2 LLCC which is the closest node to Fire Station # and to LLCC in order to form a logical ring i.e the Western Ring. (ii) add a PDH node at the metering station located close to the IPP LLCC. This PDH node is being connected to the network with a copper cable to the IPP node. (iii) move the SDH STM-1 from the Port Administration Building (PAB) to the new control building for Berth 1A and 1B (LPB-1). A new SDH STM-4 node Alcatel 1660, shall be installed in PAB together with additional Cross Connect Alcatel 1515 CXC and PDH multiplexer 1511 BA This shall form another logical ring, the Port Ring. (iv) provide telecommunications facilities for LNG 1 from the existing sub plant (S) and for W 4 from Fire station. The Contractor shall perform the following Scope of Work: Interfacing to existing Telecommunication Systems at various levels including linking through fiber optic network and upgrading / re-configuring (re-programming) of the existing ALCATEL system for the additional facilities. Supply of a compatible telecommunication system which shall interface, tie-in to the existing system / network and continue to have a closed loop configuration or multiple loop configuration for the existing STM-1 ring network and two new spur link locations, Fire Station # and MOV Corridor H.

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Supply of hardware and the software upgrades, as required, for the existing SDH system in order that the new terminal equipment shall be interfaced with the existing equipment. Supply of two (2) redundant Plesiochronous Digital Hierarchy (PDH) equipments with multiplexers and associated Network Management System (NMS). Supply of Fibre Optic cable and accessories up to subscriber connectivity and software configuration and upgrade. Supply of a Telephone System comprising a copper cable distribution and necessary IDF, junction boxes, patch panels etc; excluding the PABX which shall be supplied by others, together with a number of Telephones, Fax Machines, Audio Multiplexers etc. And a Hotline Telephone System operating between the CCR and the Consumer Control Rooms. Expansion of, and reconfiguration of, an existing Public Address / General Alarm System including supply of all necessary hardware and software. Connectivity to any other required utilities. Providing technical input required to support other disciplines. Providing documents and drawings, including as-built revisions. Interface with, and obtain approvals from, Tel. This shall include the design for the Telephone System infrastructure as well as any Type approvals as necessary. Provision of all data sheets for telecommunication systems, subsystems and equipment. Evaluate and confirm the adequacy of all the existing systems to accommodate the new systems, sub systems and equipment. Upgrade the PC based Telecommunication Supervisory System to include the new PDH nodes. Upgrade the Network Management System to include the new telecommunication equipments. Commission and Hand Over all systems, sub systems and equipment fully integrated. Telecommunication System Specifications & Data sheets The Contractor shall generate a stand-alone detailed specification and / or data sheet for each telecommunication system, sub system and equipment, These documents shall be regularly be updated until the as built stage. The specification shall cover complete details of the selection of type, material, requirements pertaining to manufacturing, QA / QC, inspection, painting, storage, handling, transportation and Operations & Maintenance etc. The Contractor shall use the telecommunications specifications in Appendix as an initial basis to develop the detailed engineering and the specifications. The design and specifications shall be submitted to Company / Client for approval. The Contractor shall ensure that every element in the system shall have an associated Mean Time Between Failure (MTBF) of better than 20,000 hours and that each subsystem shall have a Mean Time To Repair (MTTR) of better than two (2) hours, assuming the appropriate spare part is available. The Availability of the system shall be 99.999 %
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Scope of Work and Supply Fibre Optic Cable & Accessories For details of the guideline specification, refer Specification for Fibre Optic Cable and Accessories, Doc. No., Main Cable Routing Drawing, Doc. No. and Fibre Optic Cable Allocation Drawing, Doc. No. A duplicated (main and standby) Single Mode Fibre Optic Fire Retardant Armoured Cable Network with Accessories shall be laid in order to provide the transmission medium to facilitate Instrumentation, Telecommunication, Fire & Gas, Electrical and Security systems as indicated below: 2 x 36 core cables shall be laid in two (2) separate physical routes for embracing all llccs to be constructed to/from the CCR in CB in a loop configuration. 2 x 12 core cables shall be laid within the Intake Area to accommodate Instrumentation requirements e.g DCS at various buildings and Pump houses to/from the CCR in CB. 2 x 24 core cables shall be laid between substations in the Intake Area to accommodate Electrical requirements e.g Tele-protection and Tele-signal transferring. 4 x 6 core non-duplicated cables shall be laid to / from the Telecom Room in CB and the four (4) hubs situated within the Intake Area to cater for the CCTV system. The cables shall also be laid between the hub and its associated CCTV cameras. Optical Patch Cords / Connectors and Fibre Patch Panels shall be supplied to support the above. Optical Transmission System For details of the guideline specification, refer Specification for Optical Transmission System, Doc. No. and System Diagram - Optical Transmission System Doc.. A redundant PDH spur optical link is to be implemented between Fire Station and MOV Corridor H. Each of the FO transmitting stations shall be equipped with at least two (2) optical receivers and two (2) optical transmall necessary hardware and software modifications shall be made in the existing SDH STM-1 Western Ring in order to ensure that phase II telecommunications facilities are seamlessly connected. The existing SDH equipment shall be upgraded to provide CCTV Camera(s) signal transport from the Intake Area, LNG 2 and RB to CCTV monitors at CCR CB and to monitors and system management and recording facilities at CR Plant situated at the Main Gate House (MGH). An independent dual optical fibre single audio channel based telephone connection shall be provided to four (4) llccs from a PABX, to be implanted by others, in the Telecom Equipment Room at CB on audio multiplexer systems. PCM Multiplexes and Channel Interface PCM Multiplexers shall be provided in order to provide the required telecommunication facilities associated with Corridor H and shall be equipped with common equipment DCDC converter (from -48VDC), equipment controller board, alarm board, 25Hz generator with the following user interfaces: 2W FXO channels, -2W FXS channels, The terminal equipment shall be of Alcatel make, type PCM 1511BA. Cross Connect Equipment The existing equipment (duplicated Alcatel 1515 CXC connected in series) shall be reconfigured, as necessary, in order to complete the system requirements.
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Network Management System (NMS) The existing Alcatel 1320/1353 CT/CX Network Management System (NMS) for control and monitoring of all PDH / SDH nodes shall be upgraded with hardware for the new sites and the latest version software and reconfigured as necessary to include the new PDH nodes and other routing channels to provide connectivity across the new llccs. In addition the software shall be made available on two existing desktop personal computers in CCR CB and PAB and additionally on two laptop personal computers, to be provided, for maintenance personnel at site(s). Telecommunication Equipment Supervisory System For details of the guideline specification, refer Specifications for Telecommunication Supervisory System, Doc No The existing Hitachi make Telecommunication Equipment Supervisory System which operates on a separate LAN and provides alarm monitoring of the entire Telecommunication System shall be upgraded with hardware for the new sites and the latest version software and reconfigured as necessary to include the new PDH nodes. Further a Laptop PC shall be provided, equipped with the appropriate software and hardware accessories for programming fault detection and engineering purposes. The Remote Supervisory Unit(s) shall be modular consisting of one or more modules. Each module shall include 32 x volts less contact shall be poared from the 48V DC supply. PA / GA System For details of the guideline specification, refer Specification for Public Address and General Alarm System, Doc. No. and PAGA Field Location Layout Drawing No. The existing PA / GA equipment is NOVA 2001 and manufactured by GAI-TRONICS of Italy. In order to ensure adequate acoustical coverage shall be available in the Intake Area an acoustical analysis shall be conducted including site investigation and measurement, together with desktop calculations. The analysis shall take into account existing and future ambient noise levels. The analysis shall be performed, utilising a procedure to be approved by Company / Client, within three (3) months of the Effective Date. The results of the analysis shall be used to optimize the quantities and locations which shall to be included in a report to included coverage drawings, with rational and recommendations, to be submitted for the approval of Company / Client. The report shall also contain recommendations with rational on the existing Phase coverage. The coverage in the Intake Area shall be verified, by measurement, as conforming to the acoustic analysis as part of the commissioning procedure. The existing system shall be extended and upgraded as necessary, both hardware and software, in order to provide coverage at the new llccs and buildings in the Intake Area. The system shall be re-configured and re-zoned for the new and existing sites to meet the operational needs of Company / Client. Further a Laptop PC shall be provided, equipped with the appropriate software and hardware accessories for programming fault detection and engineering purposes. Hotline Telephone System For details of the guideline specification, refer Specification for Hotline Telephone System Doc. No. and System Diagram - Hotline System Drawing No.
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Hotline Telephones shall be installed between the CCR in the CB to two (2) new customer sites associated with llccs LNG-1 and LNG-2. Provision of the Hotline Telephone service shall include the telephones and the PCM FXO / FXS circuits. The existing Hotline Console at CCR shall be upgraded to accommodate the new handsets and indicators, refer Hotline Console Layout Drawing No. In the event that the customers sites are not available at the time of commissioning then commissioning shall take place in the applicable LLCC. Telephone & Data System For details of the guideline specification, refer Specification for Telephone System Doc. No.. A PABX, Ericsson model MD 110, exists at PAB and all telephone users at existing llccs and in the Intake Area operate as remote subscribers via FXS/FXO circuits on the SDH Optical Transmission System. In 2nd quarter 2006 a PABX shall be provided, by others, at CB therefore all new llccs shall operate as remote subscribers from the PABX at CB and all users in the Intake Area shall operate as direct subscribers. The PABX at CB shall have sufficient capacity and be equipped for all new subscribers in the Intake Area and remote subscribers at llccs The active components of the Data Network shall be supplied by others and the LAN shall be commissioned by others. All cables, structured cabling, idfs, junction boxes, interfaces, interconnections etc to effect a comprehensive infrastructure shall form part of this Scope of Work. Telephones, Fax Machines and Audio Mux For details of the guideline specification, refer Specification for Telephones and Fax Machines Doc. No.. All telephone shall have RJ-45 connectors and the types of telephones installed shall be different for different areas and functions, as tentatively defined on drawings and relevant documents. Refer: Equipment List Telecommunication Equipment, Document No. for quantities. All Fax Machines shall have RJ-45 connectors and be installed in locations tentatively defined on drawings and documents and shall be model L-360 or later version from Canon or equivalent. Four (4) Audio Mux with FXO / FSX capability are required to provide individual telephone communications, over dual optical fibre, between the PABX at CB and llccs. Earthing All telecommunication equipment shall be connected to the telecom earth at existing stations and a separate telecom clean earth of less than one (1) ohm at each new location. Power Supplies A fully redundant nominal - 48VDC battery / charger system with 8 hours autonomy shall be provided and used to supply all telecommunications related equipment at LLCC MOV Corridor H. The battery / charger system shall be designed in accordance with Data Sheet, DC UPS, Document No. in order to supply power to the telecommunication equipment and shall have 50% spare capacity.
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A fully redundant nominal -48VDC battery / charger system with nominal 8 hours autonomy shall be provided, by others, and used to supply all telecommunications related equipment at Fire Station. The PDH and associated equipment at Fire Station shall connect to this existing supply. A fully redundant nominal -48VDC battery / charger system with nominal 8 hours autonomy exists at each node in the SDH / PDH Optical Transmission System and can be utilized for like equipment. Each new site shall contain a 230 V AC UPS which shall be utilised for any new PA / GA equipment. Testing Testing shall take place in order to demonstrate the specifications of the equipment, sub system and system have been achieved and as stated in the applicable system specifications. Training Training shall be provided as stated in the applicable system specifications in Appendix and is to take place at site. The training shall be as per manufacturers standard syllabus and shall be conducted by the manufacturer. Documentation Documentation shall be provided for the design, purchase, installation, as built and O&M phases and as stated in the applicable system specifications in Appendix. Security System The Contractor shall be responsible for the complete design and provision of the Security System for the project. The responsibility extends to all required detailed design, material supply, engineering, factory inspection and testing, packaging, logistics, installation, hook-up, Integration and field verification. General The Security System for the Plant Industrial City shall be highly confidential. The details shall not be reproduced or / and copied. The Contractor shall provide a Security System for the Intake Area, along the Pipeline Corridor and at the Receiving Basin (RB). Refer Specification for Security Control System, Document No., Closed Circuit Television System Diagram, Drawing No., Card Access Control System Diagram, Drawing No., Field Location Layout Security System, Drawing No. and Equipment Layout Security System, Drawing No.. The Contractor is required to make himself fully aware of all relevant standards and regulations, including Company / Client standards, base his design and installation on those standards and regulations. The Contractor shall note that the Company / Client Standard, Cable Infrastructure Standards of the IT Department is vendor limited, in some cases, and therefore shall not be issued to vendors. The Contractor shall ensure that the entire Security Works shall be carried out through a qualified Security & Telecommunications Systems Integrator. The Contractor and Systems Integrator shall attend liaison, review and progress meetings, in National, on a monthly basis during the design phase and weekly site meetings during the construction phase. The monthly meetings during the design phase to be for a period of 3 days and shall include site visits. Company / Client, at its discretion, may choose to conduct certain monthly meetings via teleconference. The weekly meeting during the
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construction phase to be for a limited period, as required, and shall include a joint inspection of the work taking place at that time. Company / Client shall agree to combine the Telecommunications meetings with those of Security in the event the same System Integrator is chosen. The Contractor shall study and revalidate the FEED both as a desktop exercise and via a number of site visits to be conducted during the initial stage of the Project to familiarize and study the Telecommunication System implemented, as well as the changes being implemented, within Plant city. The Contractor shall make four (4) site visits for a period of two (2) full days each visit. Company / Client shall agree to combine the Telecommunications site visits with those of Security in the event the same System Integrator is chosen. The Contractor shall suggest any enhancements, with rational, to the FEED following the FEED verification, in the form of a report, for the approval of Company / Client. The Contractor shall submit, for the approval of Company / Client, Site Visit Reports for each site visit. The Contractor shall provide load analysis on any of the existing power supplies that shall be directly utilised as part this project and provide a report with rational and recommendations, having considered all alternatives. The Contractor shall be aware that the existing CCTV System at Plant is in the process of being upgraded to a an IP Ethernet based network and this is due for completion. The coverage of the existing and upgraded system does not include the location areas that form part of this Scope of Work. All systems shall be provided fully assembled, supplied, configured and tested in accordance with the relevant project specifications. Also, the Contractor shall be responsible for interfacing the new systems with existing telecommunication systems; any upgrade work required on the hardware / software of the existing system for this purpose shall be carried out by the Contractor. The Contractor shall obtain prior approval from Company / Client of his detailed design before proceeding with any purchase of equipment and any installation work. The Contractor shall participate in a formal design review, in National, six (6) weeks prior to purchase of equipment and include appropriate Company / Client comments in the design. The Contractor shall ensure adequate co-ordination between the Security System Integrator and all other disciplines / activities on site takes place in order to ensure an efficient installation. The Contractor shall perform the following Scope of Work: Provide a new CCTV system consisting of cameras, hubs/switches and monitors interfacing to an upgraded existing CCTV System. Provide a Card Access Control System (CACS) at Gate House # and Gate House # to automate inbound / outbound vehicle & personnel movements. Provide security fencing and lighting around the intake facility. Security System Specifications & Data sheets The Contractor shall generate a stand-alone detailed specification and / or data sheet for each of the security system, sub system and equipment. These documents shall be regularly updated until the as built stage.
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The specification shall cover complete details of the selection of type, material, requirements pertaining to manufacturing, QA / QC, inspection, painting, storage, handling, transportation and Operations & Maintenance etc. The Contractor shall use the Specification for Security Control System, Document No. as an initial basis of the specifications to be developed. The specifications shall be submitted to Company / Client for approval. The Contractor shall ensure that every element in the system shall have an associated Mean Time Between Failure (MTBF) of better than 20,000 hours and that each subsystem shall have a Mean Time To Repair (MTTR) of better than two (2) hours, assuming the appropriate spare part is available. The Availability of the system shall be 99.999 % Scope of Work and Supply Closed Circuit Television (CCTV) System The CCTV System shall include PTZ (Pan / Tilt / Zoom) cameras at the Intake Area, Pipeline Corridor and Receiving Basin (RB) together with fixed cameras, with alarm capability, to accommodate the provision of motion detection facilities around the perimeter of the Intake Area. All cameras shall be IP. Company / Client is in the process of evaluating whether to proceed with motion detection or not in the Intake Area and consequently Security Field Layout Drawing No. show layouts with and without motion detection. There shall be a combination of fixed focus cameras and PTZ dome type cameras around the fence of the Intake Area to provide a system capable of motion detection. Only PTZ dome type cameras shall be utilised for a system with no motion detection. In both systems additional PTZ cameras for enhanced monitoring within the Intake Area shall be installed. Refer Equipment List Telecommunication Equipment, Document No. for quantities. The Contractor shall state in Appendix B the price reduction should motion detection not be implemented. There shall be two (2) PTZ dome type cameras installed at each the Pipeline Corridor and RB. Three (3) new monitors shall be installed in the CCR in the existing CB. Signals from all the cameras in the Intake area shall be available on these monitors. These signals shall also be monitored at the four (4) new monitors located in the PLANT CR at Main Gate House (MGH) via the existing upgraded CCTV network. System control shall be from the existing upgraded CCTV system. The signals from the CCTV cameras at the Pipeline Corridor and the Receiving Basin (RB) shall be monitored / controlled by the existing upgraded CCTV system from PLANT CR at MGH. The existing SDH Optical Transmission System shall be upgraded with Ethernet Modules to provide CCTV Camera(s) signal transport from the Intake area, LNG2 and Receiving Basin (RB) to CCTV monitors at CCR CB and CR PLANT at the Main Gate House and to the existing Network Video Recording System at PLANT CR at MGH which shall be upgraded to accommodate the additional data to be received. The existing upgraded CCTV System Management shall be further upgraded, including software configuration, in order to connect and activate the peripherals e.g cameras and monitors, as required to ensure a seamless integration of the CCTV System at the Intake Area, Pipeline Corridor and RB. Card Access Control System (CACS).
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The CACS shall be a stand-alone system installed in Gate Houses of the Intake area. Separate controllers shall be installed in each Gate House, integrated together in order to provide redundancy for each Gate House. The Access Control system shall have following facilities: Card Readers to enable in-bound and out-bound vehicle and personnel traffic. Vehicle gates; Turnstile gates; Automatic opening and closure of vehicle gates and turnstiles, Controlled access by pre-programmed access card(s) or by security personnel access control. Recording of time and date of in-bound and out-bound movement. The card readers shall be compatible to the existing CACS being used at the Main Gate. Security Lighting A photocell controlled, security lighting system shall be provided for the Intake Area perimeter fence. This shall consist of pole mounted floodlights. The poles shall be located inside the perimeter fence. The flood lights with high pressure HPSV lamps shall be used for the same. The illumination level at the fence shall be 150 Lux with overlapping fields facing towards the fence so that failure of one lamp shall not create any dark area on the fence. Refer: Perimeter Security Lighting Layout, Document No. Testing Testing shall take place in order to demonstrate the specifications of the equipment, sub system and system have been achieved Training Training shall be provided as stated in the applicable system Specification for Security Control and is to take place at site. The training shall be as per manufacturers standard syllabus and shall be conducted by the manufacturer. Documentation Documentation shall be provided for the design, purchase, installation, as built and O&M phases and as stated in Specification for Security Control, Safety, Fire Protection and Loss Prevention General Contractor shall be responsible for but not limited to the following: The Scope of Work includes the design, fabrication, procurement, installation testing and commissioning of the Fire Protection, Fire & Gas and Safety Systems described in the project specifications, Loss Control Philosophies and Drawings in the EPIC package, Appendix and Company / Client Corporate Philosophy for Fire and Safety Company / Client-PHL-S-001 and other related documents. Firewater Systems The existing firewater (seawater) system is to be extended to all end user plots at Plant Industrial City. Drawing A new firewater (fresh water) system is to be provided at the intake area. The power transformers (220 / 33 kv) located at the intake area, both existing and new (to be installed) are to be provided with deluge protection. The existing collection pit shall therefore have to be enlarged. Contractor shall verify the project Specifications and drawings for the following systems and develop as required and implement them. Fire protection system including: Fire water (Fresh Water) supply, storage. And Fire pumps (electric motor driven, diesel engine driven and jockey pumps).
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Fire water distribution layouts (seawater & fresh water network systems) including the deluge system. Fixed and portable, manual and mobile fire fighting equipment (including hydrants, hose reels, water spray nozzles and other specialised fire protection systems). Fire protection of Analyser Houses Fire and gas detection and alarm system Fire and Gas cause & Effect Charts Contractor shall verify the project specifications on Fire and Safety System and Fire Alarm and Gas Detection System and develop them as required and utilise HSSD (High Sensitivity Smoke Detection) system. The individual smoke detectors shall be ionisation type. Contractor shall obtain the necessary permits from Supreme Council and obtain import licence for these detectors Company / Client shall issue recommendation letter to concerned authorities if requested by Contractor Interface these fire alarm systems with the DCS system to alarm at the Main Control Room, existing PLANT Fire / Incident Control Room at the Main Gatehouse and a Fire Station # . All the buildings, Main Control Room, LLCCs, Sub-stations, chlorination units etc. Shall have fire and smoke detection and alarm systems which shall be interfaced to the DCS at respective locations and eventually to CCR. All the information from Phase system shall be available on the operator desk in the existing control room, existing gate house and in the new Fire Station #3. Presently all the existing data & displays of Phase are made available at PLANT Fire / Incident Control room at the main gatehouse through Telephone link. Location of this PLANT Fire / Incident Control Room is within the Security building located at the main entrance of the Plant Industrial City. Fixed and portable personnel safety equipment, including safety showers and face/eye wash stations are to be located at the electro chlorination plant and 33 kv Switchgear Building, while self contained eye wash stations are to be located at all battery rooms and analyser houses. Safety studies and calculation reports performed during FEED, including Operational Safety Study, and FMEA / FTA Study shall be updated by the Contractor. Contractor shall carry out, in consultation with Company / Client, a complete and detailed HAZOP Study during detailed engineering phase. A third party independent chairman shall be the team leader and the HAZOP shall be carried out as per Company / Client. HAZOP review shall also be carried out for Vendor Packages. Contractor in a report issued to Company / Client for review and approval shall detail the findings and the actions of the study. Contractor shall incorporate, as part of the detailed engineering work any / all modifications in the network design as requested and required by Company / Client, to comply with any portion of the study actions. Contractor shall verify storm water sewer systems, taking into account appropriate firewater disposal in the event of a fire in accordance with project Specification. Contractor shall develop escape route drawings for the buildings. Fire Protection, Detection and Safety System Contractor shall update, design and provide the Fire Protection, Detection and Safety Systems as developed during FEED. Contractor shall be responsible for developing and establishing the fire protection system, avoiding interference with underground facilities. Guidelines on the number
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and types of fire fighting equipment are given in the Company / Client Corporate Philosophy for Fire & Safety (Company / Client) and its references. Contractor shall verify, finalise and provide the number and types of fire protection, detection and safety items shown as a minimum. Mechanical Equipment Contractor shall be responsible for but not limited to the following. The Scope of Work includes the review and update of FEED specification and data sheets (as required for detail engineering development), fabrication, installation, testing and commissioning of the equipment installed at: Mechanical Cleaning Plant, Main Cooling Water Pump Packages (Novated items), Utility Services, Electro Chlorination Plant, Lifting Equipment (for maintenance service), Equipments installed at plant facilities are listed in Equipment List of Project Phase. All activities of procurement shall be carried out during detail engineering including development of Material Requisition / VDRL dossier. Contractor shall verify the FEED Specifications, data sheets and drawings and update / develop as required to implement them. Contractor shall include in his work scope for development of equipment specification and procurement engineering documentation, as required, when not included (missing or detail engineering development) in Equipment List of Project Phase. Main Cooling Water Pump Packages Contractor shall take full responsibility of owning novated Main Cooling Seawater Pump Packages (including electrical motor and VSDS system items) for Phase in accordance with Contract and ensuring guaranteed pump performance. The items included in above pumps package shall be as per Purchase Order dossier, further procurement engineering up to commissioning shall be the Contractors responsibility and scope shall include the following: Expedite, review and approve Vendors data sheets and drawings. Participate and witness all required Factory and / or site inspection and testing; ensure TPC is made available for the items of these packages. Organizing / conducting pump physical model tests at Pump Vendor works to demonstrate pump selection / performance, Organizing / conducting sump (pit) model tests at specified sub-Contractor works to demonstrate pump hydraulic performance with all required functional flexibility, considering intake screening equipment, to verify the intake sump and consequently the screening equipment, to finalize the intake sump (and consequently the pumps house dimensions). The sump model tests shall be carried out in the presence of Company / Client and Pump Vendor. Contractor shall take full responsibility to design and construct the sump pit in accordance with above results. Findings of Sump model test report conducted by sub-Contractor shall be endorsed and implemented by the Contractor. This may include provision for additional splitter, flow stabilizing device, a weir, etc. as recommended in sump model test report. Carry out the String test at Vendors shop for the first two Main Cooling Water Pump Packages including pumps, drivers, vsdss and associated auxiliaries. For other identical pump models, required performance tests shall be carried out at pump vendor works using electrical test setup established for previous string test. All necessary co-ordination with Vendors and/or Sub- Contractors for timely delivery of contracted scope. Prepare all as-built data sheets and drawings. Carry out pre-commissioning, commissioning and start-up of pumps.
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Deionised Water for VSDS The first fill of deionised water used for the VSDS cooling system shall be provided by Pump Packages supplier. Any further topping up requirements shall be accomplished by supply of deionised water by Contractor till Contract Completion. Electro-Chlorination Plant Verify and confirm Chlorination package sizing and selection. Prepare and update the package data sheets and specifications. Prepare material requisition packages. Carry out bid evaluation and vendor recommendation. Expedite review and approve Vendors data sheets and drawings. Participate and witness all required inspection and testing. Prepare all as-built data sheets and drawings. Carry out pre-commissioning, commissioning and start-up of the packages. Co-ordination with Vendors and Subcontractors. Mechanical Cleaning Plant Contractor shall procure these items in accordance with project specifications / data sheet included in FEED dossier (and covered in Equipment List) after review, verification and detailed engineering and design. Coarse screening shall be performed at Fixed Bar Screens installed at Screen Yard upstream of pumps houses. Common traversing trash rake (grab bucket cleaner) and debris collection system shall be installed as covered in applicable specifications / data sheets. Screen bar material shall be to accomplish detachment / retarding of marine shells clinging to bars. Rotary Drum Screens are to be installed for finer (mesh opening 3 x 3 mm) screening before seawater (service fluid) is fed for further pumping and construction materials requirements are covered in applicable specifications / data sheets. Contractor shall provide the falling object protection for drum screens. Design approval of Company / Client shall be required. Utility Services Contractor shall procure these items in accordance with project specifications / data sheets included in FEED dossier (and covered in Equipment List) after review, verification and detailed engineering and design. Utility services include Instrument Air Compressor Dryer Packages, Portable Submersible Pumps (for emptying compartments of Pump Sump Pits, Receiving Basin) and pumps for draining of piping sections / manifolds. Lifting Equipment Pump Houses and Screen-Yard Cranes (Common crane and additional cranes): In Phase of the project extending of existing 60T / 40T capacity EOT Crane at pumphouse and 10T capacity Semi-Portal Crane at screen-yard is envisaged. Common crane study report included in FEED dossier provides details of modification to be implemented. Besides this, an additional crane requirement at above two locations is subject to RAM study recommendation. Contractor shall carryout RAM study and confirm requirement of additional Cranes at pump house and Screen Yard.

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Contractor shall procure these items in accordance with project specifications / data sheets included in FEED dossier after review, verification and detailed engineering and design. Manifold Area Cranes: Phase II of project facilities envisages Craneage to handle ccvs and Isolation Valves installed at manifold area. This new facility requirement is addressed in Material Handling Study Report and FEED dossier Equipment List covers the required equipment to be installed for servicing of manifold area items. Other Handling / Lifting Facility: Contractor shall procure and supply all material handling items covered in Equipment List as stated in Material Handling Study Report, which shall be updated during detailed engineering stage after review and verification. Contractor shall prepare procurement-engineering dossier when required for procurement of off-the-shelf items such as manual chain-hoist with trolley on monorail beam etc. And supply the same. Mobile equipment viz. Mobile Crane, Fork Lifts etc. To assist transportation and handling of materials are not covered in equipment list / material handling studies. Being construction / operation aids these mobile facilities are envisaged to be directly purchased by Company / Client, only guiding specification / data shall be provided by Contractor as per detail engineering developments. Noise Control Contractor shall be responsible for but not limited to the following: General Requirements (Refer to Company / Client Corporate Philosophy for Fire & Safety Company / Client-Environment Protection Law National) Contractor shall comply with all rules, guidelines, regulations, procedures, programmes and policies in the Environmental Guidelines & Environmental Protection Criteria for Plant Industrial City during the execution of the WORK. The Environmental Guidelines & Environmental Protection Criteria for Plant Industrial City The initial calculation shall be based on equipment meeting the sound level and sound power level limits of Company / Client Specification. The final calculation shall be based on the vendor quoted and tested equipment sound levels. These calculations shall be included in an initial and final report, which shall be submitted for Company / Client approval. These reports shall contain the following: Equipment list. Equipment physical data such as size, speed, and power. Equipment location. Estimated industrial community sound level at Company / Client determined locations. Estimated sound level contours including in-plant areas, at fence line, and at inner edge of perimeter infrastructure road in 2.5-decibel (dba) increments. Equipment sound power levels used in the model. Equipment sound levels at one meter. Noise control treatments proposed. Vendor sound level reports. Vendors shop test reports. The final report shall be called the "Noise Control Design Basis - Summary Report". Contractor shall conduct a co-ordinated overall noise control program, including cost effectiveness comparisons. In addition, Contractor shall recommend such alternative or additional acoustical design features or treatment as needed to meet the requirements. Contractor shall ensure that the sound pressure level of cooling water pumps shall not exceed the values specified in Contract by applying any attenuation devices.
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Contractor shall be responsible for identifying any necessary reduction of equipment sound level limits specified in Company / Client specification, to ensure compliance with the FACILITY sound level provisions. Environmental Control Contractor shall be responsible for but not limited to the following: General Design Requirements Contractor shall finalise the design documents incorporating design data including emission data obtained from the Vendors. Contractor shall be responsible for compliance with the local Environmental Control Regulation and Project Specifications provided in the Contract. In general, the FACILITY should be designed to meet the ambient air quality and water quality guidelines of the National regulations as specified in the Project Specifications. Engineering Evaluations Contractor shall verify or finalise the engineering evaluations to ensure that the environmental control systems as designed shall comply with the required regulations. Cathodic Protection System Contractor shall be responsible for the pre-design survey, design, detail engineering, supply of material, installation supervision, commissioning and start up of cathodic protection systems. An impressed current cathodic protection technique shall be utilized / applied to provide the corrosion protection for seawater screen equipments, earthing system, concrete rebars of facility foundations and pipe support foundations adjacent to the Intake Area. Sacrificial anode cathodic protection technique shall be utilized / applied for the protection of pipe support foundations in areas remote from Intake Are. Cathodic Protection Systems shall cover the following: Seawater screen equipments-Bar screens-Drum screens-Stop log guides-Stop logsFacility Foundations-Pump house pit concrete re-bars-Receiving basin concrete rebars-Outfall structure concrete re-bars including discharge channels-All building foundations-All structure pipe supports/ foundations within the water table or / and below + /- 0.0 m -Earthing Systems -Pump houses-Building area at Intake-Receiving basin-Manifold areas-LLCCs-Detail Design Specifics Contractor shall incorporate the specific following requirements into the detailed design Scope of Work. Contractor shall engineer, connect and configure the signals for monitoring and controlling the FACILITY pertaining to this Project only. Twenty percent (20%) of the spares shall be connected and configured as spares as detailed in the specification provided under Appendix. Provision for expansion shall be made for connecting any additional signals (future). Contractor to co-ordinate with PLANT and Electrical authority through Company / Client. Due to the marine / dusty / humid environment at Plant area, all transformers shall be designed with suitable bushing / terminal enclosures or bus-ducts, to avoid pollution and random tripping. Contractor shall submit to Company / Client Hydraulic Models of Phase along with licensed Software programme, spreadsheets & Manuals used for the analysis.
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Company / Client shall have access to the simulation models while the simulation work is being done by the Contractor. Contractor shall undertake Hydraulic Model studies and submit results during the detail design stage. Contractor shall comply with the following when preparing the hydraulic model: Marine Works in particular Physical model requirement Ensure that minimum flow of seawater is 300000. m3/hr. Allow to clean up the beach twice at start and at completion of works (at intake and outfall areas) for a distance of 500m extending both sides of intake and outfall areas, i.e. Total distance of 3000m. Allow for cut and fill complete with compaction to 100% of Maximum Dry Density (MDD) as specified for the full widths and lengths of pipe corridors. Excavation may require blasting. Excavation in rock & varying materials and backfilling shall be carried out in Phase. All pipes shall be installed above finished grade on pipe supports / saddles (complete with inserts) as the design shall dictate. Contractor shall develop and optimise pipe corridors to take all Phase pipes, mainly pipeline routing / layout. Contractor shall carry out site grading of pipe corridors to allow the flow of rain, surface and spill water to the surface water drainage. Allow for grading area completely around intake structure by cut / fill and compact to receive Phase structures. Allow for the design and construction of surface water drainage to cater for rain and spill water. Water shall be collected by a network of concrete paved ditches and discharged into the sea. V or trapezoid concrete paved ditches shall be designed and constructed. Protection to ditches and warning signs shall be allowed for. Design and install chain link fences around building and local Control room areas as a minimum. Covered car parking is required for the operation building and as shown on the drawing attached in Appendix Contractor is to allow for the design and construction of 10% extra for each building, e.g. Building X has to be minimum 500m2 to accommodate all personnel and equipment in accordance with the best international standards. Therefore, Contractor shall have to design and construct building X to be 550 m2. Allow for temporary access roads during construction such as diversion roads. Such roads shall be subject to Company / Client formal approval. Allow for seismic loading, where appropriate, in accordance with the Uniform Building Code for Zone 1. Allow for the design and installation of access over Cooling Water Piping. Number, type and location are subject to Company / Client formal approval. Allow for all concrete, whether mixed and placed in Marine works and/or other structures to comply with project specifications. Design and construct roads as access to substations, chlorination building, control building, pump house and other buildings as shown in the Plot Plan. Allow for surveying and relocating sand dunes within the pipe corridors, intake and outfall areas. All the local Control Rooms at the consumer lot interface as well as other electrical installations shall have separate battery rooms and space for telecommunication equipment. At the Consumer Lots / Interfaces, existing consumers have generally agreed to provide the required LV power supplies up to the battery limit.
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The Contractor shall carry out a complete study on Material for the entire Phase project and produce a report for Company / Clients approval during the early stages of the project. The work shall be carried out by a third party consultant or by the Contractor itself provided it has the in-house capability to the satisfaction of Company / Client. The Contractor shall implement any approved recommendation or findings of studies carried out during FEED such as RAM, FMEA, Hydraulic Studies by HRW, SYSOP, SAFOP, OPTAN etc. Design of elevated floor slabs of substations shall be as per Drg. The PLANT 11kv network is not part of the CCWP Phase I installation, therefore all works involving tapping into the existing 11kv network of PLANT shall involve the following: Collection of As-Builts drawings and CYME calculations if any, from PLANT and verify that they are suitable for the proposed modifications i.e. Perform load survey, check protection settings etc. Verify that the new loads when added shall not affect operations. Calculations (using CYME) & report of load flow, protection settings, etc. Shall be submitted to Company / Client for review. Protection settings shall include 11kv source circuit breaker upto down stream LV circuits of LLCCS. On completion of the proposed works, existing As-Built drawings shall be updated to reflect the new works, as performed by Contractor. Also, soft copy of CYME calculations shall be handed over as part of final documentation

