Professional Book
Index Dear Reader
Buildings Practice
Plants
Facility
Petrochemicals
Industrial Projects
Onshore
An Overview
Preface
The objective of this work is to present to the engineering reader information about the practical professional aspects of Engineering involvement within Oil & Energy Industrial facilities promotion. These industries produce various types of gases in condensed form for the transportation through the pipelines for supply to the real consumer or the end user and also various petrochemical products as well as many bye products are produced. All disciplinary budding working engineers in the industry & particularly in the execution field shall be benefited by the information provided. The contents have been extracted from the practical experience earned in the field.
A brief on the description of the terms used has been included. It has been noted that experiences attained are usually not recorded on documents for the benefit of the incoming young engineers to learn from the seniors’ experience resulting adversely on that these budding engineers depend solely on their individuals exclusive learning in the field based on the university learning which is not virtually adequate for a fast progress achievement. Therefore, to fulfill the requirement to extend the learned resources to the incoming new engineers, this small work in hard copy is presented to help those who intend to know in advance about an overall perspective of building new facilities or extending the existing one to further development.
The information has been given in text only. No photo or diagram could be incorporated as under the obligations of the contracts such information should not be revealed for a definite number of years from the contract commencement day to maintain the secrecy conduct clause on various contracts. Only certain google earth images included to assist the reader. This work may not provide with the in-depth specialized subjective knowledge but definitely, illumine with an idea how the procedures move in the field which knowledge cannot be drawn from the university.
This book might prove beneficial for the candidates aspiring to become Certified Professional Engineers within the purview of EMF (Engineers Mobility Forum, the Bharat represebtation by The Institution Of Engineers India). Of course, the contents of the book are very boring but practical. The contents vary in nature including the usual procedures of the EPC nature of contracts involving in general types of Industrial jobs carried out in the industry. Also, included certain statements & reporting procedures as well as contract matters generally adopted. It is uncommon among engineers to be used to reading this type of work but practically, it is necessary. It is hoped that reader shall enjoy the boring work.
I am grateful to Cdr Eng A K Poothia, The Secretary & Director general of The Institution of Engineers (India) for commending this work & extending most useful advise for which attempts were made to incorporate to some extent. Attempts shall continue to incorporate the readers’ suggestions as much as practically feasible.
Author -– IEI Professional Engineer Suraj Singh August 15, 2009March 8, 2006
Published by – Ms Sumitra, SLSM Publishers, Edited by Dr Mala Saini MBBS, 3373, Delhi Gate, New Delhi 110002
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Refer to the various photographs appended somewhere else.Source Google
| |Index |Heading |
|1 |Chapter 1 |Industrial development, policy, components |
|2 |Chapter 2 |Project Design, Contract award & Miscellaneous |
|3 |Chapter 3 |Engineering |
|4 |Chapter 4 |Construction & Controls |
|5 |Chapter 5 |Testing- Pre Commissioning, commissioning, start up, performance |
| | |& maintenance |
|6 |Chapter 6 |Project management |
|7 |Chapter 7 |Detailed Engineering Requirements |
|8 |Chapter 8 |Building Design Concept |
|9 |Chapter 9 |Procurement |
|10 |Chapter 10 |Construction |
|11 |Chapter 11 |Pre-Commissioning |
|12 |Chapter 12 |Execution Plan |
|13 |Chapter 13 |Environmental clauses for plant Industrial city in |
| | |Construction Contracts |
|14 |Chapter 14 |HSES |
|15 |Chapter 15 |Commercial Sub Contracts |
|16 |Chapter 16 |References |
Chapter 1
General
A Industrial development- Processing Facility formation
(Refer to photos)
It is necessary in the interest of the economical development, industrial project should be efficiently promoted as Industry being backbone of a nation. Sooner the industry creation, better the prospects for the nation. Therefore, the value engineering should efficiently be applied for the product proposed to be facilitated to enable the consumer delivered with the most economic & qualitative products.
B Policy decision- Authorization-Technology Promotion
The government should promptly decide relevant policy in a positive manner for the time is extremely important to be used properly to get the optimum use of the project provided adequate funds are available within the budget or finance borrowing should be made. Value engineering should be properly studied by experts to reach a conclusion that the product shall be processed imparting no adverse effect to the environment, shall be most economical in production cost, shall be easy to be transported to the end user facility, shall be most beneficial to the society from every aspect/view of cost & economy uplift as well as shall promote the technology & provide benefits to the people globally in long run.
C Facility requirement –
Value Engineering effective application, Effective Technology, Product end User Requirement Necessity, Approval & Financing, international competition, Cost effectiveness & environment tenability, Sustainability. Should these points be met by the proposal, the project may be given a go ahead subject to the meeting other criteria.
D Facility Justification & Feasibility –
Environment sustainability - Cost viability in long term – Nationally beneficial to add to economic growth – multi purpose approach & creation of employment casual as well as regular. Export potential of the product.
Processing Technology & availability of raw material.
Adequacy of availability of terrain & routes.
Selection of the planning & execution mode. Availability of the expertise & experts along with all other inter related professionals.
A Components Elements of any Facility - inclusions in general
1 Availability of the natural gas or oil fields from where the natural resources are being tapped out at offshore location
2 Availability of the land for the required processing area onshore with acceptable terrain that may be used for the complete chemical engineering applications as well as transportation of the processed products to the outlet leading to the consumers’ locations
3 Plant processing scheme & Technology with legal license for the defined period
Liquefied Natural Gas tanks, cryogenic containments with spillage & other components etc for the storage purpose at minus temperature
Plant processing trains elements, complete with complete descriptions of heavy & light industrial equipment
4 Utilities areas element for the integration with plant equipment
Off sites element for sub assistance to aforesaid
Intake Piping for circulation & delivery into plant equipment for cooling
Seawater basin for storage of seawater & delivery to plant
5 Piping, pipe supports, pipe sleepers & pipe racks for the product transportation & handling
Service air & Instrument air circulation piping
Chlorination plant & its system for the purpose of chlorinating the water
Storage & Warehousing for the physical handlings of subsidiaries
Drainage infrastructure from plant to receiving basin & then to outfall structure through the discharge channels duly provided with metal lugs & channels
Ditches completely lined to carry out to the final discharge the storm water from various catchments areas of the plant.
6 Complete Package drainage system for, oily water, acid water, dusty water, sewage etc.
7 Water line for the whole site for various purposes including loss prevention i.e. fire fighting with fresh water as well as back up sea water supply
8 Cooling water line throughout the whole industrial area zone taking in water from the intake at sea, supplying to the industries & then through the return headers discharging to the sea directly after being supplied once as well as employing cooling water system technology to re-circulate the water & only make up water to be supplied.
9 Pipe supports, pipe anchors, general anchors, big anchors/thrust blocks at various spacing. Pipes supports to be connected to sleepers & direct supports using structural steel connection for both direct clamping as well as achieving sliding action to make up for the expansion
10 Electrical heat tracing system for the piping system carrying minus temperature liquid or gas to keep the pipe on required temperature not allowing freezing of the material for example Sulphur can freeze within pipe line.
11 Administration as well as Amenities buildings elements for the operation & maintenance as well as supply that should contain various offices with access control
12 Electrical main, sub stations, switchgears, package sub stations, Pump houses, Guard houses, Visitor’s areas, Ring Main Units, transformers, heavy duty armoured cables
13 Central controlled as well as Operations building to control the whole plants from one single location
14 Consumer receipt stations to be used by the consumer delivery control
15 Pump houses at various locations
16 Water retaining structures such as sumps, receiving basins, drainage channel, outfall discharge to the sea.
17 Site security arrangements, fencing, surveillance
18 Site telecommunications
19 All loss prevention arrangements including internal & external fire fighting.
20 Adequacy of plant & non- plant area of roads & paving, maintenance tracks, road crossings, utility crossings, road culverts, pipe culverts, transit manholes,
21 Soil erosion protection for the machines & equipment
22 Facility bye product plants as extensions & every required elements for that.
23 All related civil engineering disciplinary structures for the buildings, sheds, equipment vessels as well as other equipment.
24 Vessels such as cracking furnace, wash water structures, cracked gas compressor, propane compressor, ethane compressor, boilers, auxiliary boilers, various types of spheres, steel tanks, fuel towers, rotary equipment, reciprocating equipment etc. Shall be a part of the plant & necessary foundations for these be constructed according to the requirement. Massive concrete blocks shall be required for many of such major foundations.
24 Civil engineering foundation structural requirement shall vary from a simple machine plinth to independent footings to combined footing to strip footing to raft & piles as well as massive block foundations. Concrete shall generally be low heat cement based produced by using micro silica or GGBS ground granulated blast furnace slag replacement up to an extent of 70% as also pulverized fly ash PFA. The bases of pipe racks may be either steel structure or RCC construction. Foundations of the pipe racks shall generally be of RCC bases or independent footings.
25 Overhead crossing shall be required at many locations for the pipe to jump over roads.
26 Cathodic protection boyh critical & non critical requirement for the corrosion control of the reinforcement from a central control anode station shall also be necessary.
27 Earthing for the individual structures, equipment as well as network.
28 Coloured Covered Cable trenches RCC walled, buried directly to ground or cable ducts shall also be included in design forming a major part of the facility. These ducts shall be coordinated to various interface crossing requiring site resolutions to protect interface clashes.
29 Heavy-duty Concrete pavement shall be required in the plant area for the purpose of the maintenance of the machines as well as movement of heavy vehicles. On the area where no pavement is included, stone aggregate shall be spread & compacted to avoid soil effect on the vessel or equipment.
30 In addition important administration areas shall be given an attractive soft & hard landscape provision. Access security arrangement shall also be made with automatic controls using card readers etc.& installation of CCTV.
Inclusion of flare towers & radio masts is also contemplated.
B Components brief
LNG tanks- (Refer to photo) These components are meant to store Liquefied Natural Gas 80000cum capacity each within the steel tank. A RCC with pre-stress arrangement for the cables structure of about 80 m dia, 800 mm thick wall as we as a height of 50 m was used for the prevention spillage. Each tank was provided a spillage tank outside at finished ground level. The top of the tank was a permanent formed cupola structure raised to the level by compressed air. Cryogenic steel was used to maintain about (–)60 degrees temperature of the condensed gas. The concrete of the circular walls was poured using kwickform in 5 m lifts. A cantilever operational platform was constructed on the cupola.
Compressors- (Refer to photo) Compressors are to be installed as a part of trains for the Ethylene production unit. Being heavy reciprocating machines to be installed on massive foundations at elevated levels tabletops are constructed resting on massive concrete foundation. Foundation concrete for one compressor being 400 cum about 25m long, 12 m wide as well as 2 m deep. This carried thick columns above to support tabletop. Steel plate inserted between the equipment & epoxy grout. Tabletops are constructed of thick framed slabs resting on thick columns. The arrangement of the tabletop slabs are complicated in all respects about civil as well as mechanical inserts. Such type of thick & massive elements require special type of cement probably with high slag replacement which could be pulverized fly ash or ground granulated fibres or microsilica. Particular arrangements are worked for the curing solutions for such low heat generating cements to effect thermal curing methods.
Cracking gas furnaces- (Refer to photo) this meant for the purpose of cracking gas from the refinery as bye product for the transmission to the compressors for the production of ethane as well as propane. These are tall heavy structures vertically oriented in group of vessels & founded on a common base.
Other structures (Refer to photo) included wash water structures, auxiliary boilers within the processing train. Also included various spheres to contain gases as well as tanks for storage. Foundations for the tanks are generally constructed of RCC ring beams. Other structures are provided with independent footings stripped using grade beams.
Seawater basin- (Refer to photo) A RCC open reservoir meant to collect water from sea through 2 # 84” pipes, supply to the plant various trains requirement & after cooling the system dispose water to be disposed from the industrial locations to the receiving basin & then to outfall chamber. It is a huge voluminous open structure constructed of RCC base slabs provided construction joints during construction, peripheral retaining walls up to 12 m high not more than 9 m panel as well as covered pump house area & baffles. Such structures must be water tight from all locations of the water storage portions duly tested for water tightness using BS 8007 criteria. Concrete protection is applied for both below ground as well as above ground surfaces.
Many other stationary (Refer to photo) as well as vibratory equipments are included for the processing plants for which foundations are constructed accordingly either as footings bases or combined footings. These horizontal or vertical vessels are erected on these bases connected using anchor bolts & grouting done between the sitting steel plate & the top of concrete. For vibratory equipment, epoxy grouting is applied while for stationary, cementitious.
Sump chambers – These covered chambers are used for the collection of water from various catchment areas & constructed of RCC underground structures duly tested for water tightness using BS 8007 criteria. Concrete protection is applied for both below ground as well as above ground surfaces.
Manholes, catch basins, rainwater ditches, etc are constructed using RCC.
Manholes are meant for the sewerage line oily manholes for oily discharge, catch basins for rainwater. Generally, these units are in large numbers for any plant area making it preferable to produce by pre casting on site for which all working details for the yard are required to be issued to site.
Open ditches are constructed for the discharge of storm water. These ditches can also be used for the purpose to give way to fire water disposal during any fire on the installation. This may also be used for the purpose of any water line maintenance discharge from any single loop. At the commencement the section is shallow but as it reached moving within various catchments, the section is considerably deepened like a big drain.
Piping (Refer to photo) of carbon steel or ductile iron or Fiber reinforced plastics family GRP, ERP, GRE etc are used depending on the requirement & structural adequacy to sustain various imposable stresses. Stress analysis is carried out for various loops giving the location of various supports as well as anchoring requirement. Various types of supports are designed for varying diameter of the pipes for the on ground or underground or aboveground use.
FRP (Fiber Reinforced Plastic) Pipes
RTRP stands for reinforced thermosetting resin pipe, a composite material consisting of a thermosetting polymer, a type of polyster reinforced with glass or other fibers that provide strength & stiffness to a composite material. Different types of resins used for manufacturing GRP, GRV & GRE pipes are Isophthalic resin, Vinylester resin & Epoxy resin respectively that are selected according to the required properties like chemical resistance, temperature resistance & mechanical properties. The resins provide thermal & chemical properties such as glass transition temperature, resistance to heat, chemical resistance etc. required for finished product. The properties of GRP pipes can be varied by changing the ratio of raw materials as well as winding angle. These pipes consist of three layers adherent to each having different characteristics in relation to functional requirement.
Inner Liner – Veil (Glass), Resin: CSM (Glass), Resin
Structural wall - Roving (Glass), Resin
External liner- Veil (Glass), Resin
Inner Liner – Veil (Glass), Resin: CSM (Glass), Resin
Inner Liner one is chemical resistant being in direct contact with fluid & therefore, responsible to resist chemical corrosion as well as permeability. The internal surface is particularly smooth to reduce the fluid head losses & also opposes the growth of minerals & algae. Lines has two monolithic sub layers. Inner in contact with fluid is reinforced with glass veil with a resin content 90 %, outer reinforced with CSM glass with resin content 70 % by weight. The standard liner thickness is about 0.5 to 1.5 mm.
Structural wall - Roving (Glass), Resin
Glass Reinforced layers guarantee the mechanical resistance of the whole pipe against stresses due to internal & external pressure, external loads as well as thermal loads. For GRP / GRV pipes, the layer is obtained by applying on the previous partly cured liner continuous riving of glass wetted with resin under controlled tension. For GRE pipes, the structural wall is wound directly on a wet liner. The layer can contain aggregates like silica sand if allowed by specifications while thickness depends on design conditions.
