Вы находитесь на странице: 1из 11

CLIENT APPROVAL

0
21-Aug-10
A
21-July-10
Rev.
Date
PROJECT:

ISSUED FOR CONSTRUCTION


ISSUED FOR APPROVAL
Description

A.T.
A.T.
Prepared By

A.K.
A.K.
Checked By

LPG SPHERES & RELATED FACILITIES PHASE II PROJECT (LPG-II)


CONTRACT No. SPC/LPGII/12/2009
OWNER:

CONTRACTOR:

TETCO

MINISTRY OF ENERGY &


MINING (MEM)
SUDANESE PETROLEUM
COORPORATION (SPC)

Tahan engineering
Trading and Contracting
Tel: +961 4 524 460.
Fax: +961 4 524 458

DOCUMENT TITLE:

PROJECT EXECUTION PLAN


PROJECT DOCUMENT INFORMATION
PROJECT NO.

DOCUMENT NO.

SHEET NO.

REVISION NO.

SG-912

OM-2004

Page 1 of 12

CONTRACTOR DOCUMENT INFORMATION


DOCUMENT/FORM NO.

---

REVISION NO.

TETCO

LPG SPHERES & RELATED FACILITIES


PHASE II PROJECT (LPG-II)

MEM
SPC

PROJECT EXECUTION PLAN

TableofContents
1- Purpose .......................................................................................................................................................3
2- References ..................................................................................................................................................3
3- Work Breakdown Structure ....................................................................................................................3
4- Project Activities and Deliverables.......................................................................................................3
4.1- Pre- Start Activities ...............................................................................................................................3
4.2- Mobilization ............................................................................................................................................4
4.3 Engineering ...............................................................................................................................................5
4.4 Procurement .............................................................................................................................................6
4.5 Construction .............................................................................................................................................7
A- Civil Construction ...................................................................................................................................7
B- Mechanical Construction ....................................................................................................................8
C- Electric and I&C construction ......................................................................................................... 10
5- Inspection and Testing.......................................................................................................................... 11
6- Commissioning ...................................................................................................................................... 11
7- Attachments .......................................................................................................................................... 11

21 August 10

SG-912-OM-2004 REV 0

Page 2 of 11

TETCO

LPG SPHERES & RELATED FACILITIES


PHASE II PROJECT (LPG-II)

MEM
SPC

PROJECT EXECUTION PLAN

1- Purpose
The purpose of this document is to describe the methods, sequences and resources
planned to be considered in the execution of the LPG-II project.

2- References
The contract, signed between Owner and Contractor with its Exhibits is the major
reference for this plan in addition to the Contractor experience from previous
projects.
This document shall be read with reference to the Primavera Project Plan.

3- Work Breakdown Structure


The Work Breakdown Structure considered for this project is oriented towards the
deliverables that can be handed, as main entities, from the Scope of Works.
These deliverables are split under six main categories as following:
- Pre- Start Activities.
- Mobilization
- Engineering
- Procurement
- Construction
- Inspection and Testing
- Commissioning
Each of these sections shall be detailed in below sections

4- Project Activities and Deliverables


Following details of activities and deliverable items shall be considered.

4.1PreStartActivities
After contract award and finalization of the contract and signature, contractor started
the following pre requisit activities for other sections:
-

Carry out survey, adopting an approved surveyor, to mark the site benchmarks
and the major structures and facilities as well as to provide the natural ground
elevations. Another task was assigned to the surveyor was to provide a survey for
the feeding and dispatch lines rooting and elevations.

21 August 10

SG-912-OM-2004 REV 0

Page 3 of 11

TETCO

LPG SPHERES & RELATED FACILITIES


PHASE II PROJECT (LPG-II)

MEM
SPC

PROJECT EXECUTION PLAN


-

After marking the centers of spheres and sheds, soil test was carried, by Khartoum
University geology laboratory, to confirm the soil nature and physical and
chemical properties and set recommendations for foundations and structures
design.
Contractor shall carry out clearance of any obstructions from site and remove all
bushes, shrubs and excess material or existing structures above natural ground, in
order to allow for safe site accessing.
Arrangement of Insurances shall be carried according to contract requirements,
prior to mobilize personnel and equipment to site.