--------------------------------------Chapter 9
Procurement
General Contractor shall perform the procurement and expediting of all materials and equipment necessary for the performance of the WORK in a timely manner and in accordance with the Execution Programme. For the purpose of this Contract, the terms seller, Vendor, Supplier and SubContractor shall be interchangeable in meaning and context. Contractor shall be responsible for the performance of the following activities. Identification of material procurement requirements and preparation of a procedure for Company / Client approval. Preparation of all materials take off. Preparation of requisitions Preparation of Purchase Orders Purchasing and Expediting All vendors selection / evaluation, taking due account of Company / Client list of approved Vendor Consideration of minimum maintenance philosophy. Adherence to any standardisation requirements from Company / Client. Consideration of quality related to Contractors warranties and guarantees. Provision of the best possible warranties and guarantees from vendors for Company / Clients benefit Inspection and testing of all procured materials by TPC. Transportation of all materials to Site including packing to sea freight/air freight standard as required.
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Storage, preservation and handling at Site. Identification of spare parts requirements. Preparation and issue to Company / Client of completed spare parts interchange ability record (SPIR) forms within 3 months of placement of Purchase Orders. Procurement of pre-commissioning, commissioning and start-up spare parts. Procurement of insurance spares (If specified to do so by Company / Client). Procurement of 1-year operations spare parts (If required to do so by Company / Client). Customs clearance including payment of customs duty and payment of legalisation fees. Payment to Vendors Efficient use of materials. Vendor support and assistance during construction, pre-commissioning, commissioning, start-up and performance testing (as necessary). Obtaining all necessary certification and as built drawings and data from vendors including Quality Assurance Record Manuals, Operations & Maintenance Manuals etc. Issue closeout report highlighting vendor performance. Long Lead Items Novated to Contractor During the FEED Phase of the Project, equipment, packages and systems that have a longer delivery time are identified as under: Main Cooling Seawater Pumps Main Seawater GRP Piping The main cooling seawater pump scope of supply includes pumps, variable speed motors, variable speed system, transformers etc. Scope of supply for main seawater GRP piping includes GRP pipes, GRP fittings, GRP flanges, etc. GRP piping is split into 11 packages, which shall be supplied by multiple Vendors. Complete purchase requisitions including specifications have been developed and issued to potential suppliers. Quotations when received shall be reviewed for technical compliance with the enquiry and requisitions. Company / Client intends to award the purchase orders for the above critical long lead items prior to Contract award, in order to maintain the project schedule. A copy of the Material Requisition package for both the above long lead items is enclosed with this tender document in Appendix. The Contractor shall consider that the items listed in the Material Requisition shall be ordered by Company / Client on ExWorks packed and loaded on truck / trailer basis. Upon award of Contract Company / Client shall assign the purchase orders to the Contractor through a novation agreement. The Contractor shall take over full responsibility for the successful design and supply of the long lead items to meet the project engineering design requirements and schedule. Contractor shall be the single point responsible party for the long lead items in all respects. contractor shall endorse the purchase order requisitions and specifications.
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Contractor shall review and verify the purchase order requisitions in all aspects and if necessary shall carry out all required additions or amendments to purchase order requisitions to cover up any omissions / errors / shortcomings/deficiencies as deemed necessary for the successful design, supply and commissioning of all long lead items with prior approval of Company / Client. Purchasing Contractor shall be responsible for the following purchasing activities as a minimum: Prepare RFQ specifications and documents for all equipment and materials in accordance with the Project specifications. Ensure that the terms and conditions of purchase, requirement of Pre-Commissioning, Commissioning, One Year Operational Spare Parts, SPIR forms, Vendor site support services and Final Documentation have been reviewed by Company / Client and included properly in the enquiry document. Rfqs shall be subjected to Company / Client Approval. RFQ shall specify the Quality Program of Vendor(s) which shall comply with the requirements of ISO 9000 series, 2001 edition and requirement of Company / Client QA/QC procedure Conduct purchasing in accordance with Company / Client approved vendors, and Subcontractor List. Procurement of those items which are not listed in approved List shall be subject to Company / Client approval and shall be carried out on a world-wide competitive basis except when technical regulations or specifications require otherwise. Contractor shall abide by the National regulations regarding the countries of origin. Review bids received from vendors and prepare technical and non-priced bid tabulations advising the selected vendor and the ranking of the others. Company / Client review and approval shall be sought prior to placement of purchase orders for all major / critical equipment/items. Review all equipment/ material selection and verify their suitability and operability for the service intended. Before placement of purchase orders, assess and ensure that the financial status, availability of Vendors recommended Pre-Commissioning, Commissioning, One Year Operational Spare Parts, including quantity and unit prices thereof, present work load and suitability of the vendors are satisfactory to meet project objectives. Technical bid tabulation and Vendors technical proposals / clarifications shall also be provided to Company / Client for approval if Vendor is technically acceptable. Contractor shall submit to Company / Client lists and prices of 1 Year Operational Spare Parts with the technical and non-priced bid tabulation. Prepare purchase orders, complete with all attachments (i.e. Purchase requisitions, specifications, drawings, shop inspection and testing requirements), spare parts requirements, Vendors and Suppliers assistance requirements. Provide copies of nonpriced purchase orders or any revision thereto to Company / Client. Purchase all project equipment and materials as per the specifications and in accordance with the requirements of Execution Programme. Contractor shall ensure that Purchase Orders are placed with only reliable Vendors/Suppliers approved by Company / Client.
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Contractor shall ensure that Critical Equipment such as Main Cooling Water Pumps, VSDS, Chlorination Plant, Mechanical Cleaning Equipment, Switchgears, Motor Operated Valves, Control Valves etc. Shall be of proven type equipment, not prototype. Issue status reports on purchasing activities to Company / Client in accordance with Appendix D. Review and approval of Vendors drawings and documents (core drawings / specification to be submitted to Company / Client prior to approval by Contractor). All Vendors drawings and documentation shall be in accordance with Company / Client Engineering Standard for draughting Contractor shall engage the services of Glass Reinforced Polyester (GRP) pipeline manufacturer / designer, as a single point responsible party, to carry out detail pipeline engineering, manufacturing, fabrication, jointing, installation, QA / QC, inspection and commissioning for the piping system supplied by the particular manufacturer. All the activities related to novated items as per item 5.2 above. Expediting In accordance with execution program, Contractor shall perform expediting of equipment, materials, Vendors data, technical assistance, personnel and documentation from RFQ to delivery at Construction Site for Vendors items including the materials on suborders. Contractor shall maintain a system to monitor progress on all the purchase orders and prepare and issue a detailed schedule to Company / Client in accordance with Appendix. The system shall be able to identify those items of the equipment and materials which are critical or are potentially critical from Execution Programme point of view and require special attention to ensure timely delivery, along with an action plan to achieve it. Contractor shall not limit his expediting activities to only the progress reporting. Contractor shall take appropriate remedial action with Vendors who are behind schedule. Contractor shall promptly recommend appropriate alternative remedial action to Company / Client and implement the same. All expediting efforts shall be directed towards achieving or improving the equipment and material delivery dates while maintaining the purchase order design specification, conditions and Schedule Completion Date. Any actual or potential deviations or slippage from these requirements shall be immediately transmitted to Company / Client in writing. Contractors expediting activities shall include, but not be limited to, the following: Contractor shall expedite and take all appropriate actions to obtain all technical data and other documentation, including completed SPIR forms and Final Documentation, from the vendors and their sub-vendors in a timely manner. During the Guarantee Period, Contractor shall expedite all the replacement materials, associated documents and vendors assistance. Contractor shall submit weekly Material Status Report to Company / Client.
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Inspection and Testing Contractor shall execute inspection activities for all equipment and materials in accordance with the following requirements: Contractor shall carry out all inspection and testing required for all equipment and materials, and shall be responsible for ensuring that all equipment and materials are strictly in accordance with the specifications as defined in the Purchase Order. Contractor shall specify identifiable requirements based on Company / Client' class of inspection' for each material requisition, or alternative procedures designed to ensure an equally high standard of inspection. The minimum requirement of Company / Client is specified in Exhibit of Appendix. Contractor shall prepare a document establishing criticality rating system of all equipment and identify the level of surveillance inspection required for Company / Clients review and approval and shall form part of its overall quality management system and plan. Full load tests, reduced load tests and / or no load string tests shall be as specified in the Contract. The minimum Company / Clients requirements are listed below: Inspection shall be performed by qualified Third Party inspectors employed by Contractor. Shop inspection shall be carried out by Contractor at both the point of manufacture and, where necessary at the source of Vendor(s) and / or sub-vendors materials. Contractor shall be responsible for all quality assurance activities including Vendor(s) and / or sub-vendors inspection. Provision shall be made at all times for Company / Client to have the option of participating in pre-inspection meetings, inspection visits and test witnessing. Contractor shall prepare anticipated weekly testing programs providing Company / Client sufficient advance notice for their participation (at least fourteen (14) days). Contractor shall note that FAT shall be witnessed by Company / Client Engineers and all the services and facilities to Company / Client Engineers shall be provided by Contractor in accordance with relevant Section of Appendix (not included). Contractor shall provide twenty-one (21) days notice to Company / Client for FAT. Contractor shall submit to Company / Client written reports on expediting and inspection carried out in sufficient detail for Company / Client to monitor the effectiveness of inspection. Inspection reports shall be issued to Company / Client within three (3) calendar days of the inspection visit. Contractor shall prepare and provide to Company / Client an inspection co-ordination procedure to be developed in accordance with the Contract. Contractor shall compile all fabrication and manufacturing data folders containing mill test certificates, machinery test certificates, performance test Certificates, type Test Certificate where required, and all other relevant inspection data and submit the same upon delivery of equipment and /or material to Construction Site. Contractor shall be responsible for checking all material on arrival at site and the issuance of any Overage, Storage and Damage Reports (OS & DRS) may be required.
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Certification Contractor shall be responsible for arranging and co-ordinating the use of TPC services where required for equipment and materials in the country of origin, for statutory, insurance, or any other reasons. Minimum requirement of TPC services is provided in Exhibit of Appendix Such requirement shall in no way relieve Contractor of his responsibilities under the Contract. The TPC shall function independently and report simultaneously to Company / Client and Contractor. The list of Company / Client approved TPC Subcontractors is provided in Exhibit of Appendix. Contractor shall prepare a Certification Matrix in accordance with the requirement of Exhibit of Appendix for Company / Client Review / approval. The TPC scope shall include but not limited to the following: Checking Project equipment and bulk material list. Attending kick-off meetings and pre-inspection meetings to specify and ensure that the entire Quality requirements have been met. Reviewing the high criticality rating of equipment and packages before the placement of purchase orders. Ensuring that type of certification required by Company / Client is compliant with the requirements. Reviewing Vendors data requirements lists and identifying those documents required for certification purpose. Checking that the standards requested by Company / Client have been implemented for a wide range of products and the minimal approach has been adopted. Reviewing and certifying Vendors quality plans and specifications for the procurement certification level. Conducting monitoring visits to Vendors to review procedures for generating certification. Reviewing the documentation prepared by Vendors as part of the Final Documentation. Insuring that all special requirements for equipment in sour service have been complied with. Shipment and Freight forwarding Contractor shall be responsible for sanctioning the release of completed equipment and materials for shipment after satisfactory completion of final inspections and certification and shall execute forwarding activities for all equipment / material (including long lead equipment items). Contractor shall be responsible for organising and co-ordinating packing, marking and transport of equipment from the source of supply determined in the purchase order to the Construction Site. Such work shall include:
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Preparation of seaworthy / airworthy packing, marking, shipping and documentation specifications. Inspection and certification as the case may be of packing, marking and loading. Taking responsibility for authentication of shipping documents (including Certificate of Origin) by National Embassy / Consulate. Develop plans and procedures for freight forwarding, handling and customs clearance of equipment and materials to ensure that all freight is consigned to arrive at the Construction Site on time. Organise and ensure timely shipment of materials and equipment to Construction Site. Prepare, maintain and issue a monthly shipping progress report and monthly shipping forecast in a format approved by Company / Client. Arrange for the importation of all materials and equipment purchased, for receiving and off-loading at Construction Site including organizing and securing approval from relevant authorities for shipment and transportation of heavy and bulky equipments and materials. contractor shall give preference to Plant Port while importing materials. Plant Port is a modern port and has necessary FACILITY like exclusive heavy load berth, cargo berths etc. To facilitate Project import materials. Contractor shall provide its own craneage facilities for all loading and offloading operations at the heavy load and dry dock berths at Plant Port. Contractor shall be charged by PLANT for the use of the port facilities at Ras Laffan. Details of these charges are given in Appendix. Contractor shall comply with Plant Port Regulations given in Appendix. Sea / Air shipment, Inland Transportation and Customs clearance Contractor is fully responsible for arranging inland transportation, sea/air freight, legalising/authorisation of Certificate of origin and other shipping documents, voyage insurance, customs clearance including payment of customs duty, legalisation fees and transportation of all equipment / material to the Construction Site Storing and Material traceability All equipment and materials shall be carefully handled and stored in adesignated area at Construction Site. Fragile equipment sensitive to the weather conditions (such as instruments) shall be stored in totally enclosed, heated and/or air-conditioned rooms. When installed, they shall be protected from the sun or from sand ingress by temporary shelters or plastic sheets. Handling, preservation and storage of equipment and materials shall be carried out in conformance with Vendors' instructions and Company / Client specifications.
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All Materials including spare parts shall be subjected to an appropriate traceability procedure so as to ensure easy retrieval of materials and related documentation for each item in all circumstances. For this purpose, Contractor shall provide experienced personnel for warehouse management and goods inward / outward control utilising PC based software allowing status progress at all times. Spare Parts While floating RFQ, Contractor shall instruct the Vendors to indicate the requirement of Spare Parts as shown below: Commissioning Spare Parts spares for pre-commissioning and commissioning. Initial Spare Parts spare parts to safe guard the operation of equipment during the start up / running in and first year of operation. Spare Parts for Normal Operation spares for day-to-day maintenance for the period of one year following the initial operation. Contractor to ensure that while submitting their quotation, Vendors shall provide description of the Spare Part items, number of Units recommended, ex-work Unit Price including seaworthy packing. Company / Client shall not approve any purchase order to be placed unless accompanied by One Year Operational Spare Parts and Capital spares list and prices. Pre-Commissioning, Commissioning and Initial Operation &Maintenance Spare Parts and others Contractor shall procure and supply Pre-Commissioning, Commissioning and Initial Operation and Maintenance spare parts, chemicals and lubricants, special tools and handling gear for each equipment as necessary up to Completion. Contractor shall develop a procedure for the proper receipt, stacking, storage and handling of the spare parts and provide all the supplies and services in accordance with the same. The Contractor shall provide list of all spares prior to their usage for site activities. The Contractor shall record all spares used during the site activities and update the list on a monthly basis. The Contractor shall be responsible for ensuring that the spares provided (type and quantity) match with the requirements of the equipment. Spare Parts for Normal Operation One Year Operational Spare Parts as such do not form part of Contractor supplied items under the Lump Sum Contract Price. Company / Client may procure One Year Operational Spare Parts and Capital Spares through Contractor for which Contractor shall be reimbursed in accordance with the provisions of Appendix of the Contract. The Prices quoted by Vendors are to be kept firm throughout the duration of the Contract and no escalation in this regard shall be entertained by Company / Client. SPIR Forms SPIR procedure and a sample SPIR form are enclosed in Appendix. Contractor shall obtain through the successful Vendors a completed SPIR form duly filled in within three
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(3) months of placement of Purchase Orders. Following review of the SPIR, Company / Client may instruct Contractor to procure the One Year Operational Spare Parts. It shall be noted that One year Operational spare parts are required to maintain the FACILITY immediately after Completion Date. Consequently completion of the SPIR form with all related drawings, etc. Shall be undertaken expeditiously by Contractor. Company / Client approved vendors and Sub-Cont Contractor shall ensure that it procures equipment and materials only from Company / Client approved Vendors (Ref Exhibit of Appendix not included). For procurement of equipment and material for which no vendor list has been provided by Company / Client, Contractor shall propose suitable Vendors. Contractor shall establish that the Vendors / Suppliers proposed have previous experience of supplying similar type of equipment / materials to such projects. Contractor shall provide all relevant information for the vendor proposed for Company / Client to determine the suitability of vendor and its ability to comply with the pertinent requirements of the Contract. Any deviation to the Company / Client approved vendor list shall be avoided. When specifications call for a particular brand or type, any proposed substitutions shall be subject to prior approval by Company / Client. Notwithstanding the foregoing, Contractor shall be fully responsible for the procurement, timely delivery and performance of the vendors equipment, materials and services. Should Contractor propose the use of non-recommended vendors, it shall present the following information to Company / Client in the form of Pre-qualification document for review and approval prior to placing related Purchase Order(s): Financial records demonstrating the commercial stability of the proposed vendor for the last three (3) years. Records demonstrating that the vendor has appropriate and relevant industry experience and in particular experience for supplying similar item. Records demonstrating that the vendor has services support for its products or services in National (preferred) or in the Middle East. Records in the form of correspondence / confirmation from vendor demonstrating inability of the listed Company / Client approved vendors to supply the equipment / materials. Once the pre-qualification documents have been reviewed, Company / Client may instruct Contractor to undertake registration of some Vendors / Suppliers with Company / Client Materials Department before approval of Vendor / Supplier.

---------------------------------Chapter 10
Construction
Introduction
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Contractor shall carry out all construction work in accordance with procedures and methods prepared during detail engineering for all construction trades in accordance with the Project specifications. All details of the FACILITY shall comply with Approved For Construction drawings, specifications, and all applicable engineering and technical standards and codes. Contractor shall plan construction in such a way that the FACILITY can be built, PreCommissioned, Commissioned and Started-Up in sequence. In particular, Contractor shall Commission the utilities well in advance for the purpose of Start-Up of the FACILITY. General Construction Requirements The FACILITY for the Project shall be provided and constructed in a safe, timely and reliable manner. The latest construction techniques and equipment shall be used to provide an effective construction approach, to achieve the Scheduled Completion Date. During construction of the FACILITY, Contractor shall comply with Company / Client safety and work permit procedures, and shall enforce a set of Approved safety rules and precautions for Work at Construction Sites. Contractor construction work shall include, but not limited to, the following: Obtaining all approvals, and permits for the Work as per Company / Client regulations. Establishing Construction Site safety rules and providing a Safety Manager, Officers and staff for the Work. Providing construction personnel, temporary works, Temporary Facilities and other facilities required for construction: In order to ensure the proper performance of the Work in accordance with the Subcontract Schedule, from the commencement of the Work to its completion, Subcontractor shall fully adapt his organisation for each specific phase of the Work to fulfil all Subcontract requirements and accordingly shall mobilise, develop and maintain the overall functional organisation and corresponding resources, including when, where and as necessary by providing additional means. All construction equipment, scaffolding, tools, protection, testing and control equipment, auxiliaries, consumables, etc., and personnel (including management and supervision), necessary for the performance of the Work in particular for handling, transportation, warehousing, prefabrication, erection, testing. These include, but are not limited to: Provision of maintenance and running of construction equipment Provision of safety equipment and tools for personnel and works Provision of personnel small tools Provision of mechanical equipment and material necessary for working in water free conditions, whatever the volume or flow Provision, storage, distribution and disposal of consumables (oil, lubricants, gas, etc.) And auxiliary materials (planks, timbers, tarpaulins etc.) Provision of scaffolding and protection material Provision of materials and apparatus for the technological laboratory to test materials, welders and provision of materials and apparatus to test all completed works Safety equipment Providing accommodation, lodging and transportation for construction personnel from Contractor, Subcontractors and Vendors.
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Preparing construction procedures for the Work, which shall be submitted for Company / Client approval. In addition Contractor shall ensure: Preparation of the Inspection and Test Plan (ITP) in compliance with the above and the Contract conditions, to be submitted for approval to Company / Client Execution and recording of all test and inspection for equipment / materials and Work Verification / checking the conformity of the Work and provide records Issuance of construction method statement as per Company / Client request (for critical works) Contractor must be able to prove at all times that the quality of the Supply incorporated in the Work complies with the quality specified in the Contract. Managing and co-ordinating and supervising the work of Subcontractors and Vendors to ensure Work is performed on schedule and in accordance with the quality and safety requirements. Preparing detailed schedules for the Work in accordance with the Execution Programme, regular monitoring of this schedule and making appropriate adjustments to obtain most efficient usage, taking into account the interfaces with TEL, Electrical authorirty, MMAA and other parties involved. Providing detailed manpower and construction facilities deployment charts. Providing schedule and progress reporting in accordance with the requirements of the Contract: Progress reports (daily, weekly, monthly, flash) HSE report Work schedules Physical progress reports Construction equipment status reports Supplies status reports, unpriced copy of purchase orders, certificate of origin of all equipment and materials to be provided by the Contractor. Monthly status of material taken over by Contractor Updating of the list of work items drawings Providing a quality assurance plan and developing quality control procedures. Providing all Temporary Facilities required for the Work: Erection, maintenance, dismantling and removal of all temporary Site facilities, including all complementary works, civil, electrical, etc. Inside the allocated areas. It includes, but is not limited to: Contractor and Subcontractors site facilities such as office, workshop, warehouse, shelter, sanitary building, storage area, concrete or bituminous mix production plant, etc. Including all complementary works, civil, raw and potable water and sewer networks, power supply, etc. Inside the allocated areas, Lighting of the works areas Temporary works to prevent personnel from injuries and/or properties from damage Scaffolding and safety equipment necessary for the Works. Such scaffolding and safety equipment must be left in place as long as necessary to allow inspection, tests and control Contractor and Subcontractor office facilities Company / Client office facilities Contractor and Subcontractor warehouse All site utilities for Contractor needs to include, but not limited to: Power supply Power supply cost (for Contractor use) Water supply (Potable, Raw) Potable water Supply cost (for Contractor use)
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Potable or raw water supply cost (for construction works use except for piping hydro test) Raw water supply cost (for piping or equipment hydro test) Treatment of the raw water for hydro tests Nitrogen supply for pre-commissioning works Nitrogen supply for Works including cost (for Contractor use) Air supply Air supply costs (for Contractor use) Disposal of all sewer and wastewater, rubbish and trash Fuels and lubricants for the temporary facilities and construction equipment Maintaining construction records in formats to be submitted for Company / Client approval. Ensuring timely mobilisation of Vendors' representatives and/or any specialists, and their retention at Construction Site for the required duration. Providing QA / QC and inspection services for the Work. This shall include, but not limited to civil, structural, welding, piping, mechanical, electrical, instrument and painting inspectors. Contractor shall mobilise a Third Party Inspection Agency (TPI) to perform the following: NDT and interpretation-Civil Lab Testing-Load Tests Any other required Personnel and QA / QC Inspectors shall be provided by Contractor. Contractor shall mobilise adequate level of Inspectors. QA / QC Procedures and Equipment shall be subject to Company / Clients approval. Maintaining and operating an adequate system of control of availability of drawings and specifications at their latest revision at all places where the Work is performed. Maintaining and operating an adequate material control procedure at all places where the Work is performed. Assisting Company / Client with technical safety reviews to confirm that the FACILITY can be operated, maintained, shutdown and started up in a satisfactory manner. Managing field queries, field changes and revision of drawings. Preparing a complete set of data sheets, specifications and as-built drawings. Preparing rigging studies as required. Mobilize in a timely manner the construction management team to Construction Site in National. Contractor should in particular submit: Detailed construction execution plan, taking into account the Site constraints Mobilisation plan Scaffolding plan, including resources, technical solution proposed material specification and scaffolding management (HSE) procedure The nominative organisation charts down to but excluding Foremen level and corresponding CV's The list of resources assigned to the Work: Personnel per category and nationality and split between the different disciplines and significant activities within each discipline as required in the Particular Exhibits Construction equipment (type and quantity) Allocation of Site temporary facilities and storage areas to Contractor The Site temporary facilities detailed layout drawing and description The Site storage areas (raw materials, finished materials) detailed layout Provide housekeeping personnel for the Work on the basis of one cleaner per 25 persons. Reinstate existing roads, track, channels and secondary roads to original conditions and specification. Arrange for protection of turtle eggs during construction.
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Contractor shall do whatever is necessary to take care of rock, obstructions or/and unsuitable materials present within the Construction Site. Contractor shall dismantle and remove X nos. Temporary Cofferdam and take ownership of sheet piles and deliver the pre-cast units to Plant Port as directed by Company / Client. Contractor shall within 30 calendar days from Contract Effective Date supply and install its own dewatering system in the cofferdam constructed by other Contractor. Contractor is aware that there are buried services (pipe, cable, and duct) within the battery limits, and that co-ordination with Company / Client / Plant (for as-built drawings) shall be required during detail design, and that hand excavation shall be required in certain areas during construction unless confirmed in writing by Company / Client. Protection and preventive maintenance of the Material handed over to or supply by Contractor as per the state of art and the suppliers recommendations. Contractor shall be responsible for the following: Respect of Site constraints (safety, units in operation, site layout, location and set-up of temporary Site facilities etc.) Protection of all tracks and roads used by Contractor and subcontractor and located in the vicinity of the Site Make good to the original condition at Contractor's cost of the parts damaged by Contractor or his representatives (Concrete, steel structures, piping, instruments, painting, etc.) Installation, dismantling and removal of all temporary protection devices used by Contractor to protect personnel, structures, piping, facilities and equipment on the Site Any precaution and measure to avoid damage caused by traffic, dust, noise and any other cause that may affect the personnel, buildings, equipment or goods located nearby Contractor shall be responsible for the following: Daily collecting and removal of any materials used within the works areas such as iron scrap, debris etc Disposal of refuse and debris in the relevant authorised dumps Housekeeping of the areas allocated to Contractor Daily cleaning of Site and of all tracks and roads used by Contractor and located in the vicinity of the Site. This also includes spraying of water, if required, for stabilising the dust. Destruction of temporary paving and concrete works including removal, transportation to an authorised dump and levelling of the concerned areas Returning the Site to a suitable condition at Completion of the Work Work Permits Procedures and Regulations Contractor shall comply with Company / Client Work Permit Procedures and Regulations appended in Appendix and with Electrical Authority / Plant Work Procedures, when working at Plant and at NCC. The following Company / Client Regulations shall also apply: Electrical Safety Instructions Plant Security guidelines Consolidated Permit to Work system in PlantIndustrial City. Company / Client Lifting Equipment regulations Plant Mutual Aid programme Regulations for disposal of Dredged Materials within Plant Industrial City Health, Safety and Environment Plan in conformance with Company / Client requirements
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Construction Site Preparation and Construction Site Access Contractor shall accept the Construction Site work "as it is", and shall complete the excavation work as required, dispose of ground and rain water, provide the complete required infrastructure, including additional temporary fencing, security gates for the FACILITY, roads, ditching, sewers, and more generally, be ultimately responsible for finalization of any Construction Site preparation work required. The Construction Site preparation shall include Construction Site clearance, rough grading, general earth works, leveling to grade selected, temporary boundary fencing, opening of roads on Construction Site, excavation and blasting, if required. Contours are provided, but the ultimate responsibility for the final contours shall be with Contractor. Site preparations and transport of quarried construction materials shall be carried out in an environmentally acceptable manner so as not to impact the surroundings. Construction Facilities Contractor shall obtain permission from Plant for access to areas close to Construction Sites for offices, lay down, fabrication yard etc. Contractor shall provide office facilities to Company / Client as specified in Appendix. All utilities required in all areas during the execution of Work shall be the responsibility of Contractor. Safety and Security Contractor shall take sole responsibility for safety (including fire prevention) of the Work. The scope of safety shall include, but not limited to, the following: Providing safety and fire prevention procedures at Construction Site. Providing evacuation and first aid facilities in accordance with the local regulations, for all personnel assigned to the Construction Site. Providing adequate safety management and personnel, safety procedures, safety plans, safety organization charts, safety instructions and safety talks, and ensuring that these procedures together with Company / Client's requirements are promulgated and enforced. Supervising all personnel assigned at Construction Site to ensure that they abide by the safety program. Generally, providing one safety officer for every 50 persons. Regularly verifying adequacy of Subcontractors' craneage, rigging and scaffolding to function safely and reliably. Ensuring safety regulations and keeping safety records. Reporting to Company / Client on status of planning and implementation of activities to ensure safe construction and operation installations. Issuing safety reports to Company / Client as specified in Appendix .
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Extent Of Construction Scope Of Work The construction work includes but is not limited to the activities described here after. Those descriptions are not exhaustive and are given solely for Contractor guidance and shall be read and continued within the context of present scope of work document. Above Ground Piping Work Prefabrication and Erection including material management, prefabrication and erection works including all tests and control and flushing operation. Instrumentation Work including the installation, connection, testing of all material and equipment in units and in technical rooms / control rooms including loop testing from control systems such as DCS, PLC, to each local instrument. Electrical Work including the installation, connection, testing of all material and equipment in units and in substations including testing and energisation. Site Preparation and Road, Piling, Underground Piping, Civil works and Building Works including earthworks, road, site preparation including fencing works, drainage, pressurized underground piping erection, gravity pipe networks, all concrete works such as foundation, structure, paving building construction including detailed design and supply / erection of secondary works and HVAC systems and all related test and control. Steel Structure Fabrication and Erection Works including detailed design, supply, fabrication, transportation, erection and all associated tests and controls. Insulation Works of piping and equipment including supply and erection of all type of insulation and associated tests and controls. Painting Works of piping, steel structure and equipment including supply and application on field (or on shop for piping elementary components) of paint on but not limited to steel structure, piping and equipment. GRP Piping Prefabrication and erection including material management, prefabrication and erection work including all test and control and flushing operation. Hoisting, mechanical assembly of all equipment and material including erection work, alignment, test and control. Heating, ventilation and air conditioning including installation, connection testing of all material and equipment. Storage facilities including detailed design, supply, fabrication, transportation, erection and all associated tests and control. Fire water tank, erection of fabrication tank, site construction, assembly and all associated field tests. Pipeline construction-pipeline routing Introduction Pipeline construction scope shall compose of all works in relation to Piping / Pipeline construction as outlined below and as defined by the FEED Specifications, drawings, documents. Contractor shall be responsible for identifying all disciplines in the extent of work requested for piping / pipeline construction activities. Pipeline construction activities shall include, but not limited to the following activities. Installation of GRP piping manifolds at Pump Houses. Installation of all Pump House Piping for Pump Houses. Installation of all utility Piping in Intake Area. Installation of all Piping for packages including electro chlorination unit. Installation of Piping (above ground / buried) for fresh water firewater system.
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Installation of the extension of seawater, firewater system (above ground / buried) to cover all new plots / facilities. Installation of cooling water supply pipelines (above ground / buried) from Pump House to end user battery limits. Installation of cooling water return pipelines (above ground / buried) from end user battery limits to receiving basin. Note that Installation includes all pipe, joints, valves, fittings, flanges, spectacles, supports, anchors, manholes, inspection holes, vents, drains, sumps, pits, welding, jointing, non-destructive / destructive testing, inspection & repair, trenching, lowering, backfilling, crossings of pipelines / utilities / roads, ROW preparation, hydrostatic testing, any temporary supports, etc. Contractor shall make due allowance in its schedule and management of its Construction activities for other ongoing Third Party activities at Construction Site and the surrounding area. Contractor shall be responsible for contacting and obtaining necessary permissions from all relevant Governmental Authorities and Third Parties before construction works commence. Contractor shall obtain all necessary permits and consents in compliance with the requirements. Contractor shall verify the location of any existing installations and services to the satisfaction of Company / Client and applicable service owners. Contractor shall allow the Governmental Authorities and Third Party service owners all possible access to inspect and witness Works execution in the vicinity of their installation(s) and shall conduct such works in accordance with their requirements. Contractor shall meet all its obligations in this respect in a timely manner such that there is no delay in the Works. Contractor shall utilize only approved certified testing laboratories for all destructive testing to be carried out on the Works under construction. If Contractor wishes to provide testing facilities on Construction Site to carry out such destructive testing, the facilities shall be certified in accordance with relevant international standards and also approved. Contractor shall note that Works include at least the receipt, transportation, handling and storage (in addition to all other construction activities) of all items included in the novated purchase orders by Company / Client to Contractor. Contractor shall comply with all Company / Client instructions with respect to these particular items and its delivery to Site. The following drawings form part of Appendix of this document. Plot Plan. Pipeline Routing Plans including sections and details. Survey Drawings for the cooling water and firewater route corridors. Contractor shall be responsible for verification and confirmation of all FEED deliverables. Contractor shall initially locate existing pipelines and other facilities and shall place barriers to prevent his personnel or equipment from working over and damaging existing pipelines and other utilities. General Contractors scope of work shall include but not limited to the following: Installation of the piping systems generally indicated on the P&IDs, preliminary plot plans and preliminary main routing plans included in the Contract. All material handling, craneage and scaffolding All prefabrication of piping systems All erection of piping systems, including tie-ins and crossings All prefabrication and installation of supports including material supply
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All welding All heat treatment, if applicable All non destructive testing All hydro testing, construction cleaning, draining and drying of piping systems. All chemical cleaning, if applicable. All reinstatement All nitrogen or air testing Performing all inspections and tests Providing all weather protection measures when and as required Bolt tensioning Provide all pipe spools and pipe fittings necessary for hydro test Provision and installation of locking devices, to lock open certain valves where necessary Scope of Modification Works All works necessary for implementation of the modifications at the various sites or, alternatively, in workshops or other designated locations. Scope of installation works Installation at a definite location of equipment for the project, the activities to include setting, first alignment and tightening and tensioning of equipment foundation bolts. Installation of all Equipments / Packages / etc. Provide support structure Second alignment after final connection of piping Provision and installation of services items such as temporary blinds, caps, grease, etc. Provision of protection against mechanical damage and damage from weather conditions. Performing initial fill of lube oil, grease, etc. Prefabrication of Piping Contractor shall perform a site survey and ensure spooling of correct dimensions suitable for erection at site and determination of field welds. Contractor shall prefabricate piping in quality controlled conditions (offsite) to the maximum extent possible. The scope of prefabrication work shall include but not be limited to : Transport, receipt inspection, storage, conservation, handling and administration of all materials at Contractors prefabrication shop location. All prefabrication, hydro test (including supply and disposal of test water) and NDT works and send it to painting yard for blasting and painting. Transport (incl. Loading and off-loading) of prefabricated elements from the prefabrication shop to the worksites. Tagging of all spools with isometric number and storage it in a safe designated area at erection site. Erection of piping Access to existing facilities shall not be interrupted. Future corridors reserved for other facilities shall not be encroached. Temporary access to existing facilities/roads shall always be maintained. Prepare workpacks and identify piping spools for erection. Erect rack structure, supports etc and align All erecting, testing and re-instating of the piping systems, including supporting (both temporary & permanent). All bolt tensioning required according to pipe specifications. Installation of temporary strainers and removal after flushing.
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Arrange and provide all testing and drying facilities Supply, installation and dismantling of temporary supports. All other necessary activities such as marking, re-stamping, inspections, documenting, establishing procedures, obtaining approvals from Company / Client, etc. Surface protection, priming, painting, touch up etc. Fabrication, erection and installation of U-bolts, pipe clamps, and / or other restraining devices necessary for the Work. Pipe protection At each location where pipes cross roadways at an elevated level inside the plant areas, permanent bunting poles with warning signs shall be erected. At all locations where pipes are located adjacent to plant roadways and at all locations where new facilities are being constructed or modified, permanent armco type barrier protection shall be provided. Installation of GRE / GRP piping Construction Supervision Coordination with all GRP vendors / suppliers at site Arrange meetings with other Contractors (interface) to avoid fouling with existing facilities. Access to existing facilities shall not be interrupted. Future corridors reserved for other facilities shall not be encroached. Temporary access to existing facilities/roads shall always be maintained. On/off loading and storage Installation of piping system Insertion of all sealing rings, gaskets and locking devices Make up of all laminated / bonded joints and coupled connections Acceptance of anchor bolts Acceptance of trenching backfill and compaction Acceptance of each system as ready for hydro test Hydro test of spools / joints and double bell couplers prior to system hydro test. Guarantee of successful hydro test The above acceptance shall be signed by the Site Representative of the GRE / GRP Manufacturer prior to Contractor proceeding with the subsequent stage of construction in each case. Trenching Contractor shall carry out pipe trenching in accordance with the following: Contractor shall perform all required trenching and excavation by machine or by hand, including rock hammer and blasting where required and provide all necessary shoring, sheeting, dewatering, protection, stabilization and maintenance of the trenches, including the supply and installation of temporary crossings over the excavation if required. Contractor shall take all necessary precautions to protect any existing facilities encountered during the performance of his Work. Where excavation is required within three (3) meters of any gas, oil, water, sewer, electrical, telephone or power lines, Contractor shall give Company / Client ample notice (at least two weeks in advance) for each work permit and follow Company / Client standard practice. Contractor shall also arrange for permits from the various local authorities.
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Contractor shall take special precautions when working parallel and within five meters of any existing pipes or below overhead lines. All Work in the existing facilities areas shall be carried out adhering to the Company / Client Work Permit Procedures. Welding and Radiographic Inspection Contractor shall carry out welding and radiography inspection in accordance with the following: Contractor shall provide all services, materials, and equipment necessary to develop and submit to Company / Client for approval all required welding procedure qualifications, welder qualifications, for production welding for the mainline, installation of the scraper traps, installation of the mainline valves and all other welding activities. Contractor shall check all controlling dimensions and pipe roundness prior to installation, to avoid any delay. If discrepancies exist, Contractor shall notify Company / Client immediately in a timely manner of its corrective action for approval. Ten percent (10%) radiographic examination of all welds shall be performed using XRays. Weld maps shall be prepared and maintained by Contractor and turned over to Company / Client at the completion of the Work. 10% Radiography shall be taken as basis; however detailed NDT requirements shall be reviewed during the execution of the Work on case by case basis depending upon criticality and nature of services. All radiograph films and test results shall be protected and stored by Contractor in a dry, secure place, until they are handed-over to the Company / Client at the completion of the Work, packed in good condition for permanent storage. Road, Track and Existing Pipeline Crossings Contractor shall carry out pipe, road, track and existing pipelines crossings according to the following: Contractor shall construct all roads, tracks, and crossings on existing pipeline and other facilities as required in accordance with approved drawings and in full compliance of all local road requirements and regulations in National. Contractor shall maintain traffic flow and movement of personnel during installation of the road crossings. Where road crossings are performed by open-cut method, detours shall be provided. Contractor shall obtain Company / Client approval for the design of detours. All detours shall be paved. After completion of the crossing, Contractor shall re-instate the roads and the surrounding area including detours to their original condition and to the satisfaction of Company / Client Pipeline Cleaning Contractor shall ensure that internals of pipeline are thoroughly cleaned and inspected prior to hydrostatic testing in accordance with approved project procedures. Hydrostatic Pressure Testing
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Contractor shall perform hydrostatic pressure testing of all piping in accordance with approved project specifications and procedures. Tie-Ins General RequirementsPreparation of a detailed tie-in index and schedule Obtaining approval from Company / Client for all tie-in locations. Marking of tie-in locations at site for Company / Client Approval. Provisions of all spades, gaskets and bolts for the tie-in Works. Removal of piping, if necessary Prefabrication of tie-in piping Connection of tie-in piping, including cutting and beveling. Non-destructive testing (NDT) of the tie-in location prior to and on completion of the works. Hydrotesting and drying of the relevant part of the existing and new piping system. Repair of coating on the existing system. Tie-Ins during Shutdowns Contractor shall furnish all equipment, materials, personnel, supplies, and consumables necessary for performing all tie-ins. Contractor shall confirm the adequacy of these tieins. Contractor shall plan and schedule tie-in activities to take place during planned plant shutdown periods or, where there is not possible, to minimise any plant shutdown required. Contractor shall submit a procedure and method statement for each of the tie-in activities, for Company / Client review and approval, including but not limited to: Procedure-Method Statement-Work execution plan-Material for permanent incorporation-Consumable requirement-Safety consideration-Hazard identificationOperational Impact Contractor shall tag (physically mark on site) each tie-in location after it is confirmed. Contractor shall produce an isometric drawing with complete material list for each tie-in. Contractor shall ensure all materials are available for the tie-in Work prior to submission of the request to commence the tie-in works. Final Cleanup The Project area and all other areas affected during construction shall be maintained clean and free of environmental pollutants. Daily cleaning of the Construction Site shall be performed. At the completion of the Work, the construction areas shall be restored as close as possible to their original condition. This includes Construction Site, staging and storage areas, excavated material stockpiles, existing structures affected, as well as any other areas disturbed by Contractor during construction. Cathodic Protection Contractor shall install cathodic protection system where necessary as indicated in Cathodic Protection Specification and Scope of Work document and provide post installation testing, interference testing, and preparation of as-built drawings and final report. Mechanical Completion Contractor shall plan, in conjunction with Company / Client, to achieve the Mechanical Completion in accordance with the Execution Programme in readiness for the PrePage 181 of 491 suraj_engineer@yahoo.co.uk