External liner- Veil (Glass), Resin
Topcoat or external liner is the outer layer of pipe consisting of pure resin. UV protectors may be added if so required to protect the pipe from solar exposure. In case of severe exposure condition like aggressive soils or very corrosive environment, the external liner can be reinforced with a surfing veil or added with filters or pigments.
Fiberglass composites consist of glass fiber reinforcements, thermosetting resins & additives designed & processed to meet specific functional performance criteria.
Amount, type & orientation of glass fibers in pipe provides mechanical strength. C Glass, E glass & ECR / Advantex glass are used commonly depending on pipe application. Various forms of glass reinforcements are surface veil, chopped strand mat (CSM), chopped roving, filament roving & woven roving (WR).
Raw materials like catalyst, accelerators, inhibitors, aggregates & pigments are used together with resin & glass reinforcements to achieve desired properties of fiber glass product. Catalyst is an organic compound which when added to resin in presence of an accelerator determines the polymerization reaction at ambient temperature. Acceletor is a chemical compound used together with a catalyst to shorten the polymerization time. Inhibitor is added to the resin to reduce reactivity at ambient temperature.
There are two manufacturing processes Dual helical filament winding process & the other being Continuous winding process (Drostholm)
Pipe racks (Refer to photo) are used for the purpose of running the piping from one point to the other over ground levels. These are generally steel structures founding on RCC footings but RCC frames structures are also used. Several km of pipes are run on these racks supported & anchored to the rack structures. These are fully accessible structures for maintenance purpose. Open flooring is provided.
Heat tracing is applied on the piping carrying minus degree gas which may freeze during flow & block pipes for the protection of which, the heat is continuously maintained on the piping to keep the gas in the condensed form. Various loops are provided on the piping routes for various purposes.
Pipe supports / sleepers are used for the purpose of carrying the pipes at near ground levels. These are RCC units located at defined spacing. For direct support of the pipes, steel structural supports are used remaining connected or touching pipe by shoes over lengths at various spacing meant for the purpose of sliding also. For deciding the locations of the supports & the anchorage, stress analysis is conducted that dictates the spacing, dimensions & the pipe structural base design. For a pipe of dia not more than 4 m, not more than 12 m spacing is adopted. For other smaller dia pipes, the spacing depends up on the standard length of the pipes. Pipes that need sliding movement at the joints are provided such a base that allows the movement of the pipe in the direction of its run. For that, PTFE (Poly Tetra Fluro Ethylene) bearings fixed on steel plates duly designed to withstand imposed force are provided. Below the pipe support shoe steel portion, a stainless steel plate is provided so that this plate slides over the PTFE pads.
Anchor sleepers, big sleepers, thrust blocks are used at various points depending on the stress analysis requirement on the en-route pipeline. These are thick & voluminous structures requiring thousand of cum of RCC for an individual sleeper connecting a group of pipes. On the pipe loops various kinds of stresses from all directions are imposed during operations or flows which are to be resisted by these sleepers. At the change in directions of the pipe routes as well as at the Tee locations etc, big sleepers or thrust blocks are provided to resist the resultant forces. These are constructed of massive blocks of RCC.
Access platforms are constructed to access to an area above the pipe level for the maintenance purpose. EOT cranes are installed for the maintenance as well as lifting & placing the pipes & other items in the shops. These also meet the crossing over pipes requirement. Proper ladders, handrails & open floorings are provided for the safe access.
RCC box culverts are used for the cross over of the underground pipes below roads. Pipes culverts are also used wherever required. For the accommodation of the spillage tanks, bunding is carried out around to hold oil during spillage. Pipes are connected to the base slab using steel connecting arrangements. Enough space is allowed for the maintenance purpose for free movement as well as circulation.
Receiving basin is meant for the collection of used water purpose to further discharge into the outfall at the sea. This is also a considerable size of structure collecting water from the return piping headers discharge, letting it accumulate & the dispose into the outfall channel for further discharge into the sea. Various types of steel stop logs are installed to control the flow according to the capacity of the channel & the receiving basin keeping abreast also the maintenance function of the piping. Structure consists of RCC retaining walls in the flow direction & RCC base slab.
Flare towers (Refer to photo) are required to establish a system to dispose safely into the environment the gases that cannot be used any further keeping in view that the compositions of the disposable gas does not deteriorate the environment. Height of these towers are kept considerably so that gases are burn away into the environment safely. Proper arrangements are done for the founding as well as the stability of the tall structure.
Pump houses are installed as large size & highly elevated steel buildings housing a train of various pumps, electrical equipment, chlorination plant, rotary drums, intake equipment etc. The piping is routed on ground, vertically as well as horizontally on various types of supports of complex design. Various types of structural steel access platforms are built for the operational & maintenance purpose. These water is pumped into the supply manifolds located just outside where is applied the chlorination & then the pipes are routed to the main route on ground up to various industrial users. Hundreds of thousand cum of RCC structures are built for the supporting bases as well as for the anchoring arrangements depending -
General components for other facilities
‘Train’ indicates the separate process trains.
‘String’ indicates parallel process line-ups of equipment within a train
‘Common’ to be used for equipment that does not exclusively belong to one
train but serves the total complex.
Process / Unit : Slug Catcher - Condensate Stabilisation (Column) - Flash Gas Compression - Acid Gas Removal - Dehydration, Mercaptan and - Mercury Removal Unit (Operating + Regeneration)
Sulphur Recovery Unit; Sulphur Degassing - Claus Offgas Treating - Off-Gas Thermal Oxidation - NGL Extraction and Fractionation (Overall) - Refrigeration Unit - LPG and Ethane Treating Unit (LTU) - Field Condensate Treating - Plant Condensate Treating - LIN & LOX Storage & Vapourisation - Air Separation Units (ASU’s) - SGP Reactors - Syngas Treatment - Steam Methane Reformer SMR Unit - One SMR plus one Pre-reformer 1x 50% One SMR plus one Pre-reformer
Hydrogen Manufacturing - One High Temperature Shift (HTS) and PSA unit with compression 1 x 50% One High Temperature Shift (HTS) and PSA unit with compression - Heavy Paraffin Synthesis - Water Distillation Unit - Catalyst Activation and Regeneration - Light Ends Stripper - Light Detergent Feedstock
Heavy Paraffin Conversion - Synthetic Crude Distiller - High Vacuum Unit
Catalytic Dewaxing - Base Oils Re-Distillation
Reliability and availability, particularly system uptime are key project drivers. A
systems effectiveness model shall be developed for the complex comprising the base case configuration of the offshore facilities and GTL (Gas to liquid) plant configuration
FEED for the project units so that the required overall system effectiveness of
335 stream days per annum is reached in a cost effective manner.
The offshore development concept is based on direct transportation of the
produced fluids and gas from the wells on platforms to shore without any offshore
process or treatment. From each platform, there shall be multiphase carbon-steel
trunk line to the common slug catcher. Chemical injection and regular pigging shall
be applied for corrosion as well as hydrate formation inhibition to the carbon steel lines. The produced fluids are received into the slug catcher in the upstream onshore facilities.
Onshore upstream - comprises Slug Catcher - Condensate Stabilisation - Acid Gas Removal - Sulphur Recovery (Claus Unit) and Storage - SRU Offgas Treating or SCOT Unit - Dehydration and Mercaptan Removal - NGL Extraction and Fractionation - Final treating for finished NGL products: LPG and Ethane Treating Unit
Field and Plant Condensate Treating
In the Onshore Upstream facilities, Condensate and water / kinetic hydrate inhibitor (KHI) & corrosion inhibitor ex the slug catcher are separated. Water is sent to a dedicated effluent treatment which caters for the KHI and possible saline components. Condensate is stabilised and treated (for sulphur removal / conversion) for export sales. Wet feed gas ex the slug catcher is routed to gas treatment followed by NGL extraction and fraction. The gas treating facilities remove sulphur components, water, CO2 and mercury from the feed gas.
Treating of the ethane (ethane recovery and treating facilities shall be installed later) and LPG products to further remove residual traces of sulphur, water and CO2. The sulphur components so removed shall be converted to elemental sulphur for export as liquid sulphur.
Onshore downstream: Synthesis
The onshore downstream synthesis comprises
Gasification Process- Air Separation Units- Heavy Paraffin Synthesis- Catalyst Activation & Regeneration - Water Distillation - Steam Methane Reformer - Hydrogen Manufacturing - The ASU’s main purpose shall be to produce oxygen for use in the SGP as well as also produce HP Nitrogen for the CAR unit, LP Nitrogen and compressed air for use as site utilities.
In the SGP syngas shall be produced from natural gas (NG) and oxygen by partial oxidation. The SGP produces the majority of the syngas for subsequent conversion to a synthetic heavy paraffin stream in the HPS. The SGP syngas requires treatment to remove soot and undesirable by-products.
In the SMR hydrogen rich syngas shall be produced from NG and steam by a catalytic reforming process. The SMR syngas has a higher H2 content than the SGP syngas and is used to supplement the syngas feed going to the second stage of the HPS reactors.
The reaction in the HPS follows the Fischer-Tropsch chemistry and produces significant quantities of process water as a by-product.
The WDU shall be used to strip hydrocarbons from the process water which be subsequently sent to the effluent treatment plant for recovery.
The CAR Unit shall be used to regenerate the HPS reactor catalyst.
The HMU uses a High Temperature Shift (on a part of the SMR syngas) and a PSA Unit to produce an ultra pure H2 stream mainly for use as a reactant in the SMR and the Liquids Processing Unit.
Onshore downstream: Liquids processing
The onshore downstream liquids processing scope comprises
Light Ends Stripper - Heavy Paraffin Conversion - Synthetic Crude Distillation & Stabilisation- Light Detergent Feedstock Units
Base Oil Units:
High Vacuum Unit - Catalytic De-Waxing Unit - Base Oils Re-distillation Unit
The LES, LDF, HPC, SCD & Base Oil (HVU, CDW and RDU) Units shall be also collectively referred to as the Liquids Processing Unit or LPU. In the LES Unit water, CO and CO2 be removed. In the LDF Unit, components shall be recovered and after hydrogenation, rundown to storage for sale as a product. The remainder of the HPS product shall be routed to the HPC where the paraffinic molecules are cracked and isomerised into middle distillate range components, which are subsequently distilled by the SCD into LPG, Naphtha, Kerosene, Gas Oil and an SCD bottom product stream. In the “Base Oil” mode of operation, the SCD bottom product stream is routed to the HVU for further separation into Vacuum Gas Oil, a Waxy Raffinate fraction and a residual fraction, that is recycled to the HPC. The Waxy Raffinate fraction is shall be catalytically isomerised in the CDW and then separated into products according to boiling range and viscosity in the RDU. In the “No Base Oil” mode, the SCD bottom product stream shall be recycled to extinction back to the HPC. For the no Base Oil case, the throughput of the complex is limited by the capacity in the HPC (one single maximum size reactor per train).
Supporting facilities: Utilities
Utility systems comprise - Boiler Feed Water, Steam & Condensate Systems - Raw, Demineralised, Potable & Service Water Systems - Power Generation and Distribution - Cooling Water Systems: Cooling Water System, Chilled Water and Closed - Cooling Water System - Instrument and Tool Air System - Nitrogen System - Heat Transfer Fluid System - Aqueous Ammonia System
Utility systems shall be designed to allow stand-alone operation of the GTL complex. Steam and gas turbines shall be provided for shaft power and generation of electrical power. The steam shall be generated in the synthesis section thereby effectively utilising the exothermic heat of the process reactions. Auxiliary boilers and gas turbines with Heat Recovery Steam Generators (HRSGs) shall be included to facilitate black start capability, to enhance reliability of the steam and power system. Cooling shall be principally by air but cooling water may also used where appropriate. Steam is the principal heating medium but fired heaters and a heat transfer fluid system shall be provided for specific applications.
Supporting facilities: Storage & off-sites - Storage and Offsite Systems comprise Relief & Blow down System, including flares - Drainage, Collection and Primary Treatment - Effluent Water Treatment - Sour Water Stripper - Flushing Oil System - Storage and Loading Facilities including onsite product storage - Slops & Intermediate Storage. In general, plant condensate (blended with naphtha) and GTL products shall be stored on site and transported to the RLC harbour for shipping. Field condensate shall be stored in an on-site as well as an off-site shipping tank prior to export via the RLC harbour. LPG shall be transported directly to the RLC facilities for refrigeration, storage and export. Liquid sulphur shall be piped to common RLC facilities.
Design Basis – Mechanical Equipment
Table Of Contents
1. General, 2. List Of Codes, Specifications and Standards, 3. Design Basis – Mechanical Equipment, 4. Equipment Selection, 5. Spare Parts, 6. Shop Testing
Design Basis – Mechanical Equipment
Objective
The purpose of this part is to provide the design basis for all mechanical
equipment (rotating equipment + static equipment) on scheme. It shall be used for
verification of selection and detailing / sizing of equipment for procurement engineering
(while developing EPIC documentation). The plant facility design and installation
shall consider 100% equipment redundancy (where applicable), 100% availability of the plant, Equipment selection to ensure 99.7% reliability, environmental conditions. The packages and equipment shall be suitable for outdoor installation in salt laden, saliferous and highly corrosive atmosphere prevalent at open Coastal area. The Basic Engineering Data developed shall be applied for development of FEED documents.
Design Life & Experience
Mechanical Equipment and associated auxiliaries shall be suitable for the specified
operating conditions including any upset, start up, shutdown and emergency, be designed and constructed for a minimum service life of 30 years with equipment
providing at least 2 years of uninterrupted continuous service while first major over-haul
requirement not before 10-years being a design criterion. Vendor experience for previous supply of at least 2 validly similar design equipment and proven track record of at least two years trouble free running history / experience (in conditions similar to this project conditions) shall be applicable.
List Of Codes, Specifications and Standards
The main cooling water pumps and associated auxiliaries and other mechanical
equipment shall be designed and manufactured in compliance with the Requisition,
documents listed in the Requisition and applicable specification / data sheets included elsewhere for the consideration as part of the FEED.
Applicable Codes, Standards and Reference Documents
The Equipment Specification lists the applicable International Codes and Standards.
Reference to any Standards or Codes shall mean the latest edition of that Standard or
Code including addenda or supplements or revisions thereto as on the effective date of
contract.
Project Documents, General, Project Design Basis, Technical Specification of Vibration Monitoring System, Piping Material Specification, company specifications, Lifting Equipment Technical Regulations, RA Pressure Vessel Design and Fabrication.
RA Above ground Welded Storage Tanks, RA Pressure Vessels, RA Air Cooled Heat Exchanger Design and Fabrication, Plate Heat Exchangers – Design and Construction
RA Piping General Design, Diesel Engines, Diesel Engine Driven Generator, Equipment Identification and Tag Numbering, Standard Specification for Painting and Wrapping of Metal, Surfaces, Company standards applicable to other disciplines shall be listed in individual, Equipment specifications and data sheets included elsewhere for the consideration as part of the FEED.
