Final 1st CS Report KFUPM BP Project

CONSTRUCTABILITY STUDY
KFUPM BUSINESS PARK PROGRAM

CONSTRUCTABILITY STUDY (CS) JULY, 2017
CONTENTS
CONSTRUCTABILITY WORKSHOP ............................................................................................................. 3
SECTION 1: PROJECT OVERVIEW ............................................................................................................... 7
1.1 Project Description & location...................................................................................................................... 7
1.2 Project Objectives ......................................................................................................................................... 7
SECTION 2: CONSTRUCTABILITY REVIEW, TEAM PARTICIPANTS & WORKSHOP OBJECTIVE 10
SECTION 3: CONSTRUCTABILITY OBJECTIVE ...................................................................................... 15
SECTION 4: CONSTRUCTABILITY REVIEW SUMMARY....................................................................... 16
SECTION 5: GENERAL CONSTRUCTABILITY CONCERNS ................................................................... 17
SECTION 6: GENERAL CONSTRUCTABILITY CONCEPTS.................................................................... 18
SECTION 7: CONSTRUCTABILITY REVIEW CHECKLIST ..................................................................... 25
SECTION 8: SUMMARY AND CONCLUSION ......................................................................................... 115
CONSTRUCTABILITY SUGGESTION FORM .......................................................................................... 116
DRAFT CONSTRUCTABILITY REPORT REV. A PAGE 2

CONSTRUCTABILITY WORKSHOP AGENDA FOR

July 18th, 2017
ACTIVITIES TIME
SESSION
ATTENDANCE 8:00 – 8:10
Welcome & Introductions
10 minutes presentation for an overview of Constructability Workshop

including the definition, objectives, timing, implementations, benefits and
sharing of an example constructability success.
OVERVIEW OF THE CONSTRUCTABILITY AS PER CII
 ORGANISATION RELATED ISSUES
 Appoint Constructability Coordinator

 Identify participants for constructability actions and reviews
1 08:10 -10:00
 Establish approval authority chain for constructability issues
 Develop schedule for reviews
 Establish and maintain a Constructability Logbook
 through project closeout
 Review Lessons Learned
 Interface with other BI’s
 Review permits and associated requirements
 The Constructability Review Team
COFFEE BREAK 10:00 -10:15
 ENGINEERING / DESIGN RELATED ISSUES
 New technologies and Materials
 Design optimization
 Standardization of material and equipment
2  Modularization and prepackaged or packaged systems 10:15 - 12:00

 Underground Work including mechanical and electrical utilities, and
shortening mechanical and electrical runs and associated work.
 CONTRACTING
 Contracting Strategies to optimize Cost / Schedule benefit

SESSION ACTIVITIES TIME

 Incorporating Constructability Clauses in Contract language
 Advantages and Disadvantages of subcontractors
 SCHEDULING RELATED ISSUES

 Type of Schedule
 Sequential of construction activities
 Sequential equipment installation
 Early erection of stairways, platforms and ladders to preclude
temporary installations
 Site access constraints impacts schedule
 Heavy hauls & lifts impact schedule
 Critical path / long-lead materials
 Weather related construction and materials handling issues (wet
season, heat, wind/sand etc.)
 Minimizing double-handling of materials
 Site congestion – crew concentrations – impact of other activities in
area
 Permits and associated delays
 Start up schedules
 PROCUREMENT RELATED ISSUES

 Reducing materials costs
 Optimizing our just in time materials sequencing
 Evaluation of procurement delay risks
 Evaluation of pre-assembly (Skid mount) options and procurement
impact
 Variation of equipment cost between vendors
LUNCH BREAK/ PRAYER TIME 12:00 – 01:00
 MATERIALS RELATED ISSUES
01:00 – 03:00
3  New construction technologies / materials
 Pre-fab / pre-cast / pre-assembled options


 Modularization / standardization issues
 Minimize double-handling
 Installation of lifting lugs being installed at the factory. Are they
placed exactly where we need them for the way we planned our lifts.
 Availability of local purchase materials
 Availability of sand and marl. Barrow pit locations and access?
 Size & location of lay yard
 Spacing requirement for pre-assembly
 SITE RELATED ISSUES
 Identification of existing utilities and facilities within LUP
 Geotechnical investigations and test bores
 Rock quantities and hardness related issues
 Sand & marl availability
 Construction site congestion and Traffic plan
 Excavation, fill & leveling related issues (SFC to prepare in
advance?)
 Site access for personnel and heavy equipment
 Site facilities ~ project offices, lay down yards, cafeterias etc.
 Site Facilities ~ Temporary power, water, sewer, communications
etc.
 Temporary power and permanent facilities
 Heavy haul and heavy lift site requirements
 Road crossings, traffic plans and permits
 Offsite fabrication facility requirements and size
 CONSTRUCTION RELATED ISSUES
 New construction technologies / materials
 Review sequencing of construction activities
 Heavy haul / lift plan and associated scheduling and site
requirements
 Construction, installation and fabrication cost containment
 Ground level construction – minimize and the use of scaffolding
 Weather related issues: wet season’s effects, winds season effect,


temperature affects on the concrete placement and weather material
handling and storage concerns.
 Specialized tools or tooling
 Crane accessibility and conflicts
 Site congestion and crew concentrations
 Concrete formwork, pour schedules, rebars cage fabrication etc.
 Early erection of permanent stairways, platforms & ladders
 Reduce scaffolding
 Man-lifts instead of some scaffolding
 Evaluation of re-work risks
 Field welds
 Work permits and related delays
 Equipment location and minimizing better revisions during designs
 Accessibility of equipment for inspection and maintenance
requirements
 Discussion of project-specific issues and challenges
 Conclusion and Recommendations
03:00 – 03:30
ADJOURN!!!

SECTION 1: PROJECT OVERVIEW
1.1 Project Description & location
King Fahd University of Petroleum and Minerals (KFUPM) though its wholly owned Affiliate,
Dhahran Techno Valley Company (DTVC), and its subsidiary, KFUPM Business Park Company
(BPCo) aims to develop and construct a State of the Art Business Park of mixed use real estate,
including Offices, Hospitality, Retail and residential assets with all supported facilities on a land
owned by KFUPM which is approximately 210,000 m2 (Phase 1) located adjacent to the
University Campus and near main Saudi Aramco main gate.
1.2 Project Objectives
The project is to create a high quality urban mixed use development comprising living and
employment opportunities consisting of residential, serviced apartment, hotel, office,
entertainment and retail facilities based on transit oriented development principles.
KFUPM Business Park Development aims to be a global landmark recognized for its unique,
iconic and compact development combining live, work and play spaces and positioned as a
premier destination in Dhahran. The project is to be completed by 2020

LOCATION


SECTION 2: CONSTRUCTABILITY REVIEW, TEAM PARTICIPANTS & WORKSHOP

OBJECTIVE
Representatives from Saudi Arabian Oil Company, VMPSC, Atkins, DAR, DTVC, CCC, MAPA, Al
KIFAH, AL BAWANI, AL YAMAMA, ESEC, AZMEEL, RTCC, KHONAINI, SINOHYDRO and
Saudi Tabreed gathered on July 18th, 2017 at DAR office building 20th floor conference room Khobar
Gate Towers, AL-Khobar to discuss constructability requirements for “KFUPM BUSINESS PARK
PROGRAM”.
The objective of this review was to identify areas of concern and potential solutions with regard to
construction of the subject project and focus on the early identification of opportunities to improve the
construction process, as well as the necessary corrective actions to avoid situations that could cause
problems or inefficiencies in construction.
Participants in the review were:
See attachment on next page





SECTION 3: CONSTRUCTABILITY OBJECTIVE
The objective of the session was to use construction knowledge and experience in planning, design and
procurement and field operations to achieve overall project objectives and integrate construction input
into planning design and construction stages. The session helped to integrate constructability input into
all stages of the project.
Construction Industry Institute (CII) research has concluded that maximum benefit occurs when people
with construction knowledge and experience become involved at the very beginning of a project.
The following Six (6) basic constructability concepts are generally applicable to the Project Design
and construction of any Project:
1. Constructability program are made integral part of project execution plans.
2. Project Planning actively involves construction knowledge.
3. Early construction involvement is considered in development of contracting strategy.
4. Ensure the overall project schedule is construction driven.
5. Basic Design approaches consider major construction methods.
6. Site layout promotes efficient construction.

SECTION 4: CONSTRUCTABILITY REVIEW SUMMARY
During the course of this review, typical project elements were examined in a constructability program
as per Construction Industrial Institute (CII) as following:
 Organizational Related Issues

 Engineering and Design Related Issues
 Contracting Related Issues
 Scheduling Related Issues
 Procurement Related Issues
 Materials Related Issues
 Site Related Issues
 Construction Related Issues

SECTION 5: GENERAL CONSTRUCTABILITY CONCERNS
During the presentation of the slides contained in the Constructability presentation, team members
were invited to comment on any topic with respect to the construction strategy and related concerns.
An effort was made to guide the discussion under the general discipline headings such as
civil/structural, piping, instrument and electrical etc. Other general concerns such as logistical issues,
contracting strategies, materials and scheduling concerns were likewise addressed in groups.
As follow-up to this effort, the project team should meet periodically to discuss constructability issues
in the weekly progress meetings, determine their impact on the construction of the project. Where
issues and concerns are identified, an assessment of cost, schedule, safety and/or quality factors should
be addressed, and whether any changes to standards or specifications are required. These issues may be
summarized and added into a logbook for periodic review and tracking.
It is useful to distribute constructability review logbook to all members of the project team for
individual review and familiarization prior to conducting periodic constructability status meetings.

SECTION 6: GENERAL CONSTRUCTABILITY CONCEPTS
The following general constructability concepts shall be followed as applicable for the project.
 Are areas available for lay down and fabrication yards, equipment parking, temporary field
offices, personnel parking, purchased material storage? If areas can be secured without
excessive cost during the planning stages, efficiency during construction will improve.
 Will double handling of materials can be avoided? Is there sufficient space on the project
for temporary stockpiling?
 Are work areas accessible for personnel, material delivery or equipment operation?
Difficult access for personnel can negatively impact productivity. In addition, difficult
access routes frequently present unsafe working conditions.
 Are designs configured to enable efficient construction? The desired result is to have an
exchange of ideas between constructions and design team members before the “pencil on
paper” design activities occur.
 Standardize design elements within the project. Both cost and schedule benefits can be
realized by standardization if the quantity is sizeable. Specific advantages include;
increased productivity from repetitive field operations, volume purchases discounts,
simplified material procurement, simplified materials management, and reduced design
time.
 Construction efficiency needs to be considered in specification development. Common

problem types associated with difficult to construct specifications include; gold-plated
designs or specs, unrealistic tolerances and/or requirements, and impractical methods of
measurement and payment.
 Constructability is enhanced by the following considerations. The standard specifications

offer clear-cut options (the less new spec writing required, the better and the probability of
error and construction rework is diminished). Clarity is sought as one of the prime
characteristics of a good specification. The cost saving potential of “or equal”
specifications is balanced against the risk involved. The specifications are up to date and
conform to latest industry work methods.

CONSTRUCTABILITY LOGBOOK
Closing
Cat Project Specific Issues Champ Accept Impact Stage Owner
S. No Date
# (Revise Content if needed) Name A,S,R H,M,L 3,4,5 Initial
Constructability team has assigned Eng. Pascal from DAR & mm/dd/yy
Eng. Latifa from DTVC to follow up on all the constructability
Constructability
1 issues and to conduct brainstorming meetings to come up with
Champion
resolution for each upcoming constructability issue and follow
up & act until closing of each item.
During construction, the main accessibility will be through the mm/dd/yy
2 lane road with a closed gate besides East Park that will lead
to Parcel 5 where all the temporary facilities are planned. The
road is partially asphalted and contractor to asphalt the access
road. The second entry is to Parcel 1 through the main roads.
Internal roads within the site running in the perimeter of the
parcels to be used for accessing the parcels.
Recommendation:
1. Contractor to consider one additional gate for accessing

equipment and workers.
2 Accessibility
2. Construction phase Vehicle Movement / Traffic Plan to
be charted and to consider having the Aramco Road 6 to
be free from construction traffic during the peak hours.
Contractor shall build concrete patch plant at parcel-5 to mm/dd/yy

minimize the impact on the traffic. However it is recommended
to have alternative supplier in case there is any failure in the
patch plant of the main supplier.
Contractor shall submit Traffic plans to PMT for review & mm/dd/yy
approval

Closing
S. No Date
Identify the items that require heavy haul and lifts, contactor mm/dd/yy
has to take crane mobilization into consideration for the lifting
and installation of pre cast panels.
During the windy season critical/ heavy lifting will be stopped,

if the wind speed exceeds 30 knots, however construction
contractor shall check with the crane manufacturer if their
equipment can be used if the wind speed above 30 knots.
Construction contractor shall submit heavy lift plans and

construction safety manual (CSM) to PMT for review &
approval.
It is envisaged to use both Mobile and Tower cranes during

3 Heavy Lifts construction. The weight of the trucks and cranes plying over
the tunnel and the slabs need to be considered according to the
loading plans.
It is recommended to clearly mark the load weight of the

podiums / slabs over which trucks and cranes move.
Construction methodology by contractor to clearly specify the

sequence of construction which should clarify minimum space
required for heavy lifts and truck movement around the
building structure. This has to be shared and approved by the
Project Management Team.
Recommendation:

Closing
S. No Date
If required, temporary support to be considered to support
cranes and heavy load trucks to go over podiums.
mm/dd/yy
Hydrotesting plans will be developed by the construction and
shall be approved by the PMT
Hydrotesting
4 Contractors shall be responsible to provide water for
plans
hydrotesting and it has to be mentioned in contractor’s scope of
work.
Existing pond can be used for dumping hydro testing water mm/dd/yy
Parcel 5 area has been demarcated for Temporary facilities. The mm/dd/yy
same can be accessed by the closed gate near East Park.
Contractors shall be responsible to provide generators for power
Temporary supply, portable water tanks for water supply and septic tanks
5
facilities for sewer system.
Suggestion: Contractor to have Parcel 5 area as a staging area
and have an external yard as the main temporary storage
facility.
Cranes, crane operators, welders, scaffolders shall be 3rd party mm/dd/yy
6 Certification
certified.
Steel bridges, elevators, exhaust fans and pumps to be mm/dd/yy
considered as long lead items. Elevators requires 12 months for
procurement, pumps & fans requires 06-12 months for
Long Lead
7 procurement; will have precedence in order and will be tracked
items
for timely delivery to ensure it does not affect the schedule of
the project. Procurement timing will be considered in the
project schedule and construction contractor will come up with
Closing
S. No Date
the contingency plan for the long lead items.
Locally mm/dd/yy
8 Procured All the materials will be locally procured except elevators
Material
Expansion joint mm/dd/yy
Connection and expansion joint between the steel bridge
between the
structure and the building concrete structure is not defined yet.
steel bridge
Coordination to be conducted in Design phase between SC &
9 structure and
SS engineers and prefabricated steel elements to be specified.
the building
concrete
Already considered in design.
structure
Precast, GRC or Siporex façade elements for free maintenance. mm/dd/yy
Recessed Panels are 4m wide and to avoid showing joints inside

the rooms, it requires heavy lift. Therefore, It is recommended
Precast to use a single skin panels for lighter weight and consider either
10 Concrete gypsum board or hollow blocks for second layer inside the
Panels building
Recessed panels on balconies are hard to install which requires

big tolerance. It is recommended to consider bigger allowance
on size of panels

Closing
S. No Date
Speeding the construction process. mm/dd/yy
Estimated
11 Construction 36-40 months are estimated for construction and hand over.
Duration Incase construction is expedited; It will have a direct impact on
cost. Bidding shall start at 90% DD
Safety during construction. mm/dd/yy
Contractors shall follow OSHA 18000 requirements

Safety during
construction Contractors shall follow civil defense requirements to provide
12
and QA/QC wet standby during construction
plan
Construction contractor shall submit their QA/QC plan to PMT
for review at least one month prior to the start of the
construction activities.
Closed storage should be used to store the sensitive equipment mm/dd/yy
with adequate security measure.
13 Storage Sensitive control equipment has to be stored in a controlled

environment due to their sensitivity to dust and moisture. If
equipment arrives earlier, then secondary storage facilities shall
be provided at the lay down area.
LSTK contracting strategy has been selected for this project and mm/dd/yy
LSTK is the most suitable type of contract for this project.
Contracting &
14 Subcontracting
Recommendation:
strategy
1. Contract can have the clause of Provisional sum if
Closing
S. No Date
common items like BMS, elevators, HVACs are to be
purchased by a combined tender under supervision, to
ensure efficiency in procurement, pricing advantage,
after sales service, maintainability.
2. To consider if piling can be done commonly by a single

approved contractor for all the packages in conjunction
with the LSTK package contractor.
1. Design contractor to ensure the design option to build mm/dd/yy
over the existing service tunnel is based on the integrity
of the tunnel validated through tests.
2. Independently, Construction contractor to test and

15 Service tunnel evaluate the quality of the existing tunnel through a
testing regime to ascertain the effect of vibration, load
bearing capacity etc. before finalizing on the
construction methodology to pile and construction near
the tunnels to ensure that the existing tunnels do not get
adversely effected.

SECTION 7: CONSTRUCTABILITY REVIEW CHECKLIST
Initial Review Action Sheet

Action
Item No. Category Item
By Accepted? Rejected? Assigned to: Due Date
SECTION 1 - GENERAL ENGINEERING
1-1 General Solicit construction input on engineering drawing
Enginr'ng content and presentation methods.
1-2 General Agreement with construction and engineering on the
Enginr'ng extent of detailing required by construction on
hangers and supports, small piping, heat tracing,
vents and drains, spool fabrication, isometrics,
fixtures, instrument assemblies, tubing, junction
boxes, etc
1-3 General See to it that construction communicates tolerances
Enginr'ng that can be maintained, and identify where are needs
for greater flexibility.
1-4 General Designers should minimize the use of terms field
Enginr'ng will verify and field routing.
1-5 General Coordinate tolerances between different elements
Enginr'ng that are not compatible, e.g., machine tolerances and
reinforced concrete tolerances. Where more
stringent tolerances are required for a particular
installation, make a note of these tolerances on the
applicable design drawings.


Action
1-6 General Complete as soon as possible the design and layout
Enginr'ng of installations that become difficult to a
Construction Contractors because of the installation
of following equipment, piping, conduit, etc.
Consider the location of designed installations and
the level of a Construction Contractors difficulty for
welding tools and other required erection equipment
activities.
1-7 General Arrange permanent plant facilities so that a
Enginr'ng Construction Contractors required for construction
will not be blocked or restricted.
1-8 General When designing overhead lifting devices provided

Enginr'ng for specific plant equipment, consider the lifting
capacity and headroom required for construction
loads and rigging equipment as well as the lifting
capacity for normal maintenance loads.
1-9 General During design, emphasize and coordinate the
Enginr'ng practical constructability aspects of installation,
repair and retrofit as well as for
operations/maintenance. Consulting with the field
and/or construction can often result in considerable
savings in the field.
1-10 General Provide structural steel requirements early in the
Enginr'ng construction phase of the project. This will give the
field the flexibility of applying the fireproofing early
in areas of greater equipment concentration or
deferring application where there are to be a larger
number of attachments to the steel.


Action
1-11 General Establish comprehensive division of responsibility
Enginr'ng between engineering, procurement, contractors,
subcontractors and Owner in regard to taking off,
requisitioning, purchasing, inspecting, expediting,
receiving and storing of all types of materials.
1-12 General Check for proper equipment location to minimize

Enginr'ng later revisions during design. Incorporate an
appropriate level of pre-assembly and include work
areas for the pre-assembly activities in the site
layout.
1-13 General Often times, a sizable amount of engineering

Enginr'ng information which has been "approved for
construction" is put on "hold" due to pending change
which may affect only a portion of the "on hold"
information. An improved system is necessary for
communicating "on hold" information. A short
description on the appropriate drawing describing
the cause of delay would allow portions of
productive work to proceed.
1-14 General Rationalize standard specifications and material
Enginr'ng requirements to meet local codes, practices and
available materials.
1-15 General Visit to the site to identify all special site conditions
Enginr'ng


Action
1-16 General Keep construction access in mind when planning
Enginr'ng layout for major equipment. Good a Construction
Contractors lowers rigging costs and provides future
maintenance a Construction Contractors. An open
construction layout leaves work areas for future
turnarounds/maintenance.
1-17 General Do not place pumps or other equipment under pipe-
Enginr'ng ways. This will allow the use of rolling scaffolding
and a Construction Contractors for construction
equipment.
1-18 General Maximize ground level construction by various
Enginr'ng means, including pre-assembly. This typically
increases productivity and enhances safety.
1-19 General Size the width of roads and gates to a accommodate
Enginr'ng the largest cranes and pieces of equipment that will
be used or placed on the project.
1-20 General Plan a Construction Contractors ways for cranes to

Enginr'ng be used in both construction and maintenance.
Provide convenient crane a Construction Contractors
to heavy equipment.
1-21 General Make sure that the plot plan provides for temporary
Enginr'ng facilities and easy access to lay-down areas.
1-22 General Plan roadways and traffic patterns to facilitate safe

Enginr'ng fast handling and to avoid having traffic interfering
with earthwork activities.


Action
1-23 General Review plant layouts in relation to the construction
Enginr'ng schedule with the goal of eliminating or minimizing
access restrictions resulting from open ditches for
sewers, underground pressure lines, underground
cables, etc.
1-24 General Review possibilities of having all underground work
Enginr'ng packaged for release in designated corridors or by
areas so that closely related drain lines, pressure
pipes, electrical trenches, grounding grids,
foundations, manholes, catch basis, curbs, etc. can
be done concurrently to avoid re-excavating,
extended disruptions, and other actions which delay
progress.
1-25 General Permanent road bases can be used as construction
Enginr'ng roads with topping added near the end of job
completion. Designer should provide specifications
and routing as soon as practical.
1-26 General Review applicability of laser beam projecting
Enginr'ng surveying instruments rather than line and grade
stakes on underground drain lines and other long
straight runs in congested working areas.
1-27 General Thoroughly review the soil study at the jobsite to
Enginr'ng establish the optimum design/construct methods.
1-28 General Develop a "slurry" mix of sand and cement to

Enginr'ng facilitate backfill around congested areas.


Action
1-29 General When working in or adjacent to operating facilities,
Enginr'ng review access ways to and from installation areas,
prefabrication shops, storage areas and parking areas
with plant operation people so that traffic patterns
that minimize interferences and facilitate
construction can be established.
1-30 General Plan locations of temporary barricades, fences and
Enginr'ng gates to ensure the protection and security of the
existing plant and of the construction site.
1-31 General Locate fabrication shops adjacent to storage area.
Enginr'ng
1-32 General Establish isolated storage locations for highly
Enginr'ng combustible items as cad-weld materials, painting,
cleaning fluids, etc.
1-33 General Consider the need for emergency access and
Enginr'ng evacuation in the planning process.
1-34 General Layout roads, access ways, fabrication shops and
Enginr'ng storage areas in accordance with centers of gravity
of different types of work to avoid cross flow of
materials and to minimize interference of traffic.
Locate the main gates as close as possible to the
center of gravity of work to minimize walking on
company time.
1-35 General Get as much early permanent lighting completed as
Enginr'ng possible, so that it can be used for night work, shift
work, etc.


Action
1-36 General Determine whether any of the permanent plant
Enginr'ng utilities can be made available for use during
construction. If they can, and if a new facility is
being constructed, provide for early design.
1-37 General Preplan lay-down areas such that stored items are
Enginr'ng easy to find, maintain (if required) and remove.
Provide suitable working surface (such as gravel)
and adequate drainage.
1-38 General Develop a temporary power one-line diagram
Enginr'ng showing source, requirements and points of service;
show routing on the plot plan with installation
details and point of service; and determine the above
ground distributions system requirements.
1-39 General Ensure that there is enough temporary power at the

Enginr'ng start of construction for peak construction needs.
Ensure that there is enough temporary power
available for checkout and startup or that permanent
power will be available when primary stages of
startup begin.
1-40 General Dike wall containment change capacity for new
Enginr'ng ramps
1-41 General Look at loading G-357 from west parking lot.
Enginr'ng
1-42 General Provide temp facilities for LSPB contractor.
Enginr'ng Drawings to show locations.
1-43 General Fire watch to be construction personnel.
Enginr'ng


Action
1-44 General Water management for hydrotesting.
Enginr'ng
SECTION 2 - SAFETY AND SECURITY
2-1 Safety Provide clear, direct access ways and aisles to
Security prevent tripping and congestion hazards
2-2 Safety Provide for good escape routes in case of fire or
Security other emergencies on site.
2-3 Safety When developing the plot plan, group equipment
Security foundations in a way that permits the proper
drainage of mass excavations.
2-4 Safety Consider area drainage during construction when
Security developing the plot plan. Temporary ditching may
be appropriate.
2-5 Safety Consider using a single, separate contractor to
Security provide the security services for the entire project at
construction gates, on in-plant roads, at offsite lay-
down, storage and parking areas and for onsite
facilities.
2-6 Safety If possible, erect permanent fencing for job site
Security and/or lay-down area security during construction.
2-7 Safety Use bar-coded swipe cards or a similar electronic
Security timekeeping system.
2-8 Safety Look into the use of electronic security systems.
Security
SECTION 3 - MATERIALS MANAGEMENT
3-1 Mat'ls Minimize the number of materials used on the
project.

Action
3-2 Mat'ls Identify the computer systems required to manage
the materials and documentation, and ensure that
they are adequate and compatible.
3-3 Mat'ls Make sure that responsibilities for the supply of
subcontractor materials are clearly understood and
identified in the contract documents. Keep in mind
that materials supply can have a substantial impact
on contractor performance. The price of materials
may be small compared to the cost of delays and
other impacts.
3-4 Mat'ls Establish a comprehensive materials management
process with which all parties associated with the
project agree. Ensure that all computer tracking
systems are compatible. Keep in mind that the
objective is to get the right material item to the field
at the right time.
3-5 Mat'ls Have construction, in conjunction with engineering
and procurement; develop a well-defined field
schedule for all materials and equipment. This
schedule should be developed early in the project, so
that the design effort can be programmed to meet
construction needs.
3-6 Mat'ls Develop materials specifications in conjunction with
vendors as early as possible. These specifications
must take into consideration the true availability of
materials in the market place.
3-7 Mat'ls Use additional engineering manpower or overtime to
keep the procurement process on track. Consider the
total impact on the project.


Action
3-8 Mat'ls When delays occur, work with the vendor/supplier
to develop a plan of action to get back on track
before the next milestones. Do not limit corrective
action to getting on track by the end date.
3-9 Mat'ls Develop a plan, a tracking program and procedures
for material and equipment maintenance during
storage and installation prior to startup. There can be
considerable cost involved in this activity.
3-10 Mat'ls Select the suppliers for bulk materials as early as
possible and obtain commitments for delivery of
long lead items. Use the suppliers to assist in timing
of purchase, particularly valves.
3-11 Mat'ls See to it that test and temporary bulk materials,
particularly erection materials are not overlooked.
3-12 Mat'ls Establish a well-defined computer tracking system
for field control of bulk materials.
SECTION 4 - SCHEDULING
4-1 Schedule Develop an optimum construction sequence
schedule, one that is based on engineering or
procurement constraints; then; schedule the
engineering and procurement activities to support
this best case schedule, modifying as necessary. The
project schedule should be construction driven.
4-2 Schedule See to it that the project schedule incorporates all the
pre-assembly and modularization plans for the
project.