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commissioning activities. Mechanical completion activities are linked in Exhibit Appendix .

Navigation Without in any way limiting or detracting from the effect of any other Clause hereof, Contractor shall conform to the Byelaws and Regulations concerning navigation and shall obey the orders of any authorized and competent officer or agent of the Government or the Port Authority in reference thereof. Contractors operations must be conducted in such a manner that they do not interfere with nor endanger either the use of working of the waterways, anchorage wharves, jetties, causeways, dolphins and approaches there to, whether belonging to Company / Client or to persons or any water borne traffic except by prior arrangements with Company / Client representative and the Port Authority. Contractor is to subject full details of any of his operations that may cause any interference to shipping to Company / Clients representative for approval at least 7 days before the event and is to make such modifications as Company / Clients representative may require in order keeping such interference to the minimum. Normal movement of craft within the harbour shall be notified to Marine Operations. All crafts shall be fitted with VHF radios. HRW Hydraulic Study Notes Conclusions Contractor shall consider HRW studies conclusions as given below. This Technical Note has described a design review and a computational fluid dynamic model study of the proposed Plant CCWS pumping stations The study has considered the most recent estimates of the design flow rates, comprising -------m3 / hr from Pumping Station ------- m3 / hr from Pumping Station and ------------ m3 / hr from Pumping Station . Design flow conditions at the entrance / inlet to the pumping station The water levels at the pumping station entrance and the approach flow patterns considered in the analysis took account of the flow into Pumping Station. The minimum water level of -0.95m NHD corresponds to a head loss of only 0.07m in the channel. Approach flow patterns are direct and well-behaved. Review of layout in relation to design guidelines, etc. The typical maximum approach flow velocities to the bar screens are considered to be within acceptable limits in relation to potential turbulence levels at the bar screens. In the worst case (i.e for PH-) at maximum flow, the velocity in the double-entry channels at the drum screens shall be typically 0.86m / s. This is a little high relative to HR Wallingford's experience of other installations and it would be appropriate to confirm with relevant screen vendors that a maximum approach velocity of some 0.8-0.9m / s is acceptable in the channels approaching the drum screens. In the worst case (when one screen train is out-of-service), the maximum velocity leaving the screen units shall be approximately 0.8m / s. This is considered a little high in relation to the size of the forebay area, as confirmed by the CFD model. Flow
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modification measures (e.g. Baffles or columns) are likely to be required in the forebay to ensure satisfactory flow patterns under adverse combinations of screens and pumps in operation. Submergence of pumps The available submergence and proposed elevation for the pump bay invert (-9.50m NHD) are considered satisfactory in relation to the required submergence conditions for minimisation of free-surface vortices. Overall dimensions and internal structures The proposed overall layout and dimensions for the screen chambers is considered satisfactory for FEED. It would be recommended, however, that the required width of each screen chamber element should be subject to further review / detailed design during EPC - following identification of the actual screen vendor and actual screen dimensions. In the case of PH#, the initially designed pump chamber width of 5.0m is smaller than standard guidelines would suggest. Preliminary enquiries with pump manufacturers have indicated that a pump chamber width of 5m would be acceptable (even based upon a bell mouth diameter of 2.7m). Taking this into account, the proposed 5m width for each pump chamber is considered satisfactory for FEED. It would be recommended, however, that the required width of each pump bay should be subject to further review / detailed design during EPC - following final confirmation of the actual pump vendor and actual bell mouth diameters. The Initial Design for the pump bays provides for a standardised pump bay length of 10m, which is satisfactory with respect to the pumps for PH and PH but short relative to standard guidelines in the case of PH#. The proposed standardised distance from the rear wall of a pump bay to the pump centre line of 2.2m is in accordance with standard guidelines. In general terms, the splitter / benching, corner fillets and curtain wall arrangements are considered appropriate vortex suppression devices / methods. On the basis of "standard best practice", it is considered that these features should be included in the pump bays, as they shall help serve to inhibit severe surface and sub-surface vortex formations. Free passage of air must be allowed at the top of the pump bays and other semienclosed areas of the pumping stations. The roof slab is expected to be clear of the water surface even for extreme water level/wave conditions (notwithstanding possible transient water levels in the Intake Channel that might result from pump start-up or trip scenarios). The possible improvements identified for testing in the CFD model resulted from the short pump chambers in PH and the restricted distance between the drum screen chambers and the pump chambers. Computational fluid dynamics (CFD) model tests Simulations have been undertaken for a variety of operational conditions in the planned Plant CCWS pumping station.
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The calculated water level at the entrance to the pumping station takes account of the flow into the Phase I pumping station (PH, and the intake channel model demonstrated well-behaved approach flow to PH and PH. Therefore, although the pumping station computational model does not explicitly simulate PH, the simulations take account of the effect of the flow into PH. With the original design, and under adverse combinations of pumps and screens in operation, significant oblique flow with local velocities approaching 1m / s was observed in the pump forebays. Flow in the pump chambers under these conditions was asymmetric, locally approaching 0.8m / s and there was rotation at the pumps. Revisions to the design have been proposed, in which columns are introduced at the entrance to the pump chambers to dissipate the asymmetric jets. Further simulations have been carried out to show the effects on the flow patterns. These show significantly improved flow patterns in the pump chambers, but there is scope for further improvement in the forebays. The CFD model studies indicate that the overall pumping station dimensions are adequate, subject to provision of the dissipating structures described above and optimised during EPC. Physical model study To confirm and extend the conclusions of the CFD model study, it is recommended that a physical model study be carried out during the EPC phase. This would enable final optimisation of the internal layout, and confirmation of satisfactory performance under the final design operating conditions. For Physical modelling scope of work Refer to Appendix- (Hydraulic Study Report)

--------------------------------------Chapter 11
Pre-commissioning (PC)
Introduction Pre-commissioning shall generally include the following and should be defined and followed up by PC status Index: Systematic conformity checks in accordance with check list, carried out on each part or item of equipment or component, such as pressure gauges, motors, cables, to visually verify the condition of the equipment, the quality of installation, the compliance with project drawings and specifications, manufacturers instructions, safety rules, codes, recognised industry standards and good practice. Static, de-energized tests and test start of specific equipment, to ensure the quality of a number of critical components. This cold testing work shall concern all disciplines, and cover activities such as calibration of instruments, machinery alignment, setting of safety valves, pressure testing of piping systems, testing of cable continuity.

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Piping and vessels flushing, cleaning, hydro testing and de-watering shall be supported by specific reports. Leak testing (at 1.1 times the design pressure) is required to ensure that all inline components / isolated portions of piping during hydro testing are installed. Dynamic verifications that each elementary electrical and instrument function in the FACILITY is designed to achieve and shall perform properly. Typical examples of such tests are: electrical motor uncoupled runs, instrument loop tests, and electrical breakers operation. Energising of the electrical networks shall be part of this activity. Pre-commissioning shall be organised by sub-system following an approved sequence to be prepared by Contractor. Pre-commissioning preparation shall start at the engineering stage together with Commissioning and Start-Up preparation, and shall include the preparation of the documentation, mentioned hereafter, together with the preparation of the FACILITY breakdown in Systems and sub-systems and the FACILITY start up sequence mentioned under the Work Unit description for commissioning. Contractor responsibility of Pre-Commissioning consists of, but not limited to the following: Prepare plans, procedures-Prepare safety audit-Provide PC spares-Provide PC tools, equipment-Co-ordinate activities of Vendor(s)-Maintain all documents, records-Carry out PC activities, e.g. Conformity check-Main activities of PC are: -Flushing/air blowing, -Hydrotesting, and-No-load motor runs-PC documents as follows: Check list-Test sheet-Status index-Punch list-Dossier Pre-Commissioning Check Lists The conformity checks defined above shall be carried out in accordance with, and reported on Pre-Commissioning Check Lists. Pre-Commissioning Check Lists shall define the Scope of Work that must be systematically performed on each selected item of equipment and shall also be used as a log to record the checks made. A typical sample of such Pre-Commissioning Check Lists is attached in Exhibit 03 to this Appendix A. One Pre-Commissioning Check List shall be filled in for each sub-system and type of equipment or package. Pre-Commissioning Test Sheets The Pre-Commissioning tests shall be carried out in accordance with the relevant specifications and reported on Pre-Commissioning Test Sheets. A typical sample of such Pre-Commissioning Test Sheets is attached in Exhibit to this Appendix . One Pre-Commissioning Test Sheet shall be filled in for each test performed. Specific reports and drawings shall support all other Pre-Commissioning activities such as piping and vessels flushing and cleaning. Pre-Commissioning Status Index The Pre-Commissioning methods and procedures shall be defined and followed up in a reference document entitled Pre-Commissioning Status Index.
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The Pre-Commissioning Status Index shall be an exhaustive list, arranged per subsystem, discipline and type of equipment, for all equipment and materials subject to PreCommissioning operations. The Pre-Commissioning Status Index shall summarise for each subsystem the corresponding pre-commissioning checks and tests to be performed for each item of equipment or materials (i.e. Pressure gauges, electrical cables, pumps and the like). Each Pre-Commissioning task shall be recorded on the Pre-Commissioning Status Index. Pre-Commissioning Punch Lists Pre-Commissioning punch lists shall be established for each sub-system being PreCommissioned, for the purpose of recording all discrepancies, damaged or missing equipment, malfunctions, missing documents and any deviation from the design drawings and specifications. Pre-Commissioning punch lists shall be attached to the Ready for Commissioning Certificate for each sub-system. Pre-Commissioning Dossiers Contractor shall compile documentation pertaining to the Pre-Commissioning activities in a dossier arranged by sub-system, which shall contain all information required to demonstrate that a sub-system has reached the Ready for Commissioning status. The Pre-Commissioning dossiers shall include the following: Ready For Commissioning Certificates-Punch lists-Systems descriptions and marked up drawings-Specific procedures-Pre-Commissioning Status Index-Pre-Commissioning Check Lists-Pre-Commissioning Test Sheets-Marked up AFC drawings latest statusVendors' shop test reports-Vendors' documentation needed for commissioning.

Commissioning
Introduction This section deals primarily with Commissioning. However, in view of the required continuity of the completion activities, i.e. Pre-Commissioning, Commissioning and Start-Up, this section also deals with interfaces between such activities. Contractor shall execute all activities required for Commissioning the FACILITY, i.e. Checking, putting in operation and operating the utilities Systems required for Commissioning the process and other facilities, and all verifications required to demonstrate that the process facilities are in the Ready for Start Up. General Commissioning shall generally include the following Pipelines and Piping system: Operational Tests and leak tests Instrumentation: Loop check, Logic check and Operational Tests of DCS / F&G systems. Electrical: Operational Tests on all power system equipment, all motor runs, tests on lighting system, tests on earthing system, tests on cathodic protection system etc Telecommunication: Functional tests. Chemical loading / filling.
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Actual run in and on line tests during a significant period of the main process equipment in closed loop wherever applicable, and of the utilities systems. Checking, startup, operation and maintenance of the utility systems. Equipment packages shall be subject to Commissioning operations at Construction Site, irrespective of the amount of testing that may have taken place at manufacturers' shops. Contractor shall execute all activities required to Commission the FACILITY and shall ensure that before each functional system of the FACILITY is started that the common activities have been performed in accordance with the requirement of the Contract. All operations shall be organised by sub-system and reported on that basis. Contractor's responsibilities for Commissioning shall include but not limited to the following: Providing a team of suitable experienced and qualified personnel for Commissioning as per approved plans, schedules and procedures. Preparing interface and Commissioning coordination procedure Preparing safety audits and maintaining record of all approved safety audit items Providing necessary Commissioning spare parts and ensuring their availability at Construction Site at least three (3) months prior to Commissioning of each relevant facility Coordinating activities of vendors and any Subcontractors participating in the work Developing all required software items Maintaining all documentation and records of Completion Activities on microcomputer Maintaining records of all changes for updating the operating manual towards the end of Work Providing fresh clean water suitable for testing Providing mechanical, electrical and instrumentation test gear and small tools necessary to carry out calibration and testing. Gathering and completing the Commissioning dossier of the complete systems Operational Tests Wherever applicable and as approved at the Commissioning preparation stage, each sub-system shall be the subject of an Operational Test, provided the Basic Functions of the sub-system have been successfully functionally tested. Operational Tests shall consist of bringing a given system into operation under conditions as close as possible to normal. Included shall be testing the automated devices, controls, normal and shutdown sequences in operation, with a view to revealing mechanical or electrical faults likely to occur during prolonged normal operation of equipment. Such faults may be due to watertight performance defects, vibrations, overheating, overloading and the like. Wherever applicable, the Vendors' performance guarantees shall be verified during such Operational Tests. Typical sub-systems to be subjected to an Operational Test are: fire water pumps, air compressors, DCS system, and process pumps in recycle mode (under air or nitrogen whenever possible). Each Operational Test shall be conducted in accordance with a specific Operational Test procedure to be established and approved at the Commissioning preparation stage.
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Following successful Operational Test for any System or Sub-System, Contractor shall issue for Company / Client approval Ready for Start-Up Certificate for such System or Sub-System. Upon Company / Client approval of all Systems and Sub-System in the FACILITY, Contractor shall Start-Up the FACILITY. Vendors Assistance Contractor shall provide all required Vendors support and assistance by mobilizing Vendors representative and specialists to Construction Site. Vendor support and assistance shall be required as necessary for the following. Rotary Equipment: Main Cooling Water Pumps-Fire Fighting Pumps Mechanical Packages: Chlorination System-Fire Fighting System -Hoisting / Lifting Equipment-Pipeline Metering Packages-Drum Screens and Trash Rake Machines. Instrument Air Compressor / Drier Package.-Stoplog guide ways installation Process Items: FRP Piping Systems-Cooling Water System Valves Electrical: HV switchgear-220kv Cables-LV Switchgear and MCC-Transformers Variable speed drives and Motors-UPS / Battery system-Emergency Diesel GeneratorCathodic Protection-Substation Control and supervisory system. Control and Instrumentation: DCS systems-Pipeline / Piping-GRP Vendor Support / Supervision-F&G systemsCooling Water Pumps control systems-Flow metering stations-Telecommunication systems-Process Stream Analyzers-Laboratory Instruments. Commissioning Dossiers The Commissioning Dossiers shall include the following: Ready for Commissioning Certificate-Punch lists-All Functional Test Sheets-All calibration sheets and records-Vendor factory tests reports.-Set points of relays, protective devices-Record of site modifications in drawings-Statutory authority reports / certificates-Marked-up drawings-System Description-Commissioning Procedures Completion Activities Start-Up all Facility Upon completion of all remaining commissioning activities of the FACILITY, Contractor shall carry out the Start-Up of the entire FACILITY in accordance with procedures to be developed by Contractor and approved by Company / Client. The Start-up activities shall be planned in accordance with the Execution Programme and shall confirm the design intent of the Project in terms of all design parameters, specification and Cooling Water quality. Contractor shall provide all Personnel, Equipment, Tools, Rigging, Temporary Facilities, Consumables and any other utilities as required to undertake the FACILITY Start-up.
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Contractor shall liaise with and mobilize any Vendor and work in close coordination with Company / Client to assure a timely successful Start-up of the FACILITY. 72-Hour Performance Test Upon completion of FACILITY Start-up, Contractor shall assure that the FACILITY is operating at steady and stable conditions, whilst maintaining flow rate to all consumers including IPP. Contractor to note that not all consumers are available at the time of the test to receive their designated flow rate, as such Contractor shall produce / develop a 72-Hour Performance Test Procedure approved by Company / Client to cater for this situation and demonstrate that the performance test can be carried out with the absence of certain consumers. When ready for the 72-Hour Performance Test, Contractor shall give Company / Client 48 hours prior notice to carry out the 72-Hour Performance Test. Upon Company / Client approval, Contractor shall carry out the Performance Test in accordance with the approved Procedure for a continuous 72 hours. Contractor shall present all results of the test to Company / Client after the Test for Company / Client approval. Once satisfied of the 72-Hour Performance Test results, Company / Client shall issue Contractor a successful 72-Hour Performance Test certificate. Contractor to ensure that the water supply to PLANT and other consumers is in no way disturbed or interrupted during the test. In case not all consumers are available to receive their nominated flow Rate, Contractor Shall Design, Supply and Install Any Temporary Facilities to simulate that particular consumer in terms of flow rate, pressure drop, temperature increase, as if all consumers are actually there for the purpose to carry out and to demonstrate the 72-hour performance test. All flow rates to consumers shall be measured including those needing Temporary Facilities for the 72-hour performance test. Contractor shall design, procure and install Temporary Facilities, which shall be subject to Company / Client approval. Such Temporary Facilities can be based on plain Carbon Steel. Contractor shall have the consumer interface system connections to all consumers, inlet & outlet, Mechanically Completed and ready to be connected to each consumer. The 72- hour Performance Test shall be carried out satisfactorily by Contractor on or before the date stated in Appendix H. Initial Operation and Maintenance Contractor shall mobilize all operating and maintenance personnel and Vendor representatives as required for the operation and maintenance of all the FACILITY on 24 hour basis. The Initial Operation and Maintenance shall start after the 72 hour Performance Test and up to and including the Completion Date. The Operation and
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Maintenance of the FACILITY shall be undertaken by Contractor in accordance with the operation manuals and Vendors Instructions. Contractor shall set-up a procedure and an Operation management system for the operation and maintenance of all project equipment with a view to record, and log all interventions, operating parameters related to each equipment for the purpose of good records. These control systems shall be co-ordinated with Company / Client Operations. All spares, consumables, fills, lubricants, chemical shall be provided by Contractor during the Initial Operation and Maintenance of the FACILITY. Contractor shall study and define the optimum manpower requirement to operate and maintain the Plant FACILITY. This study shall be based on the various equipment manufacturers data, information and specific details of the FACILITY such as a FACILITY layout, consumer interface, criticality of consumer needs should also be considered. This study shall be the basis for Company / Client to set up its own operation and maintenance team. Contractor shall maintain a continuous steady flow to PLANT and other consumers during the entire Initial Operation and Maintenance period. Project Completion / Handover Contractor shall complete all remaining Works under the Contract such as, Punch List Items clearance, Material reconciliation, Final Documentation, Training and any other Works as specified in the Contract. Contractor shall ensure that Project is completed on or before the scheduled completion date. Contractor shall proceed with the FACILITY Hand-Over to Company / Client Operation in a progressive and co-ordinated manner so as to allow a smooth hand-over by the scheduled completion date after all training has been conducted by Contractor to Company / Client personnel. Upon Completion the Facility shall be considered as Handed over to Company/Client in accordance with the Contract.

--------------------------------------Chapter 12
The following statements have been included exactly as are produced during job by me for certain international bids to support technically as a part of Technical Bid

EXECUTION PLAN (PROJECT IMPLEMENTATION STRATEGY)


Process Buildings Package

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a) Building Engineering Design Management necessitates an integrated approach to formulate an overall philosophy, able to achieve an intellectual product covering & incorporating a wide range of performance & serviceability requirements that shall completely meet intended functions of the proposed building adequately satisfying architectural, structural & allied services requirements. The target achievement of this fast track EPC project shall be kept in consideration by all discipline designers to release the necessary documents on planned line. To accomplish this part of the package to the best possible standards, AJES shall invite certain (possibly 3) reputed & leading architectural engineering Firms as Engineering Services sub contractor. Based on the merits of each offer as well as applying the competency criteria, a preliminary selection shall be made. After obtaining Bechtel approval respecting this Firm, a formal appointment shall be made by executing an engineering services agreement. Engineering Services Sub Contractor hereinafter called Firm b) The scope of the Firm shall include but not be limited to carrying out the following engineering services operations for all buildings included within Process Buildings Package Undertaking additional surveys, intrusive surveys and investigations as may be necessary for the engineering designs. Soil Investigations as required accomplishing the design
(Topographic survey shall be performed by AJES)

Production of all architectural, structural & allied services schematic designs Perform all studies, design calculations etc. Secure all governmental and local Authority permits and approvals if so necessary Compilation of any outstanding data deemed necessary for the completion of the detailed engineering design Compilation of any outstanding data deemed necessary for the completion of the detailed engineering design Production of all architectural & structural detailed designs for Bechtel approval according to contract & sub contract requirement. Act as AJES Design & Engineering representative for the relevant Buildings contract scope Civil & Architectural scope from its inception to completion as & when required c) Building services : conceptual drawings only for plumbing & sanitary, small power & lighting,
HVAC, Fire Fighting & Fire & Gas Detection/Loss prevention, Structured Cabling System Liaison, co-ordinate & lead AJES services subcontractors design & engineering efforts (AJES services subcontractors shall be responsible for the detailed designs and engineering for their relevant scope based on the conceptual drawings and other basic documents issued by Firm) to obtain necessarily approvals from Bechtel Page 191 of 491 suraj_engineer@yahoo.co.uk

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Firm shall issue its whole drawings / documents production schedule immediately after the award & commence its design work keeping in line to the programme Represent AJES at Bechtel offices / officials at UK, Abu Dhabi and / or Habshan as AJESs Design & Engineering representative during the course of the contract from its inception to completion as & when required Engineering coordination with the Firm shall be conducted from AJES head office. All field interfaces shall be conducted from site offices in collaboration with AJES field engineers All other remaining functional descriptions shall be conducted by AJES personnel both in the head office as well as on site office depending on function wise technical nature All engineering design products shall be managed conforming international standards included on the contract documents for the technicalities as well as document controls. Firm shall comply with the agreed documentation system & conduct its operation in all respects accordingly. All the design documents shall be given appropriate numbering reference to meet traceability requirement. AJES operates its own system of centralized document control, which shall be used fully complying in accordance to Bechtel & Client Company Procedures by reformation, if so required Firm shall produce & issue the scheduled documents at various stages of works for reviewing, approval & AFC etc efficiently keeping in line with the project construction plan on various phases. Any delay on this account shall not be acceptable to AJES management Immediately, after the issue of the control documents to the site team, field/design engineers shall conduct over review of design & construction ability & consequently relevant design engineer raise technical queries to remedy any discrepancies among these documents if so discovered, which should immediately be resolved by the Firm & duly informed to Bechtel. All such documents shall be processed through the documentation system facilitating most convenient trace ability for consultancy & reference Consequent upon the resolution of discrepancies, the effected design drawings shall be revised & reissued for construction duly incorporated with the solutions & circulated through documents control regularly to all concerned personnel. Buildings services schematic drawings shall be issued to sub contractors for further development of shop & working drawings for Bechtel approval & issued to the concerned parties after getting duly approved for construction Necessary structural shop drawings shall be produced by AJES own engineering personnel in head as well as on site offices, which shall also be processed into document control system for Bechtel & issued to the concerned parties after getting duly approved for construction

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Preparation of requisitions for enquiry and award, technically evaluate bids and review of vendor / lower tier subcontractor documentation shall be done by purchase manager in collaboration with project manager. All these procedures have been incorporated on the company procurement procedures document. d) Detailed Engineering Design: Preparation, issue and control of calculations, specifications, drawings, material requisitions and bills of material. Extent of computer application for these activities. At the very first stage of the commencement of the detailed designs, Firm shall formulate positioning of all framing members vertically & horizontally befitting coordinates as well as level controls, meeting the architectural requirement maintaining the basic design principles that the whole structural skeleton behaves as an integral unit with its centre of gravity passing through or within the permissible vicinity of the resultant of all the applied forces considered avoiding any eccentricity and that settlement of the soil is within permissible limits. After considering all direct & indirect imposed loadings according to the relevant codes, design model shall be generated using Firm software. Loadings shall include, direct loads such as dead load, live load, seismic shear (though not applicable in Abu Dhabi geographical location) / wind load, blast load / effect, test load/application & also considering various analysis, a most critical case of resulting stresses shall be considered to be adopted for the dimensioning & further details of various vertical & horizontal members forming the framing skeleton. Generated model in 3D may be made available for the presentation to Bechtel & Company to explain & justify the adopted philosophy if so required. Calculations shall be done trying various options of loadings in 2D & 3 D & included with the design proposal for approval. These calculations shall be done & certified by a Chartered Engineer of Firm for structural adequacy & structural intended performance. e) Services Designs Designs of the services shall be carried out discipline wise. Electrical - In accordance to the provision of electrical loadings design criteria as indicated on the Bechtel/Company documents, loadings, distribution of loading & all other parameters shall be adopted & calculated adhering to the international standards, IEE as well as UAE authorities regulations & schematic drawings produced meeting the architectural schematic drawings requirement Similarly all loads from the HVAC disciplines as well as from the other remaining disciplines shall be included. This shall be done in close interface with all disciplines coordinated by the Services design coordinator / Design Project Engineer or Manager. All these details shall be included on the drawings documents for approval All designs shall be generated using appropriate computer software package f) Specialised discipline- Loss Prevention & others On the similar pattern as described in the foregoing, detailed designs shall be calculated meeting all requirements of the contract specification, disciplinary performance as well as meeting international & conventional standards, complying local bodies statutory provisions. From the foregoing approved documents, Bill of Quantities shall be generated discipline wise & building wise which document should be utilised for the purpose of Material Approval Proposal, Issue of requisitions of the approved materials to the procurement manager. The bill of quantities shall not constitute part of contract documents but serve guidance. All bills shall be generated using appropriate computer software package. g) Specifications / Supplement Specifications It is intended to adhere to Company specifications provided by Bechtel within the documents to every extent possible, however, to meet some particular requirement, supplement specifications shall be drawn & proposed for approval wherever necessary
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for producing better product or the materials for which no specification is defined. These shall be drawn in collaboration with Firm & AJES design team keeping in view an overall approach to documented specification criteria as well as conventional engineering & construction practice in similar circumstances. h) Co-ordination Procedure The following entitled co-ordinations shall be conducted during various stages of the design & execution that have been outlined below Coordination between AJES & Bechtel head office This part shall be conducted by regular interaction among AJES representatives Head Office based in Musaffa & Bechtel UK office to help resolve all pre & post award issue of Engineering services & monitoring project controls Coordination between AJES & Bechtel site office This part shall be conducted by regular interaction among AJES & Bechtel site representatives to help resolve all pre & post award issue of Engineering services & monitoring project controls Coordination between AJES & Firm This part shall be conducted by frequent interaction between AJES & Firm representatives of all disciplines for the resolution of all designs issues, issue of all documents, approval of all documents & resolution of all engineering issues on site Coordination between AJES / Firm & Bechtel This shall resolve all issues respecting engineering designs particularly during design stage as well as generally during construction phases for efficient decisions making to help smooth execution of all activities Coordination between AJES / Firm & Bechtel on site This shall resolve all issues respecting engineering designs during construction phases on site for efficient decisions making to help smooth execution of involved activities Coordination between AJES Site & Firm This is essential to keep on fast track the availability of complete design information for all ongoing as well as planned activities & should the information be pending, it shall be identified, coordinated & made available on site prior to its requirement to avoid any problem of execution AJES internal Coordination among various sections AJES in Head office organized with all corporate sections necessary to meet the requirement of this project shall operate as an integral functional team keeping on resolving regularly & as required all issues of project designs & follow up in all respects. This coordination is ongoing on daily basis & frequent interaction among all corporate managers as well as supporting professionals help the resolutions of all current & forthcoming issues. Management meetings are conducted regularly for making decisions to avoid any pending identified problems AJES internal Coordination among various sections on site Similarly on site all project sections managers & supporting professionals shall coordinate to resolve all types of problems to avoid any pending identified problems & notify to corporate management for immediate resolutions should the solution not be possible from site. i) Review and Approval of Documents This requires effecting an instant action on document is received, it must be reviewed Office/Site office as the case may be prior to submission to Bechtel, Bechtel shall process
Page 194 of 491