International Codes and Standards
API RP 500 Recommended Practice for Classification of Location of Electrical Installation, API 610 Centrifugal Pumps for Petroleum, Heavy Duty Chemical and Gas Industry Services (relevant sections shall be applicable), API 520 Sizing Selection and Installation of Pressure Relieving Devices. API 526 Flanged Steel Pressure Relief Valve
BSEN 13414 Steel Wire Rope Slings, Safety Standards, API 650 Welded Steel Tanks
UBC Uniform Building Codes (Earth Quake Zones), API 2000 Venting Atmospheric and Low Pressure Tanks, API 670 Vibration, Axial Position and Bearing Temperature Monitoring, Systems. API 673 Centrifugal fans for Petroleum, Chemical and Gas Industry Service. BS 848 Fans for General Service, HI Standards (HI-2.6) Hydraulic Institute Standards on Centrifugal Pumps, NFPA20 Standard for the Installation of Stationary Centrifugal Fire Pumps for fire Protection, NFPA 24 Standard for Installation of Fire Mains, AWWA American Water Works Association, ANSI B 73.1M Horizontal Centrifugal Pumps, ANSI B73.2M Vertical Centrifugal Pumps, ISO 2858 End Suction Centrifugal Pumps, API 675 Positive Displacement Pumps – Controlled Volume, ASME Sec.VIII Rules for Construction of Pressure Vessels (Div. I), ASME Sec. II Material Specifications (Part A, B, C & D), ASME Sec. V Non-Destructive Examination, ASME Sec. IX Welding and Brazing Qualifications, BSEN 10204 Types of Inspection Documents – Metallic Product, BS CP3, Chapter V Basic Data for Wind loads
Part2, ISO 9001 International Organisation for Standardisation, ISO:3046 Standards for Combustion Ignition Engines, ISO : 10440 (Part 2) Packaged Air Compressors (Oil Free), FEM Standards Federation of European Manufacture Standards on Drum Screens, ASME B30 Crane Safety Standards, ASME B16.5 Steel Pipe Flanges and Flanged Fittings, ASME B31.3 Petroleum Refinery Piping, ASME B16.5 Pipe Flanges and Flanged Fittings, ASME B16.47 Large diameter steel flanges (NPS 26” to NPS 60”).
AMCA Air Movement and Control Association, ISO 1940 Mechanical Vibration – Balance Requirements of Rigid Rotors, ASTM A370 American Society for Testing and Materials – Standard Test, Method for Mechanical Testing of Steel Products
The principles to be adopted during the selection & specification of prime equipment and equipment within the package can be summarised as follows:
Design life being 30 years, High availability, Standard / Proven Equipment Model.
Safe to operate and Maintain, Typical subjects to be addressed / considered during the equipment selection and final preparation of the purchase requisitions are addressed in the following sections. The nameplates indicating major design parameters / specified parameters shall be screw attached to the equipment. Nameplates shall be in SS316 materials.
Equipment Standardization
The design of rotating / mechanical equipment shall ensure high equipment availability
and maintainability. Effort shall be made to standardise the spares stocking by
minimising the variety of makes and types of auxiliary equipment used within the
package. This standardisation shall be applied so far as it does not interfere with the
selection of an optimal solution for the specified operating conditions and duly considered equipment to minimize spares stocking.
Noise
Equipment design shall meet the noise level (85 dBA @ 1m) specified in Company
standards. It is Supplier’s full responsibility to ensure that noise level of supplied
equipment (including drive equipment as a combined unit) shall not exceed the
maximum allowable as specified in Project HSE Plan. Effort shall be made to select equipment with low noise level. Where it is not feasible despite the best design available, acoustic enclosures and / or acoustic insulation shall be provided.
Supplier shall submit estimated noise level, consider / advise measures that would be applied when equipment noise level exceeds to noise level specified at respective specification and data sheets.
Instrumentation / Controls
Equipment Supplier shall include all required package / equipment / auxiliaries controls
for safe operation of equipment. The instrumentation for communication with DCS shall
be included to comply with requirements specified in respective Equipment
Specifications, Data sheets and P&ID’s.
Equipment Covered
This design basis covers the requirement for the following equipment :
➢ Main Cooling Water Pumps - Vertically suspended, submerged pump end, mixed
➢ flow seawater service Pumps complete with electric motor drive, VSD, Transformer,
➢ Local Control Panel (LCP) and associated auxiliaries.
➢ Centrifugal Pumps (General Service); includes hypochlorite dosing pumps / dilution
➢ pumps etc.
➢ Submersible Motor Pumps (Portable); includes sump pumps and drain water pumps.
➢ Firewater Pumps (as per NFPA 20)
➢ Instrument Air Compressor and Dryer Package
➢ Centrifugal Fan (at Hydrogen disengagement Tank of Chlorination Plant)
➢ EOT Cranes / Semi Portal Cranes (Pump house, Mechanical Plant, Receiving Basin,
➢ Workshop / Warehouse and Piping Manifold area cranes)
➢ Fixed Bar Screens cooling water common raking facility
➢ Rotating Drum Screens
➢ Stop Logs (Intake and Receiving Basin)
➢ Emergency Diesel Generator Set.
➢ Vessels and Storage Tanks
➢ Electro Chlorination Plant Equipment
Equipment Selection
Main Cooling Water Pump Sets
The electric motor driven (through VSD), vertically suspended, submerged pump end
mixed flow seawater service line shaft Pumps with right angle discharge head shall
comply with Project Specification requirements, HIS Standards and in general
compliance to API 610 Standards (where applicable for this service such as pump rotor
dynamics, vibration levels, line shaft and thrust bearing design criteria etc).
The offered vibration monitoring system for pump / motor shall be in compliance with API 670 recommendations.
The pump datasheets shall address the pump drive train requirements; VSD’s, Local
Control Panel (LCP) and complete electrical set-up shall be provided by Pump Vendor
(single point responsibility for Tender Scope).
The vertical centrifugal pumps handling liquids whose vapour pressure is below
atmospheric pressure, can be provided with gland packing suitable for the service.
Pumps line shaft bearings shall be service fluid lubricated however, Supplier
incorporate pump bearing design or operation strategy that shall take care of start-up
scenario of stand-by pumps that would be with dried up bearings. The pumps shall be shop assembled to the maximum extent possible to consider minimum site assembly work and shipment limitations. The pump houses being in non-hazardous area while the pumps are operating in very corrosive environment i.e. salt laden sea mist, dust, wind etc. Flexible coupling shall be selected for the duty by main cooling water pump sets’ Vendor. Coupling guards shall be made from non-sparking material. The pumps and auxiliary items located at Pump House shall be designed for outdoor conditions as pump house is only a shelter with partially covered sides. Pumps shall be in parallel operation with head rising continuously to shutoff are required. Pump’s right angle discharge head shall be with expansion-joint to tie-in with downstream flanged CCV (Combined Check Valve).
In case of blocked discharge the specific unit shall be able to withstand shut off head
condition for at least 5 minutes without any damage to pump and its auxiliary items. In
case of CCV failure, the specific unit shall be able to withstand reverse rotation up to full
speed. Pumps materials for major items / wetted parts shall be specified in Pump data sheets for Vendor review, the selection correctness i.e. compatibility to service fluid / material grades availability etc. shall be the Suppliers’ responsibility for providing right pump sets for the service. Pump set items shall be new and shall be selected by Pump Vendor to provide the single point responsibility of meeting specified pump duty requirements and service.
Pumps selection shall consider common pump model (to the extent feasible) that
provides stable continuous operating range and includes governing process flow
requirements. To achieve this pump model commonality the pump driver could be of different rating and of different VSD speed range.
Pump model testing is required. Complete testing requirements shall be as specified in
pump specification and Data sheets elsewhere.
Centrifugal Pumps (General Service)
Centrifugal pumps for non-hydrocarbon service shall comply with Project Specification
and ANSI Standards B 73.1 M or B 73.2 M and ISO 2858; Pump construction shall be
specified on the pump datasheet elsewhere.
Two-stage overhung and single stage double suction overhung pumps shall not be
offered. Maximum allowable flow shall not be less than 120% of best efficiency capacity of the rated impeller. Pumps shall be selected so that it is possible to achieve 10% head rise / 5% head decrease at rated capacity by replacement with new impellers.
Pumps shall have head curves rising continuously to shutoff. Shutoff head shall
preferably be in the range of 110 - 120% of rated head.
Pump impellers shall be closed or semi-open type – open impellers are not acceptable.
Use of inducers to enhance NPSH is not acceptable.
The mechanical seal when specified in data sheet, shall comply with requirements of
API 682. Mechanical seal design and material selection shall be suitable for the service
fluid continuous operation with maximum operating temperature. Seal system piping
shall be as a minimum in SS 316L or suitable to service. Material of construction of pump components shall meet the requirements as specified in equipment data sheet and compatible to service. Coupling shall be forged steel flexible type with spacer. Removable coupling guards shall be made from non sparking material suitable for very corrosive environment. As a minimum, electric motor nameplate rating shall be as below. Motor Nameplate Rating Percentage of Rated Pump Power = 18.5kW 120 20 – 55kW 110 = 75kW 105. Inspection and Tests shall be carried out as per Engineering Standards and as covered in applicable specification.
Sump Pumps (Portable Submersible Motor-Pumps)
Portable Submersible Motor Pump shall be utilised for dewatering of pump house and
receiving basins. When piping sections are to be cleaned from sediments, the pumps
are required to be compatible with nature of seawater service fluid with sediments / grits. The Manufacturer’s Standard design shall be acceptable for sump pit installation drainage duty portable submersible motor-pumps. The pump motor shall be oil filled type and provided with two sets of mechanical seals for double security. Pump shall be fitted with cable and watertight cable connector. These drainage pumps shall be with lifting hook for portability and placed / lowered in sump pits of pump basin / receiving basin area whenever basin emptying is planned. For safe custody, these pumps shall be stored in warehouse / maintenance workshop when not in use. The tough duty submersible-motor pump’s housing and impeller shall be in aluminum bronze (or alternately in super duplex stainless steel) material and all major components subjected to wear be coated with polyurethane for longer service life in fine grain abrasive application. The pump impeller shall be semi open type. The pump motor shall be water jacketed to provide cooling to motor by service fluid.
Firewater Pumps
Fresh water service Firewater Pumps shall be planned to provide fire protection to equipment by deluge. The horizontal centrifugal type Fire Pump sets shall be in accordance with NFPA (National Fire Protection Association) 20 design requirements. One pump set shall be with electric
motor drive and other with a diesel engine driver. An electric motor driven jockey (make-up) pump shall also be installed to maintain the header pressure of fire Main Ring. The fire pump packages shall be with listed (UL / FM approved) pump set items and pump controller for fire protection service auxiliary items included in the packages comprise of circulation relief valve, water flow test devices etc.
The selected pumps shall be a listed one per Firewater Pumps specifications and
pump requirements in-line with NFPA 20.
Pumps shall get supply from storage tank(s) of adequate capacity for the expected
duration. Pump capacity selection shall be to NFPA 20 rated provisions and be specified at respective data sheets. Fire pump shall not furnish less than 150% of rated capacity at a total head of not less than 65% of the rated head and total shutoff head shall not exceed 140% of the rated head. Each pump shall have automatic relief valve listed for the fire pump service installed and set below the shutoff pressure at minimum expected suction pressure. The flexible coupling between pump and driver shall also be listed for the service.
When more than one pump is installed on single suction line, the suction pipe layout at
the pumps shall be arranged so that each pump receive its proportional supply. The automatically controlled Fire Pumps shall be provided with a listed float operated air
release valve (when automatically controlled deluge system is planned). The Fire Pump installation shall include water flow test devices to allow test of the pump at its rated conditions as well as the maximum flow condition. Metering devices for pump tests shall be listed. Each pump shall have its own test loop. Each individual pump shall be tested at the factory to provide detailed performance data and demonstrate compliance to specification. Jockey / Make-up pumps shall have rated capacities not less than any normal leakage rate and discharge pressure sufficient to maintain the system pressure.
Fire Pump Driver – The lead fire pump and Jockey pump shall be with electric motor drive while back-up fire pump with diesel engine drive. The diesel engine and drive train components shall be listed items for the fire pump service.
Controls – Each pump shall have its dedicated driver and each driver its controller. The controllers for the motor and diesel engine shall comply to specification of NFPA 20 Chapter 7 (motor) / Chapter 9 (engine).
Instrument Air Compressor – Dryer Package
The Air Compressor – Dryer Package construction shall be to Vendor Standards designed for Coastal Area installations. Package units (train of compressor and dryer) shall be installed on single lift skid and compressor unit be inside its enclosure for sound attenuation. The plant facility shall be provided with two numbers of packages operating under lead lag basis. Air Compressor shall be oil-free, air cooled, electric motor driven Screw type Air Compressor unit complete with its UCP (Unit Control Panel), lube oil console and air cooler for lube oil and compressed air (inter and after cooler of compressor). Package Start / Stop and lead / lag operation shall be monitored from skid installed UCP on pressure level signals. The daily maximum average temperature shall be considered for compressor and its compressed air cooler sizing. The oil-field type air-to-air heat exchange cooler in SS316 (SS – Stainless Steel) or construction with marine installation coating shall be specified to provide rugged construction in corrosive sea coast environment. The compressed air temperature down stream of air cooler shall be limited to 58°C (with air cooler sized for ambient temperature of 50°C).
Air Dryer unit shall be heatless PSA (Pressure Swing Adsorption) type complete with twin molecular seive (aluminum silicate) desiccants towers and timer based controls for air flow switch-over. This unit shall be located downstream of Air Compressor unit and shall handle specified flow delivered by upstream air compressor unit. Compressed air shall be stored in Plant’s Service Air Storage Vessel and dried instrument quality air stored at Instrument Air Storage Vessel sized to cater for the Plant needs. Package instrumentation (PLC controls) for lead-lag controls shall be in Vendor’s local control cabinet; DCS communication as per package P&ID shall be achievable as a minimum battery limit pressure, temperature and dew point level shall be reported besides running status. A common facility delivering complete plant needs including instrument air needed for Chlorination Plant is envisaged in this Phase of project.
Fans (Cf Blower) - Fans shall comply with requirements of specifications generally per API 673 and company engineering standard. Fans shall be sized to deliver the air flow & differential pressure required for the H2 disengagement duty under all operating conditions. Normally two fans (2 x 100%) shall be installed each to run and deliver the required dilution air – with automatic switch over controls to other fan in case one fan trips. The power margin for electric motor drivers shall be in accordance with Specification at the rated conditions. Fans shall be provided with barrier type filter systems, filter shall be suitable for severe sandy & dusty atmosphere with rain hood and bird-screen. Fans shall be shop tested for the performance and stand by switch-over controls.
Electric Overhead Travelling (EOT) Cranes / Semi Portal Cranes
EOT Crane -
The Pump House is provided with maintenance duty EOT Crane to handle load lifts
during pump overhaul and general lifting needs. Currently PH has one 17m span
crane with main hook capacity of 60T and auxiliary hook capacity of 14T. The power
distribution to the long travel is by enclosed type bus bars system (with rubber lip seal)
and cross travel / hoisting power distribution is through power festoon cable system. In
Project, the possibility of extending the long travel of installed crane and any
considerations for additional second crane shall be reviewed (as a separate study) and
study recommendations shall be implemented. The crane construction as defined below
shall apply for any additional crane purchase.
The EOT Crane shall be top running double girder type designed for maintenance duty class 2M (FEM 9.511) and suitable for safe area outdoor location (though installed in Pump house shelter). The crane shall be with operator cabin located at one end of the crane bridge (girder) & provided with remote radio communication set-up for crane operator use. The complete crane shall be designed to provide access platform / service walk-way for servicing the equipment and flood-lights to illumine the work area. The power distribution to the long / cross travel and hoisting motion shall be Similar to Phase power distribution system, crane controls to incorporate normal and creep speed motion controls for precise adjustment. Crane load lift capacity per Phase crane and provision for auxiliary hook shall be maintained as the load lifts provision are with adequate margin.