Action
4-3 Schedule Identify repetitive work and use the same crew to
perform this work.
4-4 Schedule On portions of the job where engineering and

procurement lead-time restrictions are at a
minimum, push construction operations ahead
quickly.
4-5 Schedule Plan equipment and material deliveries to avoid

double handling by setting the items directly in
position when received and incorporating the
principle of just-on-time delivery to the maximum
extent feasible.
4-6 Schedule Study field manpower requirements in relation to
this schedule, and work with engineering to modify
the sequences of design release in ways to achieve
leveling of critical labor peaks.
4-7 Schedule Study the effect of crane and other equipment
movements on the permissible density of workers in
congested areas, and plan shift-work or other
programs to relieve overload problems with either
equipment of people.
4-8 Schedule Time heavy lifts to optimize crane usage.


Action
4-9 Schedule Arrange equipment to facilitate construction
sequencing. Develop a specific sub-schedule to
ensure that the plot plan arrangement will allow
equipment setting.
4-10 Schedule Develop a plot plan to support the delivery of all
pre-assemblies, skids and modules. Consider
locating underground facilities on aboveground
equipment. Also consider the impact of these
facilities on the movement and location of
construction equipment.
4-11 Schedule Locate underground utility corridors so that
underground work does not affect the construction
of deep foundations.
SECTION 5 - CIVIL WORKS
5-1 Civil On concrete, plumbing and architectural drawings,
Works the invert elevation for floor drains and clean-outs
should be indicated along with the thickness of floor
tiles or ceramic tile.
5-2 Civil Identify long lead items and order early computer
Works floors, blast door, drop ceiling, etc.
5-3 Civil Try to use packaged HVAC system to save design

Works and installation cost over installing custom systems.


Action
5-4 Civil Reduce HVAC requirement in areas where the
Works surrounding temperature is not critical to the process
and in non-production areas (storage, shops, etc.).
5-5 Civil Design foundations to avoid excessive use of sheet

Works piling (shoring) to prevent the undermining of
adjacent (in- place) foundations, manholes, sumps,
etc.
5-6 Civil Design foundations in 2" or 4" increments so field
Works has flexibility in the type of forms to use; for
example, patent forming systems (rental) can be a
cost savings on some jobs. Patent forming systems
are most economical when dimensions are in 2" or
4" increments.
5-7 Civil Standardize foundation sizes for pipe racks,
Works structures, and miscellaneous support foundations.
5-8 Civil Larger diameter foundations should be octagonal or

Works some other easily constructed shape.
5-9 Civil Strive for early road crossing structures for U.G.
Works utilities.


Action
5-10 Civil Early and preliminary issue of all deep foundations,
Works manholes, pumps, underground piping, and site
improvement plans including rough
grading/drainage/road base is essential. Preliminary
issue should be revised if significant changes occur.
5-11 Civil Where possible, drill and epoxy small foundations

Works (pumps, supports, etc) into the top of area paving.
5-12 Civil Slope area paving minimum 1/8" maximum ¼"

Works per1'-0" to prevent ponding.
5-13 Civil Provide area paving drawings that locate control

Works and/or expansion joints. Expansion joints should
have keyway or smooth dowels to prevent
differential settlement in slabs.
5-14 Civil Design elevated slabs for utilization of "Q-Decking"
Works in lieu of forming and shoring. Elevated slab
drawings should show all block-out requirements.
5-15 Civil Issue standard reinforcing details (cut-sheets) early
Works so fabrication can start prior to actual installation of
foundation. In the case of offsite fabrication, issue
drawing early to fabricator. "CUT SHEETS WILL
BE BY FABRICATOR OR CIVIL
SUBCONTRACTOR."


Action
5-16 Civil Utilize wire mesh in sheets for reinforcing in slabs
Works instead of rebar where design requirements allow it.
5-17 Civil Use reinforcing or smooth bars for anchors (welded)
Works instead of "Nelson Studs" for anchoring embedded
items.
5-18 Civil Use embedded (weld) plates OR THREADED
Works INSERT for horizontal anchor bolts, where
practical, to avoid bolts sticking through forms,
especially on patent form systems.
5-19 Civil Standardize anchor bolts where practical, i.e., keep
Works "type," thread type, and length of bolts consistent.
When possible, keep anchor bolt sizes to ¼"
increments. Try to avoid as many 5/8", 7/8" and 1-
1/8" bolts as possible.
5-20 Civil Issue anchor bolt list (quantity, size, etc.) early,
Works especially if there are requirements for special alloy
steel or hot dip galvanizing.
5-21 Civil Consider field fabrication of 1" and smaller carbon

Works steel anchor bolts.


Action
5-22 Civil Whenever possible, especially on major tower, tank,
Works and process structures with numerous foundation
anchor bolts, utilize "sleeved" anchor bolts on 1"
and larger to allow for a margin of error in bolt
layout or vessel/skirt fabrication error.
5-23 Civil Issue foundation drawings without anchor bolt

Works details when equipment is such that anchors may be
drilled in after the equipment is received.
5-24 Civil When designing underground systems, specify pre-
Works cast manholes, sumps, and electric pull boxes as
often as possible. Use reinforced concrete pipe for
design of valve boxes, small sumps, and manholes
where possible.
5-25 Civil Specify bell and spigot reinforced concrete pipe
Works instead of tongue and groove which sometimes
requires poured collars for leak proofing.
5-26 Civil Manholes, sumps, and any type of wall that has a
Works deep excavation, should have the bottom slab
extending to the outside of wall 3-1/2" or more in
order to have room for setting the outside forms.
5-27 Civil Sumps or manholes requiring lining should be

Works specified for coating on the exterior walls with
bitumastic or equal, to prevent repair of seepage
through hairline cracks caused by concrete shrinkage
and the subsequent repair problems.


Action
5-28 Civil Issue of "Neenah" or equal manhole covers early
Works due to long delivery.
5-29 Civil All pre-cast concrete should be reviewed by rigging

Works specialist and building superintendent before pre-
casting begins.
5-30 Civil If structural steel requires fireproofing on racks,

Works extend foundation pier to just below first load beam
to eliminate the requirement of fireproofing the
lower vertical column.
5-31 Civil Develop a "slurry" mix of sand and cement and/or

Works fly ash to facilitate backfill and develop seal side
concrete mix.
5-32 Civil Consider use of sono-tube forms for small diameter

Works (30" or less) foundations such as pipe-racks and
vessel support piers. Standardize sono-tube size as
much as possible.
5-33 Civil Request change of concrete form removal time from
Works days to 1 day (24 hours) except for elevated slabs.


Action
5-34 Civil Use non-explosive products for demolition jobs
Works when possible.
5-35 Civil Use metal screed key with removable plastic strips
Works for construction joints for pouring large area floor
slabs or paving whenever possible.
5-36 Civil Add special concrete testing requirements to

Works drawing vs. specification interpretation.
5-37 Civil Avoid unnecessary varying thickness within a given

Works floor slab. The material savings are insignificant
compared to field labor costs.
5-38 Civil Coordinate with other disciplines to require vendors

Works to provide anchor bolt size, projection, and location
early.
5-39 Civil Maximize use of site materials for backfill instead of
Works imported select materials wherever possible.
5-40 Civil Provide mild steel lifting lugs on pre-cast manholes.

Works


Action
5-41 Civil Where feasible, provide a bent plate that serves as a
Works left in place form at the perimeter or openings of
cellular sheet steel/concrete floors. This eliminates
the need of a wood form that is difficult to hold and
permits siding or walls to be installed before pouring
the floor. This applies to penetrations as well.
Standard channels or other sections may be used as
desired depending on dimensions and circumstances.
5-42 Civil Many times a footing is designed with a haunch to
Works reduce the size of the beam. However, the cost of
surveying, excavating, placing forms and rebar far
exceeds the amount of extra concrete required to
maintain a constant depth beam for the entire
footing. For the same reason, irregular plan shapes
should be avoided.
5-43 Civil Tie-rods instead of thrust blocks should be used on
Works cast iron fire mains where soils conditions do not
provide adequate bearing capacity for thrust blocks.
5-44 Civil The standard civil railroad specification and road

Works specification should contain a reference to the
appropriate electrical specification and drawings for
track grounding requirements. This will alert field
to electrical work required prior to grouting the rails
into floors and slabs.
5-45 Civil When referring to a code, be specific, reference
Works code, page, paragraph, section, etc.


Action
5-46 Civil For catch basins and manholes using R.C.P., make
Works sure elevations match standard lengths of pipe that
can be ordered from vendor. Cutting of R.C.P. is not
required when elevations are planned correctly.
5-47 Civil Area paving drawings should be marked showing

Works electrical stud-ups for grounding. Note on drawing,
showing what marks mean.
5-48 Civil When elevated concrete floors are required, consider

Works using V-Rib/Epicure metal decking and fastening
system. This allows easy installation of floor,
electrical, pipe, instrument (conduit tubing, pipe,
etc.) and lights.
5-49 Civil To help minimize rubbing concrete surfaces,
Works consider using a fiberglass form tie system (Supertie
by RJD Industries or equal) to secure concrete
forms.
5-50 Civil Construction and Engineering must thoroughly
Works review the soil study at the proposed jobsite to
establish the optimum Design/Construct method
given alternatives.
5-51 Civil Storm drainage systems should be developed as
Works early as possible in order to facilitate usage during
construction.


Action
5-52 Civil Roads should be designed early so that road bases
Works can be installed and utilized during the construction
phase.
5-53 Civil Fence plans and details should be developed early to

Works aid with security measures.
5-54 Civil Access roads should be designed to facilitate the

Works movement of major equipment during and after
construction. This should be incorporated into
permanent road design when possible.
5-55 Civil Avoid construction below water table whenever

Works possible.
5-56 Civil Underground drawings must show existing utilities.

Works


Action
5-57 Civil Prior to the start of the project, select and test
Works various sources of backfill material. The initial soils
investigation should cover pits in the area of the
jobsite. Include quantity survey as part of the
investigation.
5-58 Civil Specify mill test certificate requirements from
Works vendors for rebar, anchor bolts and embeds.
5-59 Civil Establish excavation philosophy, i.e., individual

Works footing excavation vs. major excavations, sheet
piling requirements, etc., as part of the Construction
plan.
5-60 Civil Field fabrication of rebar & embeds.
Works
5-61 Civil Concrete - Engineering/Construction to specify
Works required additives and curing compounds. Confirm
compliance with specification and location what is
available?. Concrete - Specify aggregates and
cement that are locally available.
5-62 Civil Concrete - If more than one cement type is required,
Works develop action plan to prevent inefficiencies, QC
problems, scheduling difficulties, etc. Evaluate cost
to go to one type of cement. LOOK @ TYPE 2.


Action
5-63 Civil Develop concrete placing programs and rates to
Works minimize construction joint and maximize re-use of
forms while staying within the mixing and placing
capacity of equipment. Review the use of concrete
conveyors, pumps and cranes with Engineering.
5-64 Civil Obtain catalogs from Pre-cast vendors for use in

Works engineering of manholes/catch basin.
5-65 Civil Utilize trunnion support for small inline vertical

Works pumps.
5-66 Civil Eliminate piers at ladder landings, control station,

Works junction boxes, etc. Reduce the use of piers.
Consider thickened slab in lieu.
5-67 Civil Where area containment is required, consider the use
Works of a "total slab" concept outside substations for
transformers/ equipment instead of individual block
foundations.
5-68 Civil Early paving will facilitate efficient construction,
Works drainage, and effective housekeeping.


Action
5-69 Civil Review clearances between forms, anchor bolts,
Works sleeves, rebar embedded items, and congested
connections to assure that there is sufficient room to
place bolts and rebar.
5-70 Civil Clearly specify the type and extent of grouting
Works requirements for vent holes, surface preparation,
cavity and foundation considerations, coordination
with machinery requisitioning engineer.
5-71 Civil Purchase bulk rebar in 60' lengths if possible.

Works
5-72 Civil Consider specifying mechanical anchor bolts where
Works practical instead of cast-in-place anchor bolts or
chemical anchors. Use for 1" and smaller
applications for pumps, pipe trunnions, etc.
5-73 Civil Consider prefabricated concrete with as repetitive a

Works design as possible.
5-74 Civil Investigate the economics of pre-cast concrete for

Works pipe way bents or other particular applications.


Action
5-75 Civil Identify which foundations will be pumped and
Works agree on the minimum rebar spacing which allows
for easy passage of the concrete, (i.e., bar spacing in
mats, walls, etc.) Increase bar size for greater
spacing.
5-76 Civil Electrical Design should consider using a grounding
Works buss installed in ECR walls for grounding
equipment cabinets and transformers.
5-77 Civil A&C design should provide framed openings for

Works cable tray and buss duct entry (plus specify method
for sealing) on the A&C drawings.
5-78 Civil ECR's should be sized based upon standard cable

Works tray tees, elbows and offsets when arranging the
electrical equipment.
5-79 Civil Are doors designed for the largest equipment to be

Works moved into or out of the buildings?
5-80 Civil Due to the importance of floor channels being level

Works and flush with the finished floor, it is recommended
that block-outs be utilized when pouring floor slab.
Then adjustable rails can be grouted after the
switchgear is set.


Action
5-81 Civil Review for early release deep foundations.
Works
5-82 Civil If block-outs are impractical for switchgear rails,

Works then consider flat plate so that more clearance over
the rebar is maintained.
5-83 Civil Consider composite steel and concrete structural
Works framework with formed-in-place concrete, as
fireproofing. This will allow lighter steel members
to be used.
5-84 Civil Elevated slabs should show all penetration locations

Works and size for installation with slab. (Core drilling
after the slab is poured should be viewed as last
resort only.)
5-85 Civil For conduit stub-outs from building, show routing
Works on building conduit and foundation drawings for at
least 15' beyond the perimeter of the building.
Minimize depth of conduit penetrations in grounding
foundations.
5-86 Civil Include drainage in footing design.
Works


Action
5-87 Civil Consider heavy wall polyethylene piping for
Works firewater and other similar services. Eliminates sand
bedding and most kickers.
5-88 Civil Underground pipe and electrical conduit should be

Works run at consistent elevations.
5-89 Civil Where feasible, underground piping should be

Works located so that multiple installations can be achieved
with a single excavation, particularly at road
crossings.
5-90 Civil Provide culvert schedule. Consider galvanized

Works corrugated or bitumastic coated pipe.
5-91 Civil Underground electrical plan drawings should show

Works the location and elevations of all conduits, cables,
ducts, etc., and also any underground piping which
cross these underground ducts. (Profile views
should be provided whenever runs change direction
or cross.)