4.2Mobilization
The mobilization is carried on two main lines. The first is to allocate and assign the
project key personnel starting from the project Director, Head Office staff assigned to
the project, mainly for the engineering, procurement and logistics, QA/QC and
planning as well as the site key personnel starting from Site Manager, Mechanical,
Electrical and I&C engineers, Safety Officer and QA/QC in addition to the sections
Foremen, Superintendents and Supervisors.
Details and CVs for key personnel are attached to the Project Organization chart.
After assigning the key staff, manpower and skills for each section are determined
and selected between the site key staff and the head office.
The Tetco Sudan Office in coordination with head office Human Resource shall
arrange all necessary visas, tickets, work permits, gate passes and related issues for
the staff and manpower assigned to site, according to relative histogram. Necessary
support from SPC shall be requested when necessary for local formalities.
One important issue shall be given attention that all welders shall be qualified by
testing with third party witnessing, prior to mobilize this type of skilled manpower to
site.
The other main line in the mobilization is to mobilize site facilities including:
- Camp for site staff and manpower with relative facilities
- Site offices and relative facilities
- Site workshop and stores
- Tools and construction equipment for each discipline
The site offices are allocated from Sudan and mobilized and set up at site, while the
camp and related facilities are mobilized from abroad.
Civil construction equipments are allocated from Sudan and will be available at site,
based on relative workloads.
The civil tools as well as the mechanical equipment and tools are allocated from
Sudan and abroad and mobilized to site on due time.
Electric and I&C tools and equipment shall be arranged on due time to carry out the
relative works.
21 August 10

SG-912-OM-2004 REV 0

Page 4 of 11

TETCO

LPG SPHERES & RELATED FACILITIES


PHASE II PROJECT (LPG-II)

MEM
SPC

PROJECT EXECUTION PLAN

4.3Engineering
As TETCO has nominated from the tender stages, PARESA as subcontractor for the
design and supply of fabricated material for spheres, the design of the spheres,
which is a major project item, is carried by PARESA and verified by the Owner
representatives at PARESA premises as first engineering session.
The basic engineering and balance of plant systems and utilities, are designed by
TETCO, at head office in Beirut and verification takes place there. Accordingly, the
plant process design covering the PIDs, PFDs and hydraulic calculations of the LPG,
Fire Fighting and Oily Water systems are prepared as well as the piping layouts and
stress analysis of the three systems with relative equipment specifications are carried
for the first engineering session in Beirut.
Also the full design of the major civil structures as the spheres foundations, based on
the loading data from the spheres mechanical calculations and soil test report, the
bund walls and slabs around the spheres, the compressors and pumps sheds steel
structures and foundations, the access stairs and platforms to the spheres steel
structures and foundations, the roads under passes and the pipe supports for the
feeding and dispatch lines as well as relative specifications and procedures for
structures and materials are prepared for the same session.
The rain and oily water evacuation system is also prepared for coordination with the
GSSP design for the Industrial Water sewer.
Concerning electric design, the general, MV, LV, Lighting and UPS SLDs with relative
specifications for cables, transformers, RMU, lighting devices and panels are
prepared. The cables schedule with relative voltage drop calculations and short
circuit calculations as well as the design of the earthing system with the lighting and
earthing layout are considered for the engineering session in Beirut.
The control system specifications and architecture as well the instruments, radar level
and metering units specifications with the fire alarm and detection system
specifications are prepared for the same session.
In addition to the design, all administrative and general procedure as well as the
work instructions, ITPs and Inspection procedures for the major works to be carried
and starting at the early stages of the project are also prepared for review and
approval.
However, some items and parts having secondary priority and not required from the
early stages of the project, like the specifications and data sheets for the fire fighting
devices, BOMs, design of roads, isometric drawings for piping, wiring diagrams of
panels, cabling layouts and relative details as well as relative Work Instructions and
Inspection forms are left for approval during an engineering session at TETCO offices
in Khartoum.