the part of AJES that, whenever any by its design team located at Head formally submitting to Bechtel. After its it through its system & after obtaining
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company approval, return approved or commented original to AJES for further necessary AJES action. All documentation shall be carried out adhering to the AJES documentation system after tuning that in line to Bechtel & Company requirement j) CAD Procedure It is intended to use standard CAD software for the production of design & drawings. All standard system of designing shall be adopted at every workstation available in Firm offices. The details of all available software & hardware have been given in attachment. Also included the hardware & software details which are functional in proposed Engineering sub contractor/Firm office k) Engineering Reporting and Change Control The status of design progress shall be submitted to Bechtel on a weekly basis during progress meeting. Should any change be required, that shall be affirmatively considered subject to cost impact resolution & then the change incorporation request issued by AJES to Firm. The Firm shall then work on the revision, its calculations & advise to AJES & Bechtel of any adverse effect on the structural adequacy / performance or if any amendment to be applied to already worked element / member. Should there be no such adverse consideration, the design shall be revised & revised document issued following the documentation & approval procedures. l) Document Control Procedure AJES operates its centralized DCC in head office that shall be tuned to Bechtel / Company documentation system & extended to site office to meet the project requirement. AJES document control system is enclosed for reference. m) Vendor Print Numbering, Review and Distribution Procedure All vendors shall be issued schedule of document numbers to be printed on the documents adequately in advance of documents preparation. All approved procedures of documents shall also apply to vendors' designs. n) As-built Drawings As built drawings serve the purpose of telling the user about the building records that should be used for the purpose of maintenance / or for whatever purpose possible. It is therefore, an important & significant part of documentation as well as also a contractual obligation on the part of AJES & Bechtel which should be affected smoothly & regularly throughout the duration of project. Should there be no change on the Released for construction drawings i.e. the construction has been carried out all in accordance with the approved documents provisions, there shall be no purpose of As - built drawings. But in practice, to produce physical structures, some changes are imminent due to arising of new requirement, changes, effects of disciplinary interfaces to bring the work to proper use functions etc. During the whole currency of the contract, it should be an endeavour of the AJES that all changes are recorded on contract documents as Red Lines mark up & issued to Bechtel for approval. These Red Lines mark up shall form the basis of producing all As Built documents on the project. It is not the drawings only that are to be recorded but also all changes whatsoever for any document on record. All these As Built shall form part of hand over dossiers. Should as built records be maintained regularly, this part of the dossiers shall be comfortably produced. The site design engineers shall keep an eye on this activity & record changes regularly as red line mark up & process the documentation to fulfil the contractual obligation to this
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extent possible. It is expected of the site engineers, the design engineers as well as land surveyors to coordinate on site to comply with this obligation efficiently. All survey changes or variations shall also be recorded on the drawings based on the pre pour & post pour records taken from survey section. Surveyor shall present all such changes on the corresponding documents to be recorded as Red Line Mark ups. Inspection & Test Plans All necessary Inspection & Test Plans shall be originated by the Quality Engineer in collaboration with Engineering in head office & Engineering in site team. These ITPs formats shall be issued for Bechtel & Company approval according to the procedures laid down on Project Quality plan. Production of all these documents shall be the responsibility of AJES Quality Manager / Engineer. Complete details about the quality management system have been included on the respective Quality Procedures document. Generally, ITPs for all disciplinary activities shall be produced for Bechtel & Company approval from site office in due course. All defined tests shall be conducted by Bechtel/Company approved laboratory located on site. For those items the tests shall be conducted by any Bechtel / Company nominated laboratory, for which facilities are not available on site. The details of these plans shall be submitted separately. Every ITP shall be allotted a document number along with a numbered checklist. Check list shall form the basis of inspection requirements. Project Controls Project Control management requires the formation of strategies those can be utilized optimally to achieve the target in minimum cost with best quality product To achieve as aforesaid, it is extremely important that complete project should be analyzed from whole to one & all necessary resources to be used should be known prior to commencement of physical works. Based on the project design, construction, commissioning and maintenance durations, Analysis, planning & charting out at various levels shall be carried out by the Planning Engineer. Further based on these periods, all necessary resources shall be arranged & mobilized by human resources, materials, and technical managers in collaboration with Project Manager. The plans shall be monitored regularly, as the project construction progresses, on a weekly basis, monthly bases & no delay allowed & if any, immediate recovery shall be planed. The relevant reporting shall project the real quantum of planned & actual physical works, resources available, deficiency of resources, material procurement status, materials delivered & expected time of arrival etc & all necessary measures required to keep the construction on line & valuation worked accordingly. Every effort should be made to keep the progress in line with plan. Procurement Note-The term Material herein includes equipment also According to the site requirement & provisions made on the plan, for temporary materials & consumables, requisitions shall be raised from site by the relevant engineer, checked, numbered & coded by the material controller & approved by the construction manager for transmission to head office procurement manager for further action. Cost
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controller shall further check the budgetary provision applicable & give clearance to the purchase manager for procurement. Purchase manager shall then invite the inquiries from various sources of material, negotiate & prepare a comparative statement & based on the merits of responses / quotations, record his comments based on the comparative statement as well as recommendations for the considerations by the Management. After reviewing the proposal, the management shall approve or reject the proposal. Purchase order shall be made on the approved proposal. An alternative source shall be located for the rejected proposal. A copy of the approval shall be provided to the project manager for follow up the delivery. For permanent works, proposed material shall be submitted for Bechtel/Company approval on requisite Material Approval request form along with brochures, samples if applicable, processed through the document centre after Project manager approval. After obtaining Bechtel / Company approval on the request, procurement manager shall process the requisitioned approved item based on the budget quantities following in line the procedures applicable for temporary materials. After the material is delivered to site, material controller & relevant engineer shall check the quality & quantity of the delivery. Any deficiency in quantity, quality or any damage observed, shall immediately be notified to the procurement manager through construction manager. Delivery information shall be circulated to the concerned personnel & quality manager himself shall or delegate an inspector or the relevant inspector shall check the adequacy of quality & if necessary according to ITP provision, shall invite the Bechtel/Company engineer to inspect / examine the delivery. The selected samples of delivered materials shall be sent to an approved laboratory for technical tests for the purpose of certification of compliance. After inspections & approvals, delivered materials shall be recorded in stores receipt documents, an issue to site may be undertaken thereafter. Post placement of purchase order, Procurement Manager shall track various stages of material production & transportation or shipment to the site/delivery & if so noticed that an expectation exists for the delay in delivery, shall apply all efforts to expedite the delivery on appointed date. Materials shall be stored in proper designated areas complying with the manufacturers instructions. Separate area shall be located for the materials requiring certain temperature of storage. Stores shall be well constructed & shaded. Generally, all consumables shall be stored in shade provided with proper lock & key arrangement. Materials which remain unaffected by exposition to weather may be stored open duly protected under proper watch & ward. Proper protection shall be made for all stored materials inside covered area or out side. Necessary protection by removable membranes such as polythene or tarpaulins shall be used to protect material from the ingress of moistures or from effect of dust. Storage of all materials delivered shall be done complying to the set & approved procedures making sure that all inventories can be verified any time & that any material can be traced any time easily. All entries of the incoming deliveries shall be recorded into the register & verified by the store keeper & material controller that it complies with the details on deliveries
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documents. Any deficiency noticed shall be immediately reported to the procurement manager. After the acceptance of the material by the concerned authority only, a store issue shall be affected & recorded on the required issue documentation. Regularly the status of all receipts, issues & balance in stores shall be reported to the construction & project manager who shall act further depending on the project requirement. Elaborate details have been given on the AJES procurement procedures document International and local transportation and customs clearance Materials & equipment that have to be imported from overseas, shall also follow the foregoing procedures with the addition that necessary Letter of credits shall be opened by AJES adequately in advance of the required date of delivery adhering to schedule date, so that the delivery is shipped in time from original source. AJES procurement manager shall arrange all port clearances immediately of shipment arrival & material shipped to work site. Tests & Examinations shall be conducted similarly as aforesaid. Any claims of insurances for the damaged material shall be made immediately after inspections. Process to replace the damaged material shall be carried out at once to avoid any delay. If so required, AJES shall apply in time for any statutory road permit for the efficient transportation of the material by suitable vehicles. Elaborate details have been given on the AJES procurement procedures document. Procurement and provision of construction spares, commissioning spares, insurance spares and special tools These shall be processed applying the same methods of procurement & delivery received by AJES / its services or specialist sub contractors. Most probably, the spares shall form part of the order package. Elaborate details have been given on the AJES procurement procedures document Recommendation for two-year operating spares for approval by Company in accordance with the G-SPIR format requirements This provision shall be followed & spares delivered according to contract & Company requirement by AJES / its services sub contractors. Elaborate details have been given on the AJES procurement procedures document Procurement and provision of two-years operating spares, (at cost and extra over Lump Sum Subcontract Price) Similarly this provision shall be effected & spares delivered according to Bechtel/Company instruction to AJES subject to the approval of the procurement cost prior to the purchase order placement by AJES Source inspection If so required by Bechtel / Company, arrangement shall be made by AJES after meeting with the vendor or manufacturer, a date & time appointed for the inspection to the convenience of all parties concerned & required inspection at source conducted to the satisfaction of Bechtel or Company. Representatives from Bechtel and/or Company, AJES, services sub contractor & vendor shall constitute an inspection at source team. Proper record of inspection shall be made.
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Compliance with Companys criteria and procedures for selection of vendors including but not limited to compliance with local registration requirements and approval of purchase requisitions, bidders lists, technical bid summaries and award recommendations We shall adhere to Company requirements. Involvement by the UAE in particular and GCC in general with respect to the provision of local materials and services shall be encouraged AJES honor & respect with due regards to the provisions of UAE & GCC policies for the materials & professional services which need be availed out of the local & GCC sources subject to the compliance with the quality requirement. Every effort shall be attempted by Procurement Manager to chart out the available local & GCC sources & prepare a database to be used whenever any applicable procurement arises. This procedure is already followed by AJES. AJES vendors shall also comply with this requirement. Pre Mobilization Planning A thorough and logical mobilization plan is essential for the successful start-up of construction activities. This plan must detail all planning, preparation and preconstruction activities necessary to ensure the timely availability of drawings, personnel, construction equipment, temporary facilities and materials at the job site to properly support the construction efforts. This plan is already under preparation at this stage. This preliminary mobilization plan shall be further developed after contract award and concluded within a week of the contract award. The mobilization plan shall be closely coordinated with the construction plan to ensure mobilization activities properly lead into and provide a smooth transition into initial construction activities. A time scale bar chart diagram shall be prepared with early and late activity bars detailing the main activities to achieve full mobilization of staff, labour, construction equipment and camp/site facilities shall be prepared at the commencement of the contract. Mobilization plans for staff & labour, accommodation and temporary facilities established during the bid stage (as conceived in pre-mobilization planning) would be studied and re-evaluated in the light of any changes, which may have occurred since the day of preparation. All necessary adjustment measures shall be implemented. Additional site visits shall be conducted immediately after the project kick off to confirm data collected during bidding stage, reconfirm assumptions and establish additional information required to permit smooth and timely mobilization. The following items shall be reviewed and confirmed. Access to the job site Locations of temporary facilities Company requirements for properly validated licenses and certificates to be held by construction personnel
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Transport plans Loss prevention and safety requirements Arrangements for first-aid facilities Arrangements for drinking water and construction water Arrangements for electricity supply Arrangements for storage fuels and lubricants Arrangements for sanitary & its disposal facilities Final arrangements for security interface with Bechtel & Company Work Centres Ajes Head Office Upon notification of contract award, the key personnel to the site Management Team shall be assigned. Construction personnel shall be mobilized to the project site office to provide input and direction to the project team. Successful project execution requires construction experts to be active from the onset of the project. The only activity to continue from Head Office after mobilization period is procurement. All procurement for the project shall be done from the corporate procurement section located in AJES Head Office at Mussaffa, Abu Dhabi. The following specific activities must be addressed early to be fully effective: Finalize construction schedule requirements and subsequent approval from Contractor Review manpower requirements for both non-manual and manual personnel; update these requirements by means of staffing schedules, histograms and craft mixes; and ensure subcontractors manning levels are compatible. Review construction equipment needs and ensure that timely subcontractors mobilization plans are in place. Review field procedures and method statements defining standards, policies and procedures required for the execution of the works and ensure they constitute Project Specific status. Review environmental, safety and Health (ES&H) and site security plans to ensure compliance with the clients specifications and guidelines. Review Construction Quality plan in line with the guidelines of ISO 9000 and check Established QC parameters by discipline. Overview temporary facility requirements, including indirects such as tools, consumables, gases and the like and check subcontractors compliance. Actively pursue preliminary site activities such as approvals, permits, establishing contracts. Ensure Lessons Learned & Practices from previous projects are well understood & should be applied effectively from the onset of the works itself to achieve professional products. AJES Site Office
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Actual on site management would be from offices based on the site next to Contractor and Companys office. AJES Site Office is fully supported by AJES Head Office at Musaffa. The following major activities shall be carried out at site offices. Safety Regulation Enforcement Quality Assurance Enforcement and Procedures Construction Method Statements Construction Planning Site Documents Control Field Engineering & Design Controls Material Requisitions Materials Control and Tracking Materials Storage Work Procedures Physical Construction Site Administration Mobilization Mobilization shall be coordinated from the AJES Head Office at Abu Dhabi with input from AJES personnel already mobilized for the execution of Site Preparation Package and Temporary Facilities for Contractor and Company. Existing teams responsible for the execution of the those two mentioned packages already have substantial cadre of experienced professional well versed in mobilization of temporary facilities, project execution, QA / QC planning, Safety and security operations etc. Mobilization shall commence with the following activities: Kick off meeting to commence the sub contract Commencement of the required land surveys to establish various horizontal & vertical controls bench marks Incept of the engineering designs at the Firm office Soil Investigation by an approved laboratory Construction of temporary facilities Obtaining various permits from Authorities and conclusion of arrangements with local committees where necessary. Third party independent concrete testing laboratory credentials submission for approval. Shortly after contract award, site surveying shall begin utilizing the Total Station System to establish accurate control points for the performance of the work. As soon as practicable, the plans and specification for the site temporary construction facilities shall be finalized and released for installation. During the installation of the temporary facilities existing AJES site offices shall be utilized to supervise the site activities required for the temporary facilities installation.

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On completion of the site offices at Habshan, balance of the AJES construction staff shall be mobilized to the site along with construction equipment, tools, consumables, warehousing, storage and other items necessary to commence the work in accordance with the construction schedule. Temporary facilities at the job site shall include Generator Yard and Construction water storage tank, carpentry yard, re-bar fabrication, lay-down area, warehouse and workshop facilities at location A4. At the start of the construction, an emphasis shall be given on the critical requirements of the construction schedule. Work shall be carried out under continual supervision and inspection over performance. Progress shall be monitored on the basis of actual installed quantities compared to scheduled quantities. For construction areas, dedicated work crews shall be allocated for each discipline supervised by foremen and general foremen who in turn shall report to the discipline supervisors / site engineers. Based on the construction schedule requirements, necessary operational crews shall be formed and controlled over to meet the planned progress target to be physically achieved satisfactorily. It is the responsibility of the supervisor / site engineer to ensure the efficient utilization of his material, workforce, tools and equipment. For construction operation water requirement, unless an alternative arrangement is made available, water shall be trucked from nearby Desalination plant. Site construction and temporary facilities electricity requirements shall be met by installing suitable size and suitable numbers of generators. Subcontract Strategy Building Engineering services shall be utilized by appointing a consulting firm, to be responsible for the complete architectural, structural design drawings & documents productions as well as for the services schematic designs drawings production. Firm shall also represent AJES regularly during the project currency Detailed services designs shall be prepared by AJES services sub contractors AJES shall carry out broadly all civil engineering works employing its own resources of manpower, machines, equipment etc. Lower tier sub contracts shall be allowed for the execution of single operations such as supply of ready mix concrete, roofing finishes etc Ready Mixed Concrete is envisaged supplied from an established RMC supplier, an establishment with proven track record duly approved for supplying concrete by GASCO, within 10 kms of the site. However, in the mean time, without reservations, we are also seriously considering installing our own concrete batching plant. In case any minor or specialized work is necessary to be sub contracted on lower tier, Company procedures shall be apply for prequalification and award of the subcontracts.
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A field inspection and testing program shall be organized to be in line with AJES Quality manual & Approved Project plan under overall responsibility of the QA / QC Manager. Prior to conduct any testing, Contractor and Company (as required by QC Plan and ITP) shall be advised of the tests for witness. Wherever required vendor specialist shall be made available for conduct of testing and inspections. Material Management Once material has arrived at site, material management shall come under the purview and custody of the site store staff. The storekeeper, supported by his store assistant shall be responsible for the custody of the material prior to issue. Material tracking from source to the place of installation shall be conducted by the computerized system. The construction manager shall be responsible to provide the technical oversight and direction for the control of materials at the construction site area. More information has already been elaborated in the foregoing. Procurement The Central procurement department located at the Al Jaber Energy Services, Musafa, Abu Dhabi, UAE office shall be responsible for all purchases adhering to the following procedure. Preparation of Purchase Requisition shall be made based on take-offs quantities calculated from the approved drawings documents. Purchase requisition shall completely, identify all applicable drawings, data sheets, specifications, vendor documentation requirements etc. with the inclusion of following information. Quantity of each item required with comprehensive breakdown Adequate information concerning nomenclature description, Material approvals, Quality required, applicable specifications, design & other drawings, etc / or detailed outline of the material required. Required delivery dates for all major items. Delivery points of major items Inspection of the goods at the point of origin issue Certification of test data and/or compliance / warranty Method of shipment (if goods imported), conditions/packing Instruction of holding, kitting consolidation, marking Drawings, manuals etc Spare parts requirements Special Instructions to vendors A technical evaluation shall be done in house to verify the conformity with specifications.

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141822476.doc

First Web Edition 2006, Devoted to Engineering Community

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Samples and technical information shall be submitted to Contractor. Once the final approval from the client is obtained, purchase order shall be raised. Upon receipt of Purchase Requisition, a purchase order shall be raised and entered in the computer register system, indicating cost and budget allocation. The procurement department shall maintain a follow-up system so that contact suppliers and / or manufactures may be made on continuous basis. All questionable delivery commitments shall be expedited on a daily, weekly and monthly basis as required to ensure prompt delivery in accordance with the requirements. Organization Corporate Organization Al Jaber Establishment formally known as Al Jaber transport & General Contracting Establishment is an umbrella organization which has got numerous divisions within in itself and which is also the parent company for various subsidiaries. Al Jaber Energy Services (AJES) is a separately registered company specifically set-up to target the energy sectors and its clients. AJES has been operating under the Al Jaber Establishment umbrella since 1995. Broadly all the activities of the above divisions and companies can be divided into: General Construction Heavy Lifting and Transport Services. Trading Industrial Plant Construction. Site Organization Proposed site organisation and responsibilities of the key personnel are enclosed. All supervisory staff shall be highly experienced and qualified drawn from on-going projects wherever possible. Manpower Resourcing And Mobilization All the personnel on site shall be employees of Al Jaber Energy Services. All of the required personnel to execute the work are already in UAE and working on other sites. These sites are due for demobilisation in the coming months. The planning department shall produce a histogram schedule of the resources by category. These schedules shall define the monthly manpower levels. The scheduled shall also be indicative of manpower mobilization. The standard Al Jaber Energy Services site supervision is based upon the principle of training. A charge hand shall be trained and supervised by a foreman. In normal cases a foreman shall supervise four charge hands. The charge hand shall then supervise approximately ten labours. Where a special process is conducted, this ratio may be revised accordingly.
Page 204 of 491 suraj_engineer@yahoo.co.uk

IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

141822476.doc

First Web Edition 2006, Devoted to Engineering Community

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Training is a requirement of the Al Jaber Energy Services quality management system and foreman and charge hands shall conduct training of the manpower in their respective roles and functions. The recruitment of manpower shall ensure that background in the relevant job skill has been achieved. The training in quality awareness shall be an ongoing process through the quality department and the foreman. Sufficient numbers of site supporting staffs which consists of Mechanics, Electricians, Auto Electricians, Guards, Water boys etc and other ancillary staff shall be deployed for the unhindered progress of the work. The Al Jaber Group contains at all times a vast pool of manpower in all Disciplines. These workforces are at all times working on various projects in multi discipline fields. Equipment Resourcing And Mobilization Based on the project schedule the planning department shall generate the construction equipment schedules. The Al Jaber Group is one of the largest equipment rental companies in the GCC with over 5000 fleet where modern repair and machine facilities enable them to maintain a first class fleet of equipment. It has been our company policy to weed out the old equipment on a periodical basis and keep the equipment fleet very young. We have one of the youngest fleets of equipment in the GCC based on size. Construction Method Statement Process Buildings Following the award of the project, a detailed contract scope works programme for the whole project shall be developed including all disciplines separately based on already approved outline preliminary programme appended under the coordination of our Construction Manager and Planning Engineer The Method Statements related to various project activities shall be submitted for contractors approval prior to commencement of any activity during the execution stage. Subcontracting Develop and manage a lower tier subcontracting plan and subcontractor list AJES plans to carry out most of the civil activities itself but selected items shall be sub contracted on the lower tier such as ready mix concrete, roofing application, doors & windows manufacturing, painting application, raised flooring application, suspended ceiling installation etc. Perform all lower tier subcontracting activities including specification of packages of Work to be subcontracted, pre-qualification of bidders, issue of ITBs, bid evaluation, recommendation and award. All relevant information shall be provided by the Project Manager to the purchase manager who should act immediately to conduct the required functions & the lower tier deal finalized after obtaining Company recommendation by the Project manager a) Management of lower tier subcontractors and their activities
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IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

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These operations shall be manager & controlled by the Construction Manager on site & reported to the Project manager Monitoring and reporting of all lower tier-subcontracting activities. This activity shall be affected by the project manager based on the construction manager report. The report shall be regularly provided to the planning engineer, head office & Company. Involvement by the UAE in particular and GCC in general with respect to the provision of local services shall be encouraged . As included earlier somewhere else that UAE national policy shall fully be honored subject to making no compromise to the quality requirement Construction including providing labour, supervision, safety and quality management, inspection, vendor support, temporary facilities and services, and construction equipment, tools, utilities and consumables. All these issues have been elaborated earlier somewhere else

b) Provision of Construction Camp, messing, transport to Jobsite, sanitation, utilities etc. for SUBCONTRACTORs personnel. All these shall be fully undertaken by AJES based on the site requirement. Already a camp exists on site & further extension shall be made to meet the contract requirement. Messing shall be resolved by employing catering sub contractors so that all personnel & workers take good food. All utilities shall be provided to maintain the good house keeping of the camp. All safety & emergency precautionary measures shall be undertaken to the contract requirement. AJES operates its own system of transport, which shall be extended for the use of workers transportation. Similarly, the arrangements shall be made for the employed high tier & low tier sub contractors on this package All activities necessary for Mechanical Completion, Pre commissioning, commissioning, and Provisional Acceptance. All activities for the buildings part have been described on the method statement appended All testing facilities required at Jobsite AJES shall supply an independent testing laboratory equipped with all equipment necessary for involved tests for this package properly managed by qualified personnel meeting all QA testing & certification requirement. Full responsibility for co-ordination with any Third Party Inspectorate AJES aggress to extend its full cooperation to meet any Third Party Inspections. Project manager & Construction manager shall be responsible to affect this part of the contract. Supply and coordination of lower tier subcontractor and vendor representatives as necessary
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IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

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First Web Edition 2006, Devoted to Engineering Community

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AJES shall supply & coordinate with all lower tier sub contractors & vendors or their respective representatives to the requirement. Supply of these shall be managed by the Purchase Manager while the Project manager shall manage on site. Coordination shall be conducted by the Construction Manager Provision of waste management at all Jobsite locations, including disinvestments of all temporary works, upon completion of Work Waste management shall be fully operational on a day to day basis both for garbage & sewage according to the planned arrangements. Safety manager shall be responsible for the operations of all such activities & report to the Construction/Project Manager regularly Provision of medical and fire-fighting services at Jobsite and for temporary works Medical male nurse shall be employed on job site First Aid centre. Male nurse shall take care of providing First Aid treatment to injured workmen immediately & then the worker if so necessary in the opinion of the male nurse, shall be sent to Contractor site clinic for further treatment. Safety manager shall be responsible for the operations of all such activities & report to the Construction/Project Manager regularly SPECIFIC CONSTRUCTION METHOD STATEMENT BUILDINGS PACKAGE It is known from the contract documents that 15 buildings for various intending use as Sub station+Bottle Store, New Control Building, Instrument Equipment Shelter+Bottle Store and Operator Shelter have been defined to be constructed Keeping in view the nature of contract being EPC, AJES have decided to apply RCC in situ construction for all intended buildings accepting the Company direction on drawings for which a confirmation was communicated to Company on May 7, 2005. RCC framings shall meet the design criteria of blast resistant & resilient structure productions meaningfully. Sub Structurse shall also be constructed of RCC in situ. Soil report bore holes log direct to employing spread footings in isolation, which shall be integrated by grade beams/walls to form an unit for compaction settlement & long-term consolidation controls. However, to verify the validity of the soil report, AJES shall further conduct investigations based on the Engineering Services sub contracting firm recommendations, utilizing the services of an approved laboratory. Foundations shall be designed based on the laboratory recommendations. The phases of the construction shall be adhered to meeting the set out milestones, which are very tight for the purpose of physically executing the buildings package. The construction teams shall be constituted to meet the requirement as exhibited on the organization chart. One project site manager shall be an overall responsible for all on site execution operations & conduct interface with the head office duly supported by safety, construction, quality, technical & administration sections all to be well established on site. Project & Construction manager shall in collaboration constitute six independent dedicated teams for six working divisions/areas lead by each site engineer directly reporting to construction manager as shown on the organization chart. Each team shall comprise of one site engineer, required number of site foreman & further supported by charge hand from each trade. For each team one quality
Page 207 of 491 suraj_engineer@yahoo.co.uk

IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

141822476.doc

First Web Edition 2006, Devoted to Engineering Community

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assurance/control engineer shall be deployed to conduct QA / QC procedures for the relevant area. One General foreman shall be deployed for the labour engagement responsibilities on various day-to-day activities. For all other organization details please refer to Project organization plan. A surveying team shall be constituted lead by a chief / senior surveyor to carry out all site setting works from the stage of preliminary site survey to the point of recording redlines for the purpose of as built. Survey team shall coordinate with each site engineer to meet site requirement. It shall be the responsibility of each team to set out, inspect & record all layouts, pre & post concrete data for the purpose of approval & handover dossiers. All horizontal & vertical controls shall be established & monitored by the leader. All approved controlled drawings shall be issued to surveying team to commence the setting out operations. After ensuring proper safety arrangements are in, survey barricading shall be established & necessary grids control fixed & inspected by QA / QC. Excavation shall commence after the clearance is obtained & continue according to the plan. Proper safety shoring shall be arranged during this activity when it crosses 1.5 m depth & arrangement for suitable access into pit made to the satisfaction of the safety inspector & company. All unsuitable excavated material shall continuously be removed from site & suitable material tip off to designated area. All environment controls shall be taken care off during this operation. A surveyor shall continuously ensure the depth of excavation does not exceed the design requirement. When the excavation reaches the formation level, dressing shall be started followed by compaction of the soil so that area is ready for inspections. AJES QA / QC shall inspect the formation. After required clearance, arrangement shall be made for blinding all released area according to the approved method statements. Area shall be blinded to the design thickness minimum 75 mm properly levelled & trowel applied to make it suitable for the purpose to receive heavy duty concrete protection layer membrane. Then curing shall be carried out for 3 days. Application of the protection membrane shall commence thereafter over whole area of the blinding. Foundations shall be set out to design details to permit formwork erection & rebar placement. All starter rebar shall also be fixed supported by plastic spacer. On sides also plastic spacers shall be fixed to keep all rebar in proper position. Foundation top levels shall be fixed using 25 mm plastic triangular chamfers horizontally. Chamfer shall also be fixed on the vertical edges of the forms. Inspection shall be conducted followed by concrete pouring supplied by an approved ready mix plant. All ready mix record shall be maintained according to QA approved procedures. After concreting is finished, proper curing arrangements shall be made for the required number of specified days. Setting outs for further stub columns shall be done & preparatory works continued. In parallel, all works regarding grade beams/walls shall continue complying with all the approved procedures. Fabrication of rebars shall be done in a designated area while fabrication of forms too in another designated area all according to approved procedures. After completing the preparatory works for the stub columns, inspections & pouring shall be carried out following all procedures. Operations of grade beams/walls shall be taken up on similar principle as other activities.

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IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

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For sub stations where cable cellar floor slab is to be built, shall be prepared together with surrounding sub structures. After curing is done for the specified period, protection membrane shall be applied on both horizontal & vertical surfaces followed by inspection & backfill in compacted layers to specified requirement. Field density tests shall be conducted to monitor the requirement of density & water content etc. Backfill shall continue up to the formation level below the grade slabs blinding in buildings & where cellar suspended floor slab is to be built, backfill shall be done around the grade structures. Preparations shall be carried out for the cellar suspended slabs by erecting required supporting system, forms fixed, rebars placed, all services inserts provided & inspections conducted from all disciplines followed by the concrete pouring observing all QA procedures. Similarly, on the areas where grade slab is to be built, after the completion of the backfill up to the bottom of blinding concrete i.e. formation level, plastic sheet shall be laid after compaction & leveling & all necessary under ground services completion, blinding concrete shall be poured, leveled & wood floated well to make it sufficient enough to receive the grade slab. After three days of curing on blinding, preparation for the grade slab works shall commence & re-bars placed either by site fabrication or using pre fabricated mesh to design requirement. All necessary services shall be inserted, inspections conducted & concrete poured. At this stage of the building, major sub structural elements have been completed giving a way to commence the super structural works. All preparatory works of superstructure elements shall come into full swing by the fabrication of the forms & steel rebar fabrication to the BBS details. Scaffolding shall be erected for the fixing & placing vertical rebars of columns & walls in all required areas. Steel rebars shall be fixed placed with spaces & inspections conducted. Any inserts necessary for the electrical conduit or earthing, shall be installed immediately & inspection conducted. Work of vertical forms shall commence for sides of columns as well as walls fixed using removable tie bolts with cones/boss at tie rod ends. Forms shall be made of fair face ply to produce specified texture to the elevation requirement. All exposed vertical edges shall be chamfered using plastic chamfer 25 x 25 mm triangular section nailed to the forms. Inspections shall be conducted for the elements ready for pouring. Pouring shall commence keeping the height of pour not more than 2 m using vertical pipe chute of the pump reaching up to necessary level. Curing shall follow adhering to the agreed or approved procedures. Similarly walls of transformer areas shall be built adhering to all QA procedures. Next operation of erection of the propriety scaffolding to support the superstructure roof slab shall commence strictly complying with the scaffolding drawings. On parallel, operations of fabrication of forms & rebar shall be taken up. All vertical & grid controls shall be established by surveyor to keep in line & level all forms of beams alignment & soffits. Level of slab shall be established & then work of form fixing shall commence followed by placing of beams reinforcement. Services inserts such as electrical conduits, HVAC inserts or block outs if necessary & other inserts shall be marked for establishment. Works of steel rebar placement shall continue in parallel to speed up the preparatory works. An inspection of the preparatory works shall be conducted by all involved disciplines. After obtaining approval for the pour, pouring shall be carried out adhering to pouring method statement compliance. Curing shall be started immediately
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IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

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after finishing the surface as required by the curing compound manufacturers instruction for the application of compound & also by using water in combination all to agreed procedures. Intermediate slabs on the Battery rooms shall be constructed following the foregoing procedure. Erection of the scaffolding around shall extend to cover the parapet portion followed by formwork & rebar fixing. On the similar pattern as defined earlier, all inserts shall be fixed followed by all relevant inspections & pour. All aforesaid concreting operations shall be supported by necessary number of transit mixers, concrete pumps, nozzle vibrators conforming to perform 10000 oscillation per minute & all other necessary arrangements necessary to perform the best task. Well-trained teams shall be engaged for such operations. All necessary safety measures shall be installed. If necessary during hot weather, rest pauses shall be allowed to workers with the provision of liquid or salt water. Forms shall be struck form the elements carefully ensuring full safety intact. Concrete surface shall be inspected immediately after removing form, cleaned & surface treatment to the project specification applied to produce specified class of surface texture i.e. smooth finish or sandy or rough or grouted. Any defective concrete shall be applied remedial measures as agreed with the Company or Client. On New Control Building, special forms shall be erected for dome portion, followed by the steel rebar fixing & pour. Wherever special openings have been provided in designs within the structural framing, those shall be provided within the formwork itself. Now the structural framing works have been completed giving way to attack on internal walls & other items such as dry wall lining & preparation for the roofing item. All preparations shall commence for the remaining works. Block work shall be carried out wherever required for walls followed by services fix 1 items & then plastered over as specified. Roofing shall commence by scabbling the slab surface, laying of light weight foam concrete in grade minimum % to receive water proofing membrane, membrane application followed by water leak test for 72 hours & then polystyrene boards laid over to be protected by concrete pavers. Seperation geotextile shall be provided according to applicator direction. Over concrete protection paint on parapet, Aluminum flashing shall be fixed to design details. Services site team shall be inducted in full swing for carrying out all disciplinary operations. Suspended ceiling fixers shall also enter in to commence the work. Where there is no ceiling, work on the slab finishes shall continue. Wall lining work shall be carried out in accordance to design details after ensuring complete inspections of services conduits etc. are over. Fixing of cable terminations framing steel as well as framing steel for the floor openings shall be carried out according to details.

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IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

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Flooring shall be carried out in according to design details. Tiling shall be followed on required areas schedules to receive floor or wall tiles. Concrete surfaces requiring protection shall be applied accordingly with 3 coat system or any other approved. Operations of constructing transformer foundations shall be carried out & protection applied to that. Sums shall be constructed to details in floor. Gravel filling shall be done around the transformer oil containments/enclosures. All finishing items shall be carried out in wet areas & concealed piping shall be carried out prior to that. Services operations shall be completed in all areas followed by finishing works. Services inspections shall be conducted prior to commence the finishing works. When the works are ready involving the scope of telecommunication routes, an entry shall be allowed to the related other sub contractor from other scopes provided with full cooperation in all respects. Similarly, car park shed shall be worked by constructing its foundations with anchor bolts inserts. The engineered structure shall be erected on the foundations. Works for the planter beds shall also be completed accordingly to the plan requirement. Works of all ramps shall be constructed according to details. Works of external services within 5 m of building shall be completed & tested. All surrounding or backfills shall be completed to the specification provisions. Walkways works shall commence by filling & leveling around the building excluding the instrumentation room on the plant side portions. Walkway Kerb shall be fixed to the profile over the blinding concrete with haunch concrete over. Sand shall be filled over the compacted & profiled area of the walkways whereon the interlocking concrete blocks are to be fixed in to design pattern. Around new control building, work of embankment shall be carried out to the profile shown & back fill done in layers to retain the walkway. This embankment shall be used for grass growing. All internal & external light fixtures shall be installed. New control building requires complete furnishing excepting personal computers. All furniture shall be procured, inspected & installed accordingly to the relevant details. Necessary directional signs to be installed in buildings shall be fixed to approvals. All other furniture within scope shall be inspected & installed accordingly. Foundation works for a 100 m mast to support radio antenna shall be carried out at New Control Building which activities include setting out, excavation, blinding, rcc block, concrete protection. External landscape items such as gravel spreading, grass growing shall be undertaken accoding to layout shown on drawing.