Action
5-92 Civil Review duct bank and manhole layouts to keep
Works sharp bends to a minimum.
5-93 Civil All underground piping, including insulated lines,

Works should reference civil drawings and should be
shown on civil drawings.
5-94 Civil Standardize footing thicknesses and columns sizes

Works of pipe-racks, structures and miscellaneous supports.
Base the sizes of equipment foundations on the
respective equipment base plate sizes and anchor
bolt patterns, which can be standardized.
5-95 Civil Include jobsite coordinates in foundation drawings.
Works Consider providing more information in order to
reduce the number of reference drawings.
5-96 Civil Design foundations in congested areas with the

Works bottom of the concrete at the same elevation
throughout, if possible. This allows for common
work slabs in mass excavations.


Action
5-97 Civil Investigate elevating the top of foundations to grade
Works to eliminate the need for area paving.
5-98 Civil To give construction some flexibility, consider

Works allowing the field to install, without providing
documentation, larger rebar than that specified in the
documentation, and to substitute two rebar's for one.
These procedures allow work to continue even if a
certain size of rebar becomes unavailable and permit
construction in tight areas without an undue amount
of documentation.
5-99 Civil Use welded wire mesh in lieu of rods where possible
Works to minimize the number of pieces handled and to
eliminate tied joints. Maintain strict control over
mesh location in the concrete.
5-100 Civil Minimize vertical rebar splices by extending column
Works and wall rods to full height instead of using dowels.
5-101 Civil Design rebar with the expectation that some will be
Works cut at a later date. Part of the core drilling program
must include an allowance for cut bar in the original
design of reinforcing steel. This reduces costly
rework.

Action
5-102 Civil Have structural designers review their reinforced
Works concrete design from the standpoint of the difficulty
in placing rebar, placing and vibrating concrete and
concrete formwork. For instance, consideration must
be given to the available opening between vertical
and horizontal rebar for the placement of stirrups or
when hooked steel must be threaded through
openings and hooked around horizontals and
verticals. In either case, it may be more practical
from construction standpoint to detail the item in
two pieces, even though the splice will require
additional material. In some instances, increasing the
bar size and spacing will provide the necessary
clearance.
5-103 Civil Ensure that concrete specifications are practical and
Works economical with respect to curing, weather
protection, tolerances, etc.
5-104 Civil To avoid possible delays on foundation construction
Works caused by missing dimensions and details,
investigate the possibility of mounting equipment on
skids, which can be easily anchored to more simple
foundations using drilled anchor bolts.
5-105 Civil Use concrete of a single strength as much as
Works possible.


Action
5-106 Civil Consider using an automated concrete quality
Works monitor (CQM) to assess the quality of fresh
concrete while it is being placed. This device was
developed by the U.S. Army Corps of Engineers and
will predict the 28-day compressive strength of
concrete, based on the water and cement contents of
the fresh concrete. The device is easy to operate and
readily available in the marketplace. It costs under
U$10,000 and can perform a test in just 15 minutes.
5-107 Civil A28-day criterion for concrete strengths may be
Works overly conservative in most cases; consider a 90-day
strength criterion instead.
5-108 Civil Consider specifying a pre-approved repair procedure

Works for concrete with voids or rock pockets, allowing
immediate repair without documentation. This
should result in better quality repairs and reduced
documentation. Most concrete repairs are standard
and should be performed while the concrete is still
green.
SECTION 6 - STRUCTURAL
6-1 Structural Construction should participate in the conceptual
planning of all structures, pipe-racks, and bridges to
provide input into the practicality of pre assembly
and erection techniques.


Action
6-2 Structural Priorities on sequence of delivery of structural steel
from vendor to the field must follow erection
sequence and the Engineer should concentrate
efforts toward design and release of drawings in
accordance with established priorities. Shop orders
will parallel priorities.
6-3 Structural For safety purposes during steel erection, the Design
Engineer should specify that seat angles be
fabricated on all column webs having through
connections.
6-4 Structural All approved for construction design drawings
transmitted to the field should be full size (24" x
36") sepias. The title block on these drawings should
be explicit and the drawing numbers legible, and
identifying name and number for each structure or
pipe-rack. In addition, each revision to these
drawings should be subsequently issued to the field
at the time of transmittal to the fabricator.
6-5 Structural Use standard A 325 bolts.
6-6 Structural Use dipped Galvanized load indicating washers.


Action
6-7 Structural Erection drawings should resemble the engineering
design drawings except for the following
modifications:
The engineer's name should be completely
eradicated and replaced with the fabricator's
standard log. Modify the original drawing number or
title by adding "E".
The fabricator must add to each erection drawing the
specific shop order involved and erection drawing
number. The erection drawing number should be
boldly displayed as "E-1 of E-6 through E-6 of 6:,
just as an example.
On the body of the drawing, the fabricator must

boldly tag each member and "highlight", as
necessary, these erection numbers so that all items
are easy to identify.
6-8 Structural Each shop detail drawing from the steel fabricator
should have a listing of the piece marks and
structural weights. Shop detail drawings must be
transmitted to the field with the erection drawings.


Action
6-9 Structural Structural steel drawings issued to the field that
require field fabrication must be complete with all
necessary shop details, bolt placement list, bolting
schedules, and bills of material Notes should be
clear on which items are to be field fabricated. Shop
details will be made by Engineering.
6-10 Structural The engineer should not issue the erection drawings
to the field. It should be the responsibility of each
fabricator to supply the field with the necessary
(engineering approved) erection drawings. This
should be done in the form of three blue lines and
one sepia of all erection drawings. These drawings,
along with a like number of shop detail blue line
prints and sepias, should be issued to the field prior
to the first shipment of any shop order of fabricated
steel.
6-11 Structural Tagging procedures:
Put two (2) piece-marks on all fabricated steel.
Stencil each column 300mm from bottom end,
beams 300mm from east or south end, stair stringer
and special item, place it best available;
Stamped metal tags.


Action
Both will be used to show the piece-mark number,
the shop order number, and the project number (or
area number on multiple unit projects). This tagging
method should be used on all fabricated steel items,
including ladders and platforms. Tagging procedures
will be issued with the inquiry document.
6-12 Structural The delivery of fabricated steel to the galvanizer
after fabrication and to the construction site after
galvanizing should be the responsibility of the
fabricator.
6-13 Structural Where possible standardize columns and load beams
to eliminate detail piece marking.
6-14 Structural All required fasteners for a shop order should be

delivered prior to or with the first delivery of that
shop order, and should be accompanied with a
packing list giving a description, size, quantity, and
proper identification as to where they are to be used.
No bolts will be received in cardboard boxes..
6-15 Structural Vessel fabricator can be responsible for ladders and
platforms for the Vessel he fabricates if time
permits. Field fit up problems can then be back-
charged to the Vessel fabricator. Delivery of Vessel
ladders and platforms should precede vessel
delivery. Fast track projects may want others to
fabricate ladders and platforms.
6-16 Structural Design pipe-rack bridges spanning roadways to
allow for clearances for crane/rig access.

Action
6-17 Structural Rework and back-charge procedures should be
established prior to issuance of a purchase order for
steel fabrication.
6-18 Structural Handrails on elevated floors should be off set to

provide sufficient clearance for forming curbs or
should be mounted on top of curbs must follow
specs.
6-19 Structural Stair stringers, treads, grating clips, and handrails
should be shipped with the related structural tiers to
provide sequential access to elevated tiers.
6-20 Structural Minimize all boxed in connections.

6-21 Structural Engineering should permit the use of cut pipe as an
acceptable alternate to banding for grating
penetrations
6-22 Structural Use self fasteners to tie down grating rather that 1/4"
bolts with nuts.
6-23 Structural When shims are required for splices between
columns, the Engineer should designate on the
drawings. These are to be provided by the shop
fabricator.
6-24 Structural Tack welding of checkered plate used for decking in
buildings, structures or for platforms is preferable to
bolting.


Action
6-25 Structural Field structural shop fabrication, if time and labor
force permits. All imbedded items. Selective
engineering revisions (Discuss with construction)
Selective T supports and simple bents (ditto above)
all electrical and instrument supports, all shoes
(other than those installed by pipe fabricator) not a
catalogue item..
6-26 Structural Design structural connections on fireproofed
structures to allow the bolt up requirement to be
outside of the fireproofed area. Diagonal bracing
could be changed from back to back angles to WT
shapes/tie in iron by use of wing. plates with
stiffener supports for intermediate beams instead of
conventional clip angles
6-27 Structural Use prefabricated L shaped steel plates installed
with the structural steel to eliminate field forming
for exposed perimeter edges of elevated floor slabs
6-28 Structural Specify "north, south, west or east" end of beams for
piece mark locations; this helps in orientation during
erection.
6-29 Structural Avoid unnecessary use of unique connections in the
design of structural steel in an attempt to save a
slight amount of structural steel. Place 5/8" hole at
1/3 points in pipe.
6-30 Structural Design factory pre-punched 5/8" holes in structural
steel columns and pipe racks, 42" and 21" above
floor levels so that safety cabling can be run easily
on structural steel without welding nuts or washers
onto the columns.


Action
6-31 Structural Incorporate bonus/penalties for maintaining
schedule and priorities into purchase order for shop
fabricated structural steel during bid negotiations.
6-32 Structural The floor framing system and metal decking for
concrete floors must be strong enough to carry not
only normal dead loads and fluid concrete, but
additional dynamic loads, including those imposed
by concrete crews, equipment and impact of
dropping concrete. Depending on the placement size
and method of placing, etc., these loads will vary
from approximately 50 psf to 75 psf. Consideration
should be given to heavier decking or additional
beams rather than providing shoring. Additionally,
the shoring is a hindrance to other crafts working
below. Structural steel beams should be designed to
carry these loads without shoring.
6-33 Structural Machined parts of interfacing components with
tolerances in mils (thousandths of an inch) that are
bolted to structural steel should be designed to allow
for tolerances on the structural steel which are larger
than that allowed on machined surfaces.
6-34 Structural Cross bracing should be bolted rather than field
welded.
6-35 Structural When beams and girders are partially embedded in
concrete floors, allow enough clearance for
embedded conduits and drains to pass over top of
flange. Running pipes or conduits through holes in
webs of beams results in shorter spools, more
fittings and field welds..


Action
6-36 Structural When designing connections of structural steel and
positioning framing, check for interference from
stiffeners, other members, etc. at that location. A
minor change or repositioning can prevent costly
and annoying problems in the field
6-37 Structural Design and layout rigging beams with trolleys for
early fabrication and erection, preferably included in
structural steel package.
6-38 Structural Define fireproofing requirements early so this can be
accomplished before equipment or material
installation
6-39 Structural Coordinate architectural requirements with vendor

where the whole building skin is furnished by one
party. This includes such items as frames for
louvers, vents, clips for siding grits and sag rods,
etc., that should be installed by the steel fabricator
and be available at the site during erection.
Additionally, coordinate architectural requirements
of openings in concrete or masonry structures that
may require bucks or frames that should be included
in the miscellaneous metal package.
6-40 Structural Use paint from only one manufacturer for structural
steel, to avoid problems of matching colors and
assure compatibility of materials.
6-41 Structural Lifting safety for checker plate procure checker
plate with a 3/8" hole on one side. This is used as a
lifting point for loading, unloading and erection.


Action
6-42 Structural Establish backup fabricator if primary fabricator has
problems.
6-43 Structural Inspect holes in steel after galvanizing to insure
reaming will not be required at job site. Check also
for build up of galvanizing at splices and matching
faces.
6-44 Structural Set up shop visit to fabricator before steel is shipped
to discuss loading unloading of steel to insure steel
will not be damaged during shipment and can be
safely unloaded.
6-45 Structural Reduce operations and maintenance platforms, use
portable scaffold, jib lifts or ladder in areas where it
can be done safely.
6-46 Structural Delete monorails and hoists over equipment with
low prediction of use, when small crane can
accomplish same task.
6-47 Structural Specify hole at top of all columns for the installation
of lifting pin or shackle use ¼" dia hole, 2" from top
of steel.
6-48 Structural Use steel stair treads for all stairs.
6-49 Structural Who buys tie-down (fraction bolts) for erecting

equipment in steel? Civil/Mechanical/Field
6-50 Structural Erection drawings must be forwarded to the


Action
construction site prior to receipt of first steel
shipment.
6-51 Structural Shipping Papers: Fabricated steel, including
shipments from the galvanizer, must be
accompanied by a shipping list identifying each
piece by piece-mark number/ship order number (or
area number on multiple unit projects) along with
the weight of each piece.
6-52 Structural Shipping Papers: Fabricated steel from more that
one shop order should not be shipped together
without prior approval from the jobsite "color code"
all steel.
6-53 Structural Segmental Structural assembly of structural steel
minimizes exposure to falls. Saves fall protection
$$$ and "on foundation" erection time is shorter.
6-54 Structural Utilize "Quarter Point" design when laying out
stand-along bays with vessels supported by
structural steel. This makes heavy members very
short and cantilevers the surrounding platforms with
lightweight members.
6-55 Structural When it is necessary to "beef up" existing horizontal
steel for heavier loading, steer away from adding wt
shapes to bottom flange as most conduit is attached
in this location. Cost to move conduit can far
exceed cost of steel installation. An alternative is to
utilize plate that would take up less space and could
be slide between the existing steel and
conduits/piping.