Semi Portal Crane -
The Mechanical Plant (Screen Yard) is provided with maintenance duty Semi-Portal
Crane to handle load lifts during drum screen overhaul and general stop log lifting needs. Currently has one semi-portal 23m span crane with main hook capacity of 10T.
The power distribution to the cross travel and hoisting motion is through power festoon
cable system and long travel by cable reel. In Project, the possibility of extending the long travel of installed crane and any considerations for additional second crane shall be reviewed as a separate study. The crane construction as defined below shall be applied when any additional crane purchase shall be in picture. The semi portal Crane shall be top running double girder type electric overhead traveling crane with one end of the crane bridge supported at runway beam and other end resting on a portal frame.
The crane shall be designed for maintenance duty class 2M (FEM 9.511) and suitable for safe area outdoor location. The crane shall be with crane operator cabin located at one end of the crane bridge (girder). Crane shall also be provided with remote radio communication set-up for crane operator use. Complete crane shall be designed to provide access platform / service walkway for servicing the equipment and floodlights shall be attached to the crane bridge for work area lighting. The power distribution to the long travel shall be through enclosed type 7-bus bar system (with rubber lip seal) and cross travel / hoist motion power supply through power festoon cable system. A suitable sun shield shall be provided for the festoon cables – when in the parked position. Crane load lift capacity per Phase crane shall be maintained as the load lifts provision is with adequate margin.
Other EOT Cranes
The maintenance load lift facility e.g. E.O.T cranes of adequate capacity shall be installed at the following Plant Facility areas - Receiving Basin Area, Plant Workshop / Warehouse, Electro-Chlorination Plant and Piping Manifold Section.
The equipment construction shall be similar as stated in above. The power distribution for cross travel, long travel and hoist motion shall be through power festoon cable system. The crane load lift criteria as detailed in material handling study shall be accomplished.
Mechanical Plant – Bar Screen and Raking Mechanism
Bar screen panel consisting of fixed rectangular steel bar sections with 50 mm spacing
shall be installed at pump intake basin (upstream of rotating drum screens). The screen
bar panel shall be removable type and for easy cleaning these should be installed with
80 degree angle of installation. The screen panel size similar to PH installation shall
be considered for this phase.
The common raking machine shall be grab bucket type rake assembly with replaceable
tines. The assembly shall comprise of the following main components – electrically
operated travelling trolley, over head monorail traverse and power supply cable festoon,
hydraulically assisted grab bucket complete with associated hydraulic power pack, hoist
mechanism for grab bucket lowering and hoisting complete with PLC type Local Control
Panel and pendant controls, trash / debris bin (to hold and carry 0.5 T of load) for
disposal of rejects etc. The hoisting mechanism and hydraulic power pack shall be
attached to traveling trolley.
One number of rake machine for Pump House and rake machines for Pump House (1 op. + 1 sb.) shall be installed yet to remove trash / debris / marine seaweeds / sea shells etc. arrested in bar screens. In addition one complete warehouse spare suspended grab bucket c/w hydraulic power pack shall be considered for the Phase facilities.
Design Basis – Mechanical Equipment
Alternate trash rake machine would also be reviewed to consider efficient scraping of
bars at fixed bar screen panels (availability of traversing trash rake with scrapping in
ascending action for reclamation of attached sea shells and barnacles from bar screen
shall be investigated).
Mechanical Plant – Stop Logs
Plate gates type Stop Logs (stop gates) similar to Phase I installation and dimensions
compatible with civil design shall be planned for pump channels. Guide frame for each stop log shall also be provided by the stop logs supplier to embed in pump house civil work. The logs are not in use. Stop log designs construction and supply shall include equalising valve and a common lifting beam (Vendor supplied) with adequately sized slings. The stop log items supply and construction specification shall include material of construction, coating/painting requirements and other corrosion protection system viz. cathodic protection as applicable.
Rotating Drum Screens
The double side entry and central rejects disposal type rotating Drum Screen with 3 mm
(~ 6 mesh) opening wire mesh panels (removable panels) shall be installed for fine
screening of intake seawater. One screen shall serve 2 nos. of pump basins.
The Drum Screen shall consist of a rotating structure for drum and wire mesh panels
attached to drum periphery. The screen panel backwash set-up shall be incorporated in
drum screen design for efficient screening operation. The equipment shall be for sea
water service as such construction in Duplex Stainless Steel (DSS) materials (of
suitable ASTM grade) is envisaged in Phase II of the project.
The sealing between the civil work and screen drum to eliminate by-pass of fed seawater shall be achieved as per the recommendation / arrangement offered by the equipment supplier. The rotating motion to drum screen shall be through rack and pinion drive, rack shall be in sectors for attachment to drum by bolting. The drum shall be shaft mounted and supported on bearing block at both the ends. The Drum Screen Supplier shall include Lubrication console for Pillow Blocks Bearing. The inner periphery of drum shall be with elevated plate buckets to lift the screenings up to debris hopper located inside the screen structure, this debris hopper shall be in two separated section to allow rotation of drum supporting structural members. The drum screen shall be provided with PLC type local control panel (LCP); interfaced with water differential level instrument and drum screen drive to monitor & control operational speed, the LCP shall also be interfaced with DCS. The installation shall be provided with service / inspection platforms and suitable structure for falling object protection to service the equipment even in operation.
Vessels and Storage Tanks
Pressure Vessels
Pressure vessel shall be designed in accordance with ASME SEC VIII, DIV-1 ‘Boiler and Pressure Vessels: Rules for Construction of Pressure Vessels’ and shall be code
stamped. Pressure vessels shall also comply with requirements of COMPANY standard and specification. Vessel heads shall be 2:1 ellipsoidal. The minimum shell and head thickness for carbon steel pressure vessels, including corrosion allowance shall be 6.0 mm. The minimum internal corrosion allowance for carbon steel and low alloy steel vessels, without any internal coating, shall be 3 mm unless specified otherwise in the datasheets. The minimum corrosion allowance shall be added to both sides of non-removable CS internals when exposed to corrosive fluid or vapour. Removable CS internal parts shall be provided with corrosion allowance equal to half the specified value on each surface exposed to corrosion fluid or vapour. All vessel nozzles connections are to be flanged connections. Vessels shall be with manholes (24” min.) / handholes (12” min.) or end flanges as specified in equipment datasheets. These shall be provided for ease of servicing and operation and complete with davit. The structural access platforms for operation / servicing shall be supplied and installed by others, however attachment clips shall be provided on the vessels. The equipment and relevant lifting accessories as tailing lugs, trunnions and lifting lugs shall be designed to withstand the equipment lifting weight considering an impact factor of 1.5, unless otherwise specified on datasheet. Wind and earthquake loadings shall be calculated in accordance with standards. Wind and earthquake loadings shall not to be considered to act simultaneously.
Storage Tanks
Design, material fabrication, inspection, erection (where applicable), testing and
preparation for shipment (where applicable) of welded steel tanks shall be in accordance with API-650.
Rectangular tanks (if applicable) shall be designed in accordance with “Roark’s
Formulas for Stress and Strain” published by author Warren C. Young or similar
structural design practices. Tanks shall also comply with requirements of COMPANY standard and specification. Fixed roof tanks shall be of cone roof. Tank bottoms shall be sloped downward conically (either crown up or crown down) as specified in the data sheets. If tank is provided with drainage sumps, then sump shall be equipped with a drain pipe with flanged nozzle. Pressure / Vacuum relief devices shall be provided, if tank is designed for pressure/ vacuum conditions. Wind design loadings to be in accordance with BS CP3, Chapter V, Part 2. Tank shall be designed for earthquake loadings according to Uniform Building Code (UBC) with applicable Zone number as 1.
Emergency Diesel Generator Set
Emergency Diesel Generator (EDG) set shall comply with requirements of Company
standard and specification. The EDG package shall be self contained and shall not depend on external utilities for operation. Diesel engine of package shall be 4-stroke, turbocharged type and provided with primary battery start-up and back-up start by compressed service air of plant supply. Engine shall be radiator cooled. Lubrication and cooling systems shall comply with requirements specified in ISO : 3046 and COMPANY standard. Dedicated diesel fuel system shall be provided with a day tank. Day tank capacity shall be suitable for at least 8 hours running of the package at full load without replenishment. Day tank may be part of the diesel engine generator skid or as a separate tank outside the skid. The fuel system shall include spring loaded fuel valve (actuated by fusible plug / melting fuse) that shall shut upon “FIRE”. EDG shall be located indoor, inside acoustically treated and ventilated building, to meet the specified noise levels. EDG Room ventilation shall be achieved by suitably over sizing the motor driven radiator fan.
Generator & other electrical equipment shall comply with requirements specified in the
Company Standard Electrical Specification – Diesel Engine Driven
Generator / Electrical Design Basis. EDG package shall be provided with a control panel which shall be located in the switchgear room away from the package. It shall be possible to start the EDG package from remote systems on failure of mains supply or manually from the package itself. Suitable synchronising hardwired interface shall be provided for the same.
Spare Parts
Spare parts for main equipment and auxiliaries shall be in line with requirements
specified in Project Spare Parts procedure and Company standards referred therein. Generally, spare parts for pre-commissioning, commissioning & start up as well as for the defined maintenance period are provided.
Shop Testing
Main equipment and auxiliaries shall undergo shop and site testing. Supplier shall
prepare test procedures for specified tests and submit the same for Company / Contractor review / approval. Procedures shall be in line with requirements of contract specification / applicable international standards as a minimum. Test procedures shall also identify the methodology of test, applicable international standards, acceptance criteria etc. The inspection & test plan and equipment data sheets shall identify Company / Contractor witness requirements clearly. Based on the above requirements, Supplier shall prepare project specific QA plan / Inspection & Test plan.
Buildings on the plants are of two classes one being process while the other non process. Generally administrative, amenities. control, operation, main & sub stations, pump houses, gatehouses, security controls etc. are included. Also included steel buildings for the industrial support purpose namely workshops, warehouses etc. These steel buildings are provided with all mechanical furniture, heavy equipment like lathe machines, forklift, trolleys, steel furniture, tool cabinets, steel racks, lockers etc & tools. The buildings require equipments such as office furniture & also steel furniture such as lockers, shelving, benches, racks etc
Building services require HVAC chillers, package units, air handling units, ducting, fittings such as fire dampers, volume control dampers, accessories & other controls. False ceiling, grills & diffusers. Ducts for supply & return run in the plenum between the false ceiling & the slab soffit. Also included CCTV, structured cabling, fire fighting, electrical installation of low power as well as high power, fiber optics cabling, cable cellars, switchgears transformers, telecommunications, radars controls, Information technology etc. all.
Electrical supply is distributed by Main station, sub main stations, transformers etc. The area where transformers are located are constructed around by firewalls. Sub station comprises of HV & LV areas, wherein switchgears are accommodated. Proper insulation is carried out for the building envelope to reduce the thermal heat flow into the buildings to maintain the required design conditions for economical air-conditioning.
Fire suppression system is used in the buildings by the name FM 200 or Inergen etc to extinguish the fire within seconds & minutes. This gas spreads in the unventilated space & extinguishes the fire immediately. Also included smoke detection systems along with fire fighting system for internal as well as for exterior use. Industries within plant area employ their individual systems for fire fighting bust preferably a sea water back up fire fighting system is also included as stand by. Fresh water system is also included for the areas locating expensive & strategic equipment for electrical supply as well as emergency controls.
Cathodic protection is used to control the corrosion of the reinforcement by providing electrode at the structure centrally controlled from one location. All reinforcing bars are clipped & wired naked maintaining the continuity of the bars.
Cooling towers are installed when the supplied water is required to be re-circulated for many uses for the concerned industry in which case only makeup water is supplied to maintain the balance.
For once through system, the water is supplied & returned after cooling the industrial systems into the returned headers without any circulations.
In some cases a combination of both could be adopted for economy.
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Chapter 2
Project Design, Contract award & Miscellaneous
Abbreviations
Some useful abbreviations generally used on the design documents for references:-
A / G - above ground, AFC-approved for construction, AFD-approved for design, BFD- block flow diagram, CCR-central control room, CCTV-closed circuit television system, CCWS-common cooling water system, CDR-conceptual design report, COM-commissioning, CP-cathodic protection, CT-cooling tower, CW-cooling water, DC-direct current, DCS-distributed control system, Easement- all and provided by Client to be used by Contractor for the purpose of construction, EPIC- engineering, procurement, installation & commissioning, ESDV-emergency shut down valve, EWS-engineering work station, FAT-factory acceptance test, FOTS-fiber optics transmission system, FEED-front end engineering design, FMEA- failure mode & effects analysis, FO-fiber optics, FRP-fiber reinforced plastic ( generic name including GRP, GRV, & GRE piping), F&G-fire & gas system, GAD-general arrangement drawing, GIS- gas insulated switchgear, GPS-geo positioning system, GRE-glass reinforced epoxy, GRP- glass reinforced polyester, GRV- glass reinforced vinyl Easter, HVAC-heat ventilation & air conditioning, HMI-human machine interface, HSSD-high sensitivity smoke detection, ICA-instrument, control & automation, IDF- intermediate distribution frame, I / O-input /output, intool- trade mark name of Intergraph software for instrumentation eng, IST-integrated system test, ITP-inspection & test plans, IO&M-initial operating & maintenance, LAN-local area network, LBV-line break valves, LER- local equipment room, LLCC-local lot control centre, MC-mechanical completion, MCC-motor control centre, MDF-main distribution frame, MOV-motor operated valve, MTO-material take off, MWS-marine warranty surveyor, ONAF-oil natural air forced, ONON-oil natural air natural, PABX-private automated telephone exchange, PA/GA-public address / general alarm, PC-pre-commissioning, PCS-process & utility control system, PDS-power distribution control centre, PDS- plesiochronous digital hierarchy, PDS-plant design system, PMS-power management system, PEMS- power energy management system, PFD-process flow diagram. PFS-process flow scheme, PH- pump house, PIS-plant information system, PLS-programmable logical controller, P & ID- process & instrumentation diagram, PSFS-process safety flow scheme, PSS-plant safety system, PSV-pressure safety valve, PTZ-plant tilt zoom, QA/QC-quantity assurance/quality control, NCS-National construction specification, RAM-reliability, availability & maintainability, RB-receiving basin, RFC-ready for commissioning, RFQ-requisition for quotation, RMU-ring main unit, ROW-right of way, RTU-remote transmission terminal unit, SAFE- safety analysis function evaluation chart, SCADA-supervisory control & monitoring system, SDH-synchronous digital hierarchy, SPT sustained performance test, STM- synchronous time moduling, TETRA-trunked radio, TPC-Third Party Certification agency, TPI-third party inspector, TTL-transistor transistor logic, UFD-utility flow diagram, UFS-utility flow scheme, UPS-uninterrupted power system, U/G-underground, VDRL-vendor data requisition list, VSD-variable speed drive, VSDS-variable speed drive system
FEED- Front End Engineering Design
Involvement of multidisciplinary teams for the required designs.
1 Process engineers, chemical engineers, reservoir engineers, mechanical engineers, electrical engineers, IT engineers, civil engineers etc. shall be included to formulate an overall strategy of designing the plant system and supported by soil engineers, hydrographic engineers, geological engineers.
2 After having the basic design been desk conceptualized, further FEED detailed works shall be undertaken by all disciplinary teams for elaborate formations of various details to be used on the project.