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IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

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Pre commissioning, Commissioning, Provisional Acceptance and Final Acceptance All services individual items integrity & tests shall be conducted by related sub contractors & record maintained. After ensuring that each installation is efficient in performance, release for commissioning shall be given. Details are included within the technical literature/datasheet Supply and coordination of lower tier subcontractor and vendor representatives as necessary All necessary lowers tier sub contractor & vendor representatives shall be provided to the scope requirement All activities necessary to achieve Pre commissioning, commissioning and Provisional Acceptance. Services disciplines such as electrical, fire alarm, & gas detection system, fire suppression system, internal sanitary & drainage, infrastructure of all other included services require pre commissioning, commissioning & provisional acceptance. All fix 1 & fix 2 procedures shall be conducted according to ITPs & approved procedures. All utilities, fuels, lubricants, chemicals and catalysts required up to issuance of the Provisional Acceptance Certificate. Within Contractor scope All required operating and maintenance documentation . All operating & maintenance manuals shall be submitted covering work scope items WARRANTY OBLIGATIONS THROUGH TO FINAL ACCEPTANCE SHALL be submitted for the work scope items
For further details on the services method statements for the package, please refer to the CCTC documentation (not attached within this proposal).

EXECUTION PLAN

Method statement

(PROJECT IMPLEMENTATION STRATEGY) Civil Works/Site Preparations Construction Method Statements


Civil Works & site preparations shall be executed according to Company & Contractor requirement depending upon the priorities. It is expected that all the design & relevant details pertaining all involved structures shall be issued for construction by the Contractor in time according to the agreed schedule of construction. It is also expected that the site shall also be made available in time to meet the schedule requirement. It is proposed to commence the works from all available areas respecting which designs are available immediately after mobilization & upon the receipt of the Permits to Work if so required. Areas belonging to the standalone scopes may also be taken upon one by one depending upon the Company priority. Smooth execution of the construction works necessitates the organization of certain competent teams constituted of capable members fully trained in their respective callings. The team members should upon receipt of the project documents should not waste any day but immediately commence with the practical works with the resolutions of all technicalities issues. Surveyor should efficiently establish all setting outs & its controls with prompt approval according to the guidance of the site engineer. Site engineer in conjunction with the site management should arrange all equipment necessary for the
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IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

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smooth excavation & other following activities. It is also advised that feed back & homework planning has also been under charting process at the pre mobilization stage as envisaged somewhere else in this document. Since our organization works adhering to the set standards of execution in compliance with the quality manual & the project quality plan, all our staffing level shall affirmatively follow the guidance & the direction provided to, optimally utilize for the discharge of their functional responsibilities entrusted by the management, for product quality assurance as well as customer satisfaction. Our efforts shall be to organize the works in such a way that trained teams are established on site for important activities such as steel fixing, formwork, concreting, concrete protection etc. The team members shall be proficiently skilled in the respective trades & group shall be rotated on the project various locations in sequence to perform the jobs on various work elements following the guidance & direction of the trade foreman & general foreman, adhering to the instructions by the site engineer and/or construction manager. Quality team shall monitor fully these operations of the construction teams. These teams shall be extended full technical & administrative support from the engineering as well as procurement & all other controllers based on site as well as in head office immediately, whenever required. This document gives an overall strategy of proposed performance pertaining the site preparation & civil works keeping in view the quantities of various items/descriptions involved & the construction duration according to the defined milestones. Company major policies have already been incorporated within the Execution plan of the New Buildings Package which is an EPC forming a part of overall subcontract scopes. This document should be considered as an extension of that, since the main purpose herein is to serve on the communication of specifically significant procedures that may be adopted on the project based on our past experience of construct able competency which has been exhibited by outlining the procedures & definitions that should be adopted for the proficient prosecution/ execution respecting various preparatory works items involved on the project under works code groups entitling Site Preparations & Civil Works The scope involves the sub titles & their description of constructions as follows, which cover major portions of the Preparation & Civil Works for the project. Site protection & preparation- Surface levelling-Area for this activity shall be selected according to the scope indicated on the IFC drawings. Inspection of the available surface shall be done first visually & then ascertained by spot levelling & undulations noted. Undulation means certain types of ridges & valleys generally of irregular profile. Ridges shall be chipped out & filled into valleys to form a balance throughout the area under consideration. All unsuitable material shall be removed to the specified thickness using heavy equipment such as shovels or bulldozers & selected good material filled. Dressing of whole area shall be conducted to form an acceptable level line profile. Surface Compaction using water shall be carried out to maintain the required profile. Dry & wet compaction shall be carried out to a suitable state of acceptance. Similar procedure shall be applied to the sloping surfaces. Areas covered around obstacles for
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IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

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First Web Edition 2006, Devoted to Engineering Community

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both flat as well as sloping shall be dressed manually & compacted by plate compactors or light rollers. Checking procedure- Profile should be within acceptable limits. Soft spots should be removed. The survey team shall locate and mark, all services that are present upon the site (This includes above ground services as well as buried services). These services, (Electric, telephone, gas, oil, chemical, water etc), shall be clearly marked using stakes and warning tapes. These existing services shall be marked upon a site drawing and the issues raised with the client for reaching a practical resolution. The survey team shall also mark upon the site plan, all obstructions, structures and developments. Any obstruction encountered during excavation activities shall be plotted and recorded. Site Preparation & Earthwork Typical Where hazardous material is encountered, it shall be identified and isolated. Technip & client shall be informed. The hazardous material shall be collected and removed to a licensed tipping place. The details of the material and tipping arrangements shall be documented for review by the client as appropriate. Wherever within the subcontract scope, existing structures, fences and developments, shall be demolished in a safe manner, as site-stripping activities proceed. The necessary permits, approvals and permission shall be obtained from the concerned authorities, prior to the commencement of the activity. The method of removal of these existing elements shall usually be conducted by dozer or breaker. Where necessary, discussions on site shall be conducted concerning alternate methods of removal, when the full extent of these structures is exposed. The removal of the topsoil shall include all vegetation, and rubbish material, from the work site. Prior to the start of topsoil removal, the surveyor shall peg out the haul roads that shall be used by the construction equipment for all the site preparation activities. These roads shall be constructed by levelling of the existing terrain. Grade pegs shall be set to an agreed grid, to indicate existing grade and reduced grade. Dependant upon the quality of the existing soil where the roads shall be built, suitable compactable fill may be imported or re-located from other parts of the site. These roads shall be maintained as the work proceeds. Where required water shall be spayed for dust control. For general removal of the topsoil activities, using appropriate equipment, the areas concerned shall be excavated and graded to levels that shall ensure adequate surface water drainage. The Geotechnical Engineer shall monitor the activity, to ensure that the topsoil material is removed. Sampling and testing of the resultant material shall commence and be conducted for specification verification and compaction data. Upon completion of the topsoil removal activities, where appropriate, the exposed surface shall be scarified, moistened and compacted, to achieve the required density criteria. The areas shall be divided into manageable sections that shall be defined upon sketches. The Geotechnical Engineer shall monitor and test all sections. The results of the tests shall be recorded upon the relevant QC format. The number of tests conducted shall reflect the specification requirement. QC Engineer shall monitor activities regularly.
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IEI Certified Professional Engineer Suraj Singh

ISBN 81- 89090-00-3

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In excavation areas, the Geotechnical Engineer shall review the material to be excavated, to ascertain its suitability for re-use as fill material. This excavated material shall be transported to areas that require filling. The material shall be deposited onto the areas to receive filling, levelled, moisture conditioned and compacted. If necessary, stockpiling may be required. The excavated areas shall be divided into manageable sections, which have to be defined upon sketches. The excavated areas shall be monitored by the Geotechnical Engineer to ensure that any unsuitable material does not appear. Where unsuitable material appears, it shall be removed. The excavated formation surface shall be treated by scarification, moistened and compacted, according to the specification criteria. All areas shall be tested and the results recorded. Where areas are to receive fill, the material that has been excavated shall be transported to the fill area, tipped, leveled, moisture conditioned and compacted. The material shall be spread and leveled in 200mm layers. The areas to be filled shall be divided into manageable sections that shall be defined upon a sketch. The fill layer shall be moistened and compacted to achieve the required specification criteria. No further fill activity shall be conducted upon an area that has not been approved and released by the Geotechnical Engineer. Attention shall be observed at edges and slopes, to ensure that compaction criteria are achieved. Additional layers of fill material, shall be placed in the same method as described above, until the desired elevation has been achieved. Production procedure. Verification exercise for fill activity on record has been conducted to establish the economical and effective method for the fill activity. Import and place fill to controlled areas of approximately 25m wide by 100 - 150m long. Spread and level the imported fill. Add water to the fill layer by passing the water tanker over the fill layer. The water tanker should pass over the layer twice. A time gap of approximately two hours is allowed for the water to soak into the fill material. The layer is now mixed with the grader until a uniform blend of moist material is achieved. Additional water is added by passing the water tanker over the layer in a uniform sequence. A time period of approximately one-hour is allowed for this water to soak into the fill layer. The fill layer is mixed again with the grader, leaving the fill level to the correct grade. Vibrating rollers shall now compact the fill layer in a logical sequence that densifies the layer uniformly. Field Density Testing of the layer shall be conducted to the ITP requirement. Gravel Finishing- Installation of gravel crushed or natural shall be carried out by spreading to the specified thickness of 100 mm or 50 mm as the case may be over the prepared surface uniformly to site feasibility. Mechanical or manual adjustment shall be carried out to the spread gravel followed by mechanical compaction to bring the material to undisturbed acceptable profile. Work shall be done to the area indicated on IFC drawings. Vegetal Soil Surface - Landscaping - Humus for the grass shall be spread over the IFC drawing indicated area on flat as well as sloped surface to specified thickness & leveled roughly by mechanical means. Irrigation network piping & fittings
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IEI Certified Professional Engineer Suraj Singh

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shall be carried out to the indicated areas on IFC drawings. Supply, laying & pipe connection shall be carried out accordingly to the sub contract scope. Protection of Existing Services From the provision of existing site drawings, provided by the relevant authorities within ASAB, existing services shall be located, and exposed by hand excavation. The Survey Team shall check and accurately record these existing services. A line of pegs shall be positioned to indicate the route of the existing services. The use of warning tape, and/or nylon cord, to indicate and protect the route of the service shall be conducted. The Survey Team shall inform the Infrastructure Engineer of the exact location of the service relative to the warning flags. Should an existing service be disbanded or redundant, that service shall be exposed, to allow confirmation of the status of the service. The Infrastructure Engineer, through the Technip representative, shall ask the relevant authority within ASAB, to review the excavated service and confirm the status and action he requires for the removal of the service. The redundant service shall be removed under the supervision of the Infrastructure Engineer according to the agreed criteria of that relevant authority. Where an existing live service remains during the site preparation activity, such as the 33KVA electric cable, that existing live service shall be protected. The Survey Team shall locate the live service upon the ground using spray paint or small pegs. At periodic locations along the route of the existing live service, defined by the Survey Team, small hand dug pits shall be excavated, to identify the service. The purpose of this exercise is to ensure that the location of the live service is accurate. Ten meters (10m) either side of the route of the existing live service shall be erected posts. A nylon cord, with warning tape streamers, shall be strung between the posts. This shall clearly indicate the service and its route. The posts shall fixed be at suitable & sustainable centres. Signboards indicating what the live service within the marked corridor exactly is, shall be displayed at sufficient locations along the route. Where temporary roads cross-existing cables, sufficient suitable fill material shall be placed on top of the cables to afford adequate protection to by distributing the vehicle axle loadings safely minimising stress concentration. The Safety Officer shall periodically check the condition of the barriers, where necessary refurbishment shall be conducted Galvanized fence-Galvanized mesh shall be installed according to the IFC indicated location. Supply shall be affected according to the requirement. Excavation shall be carried out for the post embedment constructed to the manufacturer instructions by using RCC plug in to the holes to support the post of the fence. Reinforced concrete fence- Pre-cast RCC fence panels shall be erected & connected to the already carried out foundations & inserts to the fence requirement. Individual elements shall be stocked properly.
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Prefabricated reinforced concrete fence - Pre fabricated elements of the fence shall be procured from the market to the IFC indication & erected on site & connected to the already carried out foundations & connected to the structural requirement. Vehicle gate- gates in complete package shall be supplied to the IFC & specification requirement as approved & installation be carried out accordingly to the manufacturer instructions & details. Pedestrian gate- pedestrian gates in complete package shall be supplied to the IFC & specification requirement as approved & installation be carried out accordingly. Road barrier- road barriers in complete package shall be supplied to the IFC & specification requirement as approved & installation be carried out accordingly. Fence Erection. The final grade level of the area shall be the commencement point for the fence construction. A level survey shall demonstrate the accuracy of the site grading activity. The Survey Team shall set out the line and level of the fence, including post locations for all elements. Using a machine-mounted auger, 300 and 450mm diameter holes as appropriate, shall be drilled for the fence post foundations. The drilled holes shall be cleaned and bedded to the correct base level. The fence post foundation shall be placed in the drilled hole to the correct line and level. Dune sand shall be compacted around the foundation. The fence fabric shall be strung and tensioned as per the drawing details and manufacturers recommendations Using hand tools, a trench shall be excavated for the ground beam. The ground beam shall be placed to the correct line and level. Suitable fill material shall be used to compact around the ground beam. The fence fabric tie staple shall be grouted in position once the fence fabric is tensioned. The gap between the ground beams at the location of the fence post shall be concreted to form a continuous beam. QC procedures shall be closed out on an on-going basis. Excavation The engineer shall ensure that the current drawings relating to the excavation activity are approved for construction. The engineer shall ensure that there are no conflicts with existing services or other discipline issues. Constructability from the drawing shall be ensured. The surveyor shall provide line and level engineering that shall enable the excavation of the structure. A system for quick reference shall be established. The surveyor shall inform the excavation foreman of these lines and levels. The excavation foreman shall direct the excavation equipment in an agreed sequence. Excavated material shall be classified by laboratory test. Unsuitable material shall be removed off site to the tip area. Where material is classified as suitable, the required volume shall be stockpiled on site in an agreed location. Safety barriers shall be erected as the work proceeds. Where applicable, the sides of the excavation shall be sloped. There is no requirement for ground de-watering equipment.
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Should restrictions be imposed by adjacent structures etc that would make sloping of the sides un practical, shoring or support of the excavation sidewalls shall be agreed with Technip on site. The surveyor and site engineer shall check the excavation to confirm compliance with his levels and lines. A survey shall be conducted of formation level upon completion of the excavation. The formation shall be visually inspected for unsuitable material. Any such material shall be removed. The formation shall be scarified and compacted to the required specification criteria. The laboratory test results shall be provided. Upon acceptance of these results, the area shall be released for consequent activities. Backfill to structures The engineer shall ensure that all subsequent activities are passed and completed. Cleaning shall be done. Upon approval to backfill, the engineer shall instruct the foreman to carry out this activity. The backfill material shall be sourced from the suitable material stockpile. The backfill material shall be placed in layers according to the specification. The layer shall be moisturized and compacted to the agreed criteria. Each backfill layer shall be field density tested by the laboratory. An acceptable test result shall allow the next layer of backfill to be placed and compacted. This process shall continue until the whole fill is completed. Upon completion of the backfill activity, the area shall be cleaned of waste materials and left tidy for the next activity to follow. Any safety barriers shall be removed to the safety store. Ignore if not applicable Piling Typical - Equipment mobilization, Piling rig moving- shall be done accordingly & pile location set out by the surveyor. In case of pre cast piles, the rig shall drill the pile bore to specified dia vertically using steel insert protection at pipe toe. Pre cast/stressed piles shall be inserted into the bore with compression impact hammer gradually till the whole pile is driven into the strata. It shall be ensured that the pile remains vertical & in its set out location. After the pile is driven, sonic test, dynamic auscultation & load test shall be conducted to specified requirement. Load test shall be conducted by reaction truck loading or the actual load applied in cycles. Dynamic auscultation test shall be conducted to the code requirement. All records shall be maintained. After piles have been driven, demobilization of equipment shall be effected Pile head preparation shall be carried out by cutting pile heads to expose the rebar for connection to pile head or cap rebars. After proper placement of the rebars of the pile cap & the pile head, formwork shall be erected & concrete poured for the pile head or cap. Curing shall follow to agreed procedures. Cast in place concrete pilesDriven cast in place concrete piles with permanent casing- Location of the piles shall be set out. Casing shall be driven truly vertical into the location using the rig & continued until the design depth is reached. Soil column shall be taken out by pressurised water. Casing base shall be cleared & inspection for the plumb & profile conducted. Reinforcement cage provided with concrete spacers shall be placed into the casing properly fixed. After
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inspections, concrete shall be poured into the casing keeping a maximum drop of concrete not more than 2 m. Concrete vibrator shall be kept working into the poured concrete & gradually withdrawn progressively as the concrete moves up. In case casing is to be withdrawn, it shall also be gradually withdrawn following the gradual & progressive pour. While withdrawing, care has to be exercised that verticality is not disturbed. Pouring shall be completed up to the head of the pile. All accumulated water shall be removed by pumping continuously & piling area kept dry. Pile shall be poured continuously avoiding any construction joint. All excavated earth shall be removed from site. Pile load test shall be conducted after lapse of specified duration. Engineer shall select the piles to be load tested. Cyclic load testing shall be applied for 72 hours loading & unloading & reloading. Test record shall be maintained according to ITP & procedural requirement. To ascertain the pile integrity, sonic test shall be conducted by a hammer impact & the transmission of the sonic waves recorded using the standard equipment. This test shall be conducted for all piles for it ascertains the integrity & transparency of the material used. After the piles have been tested successfully, preparation of the pile head shall commence. Extra portion of the concrete shall be cut to the pile cap base level. All reinforcement effected by concrete shall be cleaned, new reinforcement for the pile cap & column starter bars installed. Preparatory form shall be erected for the pile cap. Concrete spacer shall be fixed properly. Any tie up beams preparatory works shall be carried out. After the inspections are conducted, concrete pouring shall be carried out & the unformed surface finished smooth enough to receive concrete protection. Ensure the side are truly aligned as well as in plumb. Ensure dimensions are correct within tolerable limits. Ensure reinforcement placed to the design details. Ensure the spacers are properly fixed & all steel bar in its design locations. Ensure concrete level at top is fixed properly using 25 x 25 mm plastic chamfers. Ensure the vertical corners edges have been fixed with plastic chamfer. Since, most of the pile caps shall be thick sections, special arrangement shall be made for curing using saturated Hessian, polythene sheets and clean sand fill below the coverings so that no heat transmission is permitted from the concrete surface. This type of curing is called thermal curing. During high temperatures, water shall be sprinkled on the forms from the sides to ensue minimum heat loss in early days of concreting. Bored Continuous flight auger (CFA) Piles, reinforcement for Continuous Flight auger (CFA) pilesSimilarly, CFA piles shall be continuously augur bored into any soil, reinforcement place in & concrete poured. All tests shall be conducted according to previous explanations. After the piles have been cast, location survey shall be conducted for 5% of the poured piles. Micro Piles, Drilled micro piles, reinforcement for Micro piles, Jet Grouting soil Improvement system- For the proposed piles, locations shall be set out. Rotary mast shall be utilized to drill a bore into the strata without removing the soil & high pressure cement grouting applied into the bore. Curing shall be carried out to the requirement. All debris shall be removed from site.

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Pile test- Sonic test by hammering for construction uniformity & homogeneity, Dynamic auscultation test by impedance, Load testing (compression), Load testing tensile test, Load testing horizontal loading test, pile location survey, EarthworkGrubbing - According to the scope included on the IFC drawings, trees, plants, bushes, roots shall all be removed completely from the soil ensuring that the soil is not effected adversely. These uprooted green materials shall be collected at one place for suitable disposal to a designated area. Scrubbing- According to the scope included on the IFC drawings, vegetation topsoil shall be removed irrespective of its consistency & water content. General ExcavationIn the controlled plant area, prior to commence with the excavation, legal permit to work shall be obtained from the operating authority It shall be made sure that no existing services run under the proposed area from the concerned authorities record. Necessary benchmarks shall be established for surveying controls & monitoring purpose. Where it is feasible to excavate the whole unit area involving all foundations & beams etc. using heavy excavation equipment, general excavation should be carried out which allows saving in excavation time keeping the area tidy. Such area shall be set out to the IFC details, grids marked on the timber rails around the area periphery. Additional marking shall be set for the general area limits & proposed convenient ramp to allow easy access & egress to & from the area. Proper safety warning signs shall be erected around proposed general area. Signs shall include KEEP AWAY DEEP EXCAVATION, HARD HATS ZONE etc In case of any mishap caused to the existing services, immediate information shall be notified to the concerned authority so that corrective action can be undertaken. Excavation shall be started by excavator directly loading the material into a dumper truck which shall remove the excavated material from the location to stock pile areas in case the material is suitable for re use as backfill or to a designated dumping area otherwise. A surveyor shall constantly monitor excavation formation level. Environment protection arrangements shall be charted out to keep the site tidy. During excavation in case of loose soils such as sand whose angle of repose does not permit, shoring shall be arranged around the periphery to prevent soil subsidence. Excavation & soil removal shall continue to reach the formation level. No further excavation shall be carried out. All debris shall be removed from area, dressing conducted on the rough formation to bring it to required profile. The surface shall be watered & compaction carried out using heavy road roller of at least 8 T capacity, which work in strips in parallel overlapping the previous strip. Compaction shall be conducted until rebound occurs. Field density test shall be conducted to ensure the correct formation density has been achieved, atterbergs limit & moisture content are within acceptable limits. In case, soil improvement is to be applied, further excavation shall be carried out to the design thickness of the improved strata. After preparing the formation for the engineered fill, selected granular material shall be placed into the prepared formation in layers, watered & compacted. Field density test shall be conducted for each layer of fill. Plate bearing test may also be carried out to know the ultimate & safe bearing capacity
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of the improved strata. Now the formation is ready to receive the foundations on it. Formation levels shall be recorded. In case water level is high & dewatering is necessary, proper plan shall be made to install the dewatering system until the whole of area is constructed up to the ground level. Water shall be pumped out & disposed to a suitable agreed discharge point keeping the location tidy. But in this case, according to investigation report, soil is free of water. No dewatering is required. Sectional ExcavationIn the controlled plant area, prior to commence with the excavation, legal permit to work shall be obtained from the operating authority Where particular foundation or trench for a cable or an isolated or combined footing or vessel base etc is to be excavated, excavation shall be carried out only for that particular area. Necessary benchmarks shall be established. Setting out shall be done accordingly for the extent of the area & grid control established. Safety signs shall be established. All arrangement for the necessary shoring resorted in advance. Excavation shall start by mechanical equipment removing the excavated soil into a dumper truck for disposal to stockpile or to a designated area. In case manual excavation is to be carried out for the protection of the existing services, no machine shall be used until specially permitted after the exposure of all existing services. In case of fibre optic cable exposure, only water jetting should be used to excavate the area. In case of any mishap caused to the existing services, immediate information shall be notified to the concerned authority so that corrective action can be taken. In case water level is high & dewatering is necessary, proper plan shall be made to install the dewatering system until the whole of area is constructed up to the ground level. Water shall be pumped out & disposed to a suitable agreed discharge point keeping the location tidy. But in this case, according to investigation report, soil is free of water. No dewatering is required. Embankment- Typical Profile shall be set for the proposed embankment base. Centreline of the embankment shall be marked. Loose soil from the base shall be removed. Embankment template shall be fixed at various spacing longitudinally. Backfill shall be carried out in layers 250 mm loose thick, watered & compacted using heavy roller. Whole layer shall be compacted to achieve non-structural fill density. Field tests shall be conducted according to the specification requirement. The quantity of samples to be taken for test shall depend on the extent of area under compaction. Filling shall continue in layers until the whole section is completely backfilled. Every layer shall be tested accordingly. Structural backfill compaction density test shall be ensured for the embankment to receive heavy loading such as tanks, roads, foundations etc. Earthwork for Storage facilityExcavated material from the other excavation areas shall be stockpiled at designated areas. Reusable material for filling shall be screened out regularly from the stockpiles. Compliance of this material shall be ascertained by conducting classification tests & if necessary, additional deficient materials of required grading be added to bring the stock to acceptable plasticity index or non-plastic standard. This material shall be used for the formation of the storage facility foundation fill works. Tank foundation area shall be set out to IFC details. Design profile shall be established & fill layers commenced with. Every layer shall be filled 250 mm thick watered & compacted down to 200 mm. Field density test shall be conducted after the compaction
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to allow the commencement of the upper layer. All forthcoming layers shall be filled adhering to same procedure & tested. The top layer to receive the bituminous surface finish shall be prepared suitable accordingly. Surface shall be cleaned, levelled properly & top of surface finish level established. Surface shall be primed with approved material. Conglomerate of 10 to 20 mm size, closed with 5 mm aggregates & bituminous emulsion @ 1 kg/m^2 or in accordance with Contractor standard to from a total compacted thickness 100 mm. Surface shall be inspected & density test conducted by taking out the compacted cores. Similar operations shall be carried out on the sloping areas. Earth dikes- To retain the basins Similarly, the filling works for the earth dike shall be carried out as stated in the foregoing from excavated material & also if required from the supplied material as the case may be. Body of the dyke shall be covered by application of an approved material to give acceptable finish to the body of the dyke per provisions on the IFC drawings. Soil Improvement- By Soil Substitution Wherever shown on the IFC drawings, the scope of replacement of the existing soil from the plant area, existing soil shall be excavated out in specified thickness & removed to dumping areas. Suitable backfill material shall be procured from an approved source including the site stockpiles & backfilling carried out to replace the excavated portion of the plant area. Watering & compaction shall be carried out all according to approved procedures. Testing shall be conducted to ascertain the field density achievement. Soil TreatmentWherever shown on IFC drawings, the scope to treat the soil belonging to an area, the soil shall be stripped out from the area & transported to stockpiles for the purpose to add into this material cement or lime, water & mix mechanically. After the mixing of the soil, re-transport to the original location shall be carried out, spread on to the area, levelled & compacted in acceptable thickness & bring the profile to the defined levels. Whole area in the scope shall be applied treatment accordingly. Walkways kerbWherever shown on IFC drawings, the scope of laying & fixing the walkway kerbs, proper preparation of the formation duly compacted shall be carried out. Blinding shall be laid to the required profile in gradient. Kerb shall be placed on the blinding using defined cement mortar mix sealing the base of kerb & end to end joints perfectly. Alignment of the kerb, gradient, verticality & joint thickness shall all be controlled. Any deviation in the alignment shall be within acceptable limits. Walkways FoundationGranular material shall be filled below the walkway finishes given required gradient. This fill shall be compacted to the non-structural requirement. Walkways FinishesFinishing over the walkway foundation shall be applied according to IFC drawings & specification requirement Wherever shown on IFC drawings, 30 mm thick rolled thickness of bituminous conglomerate shall be applied.
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Wherever shown on IFC drawings, 100 mm thick RC concrete with prefab mesh paving given float finish shall be applied with required number of joints properly spaced.
All loose soil shall be cleared and formation level made up and well compacted & pesticide treatment applied if so specified.

Laying Kerb stones Typical Sample Setting out kerb excavation lines according to drawing Excavation up to the formation level i.e. 450mm from the kerb top level Form work fixing and pouring grade 20 concrete 450mm wide and 150 mm thick Formwork fixing and pouring grade 20 concrete 150mm wide and 150 mm thick high Pouring grade 20 concrete all according to approved procedures Fixing 12 T re-bars @ 200 c/c vertically supported to forms Bedding in cement mortar 1:3, 25mm thick for kerb stones grade 20 Fixing kerb on the mortar to the true lines and levels with chamfer facing pavement & jointing with mortar. Alignment tolerance shall be 3 mm in 75 mm both ways vertically as well horizontally. End to end butting mortar thickness shall be 3 mm Placing haunch back fillet concrete grade 20, as shown in (triangular fillet section) Filling up to top of vertical concrete with earth fill & compaction All areas below proposed interlocking course to be filled with 100 mm thick sand screed all according to conventional procedures QC inspection shall be conducted for kerb laying approval and ITP requested to be signed off by QC (Laying Paving Interlocking blocks) Thickness of the interlocking blocks 60mm Thickness of the sand screed bedding 100mm Plank runs shall be used to allow barrows to move on to avoid level disturbance First surveyor shall set out the pattern borders all according to shop drawing as well as design drawings First Grey or other approved colour interlock blocks shall be laid to position & profiled to form the border pattern. The blocks shall be laid in full but at the edges of the obstacles such as inspection covers where cut blocks may be required, whole blocks shall be laid first wherever possible and the trim able blocks exactly marked & cut to the required size. After profile is well formed to the approval, the fill in course to the border areas shall be carried out by laying Red or as approved colour blocks After sufficient blocks have been laid, sand bedding shall be carried out using a plate vibrator pressing the blocks to the required level in 2 passes covering entire area with each pass to make the bedding even Sand screed shall be spread on the surface of the blocks with 2 more vibrator passes applied & brushed under the leading edge of the vibrator to allow the joints vibrated QC inspection shall be conducted & QP requested to approve the paving Ignore if not applicable Roads, Yards, Paving (Asphalt) Road Works Typical Sample The following sequences shall be involved to do the roadwork Clearing all services according to the project drawings and inspections/Approvals Preparation of the area to be structured by removing topsoil, placing in imported fill material, profiling levels to the project drawing & compaction.
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Application of all pre work items such as construction of kerbstone to complete sectional details shown on project drawing miscellaneous details. Inspection of the surface Sub base class B material shall be spread on the area in strips of required thickness keeping more than design thickness by 25mm i.e. 150+25 mm Sub base approved fill material to interlock the class B material shall be spread on the spread material & dry rolling carried out to produce correct profile of the section Water shall be sprayed on the surface to make it penetrate in to & around all the voids of the spread material & compaction by heavy roller carried out to densify the whole course. After required number of passes probably 6 given by 18 to 12 tonne rollers bringing the laid material to the required thickness 150 mm & exhibiting rebound on the surface, the compaction by rolling shall cease. Density test shall be conducted all according to approved ITPs requirement Compacted course shall be left for drying in due course allowing it to be ready to receive Prime Coat MC1. Drying time shall not be less than 48 hours. Prior to the start of the Prime course spreading, any defect is observed during visible inspection shall be repaired in rectangular or square shape or as agreed with. Asphalt concrete Asphalt concrete shall be laid in widths of driveway roads according to the project drawings. Wearing course thickness being 40mm & that of dense bitumen binder course 80mm Paving works shall be carried out in 2 stages Stage 1 Laying & compacting bottom bituminous binder course Stage 2 Laying & compacting top wearing carriageway Surface preparation Prior to the application of the dense bitumen binder course, already laid & compacted aggregate base course shall be prepared suitable for this purpose Base course shall be corrected of any deviation more than 13mm from the designed profile at any point & not more than 9mm in 3m on the longitudinal grade at any location by either adding to or removing from the surface the deficient or redundant material respectively to bring the surface to the design shape, watered & compacted in accordance to the specification all as stated above Main Operations The following main operations are involved Re-preparation of aggregate base course surface with water & compaction by pneumatic roller Application of Priming coat & drying out Application of 60mm thick dense binder course Power brooming the completed dense binder course Application of Tack coat & drying out Application of 40mm thick bitumen concrete wearing course Mixing All materials shall be mixed at an approved calibrated & approved Asphalt plant
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All trucks and other equipment as included shall be readily available for inspection Transportation Material shall be transported from the plant to the planned location in good condition by trucks cleaned of all foreign material & covered with tarpaulin to prevent dust invasion in inclement/adverse weather conditions It shall be ensured by obtaining observations using thermometer that the material when laid is within 130 to 165degree Celsius Application Coverage Primer coat 0.8 to 1.4 litre/ m^2 Tack coat 0.4 to 0.7 litre / m^2
Primer