Action
6-56 Structural Design spacing of pipe bridge bends for the larger
pipelines in the bridge, then support the smaller lines
off of the larger lines.
6-57 Structural When a large line (such as a Flare Header) along
with numerous smaller lines or conduit is run
through a new pipe-bridge, use maximum spacing
for large line with smaller lines supported from
larger line and use single pole tee supports.
6-58 Structural When the design info is available, consider showing
perimeter lighting standard clips on structural steel
drawings along with clips on stair stringers for
conduit.
6-59 Structural If heavy equipment is to be set through a new
building structure, see if key beams can be left out
so that equipment can be drifted in rather than lifted
over.
6-60 Structural Specify "off the shelf" safety gates rather than
fabricated specialty items.
6-61 Structural Design handrails to bolt to steel so they can be
erected before concrete is poured. This will save
money that is used for installing temporary
handrails.
SECTION 7 - EQUIPMENT
7-1 Equipmnt As early as possible, the Engineer should provide
the following information to formulate a Preliminary
Master Rigging Plan:


Action
· Major equipment list complete with
dimensions and estimated erection weights.
· Plot Plans showing equipment
arrangement, access, structures and other
obstructions.
· Equipment arrangement and design drawings
with center of gravity locations.
· Proposed mode of transportation for major

pieces of equipment; i.e., water, rail, or highway,
and delivery schedule.
7-2 Equipmnt The information in above item will enable the

Project to establish the following “Preliminary
Decision”:
· Type of lift: i.e., two crane, gin pole etc.
· Type of lifting attachments; the engineer will

design the attachment.
· Elevation and orientation of lifting

attachments.


Action
· Engineered concrete which will be required
such as gin poles which require concrete foundation
design. In many cases incorporated in the design of
the foundation for the process equipment being
erected.
· Anticipated geographic areas which will be
put on “hold” with respect to certain construction
activities until the lift is complete.
7-3 Equipmnt In the event equipment locations are revised and
other revisions affecting rigging plans occur, it is of
the utmost importance that the flow of information
between design and construction be executed
expeditiously and that both parties are abreast of
changes in rigging planning. Without this close
coordination substantially more expenditures can be
incurred in unusable rigging apparatus
7-4 Equipmnt During the rigging planning, consideration should be
given to other activities such as equipment
insulation, structural platforms and ladders,
tray/internal installation, instrumentation, piping
erection and other work which can possibly be
accomplished prior to final erection of the piece of
equipment, saving scaffolding and basket work.
7-5 Equipmnt Specify lifting lugs on horizontal vessels, when
feasible, to allow insulation & paint prior to
installation.
7-6 Equipmnt Provide procedures for preventative maintenance for
items in storage prior to installation.


Action
7-7 Equipmnt Engineering should work with construction to
establish requirements for vendor technical
assistance for erection, startup, and run-in
assistance, so that these requirements can be
incorporated into the formal purchase order.
7-8 Equipmnt Engineer will issue a complete lube oil and
lubrication schedule prior to arrival at the jobsite of
the first rotating equipment.
7-9 Equipmnt Oil mist systems should be given high priorities so
rotating equipment can be run prior to mechanical
and electrical completion of required.
7-10 Equipmnt Maximize use of in-line pumps as process and
specifications will allow.
7-11 Equipmnt Correct bills of material and vendor drawings for
equipment needed in advance to determine if
complete units are received. DETAILED shipping
lists WILL include gaskets, bolts, etc.
7-12 Equipmnt Provide field inspection criteria for all process
equipment.
7-13 Equipmnt Provide shop installed insulation support rings on
equipment.


Action
7-14 Equipmnt Request lifting frames from vendors when vendor
will need same. When special lift beams for
equipment or equipment components are required
for lifts such as for Condensers & Turbines,
Engineering should specify and include in the bid
specifications for the Supplier to design and supply
such items. They must precede shipment of the
related component.
7-15 Equipmnt Consider scheduling deliveries of weather sensitive
equipment/materials within reasonable periods of
construction's actual needs to minimize the
maintenance and protection time requirements.
7-16 Equipmnt Select equipment on the basis of installation costs as

well as initial purchase price.
7-17 Equipmnt Engineering should expedite vendor operation,
installation, and maintenance manuals for package
systems, pumps, compressors, agitators, and all
other rotating equipment so this information will be
in the field prior to receipt of the equipment.
7-18 Equipmnt Construction will provide Engineering information

on pin clearances, impact loading, shackles to be
used, fleet angle on modules, and inventory of lifting
equipment. A review of the equipment lists shall be
done to determine all equipment and materials
which will require a lifting plan.


Action
7-19 Equipmnt Provide sufficient clearance between insulation
jacketing and platforms, ladders, pipe guides, etc.
7-20 Equipmnt Pre-assemble stacks and high elevated equipment

before setting. For example, installing hand-railing,
platforms, and painting of stacks before setting.
Stacks should be designed with flanged connections.
7-21 Equipmnt Buy major equipment skids such as turbines with

lube oil systems integrated as part of the skid so that
oil flush can be done in the shop before equipment is
received in the field.
7-22 Equipmnt Equipment specifications must include all needed
information in one document. Do not refer vendors
to general specs, insulation, painting specs, etc.
7-23 Equipmnt Forward all vendor data available on the equipment

to field as soon as possible, but definitely prior to
receipt of equipment.
7-24 Equipmnt When expansion due to temperature changes is

expected on mechanical equipment, the free end of
the equipment support plate should be provided with
a sliding base (or other equal device) to ride on the
support plate. Check Vertical growth for Pipe and
Electrical.


Action
7-25 Equipmnt When machine surfaces are involved as part of an
item, welding after machining must be kept to an
absolute minimum on the item. Welding causes
warpage which is unacceptable on precise surfaces.
In some instances, machining may be performed
after welding. Specify desired quality or grade of
machined surface(s) on applicable drawings. Also,
indicate if machining is to be done after fabrication.
7-26 Equipmnt When referring to a code, be specific. Reference
code, page, paragraph section, etc. Reference to a
total code as been a constant source of problems.
7-27 Equipmnt Vendor prints made at the jobsite (and sometimes in
the Home Office) from sepias are frequently
unreadable. Engineering should check the quality of
prints made from sepias to be sent to the field.
7-28 Equipmnt Perform a cost analysis before specifying carbon
steel tanks with interior coatings. Construction
would prefer stainless steel or aluminum.
7-29 Equipmnt Provide grounding lugs on all tanks and equipment
for field installation of grounding cables, most
particularly anything with a lining. Orient
equipment and lugs for embedded grounding
termination.
7-30 Equipmnt Processing equipment such as pumps, agitators,
motors, etc. that are to be stored outside, should be
shipped with protective covering that will not
deteriorate before it is to be installed. This would
save time and money.


Action
7-31 Equipmnt Buying extensive spare parts is costly to a project.
Consider a partnering arrangement with equipment
vendors, and place parts on consignment. Buy only
when needed.
7-32 Equipmnt Where feasible, design vessels to allow lifting by top
nozzle.
7-33 Equipmnt Where feasible, quotes shall be obtained for both
field erection and shop fabrication on vessels larger
than 14' diameter. The method of fabrication that
will optimize the overall project requirements shall
then be determined.
7-34 Equipmnt A "run-in" test shall be conducted on each air cooler
package, in order to minimize field adjustments.
7-35 Equipmnt Where feasible, insulation for shell and tube

exchangers shall be installed at fabricator's shop.
7-36 Equipmnt Heater vendors shall be required to furnish a detailed
description outlining the extent of shop assembly
and the additional field work which shall be
required, with their bid proposals.
7-37 Equipmnt Rotating equipment shall be designed for packaging
and preassembly, to the maximum extent possible,
whenever feasible.
7-38 Equipmnt Vendor furnished "packaged units" should provide
job specific (as per project specifications)
instrumentation hardware and job specific
identification and tagging requirements.
Specification sheets should be provided for the field
to receive items in crates and on skids.

Action
7-39 Equipmnt Pump assemblies shall be delivered with final coat
of paint applied, wherever feasible.
7-40 Equipmnt Pump assemblies shall include sufficient tagging on
seal flush, lubrication and cooling water connections
to assist proper installations.
7-41 Equipmnt All pump seal water requirements should be shown
on separate pump trim drawings, showing type of
service connection requirements, instrumentation
(FI, PI), and valving.
7-42 Equipmnt Rotating equipment outline drawings shall include
full arrangement details, dimensioning, weights,
anchor bolt locations, nozzle and pipe locations and
sizes, utility and service connections and lift
locations.
7-43 Equipmnt All rotating equipment will be delivered with
complete installation/operation/maintenance
manuals, plus a separate copy from Engineering.
7-44 Equipmnt Major rotating equipment and vessel outline
drawings will locate center of gravity of complete
assembly.
7-45 Equipmnt Where applicable, rotating equipment base-plates
shall be prepared for grouting. Grouting preparation
shall be compatible with grouting system to be
utilized by Constructor.


Action
7-46 Equipmnt Vessel fabricator should be responsible for ladders
and platforms for the vessel he fabricates. If he
fabricates the ladders and platforms, crucial parts
may require test before galvanizing. If the ladders
and platforms are fabricated by others, he shall be
responsible for ensuring that the vessel design and
layout will accommodate the ladder and platform
design. Field fit-up problems will be back-charged
to the vessel fabricator or platform fabricator.
Delivery of vessels and platforms should coincide
with vessel delivery.
7-47 Equipmnt If feasible, large vessels will be furnished with hard
templates in order to allow for anchor bolt location
verification prior to lifting. If template can be at site
prior to concrete placement.
7-48 Equipmnt Specify all tanks, vessels, columns to come with a
spare set of gaskets from vendor.
7-49 Equipmnt Where any equipment is close coupled to the vessel,
ensure that bolts and gaskets (including spares) are
supplied by vessel fabricator.
7-50 Equipmnt When preparing the specifications for a project or
complex contract, the general spec should be the
only section that contains any commonality for the
other sections. This includes climatic conditions,
approvals, applicable codes, inspection/testing,
painting, substitutions, guarantees of performance,
etc. This minimizes the size of the overall
specification.


Action
7-51 Equipmnt On columns - standardized rectangular platform
rather than circular platforms should be considered
where all of the platforms could be lined up
vertically on one side of the column. This allows for
significantly less expensive fabrication and provides
space for vertical lines between column and
platforms.
7-52 Equipmnt Consider having small diameter vessels with trays
that slide assembled into the vessel through the top
flange, installed in the vessel fabricator's shop.
7-53 Equipmnt Vessels with support bolting to steel should be
designed for 1"shims, and then field drilled for
anchoring.
7-54 Equipmnt The design of nozzles and other appurtenances on
vertical vessels need to be considered for lowering
vessel through structural steel.
7-55 Equipmnt If start-up screens are temporary, then align pumps
without screens. If screens are permanent, then
align pump with screen.
7-56 Equipmnt When vessels are for storage only, vertical skirt
mounting requires less space and should be less total
installed cost.
7-57 Equipmnt Nozzles on vessels should be kept to a minimum by
utilizing bridle for instrumentation and by multiple
use of other nozzles when practical.
7-58 Equipmnt Vents and drains can be on connecting piping rather
than dedicated nozzles on the vessel.


Action
7-59 Equipmnt Provide shop installed insulation support rings on
equipment. Special rings are required on domed
heads. This is to include installation of clips and
rings required for all fireproofing and insulation in
vessel fabricator's scope of work. Check if these
attachments are required on inside and outside of
skirt and bottom head. Construction should review
insulation support ring detail prior to final approval
of vendor drawings.
7-60 Equipmnt Consult with vendors to ensure complete
understanding of the full impact of design changes
prior to implementing changes.
7-61 Equipmnt Provide vessel fabricator with a transport loading
diagram that corresponds with the contractors lift
plan. Ensure that vendor follows that plan.
7-62 Equipmnt Ensure vendor provides vessel weights including
bare empty vessel weight, erected vessel weight, full
operating vessel weight, full water weight and total
lifting weight and note this on the vendor drawing.
7-63 Equipmnt Identify which discipline is responsible for
miscellaneous bolting such as equipment hold down
bolts on elevated equipment.
7-64 Equipmnt Inquire equipment by priority sequence, to maintain
downstream continuity of work. Although it may
require more work for a single discipline to issue
multiple inquiries for similar equipment, the overall
project will benefit.
7-65 Equipmnt Note any media loading with fill dimensions, and
any special loading techniques required, on
drawings.

Action
7-66 Equipmnt List the vessel purchase order numbers on the vessel
drawing.
7-67 Equipmnt Order extra tray and man-way hardware with
columns.
7-68 Equipmnt Where any equipment is close-coupled to the vessel,
ensure that bolts and gaskets (including spares) are
supplied by vessel fabricator.
7-69 Equipmnt All vessels, exchangers, drums, etc., that are
fabricated in shops need to be marked with a north
arrow for orientation on both the drawing and the
piece of equipment. This saves time and reduces
chances for mistakes. Also include markings
designating center of gravity.
7-70 Equipmnt Paint any temporary shipping braces yellow.
Indicate on drawing "Do not remove Until Set on
Foundation" if necessary.
7-71 Equipmnt Have large pieces of equipment weighed when
transported to verify calculated weight prior to
setting. The constructor must be informed of this
actual weight for lift planning.
7-72 Equipmnt Shop inspection program must include provisions
that ensure specifications for surface preparation and
coating requirements have been met.
7-73 Equipmnt Review the erection sequencing of furnaces with

construction and develop a plan.
7-74 Equipmnt Provide note on drawings if any long term
preservation is required. Engineering to prepare log.


Action
7-75 Equipmnt In some cases insulated towers do not need painting
except for bottom 3' and around appurtenances.
Follow specs.
7-76 Equipmnt Air coolers should be shipped fully assembled, if
possible.
7-77 Equipmnt Where vendors supply associated structural steel,
ensure that steel, bolts, and erection drawings are
specified to arrive on site with or ahead of the air
coolers. Especially that needed to set the coolers.
7-78 Equipmnt Small or stacked exchangers should be shipped
already bolted together.
7-79 Equipmnt Review location of all field welds in furnaces to:
a) Minimize dissimilar material welds.
b) Supply pieces with flexibility to trim, etc.
c) Design with physical clearances to do the job.
d) Provide access platforms where possible.
e) Minimize "allow verification" welds.
7-80 Equipmnt If pump/compressor drivers are supplied on separate
P.O.'s, they should be sent to the pump/compressor
vendors for factory mounting on the support
frame/base plate. Pumps shall be mounted on base-
plates complete with drivers, required harness piping
and coupling guards.
7-81 Equipmnt Vessel nozzles on top of drums, towers, etc., must
have a flange elevation which is above the grating
toe plate of the access platform. This allows for
installing and removing of slip blinds and also
bolting of flanges.