EPIC- Engineering Procurement, Installation & Construction
EPC- Engineering Procurement & Construction
Contractor, SubContractor, Supplier, Vendor
Sub Contractors as Engineering Consultants
3 Front End Engineering Design requires complete know how about the proposed facility design, technology & construction details that is fed to the Client for inception of the whole scheme which the Client approves & based on FEED tender documents are prepared for the Engineering, Procurement & Installation contract award. This class of tendering necessitates a very competitive & competent bidders to be technically, commercially & in all respects a completely sound organization. Complete Front End Loading is to be established & provided to the design scheme.
4 EPIC contracting requires complete design know how giving all detailed design calculations for the best & warranted performance of the facility as well as commercially competitive.
5 EPIC contracting proposes its own SubContractors as well as vendors organization to be included as further support. Design SubContractor shall also be included as support in case the EPIC organization is not a designer or consultancy group or not having an in-house design capability.
6 All documents based on the aforesaid abbreviations are produced schematically while preparing the FEED documents for the information purpose to the bidder about the intention of the client requirement. The FEED contractor of the client should provide as much data as possible to enable the contractor to understand the client requirement fully for the EPIC implementation contract & price according. It must again be stressed that FEED is endorsed by the EPIC contractor while submitting bid as an evidence of acceptance of FEED & its incorporation on the detailed designs based on which the works shall be executed.
Project Tender Documents
➢ The aforesaid teams of the engineers shall prepare all required documents necessary for the invitation of the EPIC tenders from the short listed parties. These documents must cover the basic requirement & design philosophy pertaining all disciplines to enable the bidder know each & every requirement precisely. All disciplines shall be given full feed back in all respects in the form of project drawings, specifications, soil test reports, survey reports, marine survey report, bathymetric survey report, marine geological report, other studies & observations, climatic conditions, various milestones, quality standards to be adhered to, all other essential parts of the project demands.
➢ These documents should be crystal clear without any ambiguity. As far as possible, details about the equipment to be included on the project should be given within the documents. All national & international codes to be followed should be enlisted explicitly.
➢ Project design parameters should be explicitly defined.
➢ Documents shall be provided in soft as well as hard copies
➢ Production of such huge volume of design documents amounts to requirement of very experienced teams of experts for all disciplines to meet the schedule requirement
Maintenance Preparation Documents
This though applies at the end of construction i.e. mechanical completion of the project but information are required to be issued at the FEED stage for the evaluation purpose
Contractor's obligations pertaining maintenance preparation
➢ General engineering and procurement
➢ Contractor shall take into account in the design of the FACILITY the maintainability Criteria, philosophy and spares to be defined in the FEED Design Package. In particular Contractor shall:
➢ Make permanent provisions for accessibility (without dismantling of other equipment), dismantling/tooling, lay down and handling of heavy parts.
➢ Make provisions for online monitoring of vital rotating machinery
➢ Define criticality ratings for equipment, sparing requirements for equipment, components and parts
➢ Contractor shall prepare and submit the required maintenance documentation as generally defined in the relevant Exhibits, integrate the maintenance requirements in the Vendor selection process, and obtain Vendor’s documentation generally defined as such.
➢ Requirements for vendors’ selection
➢ Pre-qualification
➢ Prior to issuing any call for tender for critical items, Contractor shall check Vendors' capabilities such as:
➢ Ability to submit tenders conforming conforming quality requirements
➢ Technical and financial long term stability.
➢ Existence and suitability of Quality Assurance procedures within Vendor's structure, covering the manufacturing process, the quality control process of raw materials, the assembly of components, the performance and conformity tests, the internal quality audits, capability to supply after sales service for maintenance, technical assistance, supply of parts, procedure for collection of product performance feed back etc.
Bid Evaluation
1 Contractor shall take into account at the bid evaluation stage the following Criteria for Vendors selection and accordingly advise Vendors that their bids shall be evaluated on such basis so that the vendors must include any price if so effected by such considerations:
2 Bid price and conformity to project specification.
Cost of two years or as specified in the contract recommended operating spare parts for all the machines or equipment to be installed on the project.
Reliability of Components (identification of components non standardized or non tested by Vendor under conditions similar to project conditions). The components should be fully reliable to meet the intended functional requirement for the efficient performance operations.
3 Standardization (identification of non-standard components, justifications for recommending such components, cost of spare parts needed for such components). The cost of spare parts contractually required according to the specifications shall be included within the bid correctly.
Availability guarantees-Ratio optimal conditions / optimal performances- Evidences to be obtained from the prospective vendors by visiting to the factory as well as to the references works carried out on track record. The vendor shall provide with the technical brochures of the product to the contractor along with the bid all documents giving the performance evidences. The performance shall also be witnessed by visiting the location of the spare parts.
4 Safety / Protection rating-Verification of performance evolution-Means for condition monitoring - Recommended frequency and duration of maintenance- interventions (total annual duration, maximum duration of a major intervention-Availability / Reliability / MTBF / MTTR-Availability of after sales service (rating)-Availability of spare parts lists Availability of documentation lists-Availability of documentation lists-Operational List of special tools maintainability-Modularity / Disassembly-Accessibility (rating)-The ratings should be obtained from some of the independent agencies published documents which should indicate that the observation & the relevant studies performed without any interference by the vendor. These third party agencies usually publish the effectiveness of these vendors product & services in parts or in totality at regular intervals or as required for some special assignment.
5 Handling (rating)- Similar record should be confirmed from the data base of the successful projects on the vendor’s track record & included with the submission to the engineer as an evidence to monitor the product efficiency.
Maintenance Guarantees-This guarantee is required for the contractual maintenance duration for all the machines, equipment etc.
6 Stability of Vendor, Quality Assurance, after sales structure- Proposals for maintenance contract (rating), guaranteed reliability Contract (rating), training programme (rating)-Vendor Maintenance Recommendations-Management and monitoring (rating)-First level maintenance (rating)-Diagnosis tables (rating)-Preventive and on-condition operations (rating)-Method of intervention (rating)- Identification of conformity certificates-Requirements for component testing. The provision of the aforesaid documents from the vendors records substantiate the vendor’s claim about the reliability & leads one-step to customer satisfaction.
Vendor’s obligations to be enforced by Contractor
1 Contractor shall generally carry out the procurement steps required to have the Vendors who meet maintenance requirements specifications for the supply of equipment and documentation- Contractor shall prepare and include a Vendors' maintenance requirements specification in ‘call for tenders’ and ‘purchase orders’ in line with the Client guidance and submit for approval.
2 Contractor shall obtain, check, approve and issue Vendor maintenance documentation (the Maintenance Dossier) and prepare the Mechanical Catalogue. The contractor shall comply with all the manufacturer’s instruction in respect of the equipment or the product & evidence in this respect to be provided as quality documentation to the engineer for approval & recording.
3 The Vendors’ Maintenance Dossiers shall generally include but not be limited to as the guidance is in essence.
Equipment data-Equipment descriptions-Equipment inventory-Technical data sheets (reference number, serial number, tag number, purchase order number)-Connection parameters (piping, electrical, instruments)-Software documentation both in electronic format and as a hard copy-Operating documentation-Operating procedures- On-line monitoring- On-line monitoring- First level maintenance by operators- Lubrication schedule.
4 All these documents & also any other additionally required one shall be approved by the engineer for implementation on the performance monitoring.
Maintenance documentation (per type of equipment)- Scheduled inspections or interventions-Preventive, on-failure and overhaul maintenance procedures, including description of personnel, tools, spare parts, drawings required - Trouble shooting charts- Lists of consumables- List of special tools- Spare parts lists (SPL), under format attached or equivalent- Drawing- General arrangement drawings- Section drawings- Schematic and wiring drawings- Control loop diagrams- Logic diagrams, cause and effect sheets. All these documents shall be properly numbered & recorded by the document centre.
Technical Proposal
1 It is unavoidable in this age of tendering particularly on the Industrial projects of international Quality Requirement Assurance nature, that the bids are submitted in two parts together or separately depending upon the Client requirement. Technical bid is always a lead submission package that is invited to fully assure whether or not, the bidder is capable to execute & prosecute the project smoothly. In case the technical bid is rejected, there shall be no need for the bidder propose commercial part of the bid.
2 Technical bid is a voluminous document containing complete details of the bidder’s intentions to carry out the project execution from the commencement to the completion stage describing in details ways & methods for every part of the proposed project, how these shall be handled & whether or not, bidder is adequately resourceful, technical capable & scrutinizing all other aspects, bid is evaluated.
3 Technical bid should contain fully descriptive & completely integrated infrastructure of the bidder in all respects about design & execution philosophies, execution plan, machinery & man power proposal, alternative proposal if so necessary contemplated by the bidder, full design criteria, materials proposed from the authentic source, acceptability of Third Party Certification, deviation from the contract & its controls, complete safety programme detailing & risk analysis, Hazard study, safety records, safety plans proposed, evidence of past safety capability records, various well designed forms to be employed for the whole duration of the project
4 It also requires descriptive proposals from the Quality Assurance & quality control section providing all necessary formats & detailed methods of quality control maintenance including Inspection & test plans, check lists & all quality documentation procedures, method statements, proposed independent testing laboratory.
5 All procedures pertaining company documentations shall be included involving internal documents matrix used & ensuring that documents traceability is smooth. Engineering procedures including procurement shall also be included within this proposal giving complete feed back on proposed designing system, software to be used, designer’s potential, complete requirement of the job related material, job temporary facilities to accommodate the manpower etc
6 Since the Technical Proposal is based on the provided FEED documents by the client or the client appointed FEED contractor, whatever contents of the Technical Proposal be presented, should be based on the technical directives included within the FEED. The base firm proposal should not at all deviate from the FEED requirement. The bidder is required to endorse the Technical bid stating that the bid is completely based upon the FEED meeting all requirements unconditionally. The content of certification should be in accordance to the format provided.
7 There may be an alternative proposal in addition to the firm proposal which may satisfy the requirement of FEED in addition to making cost & time saving to the client according to the Value engineering consideration that the client could accept if within the FEED. The Technical proposal is very comprehensive presentation content wise giving all information of the contract execution wise from the design to the performance & handover stage. No room is allowed for any commercial reflection within this submission. In fact the consistency & capacity of the bidder is measured from this submission.
8 Many rounds of the submission are conducted to scrutinize the submission of all chapters. These chapters should be simple in the style to allow full communication of the bidder to the engineer/client to facilitate an easy understanding of the proposed execution. All sources of the materials, equipment & all other items to be used for the permanent inclusions on the project should be enlisted in a scheduled manner in line with the FEED requirement. Proposed work schedule to meet the defined milestones should be explicitly described convincing every one concerned that the bidder approach is feasible in practical terms.
9 All workforce & staffing levels as well as management to supervise & direct the project should be clearly defined including the CVs of all key levels. These levels should meet the defined criteria according to the FEED as well as professional competencies. Design procedures should be clearly defined in a precise manner including giving all designation of Information Technology to be utilized for the project. In brief all other proposals for the proposed facilities for the temporary works as well as for the permanent works should be included explicitly. It is a long format but should be precise & to the point. The client is never interested in a voluminous documentation for show purpose but a precise content giving all true & relevant information is always welcome. It should be remembered that all these proposal documents shall be required for the actual demonstration proving the consistency as well as competency of the proposal. It is better not to propose something which is not practiced by the bidder, otherwise demonstration could detract the bidder. Many cases have been noticed when after the proposal, comments are received from the engineer asking for many clarifications which are difficult to reply positively. Be straightforward for the submission.
10 Quality required assurance as well as Execution statements constitute very important & significant role for providing value to the technical bid for which due time & devotion must be given by the bidder. The experts should be engaged for the detailed inclusions of the necessary information inclusion within the documents for the client consideration. Untoward information should preferably be avoided. Once the bidder is short listed by the engineer or client by the establishment of the bid competency, the call for the commercial presentation should be given or there is no use in case the bid fails to meet the FEED requirement.
Contract award
1 Within this procedure, the short listed parties shall be invited to tender for the EPIC bid who in turn calculate the demanded facility EPIC or EPC lump sum firm price for the whole or part of the job in defined fixed time based on the FEED documents, provided which submission shall be Technical in one part & Commercial on the other. Sufficiency of the Technical bid shall decide whether or not, the commercial bid should be considered.
2 After having the Technical bid qualified by the bidder, the qualified bidders shall be notified about the opening time schedule of the commercial bids. The EPIC contract shall be awarded after complete scrutiny of the bid documents & the availability of the performance bonds & ascertaining fully the sufficiency of the quality as well as capability of the proposed Contractor.
3 A letter of award shall be issued by the Client representative instructing the successful bidder to immediately commence the job giving the effective date of commencement. A date shall be appointed by the Client for the execution of the contract between the Client & the successful bidder as well as for the kick off meeting. An agenda shall be drawn for the kick off meeting defining the sequence of the points to be discussed & the officials & authorities from both parties to be present during the kick off meeting.
4 The successful bidder shall affirmatively make available its representative to execute the formal contract documents on that day failing which, the Client enjoys the legal right to claim the tender bond amount from the surer bank.
A date shall also be fixed by the Client instructing the Contractor to submit the performance bonds, insurance policies about the works as well as for the employees accidents coverage as well as all other document about these according to the General Conditions of the Contracts (GCC).
5 Details about all deductibles, amounts covered under all policies etc shall be submitted according to the documentation procedures.
Execution Programming a contractual binding document
1 Contractor shall immediately prepare a detailed execution plan based on the brief level 1 plan that was included within the Technical Proposal at bid stage for the complete contract works from level 1 to level 5 or as the case may be, in the primavera or MS project software format as agreed with the engineer or defined in the contract.
2 Programme shall cover an overall outline in Gnat format with CPM support, include all contract milestones defined, discipline & element or component wise detailed activities, detailed man power, detailed machineries, recovering delays methods, identification of problems with the resolutions, activities wise measurement of work percentage based on agreed method of man-hours evaluation or time based activities as well as cost wise breakdown applicable to (WBS) work activity breakdown structure. Progress S curves indicating various phases shall be included showing man-hours histograms, work planned progress, machines availability histograms, cash flow etc.
3 Once the Contractor’s programme is approved, it shall not be altered but constitute as a base programme to monitor the whole progress progress, coordinate & recovery shall be applied, should there be any delay to the project planned progress. In addition to an overall descriptive programme, monthly 90 days look ahead monthly programme shall also be charted out regularly to monitor the progress on detailed basis. This programme shall be supported by a detailed method statement giving complete information about the phases of works & their elements arranged in an order keeping in view the priorities on the project & to accomplish aforesaid approved programme effectively.
4 Major sequences of the operations to be covered from the home office activities including corporate management affairs, designing, procurement, documentation, selection of sub Contractor, engineering, procurement, deliveries controls, customs, material storing, quality assurance, cost control & taking down to the site relevant activities in all respects. This part shall be taken up & considered very seriously as the work progress movement rests on its actual level of performance.
5 Organization charts shall be presented showing contract design office, contract head office, site office, sub Contractor’s offices & all other directly or indirectly connected parties giving full description about the corporate structures of all related contracting parties on the project.