21 August 10

SG-912-OM-2004 REV 0

Page 5 of 11

TETCO

LPG SPHERES & RELATED FACILITIES


PHASE II PROJECT (LPG-II)

MEM
SPC

PROJECT EXECUTION PLAN

4.4Procurement
Procurement and logistics started for the project from the early stages to prepare
necessary material and facilities for the mobilization and non permanent material.
In parallel, finalization of agreement with PARESA and booking the steel plates, by
issuing PO for the material supply of spheres, started also after contract signature in
order to secure the delivery of spheres according to project schedule.
Based on approved specifications, data sheets and BOMs, ordering of other material
and equipment is carried taking into consideration the time required for shipping
and clearance at Port Sudan and local transportation to reach the site.
Ordering of reinforcing steel bars, for spheres foundations, from abroad with the
anchor bolts relative to the spheres foundations are found on the critical path and
shall be given priority and high importance. Approval of local suppliers for cement
and ready mixed concrete as well as backfilling material, are also at the same level of
importance.
Material for the feeding and dispatch lines, is considered also of importance in order
to proceed with this work in parallel with the spheres, prior to start the within plant
piping.
Supply of the MV cables, RMU and transformer are given importance in order to
provide electric power to the site as soon as possible.
Other plant equipment and materials like reinforcing steel for other structures and
facilities, steel structures, painting and grouting material, pumps, compressors, valves,
PSVs, motorized and control valves, metering units, LPG and oily water pipes and
fittings for within plant, fire and cooling water piping, valves and devices, drain pipes
and relative valves, LV panels, LV cables, control panels, control cables, instruments,
UPS, lighting, earthing and fire detection and alarm material and components shall
be also ordered on due time allowing for delivery time from suppliers, shipping and
clearance at Port Sudan as well as local transportation to be at site on time for
necessary installation and construction works.
The Primavera schedule is assuring the proper link between design, procurement and
construction in order to provide key dates for the ordering, shipping, clearance and
local transportation to site of every type of equipment or material. The key dates
shall be monitored by the procurement department to keep in line with the schedule
and avoid the possibility of delays. Accordingly, preliminary quotations are obtained
at early stages of the project, even prior to get approval on the relative specifications,
in order to get better view for the range of the time of delivery of each type of
equipment and confirm with the allocated times, on the schedule, and amend if
necessary.

21 August 10

SG-912-OM-2004 REV 0

Page 6 of 11

TETCO

LPG SPHERES & RELATED FACILITIES


PHASE II PROJECT (LPG-II)

MEM
SPC

PROJECT EXECUTION PLAN

4.5Construction
Construction is split in three main sections, Civil, Mechanical and Electric and I&C.

A CivilConstruction
Civil construction covers the foundations of spheres, slabs and bund walls around
spheres, structural steel sheds with cladding and relative foundations and slabs
for compressors and pumps with metering units, structural steel access stairs and
platforms with relative foundations allowing access to the top of spheres, pipe
supports and reinforced concrete roads crossings for the feeding and dispatch
lines, works relative to MV and LV cables underground laying with relative
conduits, pipe supports for piping within plant and roads crossing within plant,
pipe supports for cooling and fire water piping, excavation with lay down of drain
pipes then backfill, foundations of pumps and compressors, transformer
foundation and relative fencing as well as small foundations for firefighting
devices, lighting poles and field panels also steel pipes cross over. Roads around
the facility with related drains are considered part of the civil construction.
The items found on the critical path are the first two spheres foundations (SP 101
and 103) and this shall be given high importance starting from the excavation to
the backfilling and compaction and then go to the annular raft and the columns
supporting the spheres legs. Diesel powered shovels shall be used for the
excavation of the upper layers of soil and then can use excavators when the soil is
coming harder as well as for the proper forming and finishing of the excavations.
Excavated material shall be stored at site first and then excess material shall be
moved to damping area.
Lay down of backfill material and compaction, with 25 tons roller, of samples for
confirmation of the soil strength and then proceeding with the first layer of
backfill and test the soil bearing capacity and then the second layer and confirm
the final bearing capacity shall be considered prior to the concrete foundation.
The concrete annular rafts shall be cast using and adjustable circular formwork for
the inner and outer circumferences and covering full circumferences. Tangential
reinforcing bars shall be cold formed to match the required circular shape, using
hydraulic bars bending machine or sections rolling machine.
Once the raft is cast and the reinforcing steel of columns is extending up, two
steel formworks, supplied for the specific size of columns shall be used to cast
two columns simultaneously and be able to complete the 10 columns of one
sphere in five consecutive castings
21 August 10