Action
7-82 Equipmnt Tie-ins should be well defined on vendor drawings.
Who provides junction boxes, terminal strips, cable
lugs, piping, etc.?
7-83 Equipmnt Avoid ladders for access to equipment maintenance
areas. This improves safety during construction and
operation. Some additional space, however, may be
required for stairs.
7-84 Equipmnt Design vessels and their associated fixtures in a way

that minimizes the number of vessel skirts that
require fireproofing on the inside. For example,
inside fireproofing may be omitted if there is only
opening in the skirt.
7-85 Equipmnt Emphasize installation details such as tolerances,
elevations, centerlines with respect to the grid
system, sequence of installation and special
clearances and call them out on the engineering
documents.
7-86 Equipmnt Have construction, review the degree of
prefabrication for vendor supplied piping. Spooling
of pipe 2 inches and smaller may be desirable on
certain cases.
7-87 Equipmnt When heater-insulated wall panels are preassembled,
attach a lifting beam to facilitate erection. If the top
structural member of these panels is designed for
this purpose as well, panel erection will proceed
more quickly.


Action
7-88 Equipmnt For thin-walled vessels, have the construction
rigging engineer advise engineering on lifting points
so that stiffeners or additional reinforcing are added.
7-89 Equipmnt Consider requiring the vessel fabricator to fabricate

two identical anchor bolt templates: one to fabricate
the vessel base and the other shipped to the field for
correct positioning of the anchor bolts.
7-90 Equipmnt Evaluate whether the vessels should be dressed at

the jobsite or in the vessel fabricator's shop. If done
in a shop, consider the procurement responsibility
and related schedule impact.
SECTION 8 - PIPING
8-1 Piping Priorities for offsite shop fabricated piping will be
established by construction within the restraints of
vendor information.
8-2 Piping Provide specifications for preventative maintenance
and storage requirements of specialty items.
8-3 Piping Provide early issues of types of metals/alloys to be
utilized to enable construction to establish the
respective approved welding procedures prior to the
start of welder testing qualification.
8-4 Piping Engineer should provide pipe-rack "stuffing
drawings" in accordance with pipe-rack erection
schedules.


Action
8-5 Piping Engineering should provide specifications and
criteria for nondestructive examination
requirements, (radiography, Liquid Penetrate, etc.)
with construction input.
8-6 Piping Provide early definition of chemical cleaning
requirements, i.e., specifications to be used, valves
required, lines, etc.
8-7 Piping Design engineering should furnish routing
schematics for cooling, seal, lube, piping, etc.
8-8 Piping Line list should include line size, pipe spec, as well
as:
Paint System
Test Pressure Reference
P&ID Reference
System Reference
To and From Reference
8-9 Piping Piping isometrics and orthographics should show all
vents and drains
8-10 Piping Piping shoes, trunnions and dummy legs should be
installed on shop fabricated spools by the fabricator
and should have slots for insulation banding, if
required.
8-11 Piping Isometrics will be drawn for all piping, including
elevation changes, direction changes, and expansion
loops. Such ISO will be fully dimensioned and
include B.O.M. on ISO.


Action
8-12 Piping Where pipelines cross permanent roads and crane
access-ways around buildings, assure design
incorporates structural protection to support the
heaviest cranes routinely used. Heavier cranes can
be matted.
8-13 Piping All isometrics should have a detailed bill of
material. Such bill of material should differentiate
between shop fabrication and field erection. The bill
of material will be printed on the ISO.
8-14 Piping All isometrics should have the following call outs:
Post weld heat treatment
Boiler coded work and limits
100% x-ray requirements
Bi-metal welds noted
Gussets or special bracing (as required)
Vent hole drilling in reinforcing pad
Paint and insulation requirements
Cold spring specs per location (as required)
8-15 Piping All engineering supports and hangers should be
located with coordinates and elevations and clearly
identified by tag and/or catalogue number on
isometrics and/or orthographics.
8-16 Piping Spool piece numbers to be shown by the engineers
on ISO's.
8-17 Piping Isometrics should be made for vessel trim and issued
as early as possible.


Action
8-18 Piping Isometrics should clearly denote insulation limits for
personnel protection, acoustical, and insulation spec
break points.
8-19 Piping All branch connections should stop at the header for
shop fabrication. Laterals utilizing weld in tees or
weld-o-lets should have such fitting welded to
lateral spool and not to header. Branch connections
should be made utilizing saddle welds, where
allowed by specification, in the shop. On smaller
size headers use welded tees because of weld
distortion if allowed.
8-20 Piping Provide Isometric issue forecast curve.
8-21 Piping Preliminary material takeoffs should include non-
engineered pipe supports (shoes, guides, anchors,
etc.)
8-22 Piping Color coding (longitudinal striping) should be used
for bulk piping for identifying material type.
8-23 Piping Area color coding (circumferential striping) should
be used for shop fabricated spools and should be
shown on each isometric.
8-24 Piping Construction will estimate criteria with engineering
for location of all field welds on fabricated piping
unless dictated by design restraints or located by
design engineer for offsite shop fabrication.
Construction and engineering shall review field weld
locations at all rotating equipment on shop
fabricated piping.
8-25 Piping Field run piping will be shown on ISO's as a dotted
line.

Action
8-26 Piping Engineer to provide pressure test diagrams to be
consistent with system turnover:
Test pressure reference number
Items to be removed for pressure test
Test Medium
Blind and/or isolation requirement and specific
identification number.
8-27 Piping Early vessel dress-out ISO's will be developed to
facilitate dressing out of vessel and columns, laying
horizontal. All pipe 2" and larger will be targets of
opportunities.
8-28 Piping Valve handle orientations should be shown on the
isometrics /orthographics if handle is to be anything
other than "with the run".
8-29 Piping If any coded work is required on the project, all
piping bulks should be purchased with "mill test"
papers.
8-30 Piping Utilize maximum-minimum system for small bore
field run piping materials.
8-31 Piping Detail all pipe penetrating slabs, so field welds occur
above floor levels and can be made without using
scaffolding.
8-32 Piping Provide isometrics for all drain piping. Add floor
drains after penetrating metal deck.


Action
8-33 Piping Expansion joints for rack piping runs should be
nested together in a common location. This allows
several joints to be supported at a common point,
thus, reduces the likelihood of physical interferences
in the pipe racks.
8-34 Piping Minimize the gap between the issuance of revised
flow-sheets and the issuance of revised ISO's and
orthographics.
8-35 Piping Engineering should perform isometric / P&ID
consistency check for valves.
8-36 Piping Engineering should establish clear corridors on
piping and electrical design drawings for fire
protection piping and sprinklers.
8-37 Piping Vendor supplied piping should be shown on
isometrics or orthographics and identified according
to vendor piece-marks.
8-38 Piping Special cradles or stiffeners on fabricated pipe
should be fabricator's responsibility.
8-39 Piping Pipe clearances between pipe, structural members,
equipment, etc. should be sufficient to avoid field
trimming of insulation.
8-40 Piping Steam trace isometrics should have dimensions as
well as coordinates to facilitate shop fabrication.
8-41 Piping Pre-insulated tubing is preferable to hard insulated
piping for steam tracing supply and return lines.


Action
8-42 Piping Engineering should provide the steam tracing
requirements on P&ID's. A steam tracing index will
be generated designating steam supply and trap
stations as being either a process station or
winterization station.
8-43 Piping Design and order valves early to preclude continuing
problems of late deliveries and negative construction
impact.
8-44 Piping Valves with welding ends and soft seats or internals
that can be damaged or destroyed by field welding
should be provided with 6-inch nipples attached by
the vendor.
8-45 Piping Original isometrics of small pipe, after being
prepared by project design, should be maintained at
the jobsite to facilitate revisions (especially ASME
piping). Jobsite authority should be provided
regarding changes and modifications.
8-46 Piping Design should review vendor equipment drawings,
where equipment piping interfaces with designed
piping systems, to assure compatibility of interface
welds or connections. Items to be considered are
pipe diameter, schedule, material and location of
connection.
8-47 Piping Vendors who supply hangers, valves, spools, and
other components should be selected by reason of
their proven ability to meet required schedules and
fabrication accuracy rather than solely on a price
basis. Delivery delays and rework are becoming
increasingly costly in the field and in most instances,

Action
exceed the low bid "savings".
8-48 Piping To provide proper spacing between piping and

components, insulation requirements on large and
small piping must be considered when preparing
piping layout drawings and isometrics.
8-49 Piping Use adjustable hanger supports and restraints
wherever possible. Standardize material used in
hanger fabrication to reduce storage and inventory
difficulties.
8-50 Piping Particular attention should be taken in detailing weld
symbols on hanger details. Show necessary welds
that are accessible and proper size for material being
welded. Avoid "all around" welds.
8-51 Piping Hanger components that do not require major field
assembly/ welding will have the appropriate coating
system applied in the shop. This is particularly
important for such items as snubbers, spring cans or
struts.
8-52 Piping Permanent hangers and supports should be designed
and fabricated early. These and all associated
materials should be delivered prior to or with arrival
of pipe spools. This must include valves, nuts, bolts
and gaskets. These should be on hand, to permit
sequential installation of piping systems.

Action
8-53 Piping To help reduce conflicts at shop inspections and at
final acceptance, design engineering should closely
review the welding and Non-destructive
Examination requirements that are imposed on
vendor supplied components for compatibility and
feasibility with project's welding and NDE
Standards. Vendors should be given explicit
instructions regarding tests and documentation and
whether approval will be subject to review by design
engineering. Requirements should refer to specific
sections of applicable codes.
8-54 Piping Almost every project seems to have a problem with
bolting requirements. Standardize the requirements
as specifications are developed. Look very closely
at flange torqueing procedures for hot piping and
high pressure piping.
8-55 Piping Do not flange rate piping, this increases stress
analysis requirement.
8-56 Piping Buy level bridles assembled.
8-57 Piping Take a hard look at new technology in piping to
eliminate welding, e.g.: (1) Lock-ring Fittings and
(2) Victaulic (Press fittings). Both new products to
mechanically join pipe.
8-58 Piping Standardize and preassemble piping sub-assemblies
for vents, drains, pressure gauges, orifice taps, steam
tracing manifolds, steam traps, control valves,
PRV's, utility stations, eyewash stations, pumps and
sample connections. Indicate on isometrics.


Action
8-59 Piping Do not lay out pipe racks next to roads as this will
eliminate one side of the rack for equipment
placement and will force the use of spur pipe racks.
8-60 Piping Design to maximize preassembly.
8-61 Piping Cross reference drawings between disciplines.
Appropriate cross references save more hours in the
field than those required to incorporate reference on
drawings. Suggest using the same scale for all
disciplines.
8-62 Piping Need flex drawings for RTP systems.
8-63 Piping Do not paint screwed plug in high point and low
point vent. Add note to shop fabrication spec.
8-64 Piping Add P.O. number (if available) to specialty items
list.
8-65 Piping When allowed by pipe code and area preferences,
cold bending of piping and lapped flanges should be
utilized when the fabrication facilities are available.
8-66 Piping Buy pipe hangers and supports with high density
insulation as a component part for insulated lines if
load spreading is possible.
8-67 Piping At full port control valve stations with block valves
on both sides and a bypass line, position the pipe
reducers so that the block valves are the same size as
control valve rather than header size.
8-68 Piping When required, grinding of internal weld of weld
neck orifice flanges should be indicated on pipe
ISO.


Action
8-69 Piping The suction and discharge valves on pumps should
be same size as the pump flanges. Position reducers
on opposite side of valves from the pump.
8-70 Piping All blind flanges, plugs, drilled and tapped flanges
should be shown on pipe ISO's.
8-71 Piping Consider pipe racks at ground level rather than
overhead.
8-72 Piping When designing an above ground line attaching to
underground headers, consider adding a bypass
valve below the guard valve for recirculation.
Evaluate whether the additional cost is justified.
8-73 Piping Do not leave "over lengths" for field fit up unless
specialty pipe, i.e., refractory lined.
8-74 Piping Stops on spring hangers should be pulled just before
turnover and set to operating load by
commissioning.
8-75 Piping Indicate any slope requirements on pipe drawing.
8-76 Piping Some check valves only work in one orientation.

Understand this when designing.
8-77 Piping Check closely location of check valves at
compressor and pumps. Reduce back spend by
having check valve as close as possible to
compressor/pump discharge.
8-78 Piping Design should specify on P&ID when acid flange
guards are required.
8-79 Piping Service test all non-critical lines.


Action
8-80 Piping Ball valves should be purchased with built-in
locking devices for locking in either the open or
closed position (per OSHA regulations).
8-81 Piping Maximize manufacturers' standards for valves and
pipe supports, etc.
8-82 Piping Develop sequential turnovers by system.

8-83 Piping Verify grounding and cathodic protection
requirements early and show on affected ISO's.
8-84 Piping Cinch anchor adjustable supports directly to the slab.
8-85 Piping Use turnbuckles in rod hangers to the maximum

extent possible.
8-86 Piping On P&ID's, piping plans and ISO's label all
equipment nozzles, including those on package
equipment, with the package equipment vendor
designations.
8-87 Piping Review the use of adjustable trunnion supports.
Adjustable vertical trunnions are the company
standard at grade (to account for sloping paving) and
in structures (to allow for erection tolerances).
8-88 Piping Specify double random length pipe for bulk
purchase.
8-89 Piping Standardize color code on gaskets. Put color code

requirements in gasket requisition.