6 (CVs) curriculum vitae respecting Key Personnel to be involved for the complete execution of the contract project shall be proposed for approval by the Client. Without approval no key personnel shall be allowed to work on the contract. Every project defines its level of requirement pertaining the essential qualification & expertise for the key personnel to be dedicated to it
7 Format for Execution Programme only for guidance
Scope, Work breakdown structure, Contractor’s organization including details of its organization, sub Contractors organization, job positions & descriptions of key personnel down up to supervisory level, Contracting strategy-direct hire-direct control or management, Home office activities, other Contractors Interface coordination, Operations, Mobilization-break down of manpower by trade including manpower histograms-major equipment utilization schedule,
8 Construction sequence-temporary facilities-including utilities & camp accommodations-site preparations-underground piping-underground electrical & instrumentation-civil foundations & concrete work-structural steel-equipment erection-pipe fabrication-pipe erection-electrical-instrumentation control systems-telecommunication-painting-insulation-pipeline,
9 Quality management systems, Material management system-customs formalities-port storage-& transportation to site-warehousing-storage-material handling-general responsibilities of field materials personnel-material receiving & inspections requirements-maintenance procedures-protection & preservation procedures,
10 Health safely & environment-responsibility of safety personnel-HSE process & execution plan-HSE orientation-HSE site programs-construction environment control procedures-permitting-medical facilities,
Site security, Heavy lift & transport, Personal transport, Manpower (direct & indirect), Field non manuals, Construction automation plan, document control, acceptance,
11 Mechanical completion incorporating pre-commissioning, Pre-commissioning & commissioning organization-job descriptions, Close out, Attachment-
Site organization charts, Field non manual staffing plan, Sub contract plan-number, name & scope of each subcontract, Level 2 construction schedule, manpower loading-histogram by trade including both directs & indirects,
12 Equipment utilization plan, Temporary facilities & camp accommodation plan.
Stages of Execution-EPIC / EPC-Construction Contractor
1 Safety, Health & Environment- Safety plans-Training-Induction-Regular courses-Special courses- Site Walks-Tool Box Talks-Risks Analysis-Corrective Programmes-Inspections-Awards-Audits
2 Quality Assurance QA / QC- Quality plans-Training-Induction-Regular courses-Special courses- Audits- laboratory- dossiers
3 Engineering – Design detailed philosophy, Design, Detailing, Shop drawings- Working drawings-Schedules-Technical Queries, Site works queries, Proposals for technical resolutions, Documentation appraisals, Construction ability checks, inference of technical documents, Engineering meetings, Construction Method statements
4 Construction & Controls - Mobilization-materials-manpower- equipment-procurement-physical construction-contract management – construction project management.
5 Testing - Pre Commissioning, commissioning, performance & maintenance
Operations & maintenance
6 Third Party Certifications
7 Project records - Issued for Construction documents-Red Lines Mark ups-As built- Operation & maintenance Manuals
8 Punch List / Snags - Visual defects-Technical defects- minor non-conformance-snags- rectification- remedial measures-investigations
9 Mechanical Completion- Pre commissioning & commissioning-site acceptance test- performance - plant performance
10 Final Completion - maintenance & successful performance
11 Hand Over-Recording the learning of lessons-suggestions-about the sub Contractors- about the Client engineers-Close Out-discharge
12 Warranty liability - relevant guarantees for the required periods.
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Industrial Safety Briefs
Safety, Health & Environment-
First & foremost is the safety for any project. Slogan SAFETY FIRST is very common among the safety promoting projects. Without safety no work is allowed. Safety is the responsibility of every one. Every person working on the project must use personnel protective equipment PPE & all necessary special precautions must be taken whenever directed by the safety official responsible for the project. All activities must be conducted in a safe manner to the best possible minimum cost incurred on safety. In case no proper arrangements are made to keep safety intact, the execution of the activity should be suspended. On important works, safety team must be present & support the construction team for smooth safety management. Site engineers should abide by the instruction & direction given by the safety personnel. Proper care must be taken during deep excavation works as well as overhead works.
Safety plans-
Discipline activity based safety plans should be prepared in conjunction with construction in-charge, approved & issued by the safety department for the guidance of the construction personnel.
Training- Various classes of training are necessary to be imparted to the site personnel for onsite implementation.
Induction- Immediate on the joining, all personnel should be given safety induction course duly recorded on proper register for the training. The course must include all precautionary instructions required on the site generally to be prosecuted onsite.
House keeping- Training should be given to all personnel to keep the working & other areas tidy during & on the end of the day. Tools should be properly kept on site. Material should not lie here & there. Working environment should be felt comfortable by all concerned personnel.
Supervising safety
Every supervisor should be trained for the understanding of managing safe supervision over the site operations. How to handle the ground works & how to handle the overhead works. How to make the workers understand all procedures of safe handling the operations so as no operation should effect the workers’s health badly causing no overstress physically.
Heat stroke
On constriction sites particularly in hot & arid regions, the effects of heatstroke are imminent to workers. They should be taught the methods of how to prevent such incidents by gradually inducting the worker to the hot working conditions & over timings adjustments.
Fire watch
Every workers should be clearly taught the ways of possible fire incident & if occurs, how to handle to extinguish.
Toolbox talks
In general, prior to begin any activity, tool box talk should be given to the group working on the activity involving any or all calling. How minor or major injury may occur during carelessly using the tools & how to act if injured.
Liquid consumption & food
Every worker should consume water or available drinks after a period of work to protect one from the adverse effect of dehydration & should be allowed the intermittent rest pauses.
Dust prevention
Dust accumulation causes environment degradation & affects working on site. During such inclement weather conditions, ample means of water should be available to spread on site so that the dust does not lift into air.
Sanitary
Adequate arrangements must be made on site for the workers & staff to use sanitary facilities throughout the currency of the project to maintain the working area healthy & hygienic.
Regular courses-
In groups workers should be given feed back on the site safety as well as gas inhale prevention, during fire how & where to assemble, how the fire alarm works etc. How to construct for temporary platforms at high levels to be used for various purposes to meet the site instant requirement.
Special courses-
How to take precaution to avoid electric shocks or some other hazard.
Incentive should be given to the leading workers who keep proper safety as well as check & advise coworkers & colleagues to take due measures. Accessibility to site horizontally as well as vertically should be explicitly explained to every one. Positioning of the ladders in the trenches, which location shall not be more than 8 m. Provision of the platform guardrail of suitable height. For example use of wooden or Aluminum ladder in excavation areas or to the higher working areas. Platform construction, supports, toe board etc. Fire extinguishers use. First aids use. How to access emergency phones for hospitals.
Site Safety Walks-
Whenever necessary, site walk should be conducted by the safety engineer with the site in-charge to pin point the deficiency on safety & on site correction applied.
Tool Box Talks-
Every skilled worker, semi skilled or unskilled should know about proper use of the tools & maintenance of these. They should be explained about all types of dangers if the tools are not properly used during work
Risks Analysis-
Keeping in view all types of operations on site, what risk are imminent, should be studied by the safety engineer & in cooperation with the construction people & expected causes of risk & their relevant solutions be explained to the team for implementation on site as well as properly documented.
Safety of heavy equipment-
Crane operation, shovel operation, concrete pump operation or any other equipment operation requires a complete safe operation system. How to operate these machines safely on site. License of operators as well as banks man instruction manual. Third Party Certification for the crane particularly. Only licensed operator should be allowed to carry out the lifting operations.
Programmes-
Regular & frequently, safety programmes should be conducted on site from every aspects to make all aware of overall safety to avoid accidents
Practical training should be conducted for the equipment operators to let them understand the effects of not conforming to the safety practice.
Inspections-
Safety engineer should inspect working areas frequently to examine that the arrangements adopted on site for the running operation meet the necessary criteria of the safety rules & if observed certain deficiency, the site engineer should be intimated for the corrective measures.
Awards-
To motivate the workers on site to take due safety measures during working hours & thereafter as well, awarding system should be adopted for the workers who work on full safety on site.
Audits-
Corporate safety team should check casually & as programmed, the safety records physically on site & due observation circulated along with the proposed corrective measures.
A healthy worker on site works many times better than a sick & unsafe worker. It is better to spend reasonable amount on safety rather than spending on loss of work causing inefficiency on site.
SAFOP-Safe Operation- It is the key to the success of the project in all respects.
SAFAN- Safety Analysis- Prior to an application of the safety, complete analysis is a must to know & select the best safety methods
SYSOP- System Security & Operability Analysis-It is very significant from safety engineering viewpoint. Until complete problems are listed, applicable procedures may not be known. Systems generally involve safety against fire, gas explosion & electric default. Therefore, these import application of all precautionary measures selection of which depend on the detailed requirement as obtained from the risk analysis & details of equipment operations.
OPTAN- Operator task Analysis-Control & field Operator-This part also involves detailed study as well as precise applications. No slackening should be allowed.
Attempts should be made to take due measure to prevent accident in hot work as well as cold work areas & also in restricted & confined entry areas. Permit to Work PTW must be applied to work in such areas of the facility.
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Quality Assurance, QA / QC Briefs
Quality plans-Training-Induction-Regular courses-Special courses- Audits- laboratory- dossiers
1. The term Quality Assurance which includes quality control being significantly important form the customer satisfaction viewpoint, must be clearly understood by all participants on the project. Many have the unclear concept of these terms.
2. For information, QA is a principle term applies to overall quality system management means, Total quality management, while quality control applies to particular quality control procedure, for example laboratory testing of material, site checks, inspection & test plans & so many other technical involvement during construction operations. Follow up of the whole procedures as included within the quality plan from project inception to the handover & discharge successfully to the customer full satisfaction is termed Quality Assurance.
QA involves major policy & competency of the company. Based on the successful completion of various projects conforming to QA, past track records confirms the competent standing of the company on QA. Company mean not the company management but all members of the company at all levels of corporate & home office, middle management, lower management, workers. These include working of all departments of the company in both home office, branch office, field offices 7 in field, market contribution, market collaboration & so many other aspects which cannot be covered in brief explanation.
It is added that now QA involves quality requirement for all its intended purposes.
Quality plans
This term includes company quality manual & project quality plan.
Company quality manual
1. A primary document of the company announcing company’s quality basic policies in full. It provides the details of the corporate management, company’s organization, directors’ responsibilities, management of its various departments, documentation system, policy decisions, incorporations & accounting, company’s goals, instructions & job descriptions of its middle & lower level officers, full operational descriptions, procurement & material handlings, human resources management, accounting management, transportation but not the least. Company’s planned approach in business & how to satisfy a prospective customer. Manual is a permanent document amendable from time to depending on the advancement & progress of the organization. Virtually it is like a constitution of the company telling every thing about the company management.
2. All sections are included as completely descriptive giving elaborate information to the concerned person. Based on the contents of this document, further documents for presentation & approval are prepared for the upcoming projects or tenders submission. The major policies included within this document shall guide the contents formation within the project quality plans.
3. This documents main chapters include company policy, company’s potential, company’s objectives in national as well as international market, company’s organization approach & basis, company’s various sections or divisions, corporate structure, constitution of the governing board, staffing level, job description of the corporate & senior staff, company’s strength comprehensively giving machinery as well as manpower, company’s know how potential all but not limited to these.
Company’s project quality manual
For the purpose of including within the technical package submission for the tender bid as well as for the contract documentation submission for approval purpose, a document containing specific project details in conformance with the company quality manual giving full & elaborate explanation of the ways of executing the relevant project from the award to the handover & final completion stage is entitled Company’s project quality manual.
Project Quality Plan
1. This document is specifically constituted for the management control of the relevant project & gives all information applicable to the project, which cannot be generalized. The contents of the information depend on the specific requirement of the project & may differ from one project to another as well as from one discipline to another. Contents of this document should be like sub headings given below for guidance.
2. Description & magnitude of the project & company’s general policy towards this.-Brief details of the project & contract-Project execution programme-Corporate office involvement-Joint venture involvement-Sub Contractors involvement-Specialist vendor/s involvement-Corporate management & Co ordination-Corporate Safety, health & environment-Corporate Engineering
3. Corporate Quality assurance-Corporate Procurement-Corporate supports for all disciplines-Project site/field management & Co ordination-Project site/field Safety, health & environment-Project site/field Engineering-Project site/field Quality assurance-Project site/field Procurement-Project site/field supports for all disciplines
4. Aforesaid chapters or parts of the documents should be designed in conformance to specific requirements meeting the contract criteria, company manual, international, conventional practical standards & the ultimate objective customer satisfaction.
5. The document should be prepared by the quality manager/engineer in conjunction with corporate as well as project manager/construction manager/project engineer after studying all details & specification relevant to the contract, General Conditions of contract. The draft should be approved by the management & then by the Client. It should be distributed as controlled copy & not to be altered. In case any alteration is required, another approval should be obtained.
6. All relevant supervisory staff must know about the contents & interpretation of the documents to their respective discipline & fully explained to all how the implementation shall be effected.
7. This document should detail the proposed documentation to be made on site in relevance to the specific project. The records should provide guide lines to generally used documents namely NCR or non conformance report, ITP or inspection & test plans, check list etc. The proposed schedule of method statements about the construction & other disciplines should also be indicatively included. The term ‘quality procedures’ is applied to all such documentations.
Quality Assurance, QA / QC Briefs
Quality plans-Training-Induction-Regular courses-Special courses- Audits- laboratory- dossiers
The term Quality Assurance which includes quality control being significantly important form the customer satisfaction viewpoint, must be clearly understood by all participants on the project. Many have the unclear concept of these terms.
For information, QA is a principle term applies to overall quality system management means, Total quality management, while quality control applies to particular quality control procedure, for example laboratory testing of material, site checks, inspection & test plans & so many other technical involvement during construction operations. Follow up of the whole procedures as included within the quality plan from project inception to the handover & discharge successfully to the customer full satisfaction is termed Quality Assurance.
QA involves major policy & competency of the company. Based on the successful completion of various projects conforming to QA, past track records confirms the competent standing of the company on QA. Company mean not the company management but all members of the company at all levels of corporate & home office, middle management, lower management, workers. These include working of all departments of the company in both home office, branch office, field offices 7 in field, market contribution, market collaboration & so many other aspects which cannot be covered in brief explanation.
Quality plans
This term includes company quality manual & project quality plan.
Company quality manual
A primary document of the company announcing company’s quality basic policies in full. It provides the details of the corporate management, company’s organization, directors’ responsibilities, management of its various departments, documentation system, policy decisions, incorporations & accounting, company’s goals, instructions & job descriptions of its middle & lower level officers, full operational descriptions, procurement & material handlings, human resources management, accounting management, transportation but not the least. Company’s planned approach in business & how to satisfy a prospective customer. Manual is a permanent document amendable from time to depending on the advancement & progress of the organization. Virtually it is like a constitution of the company telling every thing about the company management.
All sections are included as completely descriptive giving elaborate information to the concerned person. Based on the contents of this document, further documents for presentation & approval are prepared for the upcoming projects or tenders submission. The major policies included within this document shall guide the contents formation within the project quality plans.
This documents main chapters include company policy, company’s potential, company’s objectives in national as well as international market, company’s organization approach & basis, company’s various sections or divisions, corporate structure, constitution of the governing board, staffing level, job description of the corporate & senior staff, company’s strength comprehensively giving machinery as well as manpower, company’s know how potential all but not limited to these.
Company’s project quality manual
For the purpose of including within the technical package submission for the tender bid as well as for the contract documentation submission for approval purpose, a document containing specific project details in conformance with the company manual giving full & elaborate explanation of the ways of executing the relevant project from the award to the handover & final completion stage is entitled Company’s project quality manual.
Project Quality Plan
This document is specifically constituted for the management control of the relevant project & gives all information applicable to the project, which cannot be generalized. The contents of the information depend on the specific requirement of the project & may differ from one project to another as well as from one discipline to another. Contents of this document should be like sub headings given below for guidance.