QC inspections shall be conducted to ascertain the true profile of the aggregate base course & corrections applied if so required All surfaces planned to be primed shall be barricaded & cleaned of all dirt & any objectionable material Bituminous material shall be applied evenly on the dry surface by means of a pressure distributor spray tanker within a temperature 30 deg to 70 deg C Surfacing Binder Course QC inspection shall be conducted prior to the commencement of binder course laying to make sure that the surface is satisfactorily clean, well dried & even to the specified priming conditions as well as to receive binder course. The material upon arrival at the location shall be spread & struck off to the prepared profile by means of self-poared spreading & finishing equipment attached with a strike off assembly distributing the mixture to a strip 3 m wide Rolling Steel Rollers # of passes 6 to 8 depending on the surface condition Steel rollers 10 T capacity equipped with adjustable wheel scrapes, water tanks & sprinkling apparatus to keep the wheel sufficiently wet to prevent the bituminous mixture from sticking to the steel surface shall be employed to roll the profiled material immediately after the material is laid to the acceptable profile to prevent the formation of undue displacement or hair cracking The roller wheels shall be kept properly moistened without excess water or oil Rolling shall be commenced from the side and proceed towards the centre each trip overlapping the previous by at least 300 mm with keeping alternate trip not more than 5 km/h & it shall continue until the surface is impression free. Mechanical compactors shall be engaged to compact the roll inaccessible area layers. Pneumatic tyres rollers shall be engaged only after the compaction by wheel roller is over. It is significant to make sure that the asphalt temperature does not fall below 80 deg C prior to full compaction is achieved Roller shall not pass over the edges of the freshly laid material generally except when the edge is located at a discontinuation for that day QC inspection shall be conducted throughout the above operations to make sure that the material is compacted to the standards and the temperature remains within limits mentioned as well as levels are maintained within specification tolerances particularly over the areas involving shoulders At the commencement of the work on the area involving the compacted & chilled edge, a bevel shall be cut out, cleaned & tack coat applied to receive adjoining material No traffic shall be permitted until 12 hours lapse post-rolling completion Wearing Course The planned surface shall be cleared of all dust & dirt using power broom or blowing
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Tack coat shall be applied to the specification requirement Immediately upon arrival, the material shall be spread & rolled similarly as described in the foregoing. QC inspection shall be conducted throughout the above operations to make sure that the material is compacted to the standards and the temperature remains within limits mentioned as well as levels are maintained within specification tolerances Reinforcement Fabrication When reinforcement is to be cut and bent, the foreman shall be issued with a current rebar schedule. The foreman shall review the schedule and allocate the fabrication process to the relevant fabricator/steel fixer. Material required shall be sourced from the yard storage facilities. The correct bar diameter shall be cropped into the specified length as given on the bar schedule. The cropper operator shall crop the required bars of each diameter. Upon bending of the first of each bar type, it shall be checked by the foreman for correctness. This bar if correct, shall be utilized as a check sample for all concurrent bars of that type. The bending operator shall fabricate the required number of bars of each shape code checking against the check sample when each bar is completed. Any error in bending of the bars shall be corrected prior to placement in storage. The correct bent bars shall be stored in bundles & protected against ingress of moisture. The bundles shall be tagged with a suitable label that indicate the relevant bar reference and BBS document reference from which these have been fabricated. The completed bundles shall be stored within the reinforcement yard until such time as those are required upon site. Storage shall be in accordance with the procedure for store control. Reinforcement Placement Typical The relevant reinforcement bars, spacer blocks, chairs, stirrups and tie wire, shall be collected from the stores as well as fabrication yard and made available at the work site. The material shall be stored at the worksite, in accordance with the storage procedure pertaining fabricated & non-fabricated re-bars. The current revision of the reinforcement drawing that applies to the structure being constructed shall be checked by the Project Engineer, Site Engineer, Q A for validity. The steel fixers shall place and tie, reinforcement bars and accessories, in accordance with the current reinforcement drawing under direct supervision of re-bar charge hand or foreman. Particular attention to the following items shall be monitored by the charge hand steel fixer and foreman: Lap length of bars. Tie wire protrusions into cover areas. Appropriate concrete cover to formwork and outside faces. Placement of adequate support chairs and stirrups. Spacing of bars.
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The Site Engineer & charge hand steel fixer/foreman shall check the fabricated reinforcement when all the placement of the reinforcement bars is complete. The result of this inspection shall be recorded upon Pre concrete inspection checklist by Site Engineer & QC. The foreman steel fixer shall ensure that the reinforcement has been correctly placed prior to informing the Site Engineer & QC. QC shall check all items of different shapes, spacing & numbers, spacer blocks, additional chairs if required. Should any inserts, conduits, pipes, bolts etc, require fixing within the structure according to design details or shop drawings, the steel fixer foreman shall arrange for the placement of these items according to directions by Project Engineer/Site Engineer. Where a reinforcement bar clashes with such items, based on the decision of Engineer, Project or Site Engineer, the steel fixer shall move the relevant bar. An additional bar may be required to offset this moved bar. Should any doubt arise about moving bars, the charge hand shall inform the foreman & Site Engineer to resolve the issue with the engineer. The foreman shall inform the Site Engineer when these activities are complete. The QC shall inspect the re-bars placed in the structure for compliance with the design drawings and details as well as other working and shop drawings. Formwork Erection Typical Based on site engineers instruction, the formwork foreman shall review the drawing of the structure to be formed & shall decide together with the site engineer, the most suitable method of formwork erection. Where pre-fabricated formwork can be assembled in the carpentry workshop, fabrication shall be carried out. The surveyor shall establish the lines and levels for the erection of the formwork. These lines and levels shall be explained to the foreman and supervisor in charge/charge hand of the formwork activity. The foreman shall check that the preceding activities have been approved, so that this activity may commence. The sections of formwork required to form the structure, shall be taken to the work site. The form carpenters shall ensure that the formwork faces are clean, in good condition for the type of finish required & applied over with shutter form oil. The form carpenters shall assemble and fix the formwork in accordance with the current drawing. The charge hand of carpenters shall monitor particular issues such as: Sealing of joints between formwork has been applied properly Verticality of formwork is according to requirement. Tie bolts are in proper positions & snug tight. Adequate bracing and supports are in tact Provision where applicable for box outs and inserts have been applied Provision where applicable of chamfer and channels have been fixed The supervisor and surveyor shall check the lines and levels of the formwork when all bracing and strutting have been completed. Wherever required, the formwork shall be adjusted to conform to the required lines and levels.
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The supervisor shall ensure that any damaged face of the formwork is repaired. The foreman shall review the formwork when completed. Where anchor bolts or embedded plates are to be suspended in the structure, the supervisor shall ensure that these arrangements are adequately supported as well as securely braced. All inserts and bolt groupings shall be checked for location and level prior to the placement of concrete as well as after the concrete is placed. When the formwork activity is complete, the supervisor shall inspect the formwork and associated works, recording his observations on approved formats, formwork checklist and insert check list. The QC inspector shall confirm the acceptance of this activity after review of the items. Where large formwork elements are encountered, the QC inspector shall review the formwork bracings and supports with the engineer. Concreting Typical sample The supply order for estimated quantity may be placed in advance but real confirmation shall be done based on the pour approval. After the inspections of the preparatory works pertaining to any element namely footings, stubs, columns, suspended slabs etc & the relevant approval, the order for the release of concrete from the batching plant shall be placed. The required quantity shall be sequenced depending on the consumption frequency on site. The concrete shall be poured either by the concrete pump or by the mobile crane depending on the necessity & convenience. Necessary access to the location shall be prepared using proper supports or platforms duly inspected by the safety officer in charge. Immediately, at the arrival of the truck mixer of concrete on site, slump, temperature, air contents etc all test samples to the specification requirement shall be taken by the ready mix supplier in the presence of the QA engineer. In case the concrete does not meet the specification requirement, the truckload shall be rejected. Arrangement shall also be made for the filling of the concrete cubes/cylinders on site & number of specimen to specification requirement. After the truck is approved by the QA to be transported to the site location, the concrete pump, which should already be located in proper position, shall receive the load & pump out to the in situ delivery location. The concrete laying gang already present on the site location shall receive & pour the concrete mix into the prepared elements from a height not more than 2 m from the edge of the boom chute pipe. As soon as enough mix is available in the element to compact the mix conveniently, insertion vibrator shall be used by a trained operator to compact the mix till no more bubbles appear. Foreman shall direct the pump remote control operator about the boom movement & stop & hold points or stages during concreting. Vibrator shall not be allowed to touch the forms side or re-bars. Over vibration shall not be permitted Each Footing shall be poured in one go if not more than 500 mm in depth. The widened portion of the stub in touch with soil shall also be poured in strips not more than 450 mm deep Into columns the mix depth at one rotation shall be 450 mm & in different strips vertically, pouring shall be completed avoiding formation of cold joint Top level of the concrete shall be levelled & the columns form top covered with plastic sheet
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The portion of the pipe chute shall be inserted into column preparatory works to allow for a 2 m vertical fall maximum. Vertical forms of the columns shall be struck after 48 hours. Inspection shall be made immediately post form striking & any defect in concrete shall be brought to QA Engineer notice for deciding remedial action. Vertical surface shall be covered with saturated Hessian, further covered with polythene sheet cover or alternatively curing compound shall be sprayed over the water-wet surface to form a impermeable membrane not to permit evaporation. The grade slab shall be poured in one go in depth bay wise between ground beams or walls. For the suspended slabs, beams shall be poured first around the slab & prior to the formation of cold joint, the slab concrete shall be poured & the whole slab completed. The joints if so required, shall be agreed in the beginning of the pour with the engineer. Water shall be sprayed over the form during hot weather prior to pouring to avoid flash setting of concrete with re-bars. In case some plant break down is reported, immediately the last poured line shall be stopped by a formed surface & concrete terminated at that point & in no way shall recommence prior to 24 hours with further approval obtained. In such case previous formed joint shall be scabbled/hacked to expose all aggregate by removing laitance completely, washed with cement slurry & new concrete commenced making proper bond with old concrete. Due care shall be taken that no spacers, electric conduits or any other insert is disturbed from its design or worked location. If so disturbed, it shall be immediately relocated according to the engineer site approval. Immediately after the compaction of concrete is over & concrete starts setting in, arrangements for applying U1 finish to the top of slab surface shall be done by timber tamper. Immediate curing shall be applied by spreading polythene sheet cover on slabs & footing. Then after about 2 hours, polythene sheet shall be withdrawn temporarily & saturated hessian placed over concrete & recovered with polythene sheet & the concrete cured for specified period If so, repair to hardened concrete is required, approved repair material shall be used according to manufacturers instructions. Concrete Paving Typical All the relevant underground services shall be laid in all respects prior to the commencement of the pavement work The area to be paved shall be made ready by clearing all weak soil & by scarifying. Approved sub base material 150mm thick or as specified, shall be filled up to the bottom of the concrete slab following the profile given on the drawing and compacted to 95 % dry proctor density. Weed killer chemical shall be applied to the soil to prevent the organic growth if so specified. The whole area shall be divided into parts to suit the services and the contraction joints formations & as shown on drawings On the compacted filled area to be paved, polythene sheet 0.25mm shall be placed with end overlaps at least 150mm at all joints and intersections.
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End forms shall be fixed on sides allowing a provision to place 20 dia MS dowel bars 650mm long & 300mm centres half painted with 2 coats bit mastic paint with 100mm long cardboard cap containing compressible material such as cotton waste at the Expansion joint to the details shown on the drawing. The thickness of the expansion joint shall be 20mm At contraction joints 25 x 25 mm plastic crack inducer shall be provided as shown in the detail & the joints cut for a depth of 20mm with a concrete cutting machine. Welded wire fabric mesh dia 6mm 200# shall be placed in the bay centrally located with concrete spacers below. Forms shall be set to correct levels so that the total thickness of the concrete is as indicated on the drawings. QC inspection shall be conducted for the pour approval. Concrete shall be poured in one layer and compacted using vibrators & given brush finish to correct levels. Curing compound shall be spread on the surface for immediate curing covered with polythene sheet and later within 2 hours damp hessian added by removing polythene sheet temporarily and recovered thereafter. The expansion joints between the two adjacent slabs shall be filled with elastic joint filler and sealed with a chemical resistant sealant complying with the details shown on the drawings. QC inspection shall be conducted. Concrete Lined Trapezoidal Ditches Earth sectional depth dimension as included within specifications Depth 300 to 500 mm; 501 to 1000mm; 1000 to 1500mm. Setting out dimension about the proposed ditches shall be marked. Excavation shall be started & shaped to the design profile. Compaction shall be done to the non-structural requirement. Proper gradient as indicated on the design drawings shall be maintained. Isolation layer shall be applied if so provided within the specification. Blinding shall be applied on the compacted base to the design thickness. Preparation for the lining concrete shall be carried out by placing in pre fabricated reinforcement to design details & sides formed at edges parallel to the ditch as well as at the construction joints. After the inspection, concrete pour shall be carried out in alternate bays with unformed horizontal as well as sloping surfaces finished smooth. Remaining bays shall be carried out in the next day operation. Curing shall be carried out accordingly to the approved procedures. Expansion Joints between ditches Size of the proposed joints to be filled/sealed is 15 mm wide x 15 mm deep. The surface shall be cleaned of all dirt, dust and loosely adhering materials. All grease and oil contamination shall be removed using hard small brushes, compressed air etc. The fibreboard shall be removed to the required depth. Under normal circumstances priming is not required. Masking tape shall be used to confine the joint borders keeping the adjoining concrete surfaces clean. The contents of the Can shall be removed by a Trowel or a Spatula.
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The Bit mastic shall be applied to the prepared and masked portions. In case of the vertical joints, bottom to top application sequence using a spatula or a trowel, shall be followed ensuring that the entire volume of the joint is filled in to effect a total contact with joint surfaces. After application, the sealant shall be smoothened and compressed into the joint using a spatula or a putty knife moistened with cleaning solvent. Masking tape shall be removed immediately after the application is completed to keep the concrete surface clean. A full cure (a stage when the solvent evaporation is completed) shall normally consume 4 to 6 weeks post application of the sealant. Painting over concrete surface if so required, shall be carried out only after full cure has taken place. Concrete Lined Rectangular Ditches Setting out dimension about the proposed ditches shall be marked. Excavation shall be started & shaped to the rectangular design profile. Compaction shall be done to the non-structural requirement. Proper gradient as indicated on the design drawings shall be maintained. Isolation layer shall be applied if so provided within the specification. Blinding shall be applied on the compacted base to the design thickness. Preparation for the lining concrete shall be carried out by placing in pre fabricated reinforcement to design details & sides formed at edges parallel to the ditch as well as at the construction joints. After the inspection, concrete pour shall be carried out in alternate bays with unformed horizontal surface finished smooth. Remaining bays shall be carried out in the next day operation. Curing shall be carried out accordingly to the approved procedures. Expansion Joints between ditches Size of the proposed joints to be filled/sealed is 15 mm wide x 15 mm deep. The surface shall be cleaned of all dirt, dust and loosely adhering materials. All grease and oil contamination shall be removed using hard small brushes, compressed air etc. The fibreboard shall be removed to the required depth. Under normal circumstances priming is not required. Masking tape shall be used to confine the joint borders keeping the adjoining concrete surfaces clean. The contents of the Can shall be removed by a Trowel or a Spatula. The Bit mastic shall be applied to the prepared and masked portions. In case of the vertical joints, bottom to top application sequence using a spatula or a trowel, shall be followed ensuring that the entire volume of the joint is filled in to effect a total contact with joint surfaces. After application, the sealant shall be smoothened and compressed into the joint using a spatula or a putty knife moistened with cleaning solvent. Masking tape shall be removed immediately after the application is completed to keep the concrete surface clean. A full cure (a stage when the solvent evaporation is completed) shall normally consume 4 to 6 weeks post application of the sealant. Painting over concrete surface if so required, shall be carried out only after full cure has taken place. Galvanized grating shall be placed on the ditch later.
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Termination Details to protective membrane The following operational sequences shall be involved Case 1 Concrete surface shall be cleaned of all dirt & dust using a brush. Application of the waterproofing membrane according to the specifications to the defined levels keeping the top 200 mm or variable dimension according to the drawing above the finished ground level. Lines shall be marked on all sides to correct level as per drawing. Bead Lengths to exact site dimensions shall be cut to suit a close fit between the ends. Every bead shall be provided with a minimum 3 # screws to be drilled and fastened into the concrete penetrating the membrane using an electrical operated Drill. After the screws have been fastened and the beads are in proper alignment, approved sealant shall be applied to top of the bead keeping about 5 mm above the bead with a down ward lap as follows. Sealant shall be applied using a gun fitted with conical nozzles adjustable to suit the width into the corner using an even trigger pressure & cleaning the nozzle occasionally to avoid contamination. A smaller timber spatula soaked in soapy water shall be used to compact the sealant into the joint/junction for a smooth polish finish formation. The mixing and application equipment shall be cleaned immediately after use. QC inspection shall be conducted & the relevant ITP signed off Case 2 Where grooves have already been chased, the waterproofing membrane shall be tacked in & sealant applied to the space left in the groove according to specifications and the manufacturers instructions. No Aluminium bead shall be used in this case. Sealant shall be applied around bead continuously. AJES QC inspection shall be conducted & the relevant ITP signed off Case 3 In gravel or soil area, membrane shall be terminated at a level 150mm plus below the footing top level keeping Aluminium bead details typical. All other details shall remain as in case 1 if no rebate has been chased. QC inspection shall be conducted & the relevant ITP signed off Case 4 In the paved area, membrane shall continue up to the termination level but the protection board cease at 20 mm below the paving level filled with mastic on top keeping all other details as in case 1 if not chased for rebate. QC inspection shall be conducted & the relevant ITP signed off Ignore if not applicable Grouting to pipe rack bases typical The surface to be grouted shall be chipped / scabbled without using mechanical bush hammer, to expose the aggregate and remove the laitance. The finished surface shall be free from oil, dust, dirt, paint, curing compounds etc and be soaked in with water for 24 hours prior to grouting to minimize the localized absorption as well as to assist the free flow of the grout. The bolt holes/pockets shall be made water free prior to placement of grout. The base plates/ bolts shall be clean and free of oil, grease and paint and correctly aligned according to the approved drawings.
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The stainless steel shims 50x50x10 mm thick shall be in correct locations covered with mortar so as to allow at least 50 mm grout cover on shim sides. The forms on the essential sides shall be erected at locations with chamfers. An electric drill fitted with a paddle shall be used for the grout mixing purpose using water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928 or any other approved grouting material depending on to requirement. The mixer shall be clean with no standing water. 90 % of the measured quantity of water required to achieve the desired consistency according to the batch volume be added to the mixer before adding the grout and the Masterflow 928 or any other approved grouting material be added gradually, simultaneously pouring in the remaining 10 % water quantity during mixing, which has to be kept on for at least 3 to 5 minutes until a uniform lump free consistency is achieved. Then the grout shall be poured continuously using the grout pour cone with a constant hydrostatic head of at least 15 cm. Having poured the grout Masterflow 928 in place, all exposed grout shall be covered with clean dampen Hessian and be kept moist until grout is firm enough to accept a curing membrane. The temperature range 4 to 32 degree C shall be maintained for the 3 post pour continuous days.
The grout thickness varies between 25 to 50 mm. Ignore if not applicable

Water Tightness Test of RCC Structure typical Sump The structure to be tested shall be completed of all RCC constructions according to the specified and agreed procedures. Complete filling of the tie rod holes with MBT Master Flow 544 or Conbextra GB or an equal approved shall be carried out according to the manufacturers instructions. Inlet shall be laid in place to the levels shown on the drawings as reflected on the water quantity schedule i.e. the Invert levels at maximum supply elevations. The external surfaces of the structure shall be prepared & applied with the specified protective system. QC Inspection shall be conducted for the approval of the membrane. Structural backfilling shall be carried out externally to the project specifications & necessary field density tests conducted to the requirement. Application of the floor screed as specified shall be carried out The entire surfaces of structure to be tested shall be sweep blasted removing all loose spalls, dust dirt etc. The prepared internal surfaces shall be inspected by QC for approval. The following operations shall be involved to conduct the water tightness test according to the BS 8007: 1987 Section 9.1 applicable to liquid retaining structures.
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A graduated stick shall be provided on wall top to show the water levels to a mm count. Potable water shall be filled into the respective pit structure at a rate 2 m per 24 hours for which the attached filling scheduled quantities shall apply. Attached schedule shall depend on the structure volume. After water is filled in to the required level, it shall be allowed to stay for a period of 7 days for stabilisation, absorption and autogeneous healing. If so required, water shall be added to maintain the maximum test level in case it is lost during this period. Test shall commence from 8th day and continue for 7 days for a design crack width of 0.1 mm according to specification requirement. Observations regarding water level drops shall be recorded every 24 hours by visual measurements on mm scale. The test records shall be documented on the approved form. Structure Leak Test and the judgement on the test made accordingly. During this 7 days period, the total permissible loss in level shall not exceed 1/500 of the average water depth of the full tank or 10 mm. After the test is successfully completed, water shall be pumped out either to the other structure for testing should that be ready to receive it or if not, to the other construction areas for curing or any other purpose as agreed leaving the pit empty. Remedial Work if required. In case of unsatisfactory performance of the water tightness test and upon the agreement with Technip, injection-grouting method may be adopted to seal the seepage routes. Should the structure not satisfy the 7 days test, then after the completion of the remedial work, it should be refilled and if necessary left for a further stabilising period; a further test of 7 days duration should then be undertaken in accordance with this clause. Concrete Protection Coating Typical The method involves the following sequences in general. Surface preparation, Mixing, Application Details- All grease, oil, dust, residual curing compound, mould release agent or other contaminants, which could impair adhesion, shall be removed from the surface by degreasing and washing. The whole surface to be coated shall be cleaned using water jetting and visually inspected to ensure that the roughness does not exceed grade 80 sandpaper. All the holes, voids, depressions, spalls etc. shall be filled with Masterseal 550 or an equal approved mixed to a trowel consistency, scraped lightly into the surface, allowed to dry and later roughened by hand wire brush on the small areas and gently water jetted on the larger areas. The filled areas shall be visually inspected to ensure that the correct mechanical key is achieved. Mixing Master seal is supplied in the pre-measured units and shall be mixed on site using clean containers. The powder shall be slowly added to the liquid component and agitated /mixed for 2 minutes by using a slow speed hand power drill fitted with a suitable paddle attachment, until a homogeneous lump free consistency is obtained.
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The mix quantity shall be such that it could be consumed in one hour during application without allowing any retempering with water. Application Coverage 1.8 Kg / sqm at 1 mm thickness. The coating shall be 1 mm thick applied in one coat. In hot weather the surface to be coated shall be shaded from direct sunlight. The areas to be coated shall be saturated with fresh and clean water. The prepared and the saturated surface shall be inspected by QC. The mixed material shall be applied while the surface is visibly damp without standing water using short stiff brush or roller. (Roller shall be used in major /large areas). The evenness and the thickness of the applied coating shall be regularly checked during application while the material is still wet. The materials shall be allowed to dry and visually inspected.
QC inspection shall be conducted.

Any missed areas shall be saturated and then touched up. Ignore if not applicable Lighting Poles Foundations Typical Pre casting Area-The existing yard being used for the pre casting of manholes, catch basins etc. shall be employed for this purpose also. The following operations are involved to carry out the production of the light poles foundation bases Pre installation operations Fabricate and erect the side forms 4 #s to the specified dimensions. Fabricate the rebars according to the specified details. Provide the non-critical cathodic protection. Provide the PVC cable duct. Provide the bolt assembly to the requirement and location. Provide the lifting lugs to carry a gravity load of at least 3 tonnes + handling stresses. Pour the concrete. Cure the concrete immediately after pouring Post casting operations. To cure for the specified period. Excavate the location to the required formation level. To blind the area to be founded with concrete. Waterproof the blinding as specified. Keep the area ready in all respects well oriented & aligned to receive the foundation directly to be offloaded. Apply the water proofing membrane around as specified. Provide the protection board as specified Back fill the surrounding space to the relevant grade level Details. The typical size of the foundation may be 1000x1000mm in plan and 1100mm deep. A possible of 10 units may be produced by pre casting every day on an average. The forms to the exact size with the preformed chamfers shall be prepared and erected. The steel rebars shall be cut, bent to the required shape, placed and the cage prepared holding 75mm concrete spacers, be positioned into the forms. 1 # 350 mm internal radius 100 mm dia PVC cable duct formed to the dimensions shall be anchored by binding wires to the exact locations shown on the drawing keeping the upper end flush with the concrete top. The Lifting lugs as shown on the sketch shall be fixed in to the correct locations. The forms for the block outs for the lifting lugs shall be fixed in to the correct locations as shown without clashing with the duct or the rebars allowing a protrusion of the hook. The bolt assembly shall be fixed in exact position according to the design details.
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The non-critical cathodic protection shall be arranged using a metallic continuous binding wire connecting all horizontal rebars terminating into a boss fixed at one location near the top in the middle of the side opposite the duct-carrying portion. All the supports and the dimensions shall be checked and the plumb monitored. QC inspection shall be conducted. The concrete shall be poured to all the prepared units in 3 layers in vertical sequence. The appropriate vibrator shall be used for the compaction of the concrete. During concreting, care shall be taken to keep the anchor bolts position undisturbed and the intermittent checks be continuously made to monitor the spacing /centres between the bolts. After the concrete is poured in full & well compacted, the surface shall be levelled using a wooden float followed by light steel trowel. Immediately after the concrete starts setting, approved curing compound shall be sprayed on the surface forming a continuous membrane which be covered over with a polythene sheet according to the specifications. After 2 hours, the polythene sheet shall be temporarily removed to spread over the concrete surface the saturated burlap cloth or hessian, and recovered immediately. The side forms shall be removed within the specified period. The vertical concrete surfaces shall be spread with the curing compound immediately after striking the forms and covered with the polythene sheet according to requirement. The curing shall be continued for the specified period. The relevant locations shall be made ready to receive the pre-cast units by completing the excavation, blinding, the horizontal waterproofing and forming the correct alignment. QC inspection shall be conducted. The unit shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the location for offloading on to the prepared location to receive the unit. The unit shall be installed on the marked location according to the correct orientation to the lighting layout drawing. QC inspection shall be conducted. The protruding lifting lug eyes shall be cut to 60 mm inside the block out, the void filled with concrete by first scabbling the internal surface followed by cement slurry grouting and pouring concrete. The external surfaces of the foundation shall be applied with the concrete protective membrane according to the specifications. QC inspection shall be conducted The membrane protection board shall be provided covering the surface to the specified details. The back filling shall be carried out according to the specification up to the required levels in layers and up to the required ground grade or the pavement. The points to locate the cathodic protection shall be provided with a marker to trace the boss. The sequence shall be repeated for all the lighting poles foundations. Pull Pits Typical Operations in Pre casting Yard Pre casting Area. The existing yard being used for the pre casting of manholes, catch basins and lighting poles foundations etc. shall be employed for this purpose also Form work. The typical size of the Pit type shall be taken from the drawings.
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On an average, 20 units shall be produced by pre casting every day The wooden forms to the exact dimensions with pre -formed chamfers shall be prepared and erected. Rebars placement The steel rebars shall be cut, bent to the required shape, placed with 75mm concrete spacers and positioned into the forms according to the details provided. The Lifting lugs shall be fixed in to the correct locations. All supports and dimensions shall be checked and corrected if required. QC inspection shall be conducted before pouring concrete and signatures appended to ITPs Pouring concrete & finishing The concrete shall be poured into all the approved preparatory works in 1 layer by directly delivering from the concrete truck / transit mixer through the chute 1 # needle vibrator shall be used to compact the concrete and 1 # reserved standby. After the concrete is poured in full & well compacted, the surface shall be levelled using a wooden float followed by light steel trowel. Curing Immediately after the concrete is finished, the surface shall be covered with polythene sheet with the edge lapped or tied down to exclude air circulation without permitting the membrane to be in touch with concrete surface according to the specifications. After the concrete has stiffened but no longer than 2 hours, the polythene sheet shall be removed followed by immediate covering the surface with saturated (soaked with mix quality water) hessian and recovered with polythene sheet to prevent evaporation from the hessian. Throughout the curing period the hessian shall be maintained in a permanent wet condition using mix quality water. The side forms shall be removed after the specified period of 24 to 36 hours as agreed. The vertical concrete surfaces shall be draped with the saturated hessian immediately after striking the forms and covered with the polythene sheet held firmly in place along all edges & kept continuously wet for duration of curing. The curing shall be continued for the agreed number of days. QC inspection shall be conducted from time to time throughout the operations. Lifting, loading & transportation The covers shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the area concerned to offload on to the prepared location to receive. On site operations- post laying of Cable ducts. The area around the excavation coverage shall be barricaded to the site requirement. Setting out The setting out shall be carried out by the surveyor to the required co-ordinates. QC inspection shall be conducted throughout the operation and ITP for the survey check signed off Excavation Excavation shall be carried out (manually if the ducts are not encased in concrete) to the specified formation levels i.e. 1300 mm (varying from area to area) from the finished grade monitored by surveyor Compaction and the tests if so required, shall be carried out accordingly. Mass concrete base The formwork for the mass concrete that may 500mm wide and 150mm deep shall be prepared and erected to the settings. AJE QC inspection shall be conducted from time to time throughout the operations and concrete pour ITPs signed off
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Concrete shall be poured to the exact levels, finished properly and cured to the specified procedures Concrete protection Concrete protection shall be applied to the mass concrete to the details & specifications. Block work in walls 200mm Block work shall be constructed according to details to the required levels so that the cover top level is 100mm from the finished grade/ground level. In case the ducts are not laid in, opening shall be provided in the wall QC inspection shall be conducted from time to time throughout the operations Compacted sand fill Uncompacted sand shall be filled as indicated on the drawing & in accordance with the specifications. Compacted backfill The remaining portion shall be backfilled and compacted to the specification requirement. The top surface shall be well prepared, compacted and levelled to receive pre cast covers. Placing the pre cast covers The covers shall be offloaded by a crane from a trailer as transported from the pre casting yard to the relevant locations ready with one layer 0.25mm thick polythene sheet with laps 300mm, spread over. The covers shall be properly spaced and levelled to the details shown on the drawing. Sand fill 300mm deep sand backfill shall be carried out over the laid ducts not encased in concrete. Backfill As dug compacted backfill shall be carried out above the sand fill to the specifications. AJE QC inspection shall be conducted from time to time throughout the operations with the relevant ITPs signed off Lugs Fill The sand shall be filled in the lifting lugs recess. Concrete Protection The exposed concrete surface is a part of pavement and therefore no protection shall be applied. Massive Block Foundation- Thick Element Typical Wherever specified any reinforced concrete structure more than 800 mm in thickness & more than 8 cum of RCC quantity, the following procedure shall be followed. Excavation shall be carried out to approved procedures. Blinding shall be carried out to approved procedures. Reinforcement & formwork fixing shall be carried out to approved procedures. Cathodic protection if so specified shall be fixed to design details & continuity checked. Specific attention shall be given to the concrete pour sequence. Since the quantity of the pour element & depth shall be considerably greater, concrete should be poured in continuous stepping fashion forming an acute angle with the vertical so that the formation of cold joints is completely avoided. The portion poured previously after vibration must receive over pour within the concrete setting time. A sketch shall be issued to site giving complete sequence of pouring. Concrete foreman must adhere to that & complete the pour successfully. Massive pour requires thermal curing as explained somewhere else in this document that shall be applicable here as well.
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Foundations connected to paving concrete These considerably small foundations shall be placed on the pavement concrete to transfer minor equipment stresses. Construction shall include erection of forms & reinforcement placement duly connected to paving. Setting out shall be done & forms erected. Set out location area shall be roughened by scabbling. Rebars shall be fixed to the details. Concrete spacers installed to sides & bottom. Any electrical insert placed in. Top-level line fixed with plastic chamfers. After inspection, concrete poured & curing effected to approved procedures. Duct banks Excavation shall be carried out to the defined sectional size. Proposed formation area shall be compacted to receive the concrete. Blinding concrete shall be placed to the required thickness. Forms for the sides of the duct bank concrete shall be erected. Nominal rebars shall be placed to the details. Design ducts shall be placed & fixed in defined positions using proper supporting arrangements so that during concreting operation these ducts remain in the set positions. Ends shall be closed properly allowing the ducts protrusion from the end forms. Ducts ends shall be closed preventing the ingress of dust or any foreign material. Inspections shall be conducted & concrete poured & cured accordingly to the specified colour. After the concreting is completed, marker shall be placed over the duct concrete & over backfill done. Cable Trenches Dummy / walled trench section Typical The following operational sequences in brief are involved. Setting out to the exact alignment the route of the trench to the specified co-ordinates. Barricading the involved area to the safety department direction and requirement. Excavating the trench to the specified levels and sectional details. Preparing the formation to achieve the required levels and dimensions. Form work for the sides of the mass concrete strip beams. Pouring the mass concrete to the strip beam forms. Setting out the alignment for the trench block walls. Block work 150mm thick in walls to the specified levels up to the pavement down stand beam soffit level. Preparation and concreting the pavement portion monolithic with the down stand beam extended up to the top of the block wall. Backfilling the trench with the excavated earth to the specifications. Placing the pre cast coloured concrete covers in 1m or 3m standard lengths on the relevant compacted area. Sealing the joint between the pavement and the trench cover. Cable marker shall be provided. Details about the above operations in general The surveyor shall set out the alignment of the trench concerned according to the relevant details given on the paving and underground services location plans to the reference Co-ordinates. QC shall conduct the inspection The safety arrangement shall be discussed with the safety department and implemented accordingly to control the trench excavation, to provide barricades, nightlights, to divert the traffic if so required, and to adopt any other necessary measure. The excavation shall be carried out by an excavator to the lines and the levels. The surveyor shall monitor all stages of excavation to achieve the required profile. The excavated material shall be transported immediately by a dump truck to the earth stockpiles
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temporarily. After the excavation is over, the formation levels shall be well dressed and compacted to the specification requirement The forms shall be fabricated for the mass concrete section. The fabricated forms of width 350mm and depth 100 mm shall be erected/ fixed on the prepared compacted formation duly aligned and levelled. QC shall conduct the inspection throughout the stages of construction The mass concrete shall be poured to the marked levels and tamped by wooden float. The forms shall be struck after the specified period. The curing of the mass concrete shall be carried out according to approved procedures and for the specified period. The alignment of the block walls 150 mm thick shall be set out and the block work carried out in courses in a straight line and plumb. The whole number of courses shall be laid. The fractional block course if so remained to make up the required wall height, shall be constructed as a part of the pavement down beam concrete by extending the bottom to the top of the block walls. The pavement /down beam monolithic pouring shall be carried out to the specified details according to the procedures. QC shall conduct the inspection throughout the stages of construction The backfilling shall commence and the trench filled according to the specifications. The pre cast covers of 1m or 3 m standard length shall be placed on the filled trench internal surface to the specified levels. The concrete shall be coloured to the specification requirement. QC shall conduct the inspection throughout the stages of construction Where the dummy trench runs over the duct bank Typical All the operations described in general shall be applicable herein as well with the following amendments/additions to certain activities. Excavation shall be carried out to the top of the duct concrete only. The walls shall be started from the duct top level. Additionally, where the underground pipe runs crossing the Trench, the specified pipe shall be laid prior to the block work is commenced or openings shall be formed in the walls (Pipe laying operation by others). Flat width of the crossing shall be in size equal to the value given by the equation Duct Bank length + 300x2 . Where the dummy trench and the direct buried trench run parallel Typical All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities. While constructing the buried trench, the profile of the dummy trench shall dictate the profile of the buried trench. Sloping profile to a grade 1 in 2 shall be formed as shown on the drawing. Where the cable trench crossing with the closed drain pipe trench Typical All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities to be supplemented. The profile of the cable duct trench shall dictate the profile of the direct buried trench. The transition of the formations between the trenches and the crossing shall be in grade 1 in 2 as shown on the drawing. The length of the duct bank shall be equal to the value given by the equation. Width of the closed drain trench in mm + 2x100. The crossing flat width shall be the duct bank length + 2x300. A gap of 100mm shall be kept between the duct bank top and the closed drain bottom surfaces. The duct bank shall be constructed according to the details. Cable tiles under the closed drain trench shall be provided in the direct buried trench only. A joint shall be provided between the pavement and the closed drain trench wall.
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Where direct buried trench crossing under dummy trench Typical All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities to be supplemented. A level difference of 350mm shall be kept between the elevations of the crossing formation and the dummy trench. The level transition shall be established by grading 1 in 2. The cables passing under the dummy trench shall be protected by cable tiles (By others) . The trench corner wall shall be constructed to the details showing the corner length on the trench internal face. Where trench with dummy Trench crossing under direct buried cable trench Typical All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities to be supplemented. The profile of the cable duct trench shall dictate the profile of the direct buried trench. The transition of the formations between the trenches and the crossing shall be in grade 1 in 2 as shown on the drawing. The length of the duct bank shall be equal to the value given by the equation. Width of the direct buried cable trench in mm + 2x100. The crossing flat width shall be the duct bank length + 2x300. A gap of 100mm shall be kept between the duct bank top and the closed drain bottom surfaces. The duct bank shall be constructed according to the details. Cable tiles under the closed drain trench shall be provided in the direct buried trench only. Where direct buried trench crossing under direct buried cable trench Typical All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities to be supplemented. A level difference 700 mm shall be kept between direct buried trench and the crossing formation level. The crossing formation width shall be equal to the value from the equation in mm. (direct buried cable trench width + 400x2). The transition of the formations between the trenches and the crossing shall be to grade 1 in 2 as shown on the drawing. Cable tiles shall be provided in unpaved areas and at trench crossing. Electric Trench Layout at Pumps Typical All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities. The pump base shall be constructed to the details. The trench walls shall be continued to the shape as shown. Option If so required and felt convenient for certain uniform section reaches, pre cast concrete units 100 mm thick may be utilised to substitute 150 mm thick walls directly resting on the prepared formation. Underground Piping
In the scope, the following types of pipes are indicated to be included.