SG-912-OM-2004 REV 0

Page 7 of 11

TETCO

LPG SPHERES & RELATED FACILITIES


PHASE II PROJECT (LPG-II)

MEM
SPC

PROJECT EXECUTION PLAN


Curing time with cooling water shall be provided to allow the foundation to reach
its required strength, prior to proceed with the steel erection.
During the curing time and after reaching the required strength of the raft
foundation, shall apply the water proofing coat and then start backfilling and
compaction, around the foundation, from the side where the first columns casting
took place.
The foundations construction of the spheres shall go in alternating mode
between two or three foundations in a way to use the allocated equipment and
manpower in the better efficiency and without waste of time.
The other critical items in the civil works are the bund walls and slabs around the
spheres, specifically for the last two spheres, since these activities shall not be
completed early and restrict the access and movement of the mechanical teams
around and to the spheres during erection and at the same time shall not delay
other works like the piping within plant and the cooling water branches up to the
spheres. Accordingly, synchronization of these activities is very important and
proper links are realized on the project schedule.
The underground drain pipes with relative manholes and valves pits as well as the
excavations and backfilling for the earthing cables, foundations of the lighting
towers and erection of the steel access stairs and platforms shall be also
synchronized properly with the bund walls and slabs construction in a way that
once the bund wall around one sphere is complete the related items shall follow.
All the other civil activities mentioned above shall go in parallel with the spheres
foundations and bund walls and slabs or in the mean time between foundations
and bund wall.
Pipe supports for the piping within plant shall be carried in three phases, the first
is upon completion of the bund walls for spheres SP 101, 102, 103 and 104, the
second upon completion of the bund walls of spheres SP105 and 106 and the left
balance in parallel with the bund wall of sphere SP 107.
Steel sheds construction shall be complete to allow the installation of pumps and
compressors when it arrives to site.
Required time combined with relative manpower and considered equipments for
use in these activities are shown on the attached Personnel and Equipment
histogram.

B MechanicalConstruction
The mechanical construction in this project is the most critical and specifically the
one related to the spheres constructions and then the activities connected to the
spheres construction, mainly the PWHT of spheres, blasting and painting and then
connection of piping to the spheres.
21 August 10

SG-912-OM-2004 REV 0

Page 8 of 11

TETCO

LPG SPHERES & RELATED FACILITIES


PHASE II PROJECT (LPG-II)

MEM
SPC

PROJECT EXECUTION PLAN


All the other activities as the feeding and dispatch lines, the piping within the
pumps and compressors sheds and up to the spheres bud walls, installation of
equipment as well as the piping connections within the DC station can go in
parallel with the spheres construction.
The fabricated meridian plates material with relative columns, for two spheres,
shall arrive to site by early October 2010, erection will be carried using two cranes
in order to reduce the erection time and allow the maximum available time for
welding, which is the most time consuming activity. Twelve welders with relative
welding machines, air arc gouging equipment with necessary diesel generators
are assigned for each sphere in order to complete the work on the available
material prior to the arrival of the second shipment after two and half months to
site.
The second shipment is planned to include the balance material for the two first
spheres and the meridian plates with columns for two other spheres and
expected to arrive to site by the end of December 2010. Accordingly, planning is
considering to finish the first two spheres in parallel with the erection and welding
of the meridian plates of the third and fourth spheres. Once welding of the first
sphere is complete and all NDT inspections confirm that the works are free from
defects, PWHT shall start immediately, on this sphere, and then move to the
second sphere while pressure testing shall take place on the first sphere to allow
starting blasting and painting and then installation of cooling rings. Attention
shall be paid that no welding shall be allowed on the spheres after PWHT and all
attachments and supports that needs welding on the spheres shell shall take
place prior to the PWHT.
Above works shall be complete prior to the arrival of the last lot of fabricated
material to site, in month twelve, and including the balance of material for the
two previous spheres and full material for three new spheres.
Same procedure shall be followed to finish the previous spheres and proceed with
its PWHT and then pressure testing and blasting, painting and installation of
relative cooling water rings and then connect piping to these spheres. At this
stage the number of welders shall be boosted up to around 36, on the spheres,
and shall consider finishing of one sphere after the other in order to allow for the
following activities as PWHT, pressure testing, blasting and painting and then
installation of cooling rings, access stairs and platforms and then connection of
relative LPG, oily water and cooling water to the completed sphere. Attention
21 August 10