Description & magnitude of the project & company’s general policy towards this.-Brief details of the project & contract-Project execution programme-Corporate office involvement-Joint venture involvement-Sub Contractors involvement-Specialist vendor/s involvement-Corporate management & Co ordination-Corporate Safety, health & environment-Corporate Engineering
Corporate Quality assurance-Corporate Procurement-Corporate supports for all disciplines-Project site/field management & Co ordination-Project site/field Safety, health & environment-Project site/field Engineering-Project site/field Quality assurance-Project site/field Procurement-Project site/field supports for all disciplines
Aforesaid chapters or parts of the documents should be designed in conformance to specific requirements meeting the contract criteria, company manual, international, conventional practical standards & the ultimate objective customer satisfaction.
The document should be prepared by the quality manager/engineer in conjunction with corporate as well as project manager/construction manager/project engineer after studying all details & specification relevant to the contract, General Conditions of contract. The draft should be approved by the management & then by the Client. It should be distributed as controlled copy & not to be altered. In case any alteration is required, another approval should be obtained.
All relevant supervisory staff must know about the contents & interpretation of the documents to their respective discipline & fully explained to all how the implementation shall be effected.
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Chapter 3
Engineering
Introduction
1 Company / Client believes from its vast experience that one of the key foundation blocks for successful, efficient and cost-effective end product FACILITY is the quality of detailed engineering and design. Therefore, Company / Client places a very high importance on the Contractor’s selection of an internationally recognised Detail Engineering and Design Sub-Contractor or “in-house” organisation with a proven track record of undertaking and successfully delivering similar projects in a single location under one roof. Accordingly, the Engineering and Design Subcontractor shall mobilise their team for the Project. Company / Client shall verify this at the time of review of CV’s and interviews of Key Personnel. This shall be one of the key bid evaluation criteria for the selection of the Contractor. The CVs shall be reviewed from an overall qualification viewpoint which means only academic qualification shall be not exclusively a basis but practical specific experience on interdisciplinary sphere to be considered for the acceptance of the proposed key personnel along with general capabilities such as communication skills, efficiency to carry out jobs in the field & in office environment & effective response the client personnel to prosecute the project coordination activities.
2 Contractor shall carry out site surveys to familiarise himself with the existing installations if any, pipelines, infrastructures, pipelines corridors and tie-ins locations. Site survey is also required to verify the proposed pipelines routes and confirm the tie-ins location and configuration etc. and to retrieve necessary information (data, drawings etc.) All survey records & database shall be verified by conducting full survey of the site to the requirement of the contractor’s scope of works. These actual surveys shall form the basis of the actual design to be approved by the engineer or the client. The survey provided with the FEED or the tender document shall be treated only for guidance.
It shall be Contractor’s responsibility to ensure that all relevant documentation and drawings available with Company / Client (at various locations) are retrieved in a timely manner, so as not to impede the progress of the detailed Design. All the records or as built drawings required for the purpose of coordination shall be required for practical interfaces & coordination criteria which should be requested to be issued by the relevant authority according to the planned requirements.
3 Engineering shall include endorsement and upgrade of FEED including design optimisations, detailed engineering, process engineering, procurement, installation, commissioning and any other engineering work that Contractor shall need to develop for the required design, detailed definition, procurement, supply, construction, Installation, Testing, Pre-Commissioning, Commissioning, Start-Up, Initial Operation and Maintenance and hand-over of the FACILITY. The contractor shall certify while submitting the tender that every criteria mentioned within the FEED documents have been considered while designing the project & included in price. Any deviation should be explicitly detailed. Any alternative proposal should also be elaborately detailed for the engineer’s or the client consideration. At the design stage, the contractor shall be bound to apply all the FEED requirement & if possible upgrade during the design.
4 Contractor shall start from the engineering documentation supplied by Company / Client contained in the FEED Design Package and shall further develop the design to achieve the Contract objectives and requirement. However, Contractor acknowledges that the FEED Design Package does not define the Work in full detail. The contractor shall consider the FEED only as a guidance for client’s requirement & therefore, fully develop the project from conceptualisation to the completion accordingly, so that the project specifications are satisfactorily met at the end of the project execution.
5 Contractor shall ensure the maintainability criteria, maintenance philosophy and spare parts philosophy, are fully considered in the development of the detailed design from the FEED.
6 In undertaking the detailed design, the Contractor shall undertake all necessary geotechnical and geophysical surveys to ensure connections to the existing Phase Installations are correct.
7 Contractor shall carry out any and all engineering required for provision of his construction Accommodation Camp, any construction facilities needed at Construction Site within Plant Industrial City, as well as any construction engineering required for the Work.
8 Contractor shall carry out engineering as per Contract Specifications. However, incase of conflict or contradiction with Company / Client Corporate Standards and the latest edition / revision of the recognised international standards, codes and practices, Company / Client shall be consulted for taking the appropriate joint decision. Company / Client’s decision shall be binding and shall have no cost and / or schedule impact to Company / Client.
Contractor shall undertake the detail design of the FACILITY utilizing the typical details pertaining to the project.
9 The Company / Client Engineering Standards, which Company / Client is in possession, shall be made available to Contractor. However, Contractor shall have to arrange for the referenced Standards not available from Company / Client.
Engineering and design of all tie-ins and tie-outs to existing Phase installations shall be undertaken in such a manner that do not cause interruption of water supply or shutdown to the existing End-Users. Contractor shall work closely with Company / Client to achieve this task.
General Engineering Requirements
1 Contractor shall prepare all engineering documentation required for the Work, the documents listed and produce all or any other documents required for the successful completion of the Work. These documents should provide comprehensive engineering design information for all disciplines involved on the project such that all details are self explanatory requiring as minimum as possible further issues to produce works executive details in the form of shop & working drawings, though which may not be unavoidable from an working engineering viewpoint. The design should be explicitly clear in its basics theoretical calculative form giving adequate details to be well understood & coordinate properly all sequential activities for the team engineers to co-relate at various stages & at various offices. Clear details save the time & provide efficiency on the performance of execution.
2 Contractor engineering group in charge of detailed engineering shall provide all details necessary to be produced for carrying out the job satisfactorily & conveniently without any break of understanding the project details smoothly by the engineers involved, but not limited to the following engineering services:
3 Develop and update / upgrade drawings, drawings lists, document index, Deliverable Review and Approval Matrix, Deliverable Register, Data Sheets, Specifications etc.
4 Review & update documents for safety, Operability, maintainability, reliability and ensure its concurrence with environmental regulations and requirements.
5 Review / update FEED specification and data sheets (as required, and prepare additional document when required), engineering drawings, PFD’s (Process flow diagrams), P&Ids (Piping & instrumentation diagrams), calculation sheets, engineering material requisitions, Vendor drawing requirements list & schedule (VDRLS) and purchase requisitions (PR) and amendments as necessary up to 'As built' status.
6 Prepare Scope of Work and Specification of Sub-Contracts. Evaluate technical bids received from Vendors and Subcontractors.
7 Review and approval of Vendors data, drawings, other documentation and include / update Project design drawings (core drawings / specification to be submitted to Company / Client prior to approval by Contractor.
8 Provide detailed material take-off and continuous monitoring of material changes for all engineering disciplines.
9 Develop and update equipment lists, drawings, specifications, Basis of Design Philosophies, Procedures, requisition schedules and all other necessary engineering deliverables.
10 Develop testing procedures including SAT (Site acceptance test) for individual facilities and Performance Test Procedure for the FACILITY.
Witness and report FAT (Factory Acceptance Tests) at Vendors Premises.
11 Provide engineering support for procurement, construction, installation, testing procedure, Commissioning, Start-up and Initial Operation and Maintenance including assistance to Subcontractors / Vendors in the interpretation of specifications and drawings.
12 Incorporate process requirements in detailed design and engineering.
Prepare Final Documentation specified
13 Where there is a conflict in specifications, codes or standards, Contractor shall immediately bring such conflict to the notice of Company / Client on a ‘Technical Query’ form. The decision on all technical queries shall be made by Company / Client in writing which shall be final and binding without any cost or schedule impact.
3DCad Model
1 Company / Client requires a 3-D CAD (PDS) model to be developed for the project. FEED 3D model may be utilized by EPIC Contractor for further development. The final 3-D CAD model shall include sufficient detail to allow plot plans and layout drawings to be produced from the model. The model shall include modeling of the following as a minimum
➢ All Piping / pipeline
➢ Pipe supports / saddles for piping larger or equal to DN50
➢ Fresh Water Distribution System (Firewater storage and distribution)
➢ Electrical and Instrumentation items including cable trays, ladders or ducts (300 mm width and larger)
➢ All civil / structural works
➢ Intake area upstream of Seawater Pumps.
2 All existing facilities (to the extent required) at locations such as tie-ins, crossover on existing piping / new pipelines, in existing culverts, etc.
All piping within package units such as Electro chlorination plant.
Vents, drains, manholes and vacuum breakers.
3 Contractor shall provide the entire model to Company / Client as part of final documentation. Contractor shall not employ any proprietary techniques or add-in programmes while developing the 3-D CAD model that may prevent Company / Client from fully maintaining the model after takeover.
4 Contractor shall provide a user manual to aid future update of 3-D CAD model by Company / Client.
5 Contractor shall provide view-only access to the 3-D CAD model for Company / Client’s nominated personnel whether they are located on Contractor’s premises [Office or site] or if they are accessing the system remotely during the course of detail engineering. A copy of (review model) updated regularly during Construction and engineering stages shall be available at Company / Client’s Offices at site. In addition, Contractor shall provide documentation, training and support for Company / Client’s nominated personnel so that their use of the system is unencumbered and effective.
Plastic Model
Contractor shall design, fabricate and assemble a plastic model for all facilities which include all pipeline / piping, all structures, buildings, etc. to be included on the Plant facility whatsoever, for making it operational. The models shall be produced to an acceptable size so that every part of the project is clearly identifiable by the user personnel. As far as possible, all essential design details shall be included for the exhibition purposes. These models should be fabricated in different modes like drawings that means bird’s eye view, sections within that & many different views for clarity.
Engineering Design-
1 For EPIC or EPC, the design part is a major contribution to the successful execution of the contract. Design of the whole project components / constituents are demanded to be produced one by one meeting the timely requirement to the project plan. The designing team should understand explicitly the contract philosophy & the FEED documents prior to commencing the design work. Complete Project Design Systems should be produced based on the FEED & the best possible design alternatives for a minimum cost. The project target to be achieved should be clearly understood.
2 First & the foremost significant part of the design process is the selection of the processing machine / equipment to be installed as a part of the processing trains, which machines may include horizontal & vertical vessels, vibratory & rotating machines, pumps, oil tanks, gas tanks, all related control instruments, electrical installations, gas installations, safety installations, all equipment necessary for the complete facility safety & controls, fire fighting controls.
3 Equipment selections may take time & delay the whole facility construction therefore, prompt decisions should be made. It should be kept in view that the foundation designs pertaining the equipment depend on the parameters of the equipment. Initial foundations designs may be amended based on the final selection for the inclusion of the equipment. Related drawings about equipment based on the feed back available from the FEED should be schematically produced for the considerations of the structural design engineers for initial use which shall vary may be to an extent of 10 to 15 % during final stage of the designs issue. All designs should be correlated in sequence so as not to miss any part of ant machine in the train. All designs of the equipment to be included other than the trains should also be similarly produced in a timely manner.
4 All constituent parts or elements of the project regarding all engineering disciplines should be enlisted & a programme charted out to show the start & issue dates pertaining various design drawings for review & approval by the Clients. The discipline wise engineering design work should then be entrusted to the charge of a disciplinary design engineer. All design discipline engineers should report to the engineering project engineer or Manager as the case may be.
Initial drawings after complete checking & review of the design calculations should be properly recorded, approved & issued for Client review & approval.
5 The Client should promptly review these drawings & issue consent to facilitate the design team to proceed further for detailed design work.
Design drawings in general may be classified to the following categories
6 Facilities Key plan showing all sections or zones
Plan showing process & non process area indicating trains, utilities, offsites, circulation, control as well administrative areas.
7 Plan showing existing facility if any, proposed location of sea intake as well as discharge into sea.
8 Plan showing out plan to facilitate construction of temporary structures for the use by the Contractor.
9 Plan showing located areas for warehousing, storage, equipment maintenance, access to site & all other necessary information the Contractor or bidder shall require to take into consideration the impact of cost on price.
10 Facilities drawings should be classified into the lay out of the trains with location of all equipment & piping scheme.
11 Facilities drawing showing all line plans & isometrics of the processing technology & piping giving capacities.
12 Plan showing hazards & non-hazard areas based on HAZOP studies conducted by a specialist agency.
13 Plan showing complete & comprehensive philosophy adopted for the proposed plant system.
14 Plan showing location of all buildings process as well as non-process.
15 Plan showing location of all utilities buildings & electrical infrastructure buildings.
16 Plan showing all major & minor buildings & other structures required for the complete control & administration of the plant operation.
17 Plan showing philosophy of the communication, satellite control, security fencing, roads, maintenance access, landscape areas, environment related issues.
18 All equipment major & minor foundation layouts
19 All underground utilities & services including drainage, sewerage, chemical disposal etc. & shall include catch basins, manholes, chemical manholes, oily manholes, open ditches, closed drains, pipe culverts, cable trench, covered trenches, buried trenches, duct banks, street lighting infrastructure, interconnecting cable infrastructures, proposed road crossings, proposed interfaces, services to be coordinated with the existing services requiring work permits from operating authorities in the form of hot & cold works etc, cathodic protection philosophy for the whole plant,
20 Architectural plans for buildings including elevation & sections
Structural plans for buildings including elevations & sections
Bar bending schedules for all members of the structures building wise
21 Discipline wise plans for services such as electrical, HVAC, mechanical, drainage, sanitary, loss prevention, fire fighting, water supply, telecommunication, CCTV closed circuit television, security access, card readers, building management,
22 Roads layouts, maintenance roads layouts including types, & sections
23 Plant Piping layouts & pipe racks around including overhead crossings
Interconnection layouts
24 Structural plans for the pipe racks giving all design details
Structural plans for the steel buildings giving all design details
25 External roads interconnection & access to plants
26 Landscaping giving all soft & hard landscape layouts
Engineering Detailing-
1 After having received the preliminary drawings approved by the Client, the design team should concentrate to produce all necessary drawings, which should then be submitted along with the building permit application to the relevant municipality if so required.
2 The design engineers should also commence with the detailing of all structural & architectural elements of the included parts of the project. All other disciplinary details should also be taken up simultaneously. This part always consumes much time & therefore adequate staffing should be allowed for details production.
3 These detailing should include sections, various details on plans, details of all elements necessary for execution or for the transmission of the information to equip the shop floor drawing engineers for working drawing production. There shall definitely hundreds of such details discipline wise. Crosscheck must be applied to all these details prior to giving a final approval. Working out of the details shall require multiple considerations of thought to be given for the end results of the design so as to make it convenient for the ease of construction execution with the application of minimum efforts with keeping cost to a minimum as far as practically feasible.
4 Concept of the detailing is a cumbersome job requiring competent skill on the part of the design engineer who coordinates mentally all possible operations related to the designing & construction by these details. The details dictate on many outcome on site & help the construction engineers a lot if well thought of in advance. Sometimes, the good-looking details are difficult for execution.
5 Details should be as easy as possible to save the procurement as well as execution duration to minimize the cost. It is suggestible that as far as practicable, standard items should be included in the designs for easy procurement. Also these items are well known to the experience supervisors involved with the construction operations. Typical details production shall give good results for the production purpose. Unnecessary details should be avoided. Details should be explicit to make the engineering coordination easy for easy references. It has been experience that multiplicity of documents coordination creates unnecessary difficulties for the execution team while clashes & absence of necessary details as well as so many other factors result in the raising of engineering & site technical queries ETQ & STQ respectively. These queries further augment the recording & execution complicity. Generally it happens due to the involvement of many hands as well as change of heads on the same job. Some competent engineer should concentrate on one activity to reach it to the conclusive decision so as to be finally sent to drafting section.