Carbon steel pipes gravity network 4 dia to 14 dia, coating material & welding, flange, gasket, bolting, testing, valve & flanges, sand filling, back filling/ pressure network etc. Non reinforced concrete pipes, cutting, jointing, sand bedding, anchor blocks 200 to 500mm etc. Reinforced concrete pipes, cutting, jointing, sand bedding, anchor blocks 200 to 2000 mm etc. Ceramic gres pipes & fittings, sand bed, Y, T, cuts, leak test, 100 to 500 mm dia etc. Bonna type pipes & fittings, sand bed, T, Y, anchor blocks 250mm to 2500mm dia etc.
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Plastic pipes PVC gravity network 110 mm to 410 mm dia etc. Polythene pipes gravity Y, T reduction piece, cuts, sleeves, leak test etc. Plastic pipes pressure network 110 mm to 410 mm sand bed etc. PVC pipes heavy-duty 110 mm to 410 mm send bed etc. Polythene pipes pressure Y, T reduction piece, cuts, sleeves, leak test etc. Cast iron cement lined pipes gravity etc. RTRP pipes pressure+ gravity 100 to 800 mm etc. The following activities are typically involved to carry out underground piping system etc. Ensure no underground existing services exist in the area concerned. Setting out the alignment of the proposed route according to survey details. Providing safety control barriers on both sides of the excavation allowing enough clearance for the excavator & truck to work without hindrance. After approval of the setting out, excavate the set out portion as trenching & continue up to the design depth according to the formation level of the pipe bedding following the approved excavation procedures. The pipes & fittings shall be stacked properly on both sides of the trench according to the manufacturers instruction. Prepare the bedding formation to the design levels & longitudinal profile specifically for gravity system. Surveyor shall monitor the levels throughout QC inspection shall be conducted to check the bedding Bed shall be filled with sand up to the pipe external surface level. Proper arrangement shall be made to down take the pipes. After down taking the pipes & fittings to the trench bed & placing roughly into set out alignment, surveyor shall give the exact alignment of the route. After the route has been aligned truly & fittings included, counter weight using sand on the pipe surround shall be applied temporarily to avoid pipe uplift during pressure testing or mechanical anchors employed depending upon dia of the pipe & the quantum of water pressure. All joints shall be connected or filled according to specifications. Wherever specified, for the steel flanges, bolting shall be carried out Wherever specified, for the plastic or p v c pipes, push fit system of jointing shall be applied Wherever specified, for the plastic pipes, joints shall be glued using tangit Wherever indicated, to anchor the bend etc at turning using thrust block, block shall be constructed of concrete to resist the, resultant pressure during pressurizing. Wherever specified, for the concrete or r c c pipes, special jointing material shall be applied to meet the requirement. Wherever required, to use cut pipes to complete the length, pipes either Bonna or carbon steel or concrete or any other make, pipe shall be cut to the actual length of the piece required. After all jointing has been completed, pressure testing shall be conducted for the ready portion with application of required bar pressure. Risers of the pipes shall be installed on both ends of the pipe line, filled with water under pressure which shall continue for the specified period of 24 to 72 hours during which period, observations of the water levels falling & the leak detection be conducted & recorded. Any leak detected in any part, that pipe part shall be removed & re installed & test repeated all according to approved ITPs
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After the test has been successful, pipe service marker shall be placed for identification purpose & granular material filled on the pipe & its surround so that at least 200 mm layer is established on the crown of the pipe. This fill shall be compacted lightly. Later from this level to the ground, granular fill material shall be used to backfill the remaining section duly compacted in layers all according to approved procedures. Ignore if not applicable
Epoxy grouting to vibrating machine bases Typical

Thin section - A gap between a base plate and substrate below 25 mm Thick section- A gap between a base plate and substrate above 80mm Normal thickness- In between the thin and the thick sections The following activities are involved for normal thickness
Surface preparation

Metal parts that should not be bonded to the grout like jack screws of the reciprocating machinery and part of the foundation bolts shall be sealed with tape prior to grouting. Base plates and equipment bases shall be uniformly supported in order to eliminate sag, distortion and levelled using both anchor bolts and jackscrews. Stainless steel shims 50x50x10 mm thick shall be placed in correct locations covered with mortar so as to allow at least 50 mm grout cover on shim sides. Full extent of the foundation surface under the base plate or equipment to be grouted shall be chipped / scabbled & brushed to remove the weak upper layer of concrete and any oil soaked concrete areas prior to the installation of the base plate. Base plate surfaces in contact with epoxy grout shall be grit blasted so as to expose white metal. All surfaces and bolt pockets to receive grout must be clean & free of rust, oil, dirt, paint and residual curing compound. All base plate holding down bolts etc must be free of rust, oil, dirt or contaminants that could impair bond Formwork Unless otherwise shown on design drawing, the entire area under the base plate shall be grouted and the forms fixed around the plate keeping a minimum of 25 mm clearance from the plate edge and at least 50 mm from the edge of the pouring side so that total grout able area is equal to underside of the plate and the clearance around the plate. Before the form work is fixed, it shall be ensured that the foundation area to be grouted and the bolts holes are clean A liquid tight formwork as practicable, shall be fixed around the base plate to prevent the leakage of the resin keeping the top of the forms 25mm above the underside of the base plate A chamfer 25mm x 25mm shall be provided on the sides so that top of the chamfer and the top of grout are in one level in case the whole of the foundation area around the plate is to be grouted, A 45 degree sloping surface above the form on the pouring side shall be constructed to create a pressure head to enable the grout material flow to cover full width of the pour. A coating of an approved release agent shall be applied to the formwork. QC inspection shall be conducted to ascertain the form profile and general preparatory works Grouting application All dirt and debris shall be removed from the form work using compressed air Sufficient Grout material to completely fill the prepared area in a continuous process shall be made available Mixing equipment shall be demonstrated to be in a suitable as well as in good working condition. A stand by equipment shall also be made available
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Concrete surfaces to be grouted shall be completely dry before grouting Mixing Base and reactor components shall be poured into a suitable mixing vessel and mixing carried out for 1 minute or until successfully blended. All required quantity of aggregate shall be added to the mixing vessel which is to be kept turning and mixing continued until a uniform lump free consistency is achieved. Over mixing shall be avoided to prevent air entrainment Placing. All bolt pockets shall be filled with grout prior to pouring the rest of the under plate space as a separate operation to prevent voids formation Pouring of the grout shall start from one end of the base plate and continued until the material reaches the far side. Mixed grout shall be steadily poured down the formwork slope to avoid air entrapment. Pouring shall be carried out only from one side of the base plate to avoid creation of voids and any reduction of the effective bearing area When the grout reaches the far side of the formwork which shall be ensured by poured material rising above the bottom of base plate, the pouring location has to move along the length of the base plate keeping the process continued until the whole area is completed. QC inspection shall be conducted throughout the above operations to ascertain the proper implementation of the procedures according to the manufacturers instructions. ShouldersExposed surfaces shall be brushed with Solvent # 2 just before or as the grout gels Curing No curing is required Ignore if not applicable As-built Drawings As built drawings serve the purpose of telling the user about the building records that should be used for the purpose of maintenance/or for whatever purpose possible. It is therefore, an important & significant part of documentation as well as also a contractual obligation on the part of AJES & Technip which should be affected smoothly & regularly throughout the duration of project. Should there be no change on the Released for construction drawings i.e. the construction has been carried out all in accordance with the approved documents provisions, there shall be no purpose of As - built drawings. But in practice, to produce physical structures, some changes are imminent due to arising of new requirement, changes, effects of disciplinary interfaces to bring the work to proper use functions etc. During the whole currency of the contract, it should be an endeavour of the AJES that all changes are recorded on contract documents as Red Lines mark up & issued to Technip for approval. These Red Lines mark up shall form the basis of producing all As Built documents on the project. It is not the drawings only that are to be recorded but also all changes whatsoever for any document on record. All these As Built shall form part of hand over dossiers. Should as built records be maintained regularly, this part of the dossiers shall be comfortably produced. The site design engineers shall keep an eye on this activity & record changes regularly as red line mark up & process the documentation to fulfil the contractual obligation to this extent possible. It is expected of the site engineers, the design engineers as well as land surveyors to coordinate on site to comply with this obligation efficiently. All survey changes or variations shall also be recorded on the drawings based on the pre pour & post pour records taken from survey section. Surveyor shall present all such changes on the corresponding documents to be recorded as Red Line Mark ups. The following paragraphs management procedures have been included just for the purpose of information as already covered within the New Buildings package Inspection & Test Plans All necessary Inspection & Test Plans shall be originated by the Quality
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Engineer in collaboration with Engineering in head office & Engineering in site team. These ITPs formats shall be issued for Technip & Company approval according to the procedures laid down on Project Quality plan. Production of all these documents shall be the responsibility of AJES Quality Manager/Engineer. Complete details about the quality management system have been included on the respective Quality Procedures document. Generally, ITPs for all disciplinary activities shall be produced for Technip & Company approval from site office in due course. All defined tests shall be conducted by Technip/Company approved laboratory located on site. For those items the tests shall be conducted by any Technip/Company nominated laboratory, for which facilities are not available on site. The details of these plans shall be submitted separately. Every ITP shall be allotted a document number along with a numbered checklist. Check list shall form the basis of inspection requirements. Project Controls Project Control management requires the formation of strategies those can be utilized optimally to achieve the target in minimum cost with best quality product To achieve as aforesaid, it is extremely important that complete project should be analyzed from whole to one & all necessary resources to be used or deployed should be known in advance prior to commencement of physical works. Based on the project design, construction, commissioning and maintenance durations, Analysis, planning & charting out at various levels shall be carried out by the Planning Engineer. Further based on these periods, all necessary resources shall be arranged & mobilized by human resources, materials, and technical managers in collaboration with Project Manager. The plans shall be monitored regularly, as the project construction progresses, on a weekly basis, monthly bases & no delay allowed & if any, immediate recovery shall be planed. The relevant reporting shall project the real quantum of planned & actual physical works, resources available, deficiency of resources, material procurement status, materials delivered & expected time of arrival etc & all necessary measures required to keep the construction on line & valuation worked accordingly. Every effort should be made to keep the progress in line with plan. Procurement Note-The term Material herein includes equipment also According to the site requirement & provisions made on the plan, for temporary materials & consumables, requisitions shall be raised from site by the relevant engineer, checked, numbered & coded by the material controller & approved by the construction manager for transmission to head office procurement manager for further action. Cost controller shall further check the budgetary provision applicable & give clearance to the purchase manager for procurement. Purchase manager shall then invite the inquiries from various sources of material, negotiate & prepare a comparative statement & based on the merits of responses / quotations, record his comments based on the comparative statement as well as recommendations for the considerations by the Management. After reviewing the proposal, the management shall approve or reject the proposal. Purchase order shall be made on the approved proposal. An alternative source shall be located
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for the rejected proposal. A copy of the approval shall be provided to the manager for follow up the delivery.

For permanent works, proposed material shall be submitted for Technip / Company approval on requisite Material Approval request form along with brochures, samples if applicable, processed through the document centre after Project manager approval. After obtaining Technip / Company approval on the request, procurement manager shall process the requisitioned approved item based on the budget quantities following in line the procedures applicable for temporary materials. After the material is delivered to site, material controller & relevant engineer shall check the quality & quantity of the delivery. Any deficiency in quantity, quality or any damage observed, shall immediately be notified to the procurement manager through construction manager. Delivery information shall be circulated to the concerned personnel & quality manager himself shall or delegate an inspector or the relevant inspector shall check the adequacy of quality & if necessary according to ITP provision, shall invite the Technip / Company engineer to inspect / examine the delivery. The selected samples of delivered materials shall be sent to an approved laboratory for technical tests for the purpose of certification of compliance. After inspections & approvals, delivered materials shall be recorded in stores receipt documents, an issue to site may be undertaken thereafter. Post placement of purchase order, Procurement Manager shall track various stages of material production & transportation or shipment to the site/delivery & if so noticed that an expectation exists for the delay in delivery, shall apply all efforts to expedite the delivery on appointed date. Materials shall be stored in proper designated areas complying with the manufacturers instructions. Separate area shall be located for the materials requiring certain temperature of storage. Stores shall be well constructed & shaded. Generally, all consumables shall be stored in shade provided with proper lock & key arrangement. Materials which remain unaffected by exposition to weather may be stored open duly protected under proper watch & ward. Proper protection shall be made for all stored materials inside covered area or out side. Necessary protection by removable membranes such as polythene or tarpaulins shall be used to protect material from the ingress of moistures or from effect of dust. Storage of all materials delivered shall be done complying to the set & approved procedures making sure that all inventories can be verified any time & that any material can be traced any time easily. All entries of the incoming deliveries shall be recorded into the register & verified by the store keeper & material controller that it complies with the details on deliveries documents. Any deficiency noticed shall be immediately reported to the procurement manager. After the acceptance of the material by the concerned authority only, a store issue shall be affected & recorded on the required issue documentation. Regularly the status of all receipts, issues & balance in stores shall be reported to the construction & project manager who shall act further depending on the project requirement.
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Elaborate details have been given on the AJES procurement procedures document PRE MOBILIZATION PLANNING An elaborated, detailed and logical mobilization plan is essential for a successful start-up of construction activities. This plan must exhibit complete schedule, preparation and pre-construction activities necessary to ensure the timely availability of drawings, personnel, construction equipment, temporary facilities and materials at the job site to properly support the construction efforts. This plan is already under preparation at tender stage & the schedule about all three packages have been included with the bid. This outline plan shall be further developed after contract award and concluded within a week of the contract award. The mobilization plan shall be closely coordinated with the construction plan to ensure mobilization activities properly lead into and provide a smooth transition into initial construction activities. A detailed bar chart schedule shall be prepared with early and late activity bars involving the main activities to achieve full mobilization of staff, labour, construction equipment and camp/site facilities, shall be prepared at the commencement of the contract. Mobilization plans for staff & labour, accommodation and temporary facilities established during the bid stage would be reviewed, re-evaluated to ensue its fitness to meet the project requirement & updated to include any other activity necessary to meet the final requirement, which might have occurred then, since the day of original preparation. All necessary adjustment measures required shall be incorporated with the update & resolutions reached. Additional site visits shall be undertaken immediately after the project kick off to confirm validity of the data collected during bidding stage, reconfirm assumptions and establish additional information required to permit smooth and timely mobilization & adhering to further activities durations strictly. The following descriptions shall be reviewed and confirmed. Access to the job site whether or not available without any obstacle. Location areas of temporary facilities whether or not available & if not resort to appropriate procedures. Company requirements for properly validated licenses and certificates to be held by construction personnel for the equipment, machines, vehicles, trades. Transport plans including the movement of equipment & vehicles. Loss prevention and safety requirements for the camp as well as for the site offices & site Arrangements for first-aid facilities Arrangements for drinking water and construction water, availability of sources Arrangements for electricity supply, requirement of generators & also study of direct supply Arrangements for storage fuels and lubricants Arrangements for sanitary & its disposal facilities Final arrangements for security interface with Technip & Company And all other essential activities needed for successful mobilization
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Aforesaid review shall provide an impetus to promptly chart out all the processes involved with the mobilization with all solutions handed to the construction team for an efficient implementation. About AJES Management Procedures in brief
Work Centres - AJES Head Office

Upon notification of contract award, the key personnel to the site Management Team shall be assigned. Construction personnel shall be mobilized to the project site office to provide input and direction to the project team. Successful project execution requires construction experts to be active from the onset of the project. The only activity to continue from Head Office after mobilization period is procurement. All procurement for the project shall be done from the corporate procurement section located in AJES Head Office at Musaffah, Abu Dhabi. The following specific activities must be addressed early to be fully effective: Finalize construction schedule requirements and subsequent approval from Contractor Review manpower requirements for both non-manual and manual personnel; update these requirements by means of staffing schedules, histograms and craft mixes; and ensure subcontractors manning levels are compatible. Review construction equipment needs and ensure that timely subcontractors mobilization plans are in place. Review field procedures and method statements defining standards, policies and procedures required for the execution of the works and ensure they constitute Project Specific status. Review environmental, safety and Health (ES&H) and site security plans to ensure compliance with the clients specifications and guidelines. Review Construction Quality plan in line with the guidelines of ISO 9000 and check Established QC parameters by discipline. Overview temporary facility requirements, including indirects such as tools, consumables, gases and the like and check subcontractors compliance. Actively pursue preliminary site activities such as approvals, permits, establishing contracts. Ensure Lessons Learned & Practices from previous projects are well understood & should be applied effectively from the onset of the works itself to achieve professional products. AJES Site Office Actual on site management would be from offices based on the site next to Contractor and Companys office. AJES Site Office is fully supported by AJES Head Office at Musaffah. The following major activities shall be carried out at site offices. Safety Regulation Enforcement Quality Assurance Enforcement and Procedures Construction Method Statements
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Mobilization Mobilization shall be coordinated from the AJES Head Office at Abu Dhabi with input from AJES personnel already mobilized for the execution of Site Preparation Package and Temporary Facilities for Contractor and Company. Existing teams responsible for the execution of the those two mentioned packages already have substantial cadre of experienced professional well versed in mobilization of temporary facilities, project execution, QA / QC planning, Safety and security operations etc. Mobilization shall commence with the following activities: Kick off meeting to commence the sub contract Commencement of the required land surveys to establish various horizontal & vertical controls bench marks Incept of the engineering designs at the Firm office Soil Investigation by an approved laboratory Construction of temporary facilities Obtaining various permits from Authorities and conclusion of arrangements with local committees where necessary. Third party independent concrete testing laboratory credentials submission for approval. Shortly after contract award, site surveying shall begin utilizing the Total Station System to establish accurate control points for the performance of the work. As soon as practicable, the plans and specification for the site temporary construction facilities shall be finalized and released for installation. During the installation of the temporary facilities existing AJES site offices shall be utilized to supervise the site activities required for the temporary facilities installation. On completion of the site offices at ASAB, balance of the AJES construction staff shall be mobilized to the site along with construction equipment, tools, consumables, warehousing, storage and other items necessary to commence the work in accordance with the construction schedule. Temporary facilities at the job site shall include Generator Yard and Construction water storage tank, carpentry yard, re-bar fabrication, lay-down area, warehouse and workshop facilities at location A4. At the start of the construction, an emphasis shall be given on the critical requirements of the construction schedule. Work shall be carried out under continual supervision and inspection over performance. Progress shall be
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monitored on the basis of actual installed quantities compared to scheduled quantities. For construction areas, dedicated work crews shall be allocated for each discipline supervised by foremen and general foremen who in turn shall report to the discipline supervisors / site engineers. Based on the construction schedule requirements, necessary operational crews shall be formed and controlled over to meet the planned progress target to be physically achieved satisfactorily. It is the responsibility of the supervisor/site engineer to ensure the efficient utilization of his material, workforce, tools and equipment. For construction operation water requirement, unless an alternative arrangement is made available, water shall be trucked from nearby Desalination plant. Site construction and temporary facilities electricity requirements shall be met by installing suitable size and suitable numbers of generators. Subcontract Strategy AJES shall carry out broadly all civil engineering works employing its own resources of manpower, machines, equipment etc. Lower tier sub contracts shall be allowed for the execution of single operations such as supply of ready mix concrete, etc Ready Mixed Concrete is envisaged supplied from an established RMC (Ready Mix Concrete) supplier, an establishment with proven track record duly approved for supplying concrete by GASCO, within 10 kms of the site. However, in the mean time, without reservations, we are also seriously considering installing our own concrete batching plant. In case any minor or specialized work is necessary to be sub contracted on lower tier, Company procedures shall be apply for prequalification and award of the subcontracts. Testing And Inspection A field inspection and testing program shall be organized to be in line with AJES Quality manual & Approved Project plan under overall responsibility of the QA / QC Manager. Prior to conduct any testing, Contractor and Company (as required by QC Plan and ITP) shall be advised of the tests for witness. Wherever required vendor specialist shall be made available for conduct of testing and inspections. Material Management Once material has arrived at site, material management shall come under the purview and custody of the site store staff. The storekeeper, supported by his store assistant shall be responsible for the custody of the material prior to issue. Material tracking from source to the place of installation shall be conducted by the computerized system. The construction manager shall be responsible to provide the technical oversight and direction for the control of materials at the construction site area. More information has already been elaborated in the foregoing.
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Procurement The Central procurement department located at the Al Jaber Energy Services, Musaffah, Abu Dhabi, UAE office shall be responsible for all purchases adhering to the following procedure. Preparation of Purchase Requisition shall be made based on take-offs quantities calculated from the approved drawings documents. Purchase requisition shall completely, identify all applicable drawings, data sheets, specifications, vendor documentation requirements etc. with the inclusion of following information. Quantity of each item required with comprehensive breakdown Adequate information concerning nomenclature description, Material approvals, Quality required, applicable specifications, design & other drawings, etc/ or detailed outline of the material required. Required delivery dates for all major items. Delivery points of major items Inspection of the goods at the point of origin issue Certification of test data and/or compliance/ warranty Method of shipment (if goods imported), conditions/packing Instruction of holding, kitting consolidation, marking Drawings, manuals etc Spare parts requirements Special Instructions to vendors A technical evaluation shall be done in house to verify the conformity with specifications. Samples and technical information shall be submitted to Contractor. Once the final approval from the client is obtained, purchase order shall be raised. Upon receipt of Purchase Requisition, a purchase order shall be raised and entered in the computer register system, indicating cost and budget allocation. The procurement department shall maintain a follow-up system so that contact suppliers and/or manufactures may be made on continuous basis. All questionable delivery commitments shall be expedited on a daily, weekly and monthly basis as required to ensure prompt delivery in accordance with the requirements. Organization - Corporate Organization Al Jaber Establishment formally known as Al Jaber transport & General Contracting Establishment is an umbrella organization which has got numerous divisions within in itself and which is also the parent company for various subsidiaries. Al Jaber Energy Services (AJES) is a separately registered company specifically set-up to target the energy sectors and its clients. AJES has been operating under the Al Jaber Establishment umbrella since 1995. Broadly all the activities of the above divisions and companies can be divided into: General Construction Heavy Lifting and Transport Services. Trading
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Site Organization Proposed site organisation and responsibilities of the key personnel are enclosed. All supervisory staff shall be highly experienced and qualified drawn from on-going projects wherever possible. Manpower Resourcing and Mobilization All the personnel on site shall be employees of Al Jaber Energy Services. All of the required personnel to execute the work are already in UAE and working on other sites. These sites are due for demobilisation in the coming months. The planning department shall produce a histogram schedule of the resources by category. These schedules shall define the monthly manpower levels. The scheduled shall also be indicative of manpower mobilization. The standard Al Jaber Energy Services site supervision is based upon the principle of training. A charge hand shall be trained and supervised by a foreman. In normal cases a foreman shall supervise four charge hands. The charge hand shall then supervise approximately ten labours. Where a special process is conducted, this ratio may be revised accordingly. Training is a requirement of the Al Jaber Energy Services quality management system and foreman and charge hands shall conduct training of the manpower in their respective roles and functions. The recruitment of manpower shall ensure that background in the relevant job skill has been achieved. The training in quality awareness shall be an ongoing process through the quality department and the foreman. Sufficient numbers of site supporting staffs which consists of Mechanics, Electricians, Auto Electricians, Guards, Water boys etc and other ancillary staff shall be deployed for the unhindered progress of the work. The Al Jaber Group contains at all times a vast pool of manpower in all Disciplines. These workforces are at all times working on various projects in multi discipline fields. Equipment Resourcing and Mobilization Based on the project schedule, the planning department shall generate the construction equipment schedules. The Al Jaber Group is one of the largest equipment rental companies in the GCC with over 5000 fleet where modern repair and machine facilities enable them to maintain a first class fleet of equipment. It has been our company policy to weed out the old equipment on a periodical basis and keep the equipment fleet very young. We have one of the youngest fleets of equipment in the GCC based on size.

Execution Plan- Method statement (project implementation strategy)


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New Buildings Package


Engineering Design a) Building Engineering Design Management necessitates an integrated approach to formulate an overall philosophy, able to achieve an intellectual product covering & incorporating a wide range of performance & serviceability requirements that shall completely meet intended functions of the proposed building adequately satisfying architectural, structural & allied services requirements. The target achievement of this fast track EPC project shall be kept in consideration by all discipline designers to release the necessary documents on planned line. To accomplish this part of the package to the best possible standards, AJES shall invite certain (possibly 3) reputed & leading architectural engineering Firms as Engineering Services sub contractor. Based on the merits of each offer as well as applying the competency criteria, a preliminary selection shall be made. After obtaining Technip approval respecting this Firm, a formal appointment shall be made by executing an engineering services agreement. Engineering Services Sub Contractor hereinafter called Firm b) The scope of the Firm shall include but not be limited to carrying out the following engineering services operations for all buildings included within New Buildings Package Undertaking additional surveys, intrusive surveys and investigations as may be necessary for the engineering designs. Soil Investigations as required accomplishing the design
(Topographic survey shall be performed by AJES)

Production of all architectural, structural & allied services schematic designs Perform all studies, design calculations etc. Secure all governmental and local Authority permits and approvals if so necessary. Compilation of any outstanding data deemed necessary for the completion of the detailed engineering design Production of all architectural & structural detailed designs for Technip approval according to contract & sub contract requirement. Act as AJES Design & Engineering representative for the relevant Buildings contract scope Civil & Architectural scope from its inception to completion as & when required c) Building services : conceptual drawings only for plumbing & sanitary, small power & lighting,
HVAC, Fire Fighting & Fire & Gas Detection / Loss prevention, Structured Cabling System Liaison, co-ordinate & lead AJES services subcontractors design & engineering efforts (AJES services subcontractors shall be responsible for the detailed designs and engineering for their relevant scope based on the conceptual drawings and other basic documents issued by Firm) to obtain necessary approvals from Technip

Firm shall issue its whole drawings / documents production schedule immediately after the award & commence its design work keeping in line to the programme
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Represent AJES at Technip offices / officials at FRANCE, Abu Dhabi and / or ASAB as AJESs Design & Engineering representative during the course of the contract from its inception to completion as & when required Engineering coordination with the Firm shall be conducted from AJES head office. All field interfaces shall be conducted from site offices in collaboration with AJES field engineers All other remaining functional descriptions shall be conducted by AJES personnel both in the head office as well as on site office depending on function wise technical nature All engineering design products shall be managed conforming international standards included on the contract documents for the technicalities as well as document controls. Firm shall comply with the agreed documentation system & conduct its operation in all respects accordingly. All the design documents shall be given appropriate numbering reference to meet traceability requirement. AJES operates its own system of centralized document control, which shall be used fully complying in accordance to Technip & Client Company Procedures by reformation, if so required Firm shall produce & issue the scheduled documents at various stages of works for reviewing, approval & AFC etc efficiently keeping in line with the project construction plan on various phases. Any delay on this account shall not be acceptable to AJES management Immediately, after the issue of the control documents to the site team, field/design engineers shall conduct over review of design & construction ability & consequently relevant design engineer raise technical queries to remedy any discrepancies among these documents if so discovered, which should immediately be resolved by the Firm & duly informed to Technip. All such documents shall be processed through the documentation system facilitating most convenient trace ability for consultancy & reference Consequent upon the resolution of discrepancies, the effected design drawings shall be revised & reissued for construction duly incorporated with the solutions & circulated through documents control regularly to all concerned personnel. Buildings services schematic drawings shall be issued to sub contractors for further development of shop & working drawings for Technip approval & issued to the concerned parties after getting duly approved for construction Necessary structural shop drawings shall be produced by AJES own engineering personnel in head as well as on site offices, which shall also be processed into document control system for Technip & issued to the concerned parties after getting duly approved for construction Preparation of requisitions for enquiry and award, technically evaluate bids and review of vendor/lower tier subcontractor documentation shall be done by purchase manager in collaboration with project manager. All these procedures have been incorporated on the company procurement procedures document.
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d) Detailed Engineering Design: Preparation, issue and control of calculations, specifications, drawings, material requisitions and bills of material. Extent of computer application for these activities. At the very first stage of the commencement of the detailed designs, Firm shall formulate positioning of all framing members vertically & horizontally befitting coordinates as well as level controls, meeting the architectural requirement maintaining the basic design principles that the whole structural skeleton behaves as an integral unit with its centre of gravity passing through or within the permissible vicinity of the resultant of all the applied forces considered avoiding any eccentricity and that settlement of the soil is within permissible limits. After considering all direct & indirect imposed loadings according to the relevant codes, design model shall be generated using Firm software. Loadings shall include, direct loads such as dead load, live load, seismic shear (though not applicable in Abu Dhabi geographical location) / wind load, blast load/effect, test load/application & also considering various analysis, a most critical case of resulting stresses shall be considered to be adopted for the dimensioning & further details of various vertical & horizontal members forming the framing skeleton. Generated model in 3D may be made available for the presentation to Technip & Company to explain & justify the adopted philosophy if so required. Calculations shall be done trying various options of loadings in 2D & 3 D & included with the design proposal for approval. These calculations shall be done & certified by a Chartered Engineer of Firm for structural adequacy & structural intended performance. e) Services Designs Designs of the services shall be carried out discipline wise. Electrical - In accordance to the provision of electrical loadings design criteria as indicated on the Technip / Company documents, loadings, distribution of loading & all other parameters shall be adopted & calculated adhering to the international standards, IEE as well as UAE authorities regulations & schematic drawings produced meeting the architectural schematic drawings requirement Similarly all loads from the HVAC disciplines as well as from the other remaining disciplines shall be included. This shall be done in close interface with all disciplines coordinated by the Services design coordinator/Design Project Engineer or Manager. All these details shall be included on the drawings documents for approval All designs shall be generated using appropriate computer software package f) Specialised discipline- Loss Prevention & others On the similar pattern as described in the foregoing, detailed designs shall be calculated meeting all requirements of the contract specification, disciplinary performance as well as meeting international & conventional standards, complying local bodies statutory provisions. From the foregoing approved documents, Bill of Quantities shall be generated discipline wise & building wise which document should be utilised for the purpose of Material Approval Proposal, Issue of requisitions of the approved materials to the procurement manager. The bill of quantities shall not constitute part of contract documents but serve guidance. All bills shall be generated using appropriate computer software package. g) Specifications/Supplement Specifications It is intended to adhere to Company specifications provided by Technip within the documents to every extent possible, however, to meet some particular requirement, supplement specifications shall be drawn & proposed for approval wherever necessary for producing better product or the materials for which no specification is defined. These shall be drawn in collaboration with Firm & AJES design team keeping in view an overall approach to documented specification criteria as well as conventional engineering & construction practice in similar circumstances.
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h) Co-ordination Procedure The following entitled co-ordinations shall be conducted during various stages of the design & execution that have been outlined below Coordination between AJES & Technip head office This part shall be conducted by regular interaction among AJES representatives Head Office based in Musaffah & Technip FRANCE office to help resolve all pre & post award issue of Engineering services & monitoring project controls Coordination between AJES & Technip site office This part shall be conducted by regular interaction among AJES & Technip site representatives to help resolve all pre & post award issue of Engineering services & monitoring project controls Coordination between AJES & Firm This part shall be conducted by frequent interaction between AJES & Firm representatives of all disciplines for the resolution of all designs issues, issue of all documents, approval of all documents & resolution of all engineering issues on site Coordination between AJES / Firm & Technip This shall resolve all issues respecting engineering designs particularly during design stage as well as generally during construction phases for efficient decisions making to help smooth execution of all activities Coordination between AJES / Firm & Technip on site This shall resolve all issues respecting engineering designs during construction phases on site for efficient decisions making to help smooth execution of involved activities Coordination between AJES Site & Firm This is essential to keep on fast track the availability of complete design information for all ongoing as well as planned activities & should the information be pending, it shall be identified, coordinated & made available on site prior to its requirement to avoid any problem of execution AJES internal Coordination among various sections AJES in Head office organized with all corporate sections necessary to meet the requirement of this project shall operate as an integral functional team keeping on resolving regularly & as required all issues of project designs & follow up in all respects. This coordination is ongoing on daily basis & frequent interaction among all corporate managers as well as supporting professionals help the resolutions of all current & forthcoming issues. Management meetings are conducted regularly for making decisions to avoid any pending identified problems AJES internal Coordination among various sections on site Similarly on site all project sections managers & supporting professionals shall coordinate to resolve all types of problems to avoid any pending identified problems & notify to corporate management for immediate resolutions should the solution not be possible from site. i) Review and Approval of Documents This requires effecting an instant action on the part of AJES that, whenever any document is received, it must be reviewed by its design team located at Head Office/Site office as the case may be prior to formally submitting to Technip. After its submission to Technip, Technip shall process it through its system & after obtaining company approval, return approved or commented original to AJES for further necessary AJES action. All documentation shall be carried out adhering to the AJES documentation system after tuning that in line to Technip & Company requirement j) CAD Procedure
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It is intended to use standard CAD software for the production of design & drawings. All standard system of designing shall be adopted at every workstation available in Firm offices. The details of all available software & hardware have been given in attachment. Also included the hardware & software details which are functional in proposed Engineering sub contractor/Firm office k) Engineering Reporting and Change Control The status of design progress shall be submitted to Technip on a weekly basis during progress meeting. Should any change be required, that shall be affirmatively considered subject to cost impact resolution & then the change incorporation request issued by AJES to Firm. The Firm shall then work on the revision, its calculations & advise to AJES & Technip of any adverse effect on the structural adequacy/performance or if any amendment to be applied to already worked element / member. Should there be no such adverse consideration, the design shall be revised & revised document issued following the documentation & approval procedures. l) Document Control Procedure AJES operates its centralized DCC (Document Control Centre) in head office that shall be tuned to Technip / Company documentation system & extended to site office to meet the project requirement. AJES document control system is enclosed for reference. m) Vendor Print Numbering, Review and Distribution Procedure All vendors shall be issued schedule of document numbers to be printed on the documents adequately in advance of documents preparation. All approved procedures of documents shall also apply to vendors' designs. n) As-built Drawings As built drawings serve the purpose of telling the user about the building records that should be used for the purpose of maintenance / or for whatever purpose possible. It is therefore, an important & significant part of documentation as well as also a contractual obligation on the part of AJES & Technip which should be affected smoothly & regularly throughout the duration of project. Should there be no change on the Released for construction drawings i.e. the construction has been carried out all in accordance with the approved documents provisions, there shall be no purpose of As - built drawings. But in practice, to produce physical structures, some changes are imminent due to arising of new requirement, changes, effects of disciplinary interfaces to bring the work to proper use functions etc. During the whole currency of the contract, it should be an endeavour of the AJES that all changes are recorded on contract documents as Red Lines mark up & issued to Technip for approval. These Red Lines mark up shall form the basis of producing all As Built documents on the project. It is not the drawings only that are to be recorded but also all changes whatsoever for any document on record. All these As Built shall form part of hand over dossiers. Should as built records be maintained regularly, this part of the dossiers shall be comfortably produced. The site design engineers shall keep an eye on this activity & record changes regularly as red line mark up & process the documentation to fulfil the contractual obligation to this extent possible. It is expected of the site engineers, the design engineers as well as land surveyors to coordinate on site to comply with this obligation efficiently. All survey changes or variations shall also be recorded on the drawings based on the pre pour & post pour records taken from survey section. Surveyor shall present all such changes on the corresponding documents to be recorded as Red Line Mark ups.
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All necessary Inspection & Test Plans shall be originated by the Quality Engineer in collaboration with Engineering in head office & Engineering in site team. These ITPs formats shall be issued for Technip & Company approval according to the procedures laid down on Project Quality plan. Production of all these documents shall be the responsibility of AJES Quality Manager / Engineer. Complete details about the quality management system have been included on the respective Quality Procedures document. Generally, ITPs for all disciplinary activities shall be produced for Technip & Company approval from site office in due course. All defined tests shall be conducted by Technip / Company approved laboratory located on site. For those items the tests shall be conducted by any Technip / Company nominated laboratory, for which facilities are not available on site. The details of these plans shall be submitted separately. Every ITP shall be allotted a document number along with a numbered checklist. Check list shall form the basis of inspection requirements. Project Controls Project Control management requires the formation of strategies those can be utilized optimally to achieve the target in minimum cost with best quality product To achieve as aforesaid, it is extremely important that complete project should be analyzed from whole to one & all necessary resources to be used should be known prior to commencement of physical works. Based on the project design, construction, commissioning and maintenance durations, Analysis, planning & charting out at various levels shall be carried out by the Planning Engineer. Further based on these periods, all necessary resources shall be arranged & mobilized by human resources, materials, and technical managers in collaboration with Project Manager. The plans shall be monitored regularly, as the project construction progresses, on a weekly basis, monthly bases & no delay allowed & if any, immediate recovery shall be planed. The relevant reporting shall project the real quantum of planned & actual physical works, resources available, deficiency of resources, material procurement status, materials delivered & expected time of arrival etc & all necessary measures required to keep the construction on line & valuation worked accordingly. Every effort should be made to keep the progress in line with plan. Procurement Note-The term Material herein includes equipment also According to the site requirement & provisions made on the plan, for temporary materials & consumables, requisitions shall be raised from site by the relevant engineer, checked, numbered & coded by the material controller & approved by the construction manager for transmission to head office procurement manager for further action. Cost controller shall further check the budgetary provision applicable & give clearance to the purchase manager for procurement. Purchase manager shall then invite the inquiries from various sources of material, negotiate & prepare a comparative statement & based on the merits of responses/quotations, record his comments based on the comparative statement as well as recommendations for the considerations by the Management. After
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reviewing the proposal, the management shall approve or reject the proposal. Purchase order shall be made on the approved proposal. An alternative source shall be located for the rejected proposal. A copy of the approval shall be provided to the project manager for follow up the delivery. For permanent works, proposed material shall be submitted for Technip / Company approval on requisite Material Approval request form along with brochures, samples if applicable, processed through the document centre after Project manager approval. After obtaining Technip / Company approval on the request, procurement manager shall process the requisitioned approved item based on the budget quantities following in line the procedures applicable for temporary materials. After the material is delivered to site, material controller & relevant engineer shall check the quality & quantity of the delivery. Any deficiency in quantity, quality or any damage observed, shall immediately be notified to the procurement manager through construction manager. Delivery information shall be circulated to the concerned personnel & quality manager himself shall or delegate an inspector or the relevant inspector shall check the adequacy of quality & if necessary according to ITP provision, shall invite the Technip / Company engineer to inspect/examine the delivery. The selected samples of delivered materials shall be sent to an approved laboratory for technical tests for the purpose of certification of compliance. After inspections & approvals, delivered materials shall be recorded in stores receipt documents, an issue to site may be undertaken thereafter. Post placement of purchase order, Procurement Manager shall track various stages of material production & transportation or shipment to the site / delivery & if so noticed that an expectation exists for the delay in delivery, shall apply all efforts to expedite the delivery on appointed date. Materials shall be stored in proper designated areas complying with the manufacturers instructions. Separate area shall be located for the materials requiring certain temperature of storage. Stores shall be well constructed & shaded. Generally, all consumables shall be stored in shade provided with proper lock & key arrangement. Materials which remain unaffected by exposition to weather may be stored open duly protected under proper watch & ward. Proper protection shall be made for all stored materials inside covered area or out side. Necessary protection by removable membranes such as polythene or tarpaulins shall be used to protect material from the ingress of moistures or from effect of dust. Storage of all materials delivered shall be done complying to the set & approved procedures making sure that all inventories can be verified any time & that any material can be traced any time easily. All entries of the incoming deliveries shall be recorded into the register & verified by the store keeper & material controller that it complies with the details on deliveries documents. Any deficiency noticed shall be immediately reported to the procurement manager. After the acceptance of the material by the concerned authority only, a store issue shall be affected & recorded on the required issue documentation. Regularly the status of all
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receipts, issues & balance in stores shall be reported to the construction & project manager who shall act further depending on the project requirement. Elaborate details have been given on the AJES procurement procedures document International and local transportation and customs clearance Materials & equipment that have to be imported from overseas, shall also follow the foregoing procedures with the addition that necessary Letter of credits shall be opened by AJES adequately in advance of the required date of delivery adhering to schedule date, so that the delivery is shipped in time from original source. AJES procurement manager shall arrange all port clearances immediately of shipment arrival & material shipped to work site. Tests & Examinations shall be conducted similarly as aforesaid. Any claims of insurances for the damaged material shall be made immediately after inspections. Process to replace the damaged material shall be carried out at once to avoid any delay. If so required, AJES shall apply in time for any statutory road permit for the efficient transportation of the material by suitable vehicles. Elaborate details have been given on the AJES procurement procedures document. Procurement and provision of construction spares, commissioning spares, insurance spares and special tools These shall be processed applying the same methods of procurement & delivery received by AJES / its services or specialist sub contractors. Most probably, the spares shall form part of the order package. Elaborate details have been given on the AJES procurement procedures document Recommendation for two-year operating spares for approval by Company in accordance with the G-SPIR format requirements This provision shall be followed & spares delivered according to contract & Company requirement by AJES / its services sub contractors. Elaborate details have been given on the AJES procurement procedures document Procurement and provision of two-years operating spares, (at cost and extra over Lump Sum Subcontract Price) Similarly this provision shall be effected & spares delivered according to Technip / Company instruction to AJES subject to the approval of the procurement cost prior to the purchase order placement by AJES Source inspection If so required by Technip / Company, arrangement shall be made by AJES after meeting with the vendor or manufacturer, a date & time appointed for the inspection to the convenience of all parties concerned & required inspection at source conducted to the satisfaction of Technip or Company. Representatives from Technip and / or Company, AJES, services sub contractor & vendor shall constitute an inspection at source team. Proper record of inspection shall be made.