Action
8-90 Piping Review routing of cooling water, seal oil and oil
mist piping around pumps and compressors to
accommodate maintenance requirements.
8-91 Piping Maximize the number of piping systems which can
be service tested by keeping the design conditions
within the allowable limits for service testing.
8-92 Piping Required systems sequence for turnover.
8-93 Piping Commit to agreed sequencing for spool fabrication
and delivery.
8-94 Piping Check the cost economics of reducing the size of
block valves and pumps. If there are no cost savings
with these reduction, leave valves or pumps the
same size as the line.
8-95 Piping Have engineering identify the need for temporary
strainers and order if necessary.
8-96 Piping Check into pipe bending technology.
8-97 Piping Early release of pipe hanger and support drawings-
assure tight tolerance requirements can be met.
8-98 Piping If 304/311 stainless pipe is to be shop fabricated,
early release of pipe support drainage and
procurement will facilitate welded supports
installation in the shop.
8-99 Piping For carbon and low alloy pipe, consider specifying
only a single type of nipple. Specifying more than
one type has in the past caused confusion and
wasted time.


Action
8-100 Piping Include in the preliminary material takeoffs the non
engineered pipe supports (shoes, guides and anchors,
etc.)
8-101 Piping Consider field run piping on ISO's (in addition to
P&ID's).
8-102 Piping Incorporate in the TQM a statistical sampling plan
for verifying the accuracy of piping ISO's.
8-103 Piping Consider checking all equipment flanges against the
isometrics at the conclusion of isometrics.
SECTION 9 - ELECTRICAL
9-1 Electrical Standardize designs where possible.
9-2 Electrical Underground electrical plan drawings should show
the location and elevations of all conduits, cables,
ducts, etc., and also any u/g piping crossing these
u/g ducts. Make every effort to flag individual
cases.
9-3 Electrical Design embedded floor channel for supporting
switchgear (in buildings) flush and level with top of
floor to permit easy installation and removal of
breakers.
9-4 Electrical Ground drawings should be issued before or in
conjunction with civil drawings.
9-5 Electrical Slightly slope foundations for outside switchgear so
that water will not pond around the gear.
9-6 Electrical Engineering must establish requirements for
electrical testing, hi-pot, relay testing, megger
inputs, etc., so that if necessary a subcontract can be
let for this specialized service.

Action
9-7 Electrical Engineering should complete all design calculations
for the high and low voltage relay settings.
9-8 Electrical For installation of grounding wire in substation
buildings, specifications should permit installation
of conduit for grounding wire under the slab with
slab penetration inside the building flush with top of
slab; the other end of the conduit should penetrate
the grade beam just below finished grade.
9-9 Electrical Conduit stub-ups under raised floors or in
termination rooms for instrument wiring should be
located near doors when possible to make wire
pulling less costly. Avoid stub ups directly under
equipment if possible.
9-10 Electrical Specify heat shrink or pre-molded stress relief
devices for medium voltage cable termination.
9-11 Electrical Review drawings to eliminate multiple runs of
conduit by replacement with an equivalent tray and
improve sequencing.
9-12 Electrical Conduit connections to equipment should be flexible
as opposed to rigid. Rigid conduit is difficult to
align prior to equipment installation and requires
more labor and material than flexible conduit to
make connections.
9-13 Electrical Group elevated cable junctions in as few places as
possible to minimize scaffolding needs.
9-14 Electrical When possible, design high voltage electrical lines
underground to minimize crane contact and other
fatal shock hazards.


Action
9-15 Electrical Portions of work which can be pushed ahead to
relieve later peaking of critical crafts should be
identified/scheduled.
9-16 Electrical Close interface between client and contractor
personnel will be maintained through construction,
thereby ensuring consistency throughout the various
new and modified process units.
9-17 Electrical Follow the project to the field. Key design
engineering personnel will be made available to be
resident at the site to assist with questions of design
intent and to help out during pre-
commissioning/loop checkout.
9-18 Electrical Long lead-time delivery items shall be purchased as
soon as possible to support the construction
schedule.
9-19 Electrical The types of bulk materials shall be standardized to

reduce the number of different sizes and/or
materials. This will assist the ETEby having fewer
deliverables to monitor and eventually issue to
construction force.
9-20 Electrical The use of galvanized "unistrut" rather than using
structural steel supports and brackets smaller than 2
inch in section shall be maximized.
9-21 Electrical Long run multi-pair cable will be identified on the
individual spools when they are shipped.
9-22 Electrical Electrical cable pulling locations for access of
equipment for banking of cable spools, for downhill
pulls, etc. shall be carefully planned as cable tray
drawings are developed.

Action
9-23 Electrical A simple and logical wire marking system which
also can be used during construction for quantity
control shall be developed.
9-24 Electrical If possible, FTA's are to be shipped to the vendor
shop for marshalling panels. I/O lining cables with
plug-in connectors at both ends will be provided to
facilitate the cable installation.
9-25 Electrical Pre-commissioning/loop check guidelines and
requirements will be developed up front so that
proper documentation can be developed to support
the field activities.
9-26 Electrical Vendor skids must comply with NEC code
requirements clearly. Vendor skids should be
inspected by Electrical Field Engineer prior to
leaving shop. Most electrical rework in the field is
associated with skids.
9-27 Electrical Motor connection boxes should be large enough for
bulky terminations, including stress relief devices.
Indicate specific sizes on purchase requisitions
rather than accepting standard NEMA sizes.
Engineering to furnish elbow connections and
bushings according to cable diameters.
9-28 Electrical Consider vendor pre-wiring and connecting

solenoids and limit switches on pneumatic valves to
a terminal box located on the valve. Be sure
adequate room is available in the terminal box to
conveniently connect the field cables and for the
proper maintenance of limit switches and other
devices that may be in the same enclosure.

Action
9-29 Electrical Provide adequate space in all cabinets, switchgear,
etc., to allow for proper field installation of jacketed
cable. Do not use plastic wireways for field run
cable.
9-30 Electrical Do not use three tube fluorescent fixtures. They are
more expensive and more difficult to obtain than
four tube fixtures.
9-31 Electrical Stacked cable trays will be used in the pipe racks.
9-32 Electrical Provide specific grounding instructions for shielded
instrumentation cables. It is important that any
isolated grounds for the above be identified during
the Civil portion of construction so conduit can be
placed through walls and floors.
9-33 Electrical When practical, design manholes with embedded
unistrut, lifting lugs, pull eyes, personal ladders and
drainage sumps.
9-34 Electrical Consider the use of shrink sleeves for 600 volt
control cable splices as authorized by design group.
9-35 Electrical Specify coding of individual conductors by different

colors of insulation for control cables rather than
identifying conductors with numbers or letters on
the same color insulation.
9-36 Electrical Cable number will be shown on schematic drawings.
9-37 Electrical Place power and control in same conduit to small

motor operated valves. Do same for small motors
that have instruments located on them.
9-38 Electrical Show conduit sizes on drawings. (LTG. & POWER
DRAWINGS)

Action
9-39 Electrical Electrical drawings should reference Civil drawings
that detail appurtenances (supports, block outs,
embeds, etc.) to accommodate electrical
components.
9-40 Electrical Electrical and instrument design should be simple
and standardized, i.e., install cable trays on the top
of pipe racks from the control room and M
ETErooms to the field. Separate all cable trays by
power and signals. Install conduit drop outs from
the bottom side of cable trays to area J boxes. J
boxes should be separated by power and signal.
Install color coded multi conductor cable L from
control and rack rooms to field J boxes via pre-
assigned cable tray systems. Pull single pair cables
from J boxes through the assigned trays to field
devices and conduits installed from cable trays to the
devices.
9-41 Electrical There should always be a minimum of 4 ft. head
room under computer floors, 6 ft. if available.
9-42 Electrical All instrument grounding and computer grounding
must be connected to an isolated ground system.
The electrical system grounds to a common ground
grid. By using this concept you will give quality
and greater savings to design and installation.
9-43 Electrical Do not utilize block diagrams for installation by
themselves. They always require layout drawings,
schematics and wiring diagrams to back them up.


Action
9-44 Electrical Engineering should ensure that the purchase orders
include the cable reel numbers from the pull
schedule so that the reels will be properly marked
when received.
9-45 Electrical All material bought for special installations should
be referenced to the drawing and the drawing
referenced to the correct BOM.
9-46 Electrical All cable tray horizontal fitting installations require
proper support on each side of the fitting. This is
commonly left off the structural design.
9-47 Electrical All layout drawings should depict any removable
grating, swing steel or removable handrails and
piping so that all other crafts' installations will
facilitate them.
9-48 Electrical Engineering shall insure that all control system
interlock information is utilized on all schematics
and referenced as required.
9-49 Electrical All special NAMEPLATE requirements should be
specified up-front to eliminate rework after
installation.
9-50 Electrical Cable schedules should have to/from routing, cut
length schedules for power cables, cable number,
MED. VOLTAGE CABLE, reel numbers, SYSTEM
TURN-OVER NUMBER and a layout reference
drawing number.
9-51 Electrical Use computer system to communicate cable
information to permit automatic information
formatting by need.
9-52 Electrical Switchgear vendor to furnish cable lugs to match the
buss or connection drilling.

Action
9-53 Electrical Overhead cable trays are preferred over underground
raceways/conduits as they offer more flexibility for
future additions.
9-54 Electrical Use P & W cable tray for fault return ground instead
of ground wires.
9-55 Electrical Use discontinuous trays with drop-outs instead of
off-sets whenever there is not a concern about fault
return grounding through the cable tray. Use
aluminum shields on dropouts to protect cabling.
9-56 Electrical Design should specify on tray drawings where cable
tray covers are required.
9-57 Electrical Avoid installing cable tray directly over the top of
electrical equipment inside substation. An offset
may be required for cable access and dropouts.
9-58 Electrical Design adequate support for cable tray that is hung
in a substation, control room or any location where
tray loading may exceed the normal.
9-59 Electrical Conduit plan drawings must show type of cable
entry into unit, panel or marshalling cabinets.
9-60 Electrical All engineering purchased tagged equipment such as
control panels, lighting/power panels and junction
boxes shall be purchased with identification tags
attached. This will aid in material control and field
erection.
9-61 Electrical Vendor will comply with specifications for marking
terminal blocks. This continues to be a source of
excessive field rework man-hours.


Action
9-62 Electrical Conduit support racks are very beneficial as they
organize the area under the rack to allow the
electrical subcontractor designated space without
interference of other disciplines.
9-63 Electrical Include excavation, backfill and trenching specs in
the Electrical and Instrumentation scope subcontract
packages, as required.
9-64 Electrical Provide welding criteria and standards for
instrument and electrical subcontract scope. Their
welders must meet all plant general welding
requirements.
9-65 Electrical Note requirements for conduit bends at periodic
distances on vessels to allow for both expansion and
contraction of the conduit and the vessel at operation
temperature.
9-66 Electrical Ensure that cathodic protection requirements have
been addressed prior to issuing underground piping
drawings.
9-67 Electrical Identify requirements for aircraft warning lights
early. Get mounting plates, etc. for aircraft warning
lights incorporated into vessel/structure design.
Include installation of aircraft warning lights in
tower/vessel early dress-out.
9-68 Electrical Clearly define hazardous area boundaries on power,
lighting and instrument wiring drawings.
9-69 Electrical Investigate use of embedded conduit in elevated
slabs for lighting to eliminate bends at beams and
girders and to avoid work being done from below
using scaffolds.


Action
9-70 Electrical Investigate use of inexpensive PVC conduit for
embedded runs.
9-71 Electrical Verify SS extension does not violate L.P. standards.
SECTION 10 - INSTRUMENTATION
10-1 Instrum- Vendor furnished "package units" should provide
entation job specific (as per design engineer spec)
instrumentation hardware and job specific
identification and tagging requirements.
Specification sheets should be provided for the field
to receive and check items received in crates and on
skids.
10-2 Inst. The instrument index should consist of:
Instrument number
Specification ref
Location of device
P&ID ref
Device type
10-3 Instrum- Engineer to specify any special preventative
entation maintenance and storage requirements for
instrumentation hardware and devices.
10-4 Inst. Use "Notes to the Field" to convey and clearly note
special engineering needs or client requirements
(issue these as part of the Instrument Spec Books).
Special Materials
Orientation
Tagging Requirements
Mounting Details


Action
Locations
Testing Requirement
Seal Fluids
10-5 Instrum- Pre-commissioning/loop check guidelines and
entation requirements will be developed up front so that
proper documentation can be developed to support
the field activities such as system turnover.
10-6 Instrum- Anytime ladder drawings are produced for the
entation project they should be issued with the loops and
schematics to construction. References are
commonly made to these ladders and the job is not
able to complete without them. Loop fold
development.
10-7 Instrum- Provide clear definition in safety showers alarms, if
entation they will be provided for in DCS.
10-8 Instrum- Pre-commissioning loop check guidelines and loop
entation folders shall be developed early to support the field
activities.
10-9 Instrum- Have fire safe requirements for valves been
entation specified on P&ID's, data sheets and requisitions?
10-10 Instrum- Ensure that trip/shutdown instruments are clearly
entation marked to distinguish them from normal control
instruments.
10-11 Instrum- Have pre-alarm and shutdown valves and critical
entation valve closing/opening speeds been established and
agreed to by Systems, Process, Project and Plant
Services personnel?


Action
10-12 Instrum- Standardize on material type and size O.D. and wall
entation thickness for pneumatic signals and air supply
tubing.
10-13 Instrum- Agree on the extent of details required by field
entation subcontractors on heat tracing/winterizing,
raceways, instrument assemblies, tubing, and
junction boxes.
10-14 Instrum- Develop procedures for procurement and control of
entation electrical and instrumentation bulk material. Pre-
bagging instrument installation hardware per
individual instrument details.
10-15 Instrum- Consider using piping stool pieces in lines in place
entation of control valves until hydro-testing is complete.
10-16 Instrum- Design shall provide a list of all in-line instruments
entation that are be installed along with special handling
instructions.
10-17 Instrum- Purchase orders for specialized instruments,
entation computers and other special items where vendors or
required, should contain vendor representative lump
sum bid price, for 10 day visits and have hourly rate
clauses for items. The field should be designated to
request the services of vendor representatives.
10-18 Instrum- Engineer should provide a steam tracing index
entation designating steam supply and trap stations as being
either a process station or winterization station.
Allow for extra taps in case instruments requiring
steam tracing are Detail Designed.