SG-912-OM-2004 REV 0

Page 9 of 11

TETCO

LPG SPHERES & RELATED FACILITIES


PHASE II PROJECT (LPG-II)

MEM
SPC

PROJECT EXECUTION PLAN


shall be given that civil and electric works interfere during this period with the
mechanical works.
The Primavera schedule has considered all these links and the relative time table
and sequence of activities shall be followed in order to complete the works on
time.
Note that improvement of the above considered delivery schedule of the
fabricated material, if possible, by increasing the number of spheres delivered
with the second delivery or increasing the number of deliveries within the same
time frame, shall reduce the acute peak in manpower and required performance
during the last three months of the project construction time.
Planned manpower and equipment allocated for the mechanical works are shown
on attached Manpower and Equipment histogram.

C ElectricandI&Cconstruction
Electric works shall be split in two phases. The first is related to the installation of
the MV RMU, MV cable and power transformer with termination and connection
of the LV power output for use at site. MV cables termination is planned to be
subcontracted to local specialized subcontractor.
The second phase shall be related to the earthing system around the spheres and
steel structures and up to the control room and transformer and then continue
with the installation of LV panels and power cables, upon installation of
equipment at site. Lighting works can start once the sheds are complete, the
roads are excavated and prepared for asphalting to allow the construction of
lighting poles foundations and installation of ducts and cables for the lighting
system. This shall be coordinated properly with the civil and mechanical works, as
considered in the Primavera schedule.
Concerning the Control and automation activities, this shall start after completing
blasting, painting and installation of cooling rings on four spheres, allowing the
installation of a batch of instruments and motorized valves with connection of
relative control cables to the field panels. As for the cables from the field panels
up to the main control panel, in the control room, this can be carried in parallel
with the instruments installation and wiring in order to allow starting the
integration of instruments in the control system.
The fire alarm and detection system shall be installed and wired in parallel with
the instruments and control system.

21 August 10

SG-912-OM-2004 REV 0

Page 10 of 11

TETCO

LPG SPHERES & RELATED FACILITIES


PHASE II PROJECT (LPG-II)

MEM
SPC

PROJECT EXECUTION PLAN


Planned manpower and equipment for electric, I&C activities are shown on
attached manpower and equipment histogram.

5- Inspection and Testing


Inspection of works with related NDT are planned to be carried, by TETCO qualified
QA/QC personnel or by third party, in parallel with the construction works, in order to
assure the quality of the works and detect possible defects from early stages and set
corrective and preventive actions as soon as possible in order to save the project
schedule
Accordingly, inspection methods like UT inspection of the spheres joints are planned
to be considered in order to allow for daily inspection of the performed welds.
For piping works, RT is planned for each lot of spools.
However, pressure testing of spheres as well as piping cannot be carried unless a
sphere is complete or a pipe system is complete.
For the sphere the pressure testing is time consuming looking the significant
quantity of water required to fill one sphere. After completion of the pressure testing
of one sphere, the same water can be transferred from one sphere to the next sphere
ready for testing.
Testing of equipment by giving electric pulse and checking the direction of rotation
as well as the alignment of pumps prior to start commissioning is planned and
enough time is available for such activity.

6- Commissioning
Commissioning is carried over a period of five month and is considering the
commissioning of the different piping systems, including the feeding and dispatch
lines as well as the piping within plant. The most time consuming part of the
commissioning is the purging of spheres, planned to be carried by removal of air
from tanks, by filling it with water, and then admission of LPG vapor during water
evacuation. After purging filling of LPG liquid inside spheres up to the LL level is also
of high importance and requires time.
These activities are planned and shown in the project schedule.

7 Attachments
Manpower and Equipment histogram, planned according to the proposed schedule,
is attached to this document.
21 August 10

SG-912-OM-2004 REV 0

Page 11 of 11