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Compliance with Companys criteria and procedures for selection of vendors including but not limited to compliance with local registration requirements and approval of purchase requisitions, bidders lists, technical bid summaries and award recommendations We shall adhere to Company requirements. Involvement by the UAE in particular and GCC in general with respect to the provision of local materials and services shall be encouraged AJES honor & respect with due regards to the provisions of UAE & GCC policies for the materials & professional services which need be availed out of the local & GCC sources subject to the compliance with the quality requirement. Every effort shall be attempted by Procurement Manager to chart out the available local & GCC sources & prepare a database to be used whenever any applicable procurement arises. This procedure is already followed by AJES. AJES vendors shall also comply with this requirement. Pre Mobilization Planning A thorough and logical mobilization plan is essential for the successful start-up of construction activities. This plan must detail all planning, preparation and preconstruction activities necessary to ensure the timely availability of drawings, personnel, construction equipment, temporary facilities and materials at the job site to properly support the construction efforts. This plan is already under preparation at this stage. This preliminary mobilization plan shall be further developed after contract award and concluded within a week of the contract award. The mobilization plan shall be closely coordinated with the construction plan to ensure mobilization activities properly lead into and provide a smooth transition into initial construction activities. A time scale bar chart diagram shall be prepared with early and late activity bars detailing the main activities to achieve full mobilization of staff, labour, construction equipment and camp/site facilities shall be prepared at the commencement of the contract. Mobilization plans for staff & labour, accommodation and temporary facilities established during the bid stage (as conceived in pre-mobilization planning) would be studied and re-evaluated in the light of any changes, which may have occurred since the day of preparation. All necessary adjustment measures shall be implemented. Additional site visits shall be conducted immediately after the project kick off to confirm data collected during bidding stage, reconfirm assumptions and establish additional information required to permit smooth and timely mobilization. The following items shall be reviewed and confirmed. Access to the job site Locations of temporary facilities Company requirements for properly validated licenses and certificates to be held by construction personnel Transport plans
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Loss prevention and safety requirements Arrangements for first-aid facilities Arrangements for drinking water and construction water Arrangements for electricity supply Arrangements for storage fuels and lubricants Arrangements for sanitary & its disposal facilities Final arrangements for security interface with Technip & Company Work Centres Ajes Head Office Upon notification of contract award, the key personnel to the site Management Team shall be assigned. Construction personnel shall be mobilized to the project site office to provide input and direction to the project team. Successful project execution requires construction experts to be active from the onset of the project. The only activity to continue from Head Office after mobilization period is procurement. All procurement for the project shall be done from the corporate procurement section located in AJES Head Office at Musaffah, Abu Dhabi. The following specific activities must be addressed early to be fully effective: Finalize construction schedule requirements and subsequent approval from Contractor Review manpower requirements for both non-manual and manual personnel; update these requirements by means of staffing schedules, histograms and craft mixes; and ensure subcontractors manning levels are compatible. Review construction equipment needs and ensure that timely subcontractors mobilization plans are in place. Review field procedures and method statements defining standards, policies and procedures required for the execution of the works and ensure they constitute Project Specific status. Review environmental, safety and Health (ES&H) and site security plans to ensure compliance with the clients specifications and guidelines. Review Construction Quality plan in line with the guidelines of ISO 9000 and check Established QC parameters by discipline. Overview temporary facility requirements, including indirects such as tools, consumables, gases and the like and check subcontractors compliance. Actively pursue preliminary site activities such as approvals, permits, establishing contracts. Ensure Lessons Learned & Practices from previous projects are well understood & should be applied effectively from the onset of the works itself to achieve professional products. AJES Site Office

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Actual on site management would be from offices based on the site next to Contractor and Companys office. AJES Site Office is fully supported by AJES Head Office at Musaffah. The following major activities shall be carried out at site offices. Safety Regulation Enforcement Quality Assurance Enforcement and Procedures Construction Method Statements Construction Planning Site Documents Control Field Engineering & Design Controls Material Requisitions Materials Control and Tracking Materials Storage Work Procedures Physical Construction Site Administration Mobilization Mobilization shall be coordinated from the AJES Head Office at Abu Dhabi with input from AJES personnel already mobilized for the execution of Site Preparation Package and Temporary Facilities for Contractor and Company. Existing teams responsible for the execution of the those two mentioned packages already have substantial cadre of experienced professional well versed in mobilization of temporary facilities, project execution, QA / QC planning, Safety and security operations etc. Mobilization shall commence with the following activities: Kick off meeting to commence the sub contract Commencement of the required land surveys to establish various horizontal & vertical controls bench marks Incept of the engineering designs at the Firm office Soil Investigation by an approved laboratory Construction of temporary facilities Obtaining various permits from Authorities and conclusion of arrangements with local committees where necessary. Third party independent concrete testing laboratory credentials submission for approval. Shortly after contract award, site surveying shall begin utilizing the Total Station System to establish accurate control points for the performance of the work. As soon as practicable, the plans and specification for the site temporary construction facilities shall be finalized and released for installation. During the installation of the temporary facilities existing AJES site offices shall be utilized to supervise the site activities required for the temporary facilities installation. On completion of the site offices at ASAB, balance of the AJES construction staff shall be mobilized to the site along with construction equipment, tools, consumables, warehousing, storage and other items necessary to commence the
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work in accordance with the construction schedule. Temporary facilities at the job site shall include Generator Yard and Construction water storage tank, carpentry yard, re-bar fabrication, lay-down area, warehouse and workshop facilities at location A4. At the start of the construction, an emphasis shall be given on the critical requirements of the construction schedule. Work shall be carried out under continual supervision and inspection over performance. Progress shall be monitored on the basis of actual installed quantities compared to scheduled quantities. For construction areas, dedicated work crews shall be allocated for each discipline supervised by foremen and general foremen who in turn shall report to the discipline supervisors/site engineers. Based on the construction schedule requirements, necessary operational crews shall be formed and controlled over to meet the planned progress target to be physically achieved satisfactorily. It is the responsibility of the supervisor/site engineer to ensure the efficient utilization of his material, workforce, tools and equipment. For construction operation water requirement, unless an alternative arrangement is made available, water shall be trucked from nearby Desalination plant. Site construction and temporary facilities electricity requirements shall be met by installing suitable size and suitable numbers of generators. Subcontract Strategy Building Engineering services shall be utilized by appointing a consulting firm, to be responsible for the complete architectural, structural design drawings & documents productions as well as for the services schematic designs drawings production. Firm shall also represent AJES regularly during the project currency Detailed services designs shall be prepared by AJES services sub contractors AJES shall carry out broadly all civil engineering works employing its own resources of manpower, machines, equipment etc. Lower tier sub contracts shall be allowed for the execution of single operations such as supply of ready mix concrete, roofing finishes etc Ready Mixed Concrete is envisaged supplied from an established RMC supplier, an establishment with proven track record duly approved for supplying concrete by GASCO, within 10 kms of the site. However, in the mean time, without reservations, we are also seriously considering installing our own concrete batching plant. In case any minor or specialized work is necessary to be sub contracted on lower tier, Company procedures shall be apply for prequalification and award of the subcontracts. Testing And Inspection A field inspection and testing program shall be organized to be in line with AJES Quality manual & Approved Project plan under overall responsibility of the QA / QC Manager.
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Prior to conduct any testing, Contractor and Company (as required by QC Plan and ITP) shall be advised of the tests for witness. Wherever required vendor specialist shall be made available for conduct of testing and inspections. Material Management Once material has arrived at site, material management shall come under the purview and custody of the site store staff. The storekeeper, supported by his store assistant shall be responsible for the custody of the material prior to issue. Material tracking from source to the place of installation shall be conducted by the computerized system. The construction manager shall be responsible to provide the technical oversight and direction for the control of materials at the construction site area. More information has already been elaborated in the foregoing. Procurement The Central procurement department located at the Al Jaber Energy Services, Musaffah, Abu Dhabi, UAE office shall be responsible for all purchases adhering to the following procedure. Preparation of Purchase Requisition shall be made based on take-offs quantities calculated from the approved drawings documents. Purchase requisition shall completely, identify all applicable drawings, data sheets, specifications, vendor documentation requirements etc. with the inclusion of following information. Quantity of each item required with comprehensive breakdown Adequate information concerning nomenclature description, Material approvals, Quality required, applicable specifications, design & other drawings, etc/ or detailed outline of the material required. Required delivery dates for all major items. Delivery points of major items Inspection of the goods at the point of origin issue Certification of test data and/or compliance/ warranty Method of shipment (if goods imported), conditions/packing Instruction of holding, kitting consolidation, marking Drawings, manuals etc Spare parts requirements Special Instructions to vendors A technical evaluation shall be done in house to verify the conformity with specifications. Samples and technical information shall be submitted to Contractor. Once the final approval from the client is obtained, purchase order shall be raised. Upon receipt of Purchase Requisition, a purchase order shall be raised and entered in the computer register system, indicating cost and budget allocation. The procurement department shall maintain a follow-up system so that contact suppliers and/or manufactures may be made on continuous basis.

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All questionable delivery commitments shall be expedited on a daily, weekly and monthly basis as required to ensure prompt delivery in accordance with the requirements. Organization Corporate Organization Al Jaber Establishment formally known as Al Jaber transport & General Contracting Establishment is an umbrella organization which has got numerous divisions within in itself and which is also the parent company for various subsidiaries. Al Jaber Energy Services (AJES) is a separately registered company specifically set-up to target the energy sectors and its clients. AJES has been operating under the Al Jaber Establishment umbrella since 1995. Broadly all the activities of the above divisions and companies can be divided into: General Construction Heavy Lifting and Transport Services. Trading Industrial Plant Construction. Site Organization Proposed site organisation and responsibilities of the key personnel are enclosed. All supervisory staff shall be highly experienced and qualified drawn from on-going projects wherever possible. Manpower Resourcing And Mobilization All the personnel on site shall be employees of Al Jaber Energy Services. All of the required personnel to execute the work are already in UAE and working on other sites. These sites are due for demobilisation in the coming months. The planning department shall produce a histogram schedule of the resources by category. These schedules shall define the monthly manpower levels. The schedule shall also be indicative of manpower mobilization. The standard Al Jaber Energy Services site supervision is based upon the principle of training. A charge hand shall be trained and supervised by a foreman. In normal cases a foreman shall supervise four charge hands. The charge hand shall then supervise approximately ten labours. Where a special process is conducted, this ratio may be revised accordingly. Training is a requirement of the Al Jaber Energy Services quality management system and foreman and charge hands shall conduct training of the manpower in their respective roles and functions. The recruitment of manpower shall ensure that background in the relevant job skill has been achieved. The training in quality awareness shall be an ongoing process through the quality department and the foreman. Sufficient numbers of site supporting staffs which consists of Mechanics, Electricians, Auto Electricians, Guards, Water boys etc and other ancillary staff shall be deployed for the unhindered progress of the work.
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The Al Jaber Group contains at all times a vast pool of manpower in all Disciplines. These workforces are at all times working on various projects in multi discipline fields. Equipment Resourcing And Mobilization Based on the project schedule, the planning department shall generate the construction equipment schedules. The Al Jaber Group is one of the largest equipment rental companies in the GCC with over 5000 fleet where modern repair and machine facilities enable them to maintain a first class fleet of equipment. It has been our company policy to weed out the old equipment on a periodical basis and keep the equipment fleet very young. We have one of the youngest fleets of equipment in the GCC based on size. Construction Method Statement New Buildings Following the award of the project, a detailed contract scope works programme for the whole project shall be developed including all disciplines separately based on already approved outline preliminary programme appended under the coordination of our Construction Manager and Planning Engineer The Method Statements related to various project activities shall be submitted for contractors approval prior to commencement of any activity during the execution stage. Subcontracting Develop and manage a lower tier subcontracting plan and subcontractor list AJES plans to carry out most of the civil activities itself but selected items shall be sub contracted on the lower tier such as ready mix concrete, roofing application, doors & windows manufacturing, painting application, raised flooring application, suspended ceiling installation etc. Perform all lower tier subcontracting activities including specification of packages of Work to be subcontracted, pre-qualification of bidders, issue of ITBs, bid evaluation, recommendation and award. All relevant information shall be provided by the Project Manager to the purchase manager who should act immediately to conduct the required functions & the lower tier deal finalized after obtaining Company recommendation by the Project manager a) Management of lower tier subcontractors and their activities These operations shall be managed & controlled by the Construction Manager on site & reported to the Project manager Monitoring and reporting of all lower tier-subcontracting activities This activity shall be affected by the project manager based on the construction manager report. The report shall be regularly provided to the planning engineer, head office & Company. Involvement by the UAE in particular and GCC in general with respect to the provision of local services shall be encouraged . As included earlier somewhere else that UAE
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national policy shall fully be honored subject to making no compromise to the quality requirement Construction including providing labour, supervision, safety and quality management, inspection, vendor support, temporary facilities and services, and construction equipment, tools, utilities and consumables. All these issues have been elaborated earlier somewhere else b) Provision of Construction Camp, messing, transport to Jobsite, sanitation, utilities etc. for SUBCONTRACTORs personnel. All these shall be fully undertaken by AJES based on the site requirement. A life camp shall be constructed on site to meet the workforce accommodation requirement. Messing shall be resolved by employing catering sub contractors so that all personnel & workers take good food. All utilities shall be provided to maintain good house keeping of the camp. All safety & emergency precautionary measures shall be undertaken to the contract requirement. AJES operates its own system of transport, which shall be extended for the use of workers transportation. Similarly, the arrangements shall be made for the employed high tier & low tier sub contractors on this package All activities necessary for Mechanical Completion, Pre commissioning, commissioning, and Provisional Acceptance. All activities for the buildings part have been described on the method statement appended as well as this document also integrates to Civil Works & Site Preparation Execution & Construction Method Statement. All testing facilities required at Jobsite AJES shall supply an independent testing laboratory equipped with all equipment necessary for involved tests for this package properly managed by qualified personnel meeting all QA testing & certification requirement. Full responsibility for co-ordination with any Third Party Inspectorate AJES aggress to extend its full cooperation to meet any Third Party Inspections. Project manager & Construction manager shall be responsible to affect this part of the contract. Supply and coordination of lower tier subcontractor and vendor representatives as necessary AJES shall supply & coordinate with all lower tier sub contractors & vendors or their respective representatives to the requirement. Supply of these shall be managed by the Purchase Manager while the Project manager shall manage on site. Coordination shall be conducted by the Construction Manager Provision of waste management at all Jobsite locations, including disinvestments of all temporary works, upon completion of Work Waste management shall be fully operational on a day to day basis both for garbage & sewage according to the planned arrangements. Safety manager shall be responsible
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for the operations of all such activities & report to the Construction/Project Manager regularly Provision of medical and fire-fighting services at Jobsite and for temporary works Medical male nurse shall be employed on job site First Aid centre. Male nurse shall take care of providing First Aid treatment to injured workmen immediately & then the worker if so necessary in the opinion of the male nurse, shall be sent to Contractor site clinic for further treatment. Safety manager shall be responsible for the operations of all such activities & report to the Construction/Project Manager regularly
SPECIFIC

SPECIFIC CONSTRUCTION METHOD STATEMENT NEW BUILDINGS PACKAGE It is known from the contract documents that 9 buildings for various intending use as Sub station +Bottle Store, Instrument Equipment Shelter+Bottle Store and Operator Shelter have been defined to be constructed Keeping in view the nature of contract being EPC, AJES have decided to apply RCC in situ construction for all intended buildings accepting the Company direction on drawings. RCC framings shall meet the design criteria of blast resistant & resilient structure productions meaningfully. Sub Structures shall also be constructed of RCC in situ. Soil on site is medium to very dense recommended to give 30 t / m^2 working bearing capacity at 4 m depth & about 10 t / m*2 at 1 m depth according to the soil investigation Geotechnical report issued by Arab Centre for Engineering Studies for ASAB area. Soil has been described as sand with some silt traces & classified as very good for the founding purpose for no water is available within explored strata. No dewatering is necessary for the foundation zones. Utilizing the good composition of the soil, the foundations shall be designed to the best of critical imposed stresses with most economical& optimum use of the construction materials. Soil report bore holes log direct to employing spread footings in isolation, which shall be integrated by grade beams/walls to form an unit for compaction settlement & long-term consolidation controls. However, to verify the validity of the soil report, AJES may without reservations further conduct investigations based on the Engineering Services sub contracting firm recommendations, utilizing the services of an approved laboratory. Foundations shall be designed based on the soil report & further laboratory recommendations combined if so required. The phases of the construction shall be adhered to meeting the set out milestones, which are very tight for the purpose of physically executing the buildings package. The construction teams shall be constituted to meet the requirement as exhibited on the organization chart. One common project site manager shall be an overall responsible for all on site execution operations & conduct interface with the head office duly supported by safety, construction, quality, technical & administration sections all to be well established on site. Project & Construction manager shall in collaboration constitute four independent dedicated teams for four working divisions/areas lead by each site engineer directly reporting to construction manager as shown on the organization chart. Each team shall comprise of one site engineer, required number of site foreman &
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further supported by charge hand from each trade. For each team one quality assurance/control engineer shall be deployed to conduct QA / QC procedures for the relevant area. One General foreman shall be deployed for the labour engagement responsibilities on various day-to-day activities. For all other organization details please refer to Project organization plan. A surveying team shall be constituted lead by a chief / senior surveyor to carry out all site setting works from the stage of preliminary site survey to the point of recording red lines for the purpose of as built. Survey team shall coordinate with each site engineer to meet site requirement. It shall be the responsibility of each team to set out, inspect & record all layouts, pre & post concrete data for the purpose of approval & handover dossiers. All horizontal & vertical controls shall be established & monitored by the leader. All approved controlled drawings shall be issued to surveying team to commence the setting out operations. After ensuring proper safety arrangements are in, survey barricading shall be established & necessary grids control fixed & inspected by QA / QC. Excavation shall commence after the clearance is obtained & continue according to the plan. Proper safety shoring shall be arranged during this activity when it crosses 1.5 m depth & arrangement for suitable access into pit made to the satisfaction of the safety inspector & company. All unsuitable excavated material shall continuously be removed from site & suitable material tip off to designated area. All environment controls shall be taken care off during this operation. A surveyor shall continuously ensure the depth of excavation does not exceed the design requirement. When the excavation reaches the formation level, dressing shall be started followed by compaction of the soil so that area is ready for inspections. AJES QA / QC shall inspect the formation. After required clearance, arrangement shall be made for blinding all released area according to the approved method statements. Area shall be blinded to the design thickness minimum 75 mm properly levelled & trowel applied to make it suitable for the purpose to receive heavy duty concrete protection layer membrane. Then curing shall be carried out for 3 days. Application of the protection membrane shall commence thereafter over whole area of the blinding. Foundations shall be set out to design details to permit formwork erection & rebar placement. All starter rebar shall also be fixed supported by plastic spacer. On sides also, plastic spacers shall be fixed to keep all rebar in proper position. Foundation top levels shall be fixed using 25 mm plastic triangular chamfers horizontally. Chamfer shall also be fixed on the vertical edges of the forms. Inspection shall be conducted followed by concrete pouring supplied by an approved ready mix plant. All ready mix record shall be maintained according to QA approved procedures. After concreting is finished, proper curing arrangements shall be made for the required number of specified days. Setting outs for further stub columns shall be done & preparatory works continued. In parallel, all works regarding grade beams / walls shall continue complying with all the approved procedures. Fabrication of rebars shall be done in a designated area while fabrication of forms too in another designated area all according to approved procedures. After completing the preparatory works for the stub columns, inspections & pouring shall be carried out following all procedures. Operations of grade beams / walls shall be taken up on similar principle as other activities.
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For sub stations where cable cellar suspended floor slab is to be built, shall be prepared together with surrounding sub structures. After curing is done for the specified period, protection membrane shall be applied on both horizontal & vertical surfaces followed by inspection & backfill in compacted layers to specified requirement. Field density tests shall be conducted to monitor the requirement of density & water content etc. Backfill shall continue up to the formation level below the grade slabs blinding in buildings & where cellar suspended floor slab is to be built, backfill shall be done around the grade structures. Preparations shall be carried out for the cellar suspended slabs by erecting required supporting system, forms fixed, rebars placed, all services inserts provided & inspections conducted from all disciplines followed by the concrete pouring observing all QA procedures. Similarly, on the areas where grade slab is to be built, after the completion of the backfill up to the bottom of blinding concrete i.e. formation level, plastic sheet shall be laid after compaction & levelling & all necessary under ground services completion, blinding concrete shall be poured, levelled & wood floated well to make it sufficient enough to receive the grade slab. After three days of curing on blinding, preparation for the grade slab works shall commence & rebars placed either by site fabrication or using pre fabricated mesh to design requirement. All necessary services shall be inserted, inspections conducted & concrete poured. At this stage of the building, major sub structural elements have been completed giving a way to commence the super structural works. All preparatory works of superstructure elements shall come into full swing by the fabrication of the forms & steel rebar fabrication to the BBS details. Scaffolding shall be erected for the fixing & placing vertical rebars of columns & walls in all required areas. Steel rebars shall be fixed placed with spaces & inspections conducted. Any inserts necessary for the electrical conduit or earthing, shall be installed immediately & inspection conducted. Work of vertical forms shall commence for sides of columns as well as walls fixed using removable tie bolts with cones / boss at tie rod ends. Forms shall be made of fair face ply to produce specified texture to the elevation requirement. All exposed vertical edges shall be chamfered using plastic chamfer 25 x 25 mm triangular section nailed to the forms. Inspections shall be conducted for the elements ready for pouring. Pouring shall commence keeping the height of pour not more than 2 m using vertical pipe chute of the pump reaching up to necessary level. Curing shall follow adhering to the agreed or approved procedures. Similarly walls of transformer areas shall be built adhering to all QA procedures. Next operation of erection of the propriety scaffolding to support the superstructure roof slab shall commence strictly complying with the scaffolding drawings. On parallel, operations of fabrication of forms & rebar shall be taken up. All vertical & grid controls shall be established by surveyor to keep in line & level all forms of beams alignment & soffits. Level of slab shall be established & then work of form fixing shall commence followed by placing of beams reinforcement. Services inserts such as electrical conduits, HVAC inserts or block outs if necessary & other inserts shall be marked for establishment. Works of steel rebar placement shall continue in parallel to speed up the preparatory works. An inspection of the preparatory works shall be conducted by all involved disciplines. After obtaining approval for the pour, pouring shall be carried out adhering to pouring method statement compliance. Curing shall be started immediately
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after finishing the surface as required by the curing compound manufacturers instruction for the application of compound & also by using water in combination all to agreed procedures. Intermediate slabs on the Battery rooms shall be constructed following the foregoing procedure. Erection of the scaffolding around shall extend to cover the parapet portion followed by formwork & rebar fixing. On the similar pattern as defined earlier, all inserts shall be fixed followed by all relevant inspections & pour. All aforesaid concreting operations shall be supported by necessary number of transit mixers, concrete pumps, nozzle vibrators conforming to perform 10000 oscillation per minute & all other necessary arrangements essential to perform the best task. Well-trained teams shall be engaged for such operations. All necessary safety measures shall be installed. If necessary during hot weather, rest pauses shall be allowed to workers with the provision of liquid or salt water. Forms shall be struck form the elements carefully ensuring full safety intact. Concrete surface shall be inspected immediately after removing form, cleaned & surface treatment to the project specification applied to produce specified class of surface texture i.e. smooth finish or sandy or rough or grouted. Any defective concrete shall be applied remedial measures as agreed with the Company or Client. Wherever special openings have been provided in designs within the structural framing, those shall be provided within the formwork itself. Now the structural framing works have been completed giving way to attack on internal walls & other items such as dry wall lining & preparation for the roofing item. All preparations shall commence for the remaining works. Block work shall be carried out wherever required for walls followed by services fix 1 items & then plastered over as specified. Roofing shall commence by scabbling the slab surface, laying of light weight foam concrete in grade minimum % to receive water proofing membrane, membrane application followed by water leak test for 72 hours & then polystyrene boards laid over to be protected by concrete pavers. Seperation geotextile shall be provided according to applicator direction. Over concrete protection paint on parapet, Aluminum flashing shall be fixed to design details. Services site team shall be inducted in full swing for carrying out all disciplinary operations. Suspended ceiling fixers shall also enter in to commence the work. Where there is no ceiling, work on the slab finishes shall continue. Wall lining work shall be carried out in accordance to design details after ensuring complete inspections of services conduits etc. are over. Fixing of cable terminations framing steel as well as framing steel for the floor openings shall be carried out according to details. Flooring shall be carried out in according to design details. Tiling shall be followed on required areas schedules to receive floor or wall tiles.
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Concrete surfaces requiring protection shall be applied accordingly with 3 coat system or any other approved. Operations of constructing transformer foundations shall be carried out & protection applied to that. Sumps shall be constructed to details in floor. Gravel filling shall be done around the transformer oil containments / enclosures. All finishing items shall be carried out in wet areas & concealed piping works prior to that. Services operations shall be completed in all areas followed by finishing works. Services inspections shall be conducted prior to commence the finishing works. When the works are ready involving the scope of telecommunication routes, an entry shall be allowed to the related other sub contractor from other scopes provided with full cooperation in all respects. Works of external services within 5 m of building shall be completed & tested. All surrounding or backfills shall be completed to the specification provisions. Walkways works shall commence by filling & leveling around the building excluding the instrumentation room on the plant side portions. Walkway Kerb shall be fixed to the profile over the blinding concrete with haunch concrete over. Sand shall be filled over the compacted & profiled area of the walkways whereon the interlocking concrete blocks are to be fixed in to design pattern. Necessary directional signs to be installed in buildings shall be fixed to approvals. Pre commissioning, Commissioning, Provisional Acceptance and Final Acceptance All services individual items integrity & tests shall be conducted by related sub contractors & record maintained. After ensuring that each installation is efficient in performance, release for commissioning shall be given. Details are included within the technical literature / datasheet. All units of every discipline shall be tested on site to confirm adequate performance. All underground services invert level & crown level shall be checked ensuring proper setting to alignment. Manholes shall be cleared of all debris, dust or any foreign material. Water shall be applied with pressure to clear the dirt. Functions of all electrical as well as HVAC appliances & equipment shall be checked for adequacy of functioning. Similarly, all other services shall be checked to ensure that testing for the commissioning can be successfully conducted. According to the direction given by the integrated datasheet & brochures, discipline wise testing & commissioning shall be carried out & continues for one month. Supply and coordination of lower tier subcontractor and vendor representatives as necessary All necessary lowers tier sub contractor & vendor representatives shall be provided to the scope requirement. Specialist vendors shall be employed for the specialist operations. These representatives shall manage all activities required to be carried out on site for the purpose of construction execution, pre commissioning & commissioning to the contract requirement. These personnel shall interact with Technip & company if so required for all technical & engineering involvement. All activities necessary to achieve Pre commissioning, commissioning and Provisional Acceptance. Services disciplines such as electrical, fire alarm, & gas detection system, fire suppression system, internal sanitary & drainage, infrastructure
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of all other included services require pre commissioning, commissioning & provisional acceptance. All fix 1 & fix 2 procedures shall be conducted according to ITPs & approved procedures. Brief description has already been elaborated in the foregoing. All utilities, fuels, lubricants, chemicals and catalysts required up to issuance of the Provisional Acceptance Certificate. Within Contractor scope All required operating and maintenance documentation . All operating & maintenance manuals shall be submitted covering work scope items. These shall be prepared, compiled, documented & transmitted according to the provision of the sub contract requirement. WARRANTY OBLIGATIONS THROUGH TO FINAL ACCEPTANCE shall be submitted for the work scope items Further detailed method statements based on each significant activities shall be proposed while physically working on site prepared & approved by the site management. Yet some more details have been included for the purpose of indication only within the presentation of Civil Works package that can be opened from this document itself on soft copy. Click here Both statements should be referred to as an integral document. For further details on the services method statements for the package, please refer to the CCTC documentation to be attached within this proposal.
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Taweelah Unit III Um Al Nar Water Transmission Scheme


Water Reservoir<