Action
10-19 Instrum- Instead of scoping the process control systems to the
entation limits of the latest technology, reduce the level of
complexity and sophistication to the minimum
required to run the process.
10-20 Instrum- Avoid using colors to identify services and voltage
entation levels.
10-21 Instrum- Interface of existing units into new units will require
entation concise definition to assist the construction
subcontractor during installation. This can be
accomplished by ensuring the integrity of existing
documentation thereby minimizing the "last minute"
changes. Documents shall also clearly show what
equipment exists and what is new.
10-22 Instrum- Pre-fabricated analyzer shelters should be purchased
entation as totally pre-assembled units - fully equipped,
dressed and shop tested.
10-23 Instrum- If possible, FTA's are to be shipped to the vendor
entation shop for marshalling panels. I/O link cables with
plug-in connectors at both ends will be provided to
facilitate the cable installation.
10-24 Instrum- Anytime PLC's are utilized, a specific module
entation assignment is needed up front as some of these items
are long term delivery and shortages need to be
identified early. Also all other peripheral equipment
needs to be identified on the installation drawings.


Action
10-25 Instrum- When existing drawings are to be utilized or when a
entation new drawing is revised, the revision needs to be
shown clearly and a brief description included in the
revision block.
10-26 Instrum- Fiberglass instrument and pushbutton stands for
entation corrosive areas are available for similar cost to
galvanized stands.
10-27 Instrum- The unloading of analyzer shelters at the jobsite
entation should be considered. Often this equipment is
designed to be lifted with spreader bars. Provide
lifting requirements to the jobsite early, so
constructor is prepared to handle.
10-28 Instrum- The capability of the contractor installing fiber
entation optics systems should be verified.
10-29 Instrum- When load cells are integral part of an equipment
entation installation, the use of equivalent spacers during the
construction phase of the project should be
considered. Install the load cells just prior to system
check-out and start-up.
10-30 Instrum- Consideration should be given to the location of new
entation nuclear level detection devices. They need to be
arranged so that no interference will result from
existing radiation sources and detection devices.
10-31 Instrum- The instrument design package should specify
entation requirements to provide mechanical contractor
assistance for service testing steam tracing system.
Emphasis should be placed on proper tagging before
service testing to expedite system turnover.


Action
10-32 Instrum- Does the Safety Protection System design partition
entation hardware to minimize the potential of tripping the
entire plant?
10-33 Instrum- When specifying and installing vent stacks for
entation analyzer houses or other remote building houses,
check all drawings to assure that clearance is
available to prevent interference and for availability
of structural support.
10-34 Instrum- All instrument grounding and computer grounding
entation must be connected to an isolated ground system.
The electrical system grounds to a common ground
grid. By using this concept you will give quality
and greater savings to design and installation.
10-35 Instrum- Consider vendor pre-wiring and connecting
entation solenoids or limit switches on pneumatic valves to a
terminal box located on the valve.
10-36 Instrum- Data Sheets should be standardized on all projects;
entation preferably one complete Data Sheet per instrument
device.
10-37 Instrum- The instrument index should be issued as early as
entation possible so it can be used to receive instruments.
10-38 Instrum- Pre-insulated tubing is preferable to hard insulated
entation piping for steam tracing supply and return lines.


Action
10-39 Instrum- Vessel trim drawings such as for level gauges and
entation switches, etc., on towers should have vertical and
horizontal dimensions (placement details),
particularly in its interface with insulation and not be
classified as "field run". (This will allow fabrication
of this piping on the ground in a shop instead of 200
feet in the air)
10-40 Instrum- Portions of work which can be pushed ahead to
entation relieve later peaking of critical crafts should be
identified.
10-41 Instrum- Vendor furnished "packaged units" should provide
entation job specific (as per design engineer spec)
instrumentation hardware and job specific I.D. and
tagging requirements. Spec sheets should be
provided for the field to receive and check items.
10-42 Instrum- Key design engineering personnel should be
entation available to be resident at the site to assist contractor
with questions of design intent and to help out
during pre-commissioning/loop checkout.
10-43 Instrum- Data sheets will be made available at jobsite for the
entation field acceptance and inspection.
10-44 Instrum- Long lead-time delivery items shall be purchased as

entation soon as possible to support the construction
schedule.
10-45 Instrum- Assure that piping and instrument items related to
entation vessel trim are specified on drawings and are
included on initial bulk purchases.


Action
10-46 Instrum- The use of wire tagging for individual wires in
entation multi-conductor cable to identify circuits and assist
in proper field connections shall be promoted.
10-47 Instrum- In order to minimize field fabrication the majority of
entation instrument supports should be engineered and a
material take-off provided to allow for offsite shop
fabrication. The purchase of standard manufactured
supports should also be considered if approved by
client.
10-48 Instrum- Each engineered item must have a discrete tag
entation number, i.e., each device, drawing, cable, conduit,
tray, software block, etc.
10-49 Instrum- Cable schedules should have schematic references,
entation number of connections, to/from routing, number of
spares, block design type.
10-50 Instrum- Installation details should include approved gaskets
entation and thread lubricants, slope of lines, etc.
10-51 Instrum- Cable type list should include testing criteria,
entation minimum banding radius, maximum pulling
tensions, etc.
10-52 Instrum- Assure IFC/As Built issue of all vendor drawings are
entation published and issued to the field.
10-53 Instrum- Make sure relief valve data sheets cover all
entation condition values they will be subjected to, including
start-up. Check how valves will discharge, i.e.,
atmosphere, closed flare header vessels. Use data
sheets to receive values from vendors and bench test
values as site prior to installation.


Action
10-54 Instrum- Maximize the use of line-mounted instruments as
entation opposed to stand mounts.
10-55 Instrum- Block diagrams should not be utilized or issued for
entation installation alone. The only purpose of these
drawings is for concepts. Installation requires
support drawings in conjunction with block
drawings.
10-56 Instrum- Install permanent labels on equipment at factory
entation instead of temporary labels.
10-57 Instrum- Purchase complete junction boxes, control panels
entation and marshalling cabinets rather than assembling on
site.
10-58 Instrum- Prefer use of pre-insulated and pre-traced (either
entation electric or steam) tube bundle for instrument
impulse lines rather than bare tubing with field
insulation installed.
10-59 Instrum- Identify sample gas requirements and calibration.
entation Early identification of sample gas bottle accessories
(locks, chain, etc.) should be considered. (90 day
supply requested.)
10-60 Instrum- Consideration must be given to analyzer
entation requirements, i.e., sewer, steam and sample disposal
regardless of who sets houses or shelters.
10-61 Instrum- Review analyzer building or shelter roofs carefully.
entation Some designs do not have self draining roofs.
10-62 Instrum- Review analyzer requirements early for UPS and
entation power requirements.


Action
10-63 Instrum- Early determination of analyzer vendors/suppliers
entation should be considered.
10-64 Instrum- Begin loop check planning and coordination early.
entation Ensure the client is aware of the construction
support required to maintain project progress. (i.e.
maintenance support, TDC literate operators,
quantity of loop checks per day required.)
10-65 Instrum- Isometrics should be made for vessel trim and
entation instrument bridles and issued as early as possible.
Bridles will be detailed by the pipe group.
10-66 Instrum- The instrument index or installation drawings should
entation identify instruments requiring individual stands or
unique mounting requirements.
10-67 Instrum- Consider showing instrument air piping distribution
entation on the instrumentation location plans.
10-68 Instrum- Having pre-bid meetings with valve & control valve
entation vendors, try to involve valve manufacturers instead
of just local suppliers. Emphasize that all valve
body dimensions from their supply are required for
piping engineering within 10 days of award.
10-69 Instrum- Consider ambient monitoring and alarm
entation requirements.
10-70 Instrum- Check factory calibrated instruments upon receipt
entation and prior to installation.
10-71 Instrum- Consider having the relief valve vendor make
entation necessary tests and provide storage until the relief
valves are required by construction.
10-72 Instrum- Have NACE requirements been included on data
entation sheets and requisitions?

Action
10-73 Instrum- Have alloy requirements been noted on data sheets
entation and requisitions?
10-74 Instrum- Check to ensure that instruments are not mounted
entation where they could obstruct the proper use of
handrails, ladders, access-ways, etc.
10-75 Instrum- Ensure all instruments have the proper labels for the
entation area classification as specified on the data sheets.
10-76 Instrum- Furnish transmitters with manifolds mounted to the
entation transmitter. Use the manifold and the 2" pipe
support to eliminate an additional bracket.
10-77 Instrum- From engineering specification through installation,
entation be aware of the mounting differences between right-
hand and left-hand displacer head mounting.
Improper installation can cause serious maintenance
inaccessibility.
10-78 Instrum- Are hazardous area monitors required? If so, are
entation these requirements reflected on P&ID's?
10-79 Instrum- Ensure that instrument analyzer and equipment
entation drains that have to be piped to a safe location are
piped directly to hubs, etc. and not to grade or slabs
that slope to drains.
10-80 Instrum- Does the Safety Protection System incorporate fail-
entation safe concepts?
10-81 Instrum- Is the Fire, Gas and Smoke Detection System
entation implemented in hardware separate from that of the
Safety Protection System and also the regulatory
Control System?


Action
10-82 Instrum- Ensure that field panels are located at proper
entation distances from hazardous equipment, such as heaters
and reactors; field trip hand switches should be
placed far enough away from the equipment to allow
an operator to approach and operate them safely.
Ensure a clear escape route for the operators from
the equipment and the panels.
10-83 Instrum- Pre-assemble control valve accessories in the shop
entation prior to shipment to the field. Shop assemble, level
gauges, sample coolers, etc.
10-84 Instrum- Utilize the bar stock block/bleed valve for pressure
entation gauge installations.
10-85 Instrum- Avoid the use of level gauge glasses in temperature
entation extremes. Note that it is a gauge vendor's
requirement that all gauge glasses be re-tightened at
operating temperature if that temperature is a
specified amount from ambient.
10-86 Instrum- Engineering to insure that all control system
entation interlock information is utilized on all schematics
and referenced as required.

SECTION 8: SUMMARY AND CONCLUSION
This concludes the subject matter of this report. This document can serve as a guiding element for
“KFUPM BUSINESS PARK PROGRAM” project personnel to begin developing their own
Construction Strategy for incorporation into the detail design and construction package.
It is hoped that this report will serve as a starting point in implementing some of the measures and
recommendations highlighted. Appointing a constructability coordinator and conducting periodic
constructability round-table meetings will also contribute greatly to the success of your efforts.
It is likewise worth noting that, where substantial gains and savings can be realized through these
efforts, nothing comes for free. A willingness to invest the time and resources toward these ends will
be critical to overall success.
All aspects of Saudi Aramco standards, specifications and procedures should be included/referred in
the final scope document such as taking base ultrasonic wall thickness readings for piping and vessels
after completion of construction, piping cleaning and drying after hydro-testing, etc. This is stated as
many small items, such as aforementioned, are overlooked in construction planning and then last
minute rush has to made for compliance.

CONSTRUCTABILITY SUGGESTION FORM
Please find the attachment on next page
DRAFT CONSTRUCTABILITY REPORT REV.A PAGE 116



Final 1st CS Report KFUPM BP Project

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CONSTRUCTABILITY STUDY

KFUPM BUSINESS PARK PROGRAM

DRAFT CONSTRUCTABILITY REPORT REV. A PAGE 2

CONSTRUCTABILITY WORKSHOP AGENDA FOR

10 minutes presentation for an overview of Constructability Workshop

OVERVIEW OF THE CONSTRUCTABILITY AS PER CII

 ORGANISATION RELATED ISSUES

 Appoint Constructability Coordinator

2  Modularization and prepackaged or packaged systems 10:15 - 12:00

DRAFT CONSTRUCTABILITY REPORT REV. A PAGE 3

SESSION ACTIVITIES TIME

 SCHEDULING RELATED ISSUES

 PROCUREMENT RELATED ISSUES

DRAFT CONSTRUCTABILITY REPORT REV. A PAGE 4

SESSION ACTIVITIES TIME

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SESSION ACTIVITIES TIME

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SECTION 1: PROJECT OVERVIEW

1.1 Project Description & location

1.2 Project Objectives

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SECTION 2: CONSTRUCTABILITY REVIEW, TEAM PARTICIPANTS & WORKSHOP

Participants in the review were:

See attachment on next page

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SECTION 3: CONSTRUCTABILITY OBJECTIVE

1. Constructability program are made integral part of project execution plans.

2. Project Planning actively involves construction knowledge.

3. Early construction involvement is considered in development of contracting strategy.

4. Ensure the overall project schedule is construction driven.

5. Basic Design approaches consider major construction methods.

6. Site layout promotes efficient construction.

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SECTION 4: CONSTRUCTABILITY REVIEW SUMMARY

 Organizational Related Issues

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SECTION 5: GENERAL CONSTRUCTABILITY CONCERNS

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SECTION 6: GENERAL CONSTRUCTABILITY CONCEPTS

 Construction efficiency needs to be considered in specification development. Common

 Constructability is enhanced by the following considerations. The standard specifications

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1. Contractor to consider one additional gate for accessing

Contractor shall build concrete patch plant at parcel-5 to mm/dd/yy

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During the windy season critical/ heavy lifting will be stopped,

Construction contractor shall submit heavy lift plans and

It is envisaged to use both Mobile and Tower cranes during

It is recommended to clearly mark the load weight of the

Construction methodology by contractor to clearly specify the

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Recessed Panels are 4m wide and to avoid showing joints inside

Recessed panels on balconies are hard to install which requires

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Contractors shall follow OSHA 18000 requirements

13 Storage Sensitive control equipment has to be stored in a controlled