6 Also cross-references on the drawings should be properly reflected for there are chances of missing these.
It is also suggested that what details are required should be planned in advance of commencing the detailing work in the form of a working schedule to keep a control on the quantity of detailing work.
Design Schedules-
1 Major items schedules respecting all disciplines should also be included within the detailed designs to guide the construction team for placing various Material Take Off MTO after due verification. After producing all necessary detailed documents, a guiding bill of quantity BOQ should be prepared for the whole project to assist the construction team to place various order after due verification of the quantities as well as the applicable specifications & codes.
2 No limit governs the quantification of the production of schedules for it depends on the discipline as well as the size of the project. There may be hundreds of such schedules for some project while some only a few. But quality schedules help the placement of the procurement orders.
3 Scheduling is no easy job. It requires complete know how of item under consideration. It also requires complete coordination within all relevant drawings & technical documents to reach final take off the quantities & the applicability of the specifications & drawings as well as specialist specifications produced by the manufacturers. Scheduler has to go through all these procedures immersing fully for all related items.
Submissions-
All aforesaid project documents which may include all design drawings, detailed drawings, schedules, project specifications designed by the specialist engineers should be registered properly according to the agreed system of documentation & thereafter be submitted under cover of a transmission sheet to the approving authority engineer for technical approval in the form of IFC Issue for Construction. It is not essential that the documents should be approved in first submission. Comments received back from the engineer should be incorporated on the revised documents & resubmitted keeping the process continued until the documents are approved for construction. After the approval for construction status, the document should be copied in required numbers as agreed within the documentation procedures duly sealed on the document & circulated to the concerned parties. Copies should also be transmitted to the engineer for site use.
Shop drawings
All details as explained above cannot be practically produced within these documents. Depending upon various factors related to available material, details provided on the approved drawings & the trade practice & further minute technicalities involved for the production operations, it shall be essential to produce some more documents to be used by the shop floor engineer. These documents shall be worked out from the coordination among all such gathered information solving probable clashes & giving a final shape for production or execution on site. These documents should also be passed through the approval procedures & IFC document should be issued to site for construction. There shall be hundreds & may be thousands such documents necessary to be produced from time to time of site requirement. These can be entitled shop drawings.
Working drawings-
Even after the availability of all approved documents, there shall be required some more drawings to be used by the supervisors on site as well as in the workshop. These drawings should support with further details of the sequence of works in the form of real fabrication & execution at shop floor or on site. These drawings should be well drawn clearly so that supervisors do not require further assistance to get the job done without further details. These drawings should also be approved but all drawings do not require approval. In some case based on the contract drawings & shop drawings further details are worked out which are consistent with approved drawings, may be used directly virtually off record.
Otherwise these drawings should also be approved by the engineer in which case proper documentation is necessary followed by the issuing procedures as explained earlier.
Technical Queries-
A technical query is raised when some discrepancy is discovered pertaining any design item not correlating or corresponding between architectural & structural or any other discipline drawing details. For the resolution of the correct detail, discrepancies are raised in the form of a technical questions format giving full details regarding the discrepancy & if possible, a solution be proposed or clarification sought or understanding for confirmation made. This document is originated by the relevant engineer, checked by the technical or engineering section & authorized by the site management for transmission to the engineer for response. Engineer scrutinizes the questions & writes back the answers for execution on site & recorded as red line mark up.
There may be engineering queries ETQ or site technical queries STQ or SC site clarification depending on the mode of the format adopted on the project.
ETQ is generally used by the Engineering team only whilst the STQ is used for the site execution purpose.
Site works queries-
During carrying out works on site, dictated by the site conditions & to comply with the specifications & design criteria, it usually happens that suitable adjustments have to be made to the design details on the safer consideration. Such situation requires an agreement between the Contractor & the engineer on site, which should be recorded on the STQ for confirmation.
1 Proposals for technical resolutions-
Other than aforesaid queries, there shall be many instances when alternative detailed proposal are to be worked out for site requirement to meet the design criteria & practicalities, proposals for such problems are made for the engineer’s approval. Full details in the form of sketches are prepared & put in the form of STQs or directly as sketches as working drawing as convenient. All virtual clashes on site due to unforeseen conditions may be resolved on site & recorded as technical resolution in the same manner.
2 Documentation appraisals-
At time of the contract execution as well as during the whole currency of the contract, the Contractor shall from time to time receive thousands of documents in the form of contract documents, post contract documents etc which should be appraised properly & competently. All such documents should be registered in such a way that traceability functions efficiently without wasting time of the engineers unnecessarily. The document controller should have on his tips on the database any required document located immediately. Arrangements should be such that documents for a particular element on the job should be proficiently filtered out for better control. Project in-charge should ensure that all required documents according to the register as well as fulfilling practical needs of the project for construction have been issued by the designers.
3 Construction ability checks-
Issued / approved for construction documents pertaining all disciplines must be checked sequence wise as well as discipline wise to make sure that these contain well-coordinated information necessary for the 100 % construction of the relevant portion or element. Project engineer should immediately notify any missing information to be provided proficiently. Any clashes observed should be recorded any ETQ or RTQ raised for a possible resolution without any delay to the execution. The approval about the queries procedure should be perused personally in some urgent cases & the resolution communicated to the supervisor concerned for on site implementation prior to the mistaken work is carried out.
4 Inference of technical documents-
Inference of the technical documents is no easier an activity. Only a competent project engineer or an experienced discipline engineer should be entrusted the job to explore any missing information as well as to know whether or not the issued documents are giving adequate information for the purpose of full construction or yet, the technical queries are necessary to be raised. This activity requires total concentration to study the contents of the design & their coordination & mutual interfaces. It depends on the volume of the documents what duration is required for complete understanding of the technicalities involved on the design. Study & review should not be confined to design drawings only but detailed specifications should also be included so that complete project requirement is properly integrated for physical execution.
5 Engineering meetings
Meetings for the engineering discipline form extremely significant portion of the contract. Actually this activity commences at the tender negotiation time when technical proposal is submitted. Hundreds of clarification questions are raised by the Client on the contents of technicalities offered by the Contractor as well as those at pre bid stage as replied by the Client based on the Contractor queries. For a collection of important queries, meeting is conducted to resolve the issues in hand directly between the two parties.
During contract stage, when the design is submitted meetings are conducted for every discipline for a satisfactory response on the design questions, clarifications & software related issues or formal presentation of PDS project document system. During this stage, meetings shall be very long but impart efficiency for the decision-making & save time for the approvals.
6 During construction stage, regularly programmed meetings are conducted for the engineering difficulties or other matter related therewith which require urgent attention. These meetings more or less form part of the regular progress meetings until lot of queries have been accumulated necessitating separate meeting. Day to day meetings are conducted on site between the area engineers of two parties to resolve the matters subject to the approval of the field engineering manager of the Client.
7 Engineering meetings cannot be confined to the aforesaid instances but according to the job requirement, these have to be conducted at any level of supervision to expedite the site works progress.
These meetings also involve the contribution from the quality assurance & control engineering section on site for urgent decisions & acceptable to the construction department.
8 Construction Method statements
During the construction phases, activity wise construction method statements are required to be issued to the supervisors on site to adhere to the statements for the smooth carrying out of the activity concerned.
9 These statements should be approved by the Client prior to the commencement of the relevant activity. Method statement should be prepared by the project or discipline engineer or quality engineer or office engineer depending on the availability on site. This documents should contain full information about the activity under consideration giving how the sequence & technicalities shall be carried out & how the inspection should be conducted based on the requirement of the Inspection & Test Plans & quality check list as well as conduction of the necessary testing & laboratory involvement from time to time.
10 All disciplines require method statement. These should therefore, be prepared in advance, checked & approved by the site manager for further transmission to the Client for the final approval as IFC or AFC & circulated to the site as a document.
11 No limit governs method statements numbers. Agreement has to be made between the Client & the Contractor on the requirement.
12 For the reference to the reader, a number of method statements have been appended only for knowledge exchange. These are based on the practical experience & are used on projects. Please use them for guidance only & create your own statements for particular requirement. But basics of the methods writing can be advised herein. Just think of what is the solution of particular construction operation.
13 Contemplate on what the involved minor activities are. What are the sequences & materials to be used for temporary as well as permanent inclusions what are the other requirement for the accomplishment of the operation from the inception of the activity to the final outcome. After having considered all these, make a sequence thinking that you are available on works & carrying out the activity. How the activity should be sequenced one after the other & write the statement lines & then recompile to a comprehensive statement.
14 There shall be a long list of method statement or procedures from different engineering disciplines.
15 For example site preparation, camp construction, temporary facilities establishments, earthworks, excavations, blinding concrete, formworks, reinforcement fabrication, reinforcement assembly or placement, concreting, finishes activities, complete HVAC system, electrical system, loss prevention system, specialist gas fire suppression system, aluminum works, cladding works, structural steel erection at low as well as high levels, road works, paving, piping both below & above ground, pre-commissioning, commissioning, performance, maintenance, quality testing & many more.
16 It is not practically possible to produce all methods in one go but quiet in advance of the relevant activity allowing time for approval; the statement should be prepared & submitted for approval. The basics of the activity should be conferred with the relevant supervisors & quality personnel & then finalized to the specification & design requirement. The document should form an integrated approach for the job as professional.
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Chapter 4
Construction & Controls-
Construction & controls are very interrelated sections for successful completion of any project. Design may be over safe or optimum but real construction involves actual expenses, contract time & reputation. It should be the motto of any organization to apply good controls on the project to keep on line with the programme or planning an actual part of controls. Control includes, progress, cost, time, budget, quality assurance & engineering & safety.
These are all integrated divisions, which should move in unison to achieve project target. A well-designed project could be jeopardized during construction phase from budget viewpoint should it not be given due controls application properly.
Schedules- Programming
1 Programming schedules indicating by GNAT bars or by CPM or PERT various graphical representations respecting the overall & detailed plans for the time, activities, milestones, manpower requirement, machinery requirement, cost flow & all other requirement & running reviews of all these during the whole currency of the project from real progress, lost time recoveries as well as look ahead projections. These documents are produced involving all sections working for the project & reports are inter considered by all departments.
2 Planning engineers or the project control engineers work for such activities dedicated on the project & report from day to day & time to time basis. The planning activities commence from the day of commencement to the final completion & documents are produced from level 1 to may be level 5 depending on the project or the contract specification requirement. Generally primavera or MS project software are used for the professional documentation for planning purpose.
3 During tender stage also programming documentation giving complete details & milestones, manpower, machines, cash flow etc are given for the inclusion with the Technical Proposal, which is considered as one of the competencies of the proposal. In case the details do not give full information about the proposed methods of execution for which it forms a part, the proposal may be liable for rejection.
Mobilization-
1 The very first step to get into the stage of physical establishment for construction. The site is taken over & all transfer stations are established using available satellite records. Surveying department commences its works for the establishment objectives. Approvals are obtained from the authorities concerned & from the engineer or Client.
2 Applications are made for the record drawings from the statutory services authorities if so required. Applications are also made to the operating authorities for the issue of all record drawings if so required for the permits. Permit to work PTW is required prior to the commencement of any excavation in hot & cold work areas. No excavation is allowed in projects until these permits are obtained. For the application of the work to start permit, documentation is carried out giving details about the applied work, official award letter, availability of the safety officers, full time supervisor, method statement etc & then application is considered for sanction.
3 Fencing is erected & the establishment of the temporary camp & offices is effected according to the engineer approved plans & method statement.
All arrangements for the accommodation for the personnel, sanitary facilities, water supply for drinking as well as for washing purpose, electrical & air conditioning, fire fighting, access to the camp, security, messing, sewage treatment plant, leisure areas, common rooms, sports courts, parking, swimming pool, local shops, etc as required by the contract & the temporary facilities that Contractor or the engineer deem necessary should be provided.
4 Similarly, site offices establishment should also be constructed according to the site establishment approved plans & Permit to Work obtained before commencing for the site establishment offices. All provisions of the utilities should be made according to the contract, engineer & Contractor requirement.
5 The site offices should start functioning on or before the appointed date according to programme of mobilization. It should be kept in view that some agreed percentage of payment should be released when the mobilization is completed & work can be commenced with.
6 Mobilization also includes deployment of required manpower, machinery & the supervisory, construction, safety, planning & engineering as well as administration staff without any loss of time. This deployment shall accelerate the procedure on the commencement of job in the beginning & time may be gained to keep in line with the programmes.
7 Smart & efficient project managers & engineers understand this aspect very well & keep very proficient at this stage as additional efforts are required to commence with the project. Running project may not be that difficult to push but starting & streamlining all departments operations demand efficiency & hard work.
8 Site offices require full fledged modern computerized facilities for fast interaction & communication, intranet, internet, telecommunication, conferencing, sanitary, water supply, drinking water dispensers, refreshments, electrical supply, standby generator, heat, ventilation & air conditioning, first aid, ambulance, doctor for immediate attention with nurse, assistants & a well established site clinic.
9 Site offices require full fledged stores, warehousing, mechanical & auto maintenance & repair workshops, vehicular & equipment parking areas, labour temporary shelters for lunch & tea etc as well as for rest pauses necessary under safety management for the prevention of heat stroke & environment attack during hot working hours.
Materials-
1 Without materials no project can be completed in time. This is the only item that may delay the completion of the project due to possible non-delivery in time. Material constitutes more than 60 t0 70 % budget for the contract & every prudent Contractor should intend to make as much saving as is possible out from this element of expenditure simultaneously keeping in line with the quality assurance & control procedures.
2 Every purchase department manager & the owner of company tries their best to procure acceptable material within reasonable & minimum cost, making trial & again from a number of interested vendors both before & after the award of a contract. There may be some delay to decide from which vendor or supplier the materials are to be procured. This is also expected in a similar fashion from the prospective sub Contractors.
3 But the relevant purchase managers should not endeavor to spend unnecessary redundant time on this activity but make a decision in time to get to the site materials in planned time including all FAT as well as SAT & performance tests.
4 Material approvals is a tedious & time consuming exercise which must be given due consideration & optimum time management for a possible successful completion of the contract. It has to be remembered that missing the approval, no purchase order can be released by the procurement manager or project engineer/manager. It should also be taken note of that there are hundreds of permanent inclusion materials respecting which approvals are to be obtained. Every submission required full manufacturer’s information, engineers specifications as well as conventional practice demand & updated standards & these should also be covered within budget cost other wise escalation shall take place should delay is allowed resulting in the delay on completion leading to imposition of liquidated damages on the contract.
5 Actually it is suggested that major homework should have been carried out at the tendering time itself to avoid such delays, of course market may fluctuate but there shall remain room for negotiations with the vendors or suppliers.
Manpower- Workforce
1 Significant is this element in the absence of which nothing is feasible. Difficulty is to be faced when well-trained workforce is not available in time from the expected source. Contractor shall try to deploy manpower costing within the job budget. There shall be so many problems for deploying them & providing demanded facilities on the contract. Human resources department should be efficient to deal with this matter so that particular delay is avoided due to non-availability of the required planned manpower.
2 Workforce shall be time wise required respecting all disciplines & be kept on mobilizing in & demobilizing according to project requirement. Similarly staff shall also be mobilized & demobilized according to contract requirement. On considerable big size projects, mobilization & demobilization programmes are prepared & approved by the engineer or the Client to ascertain that the job commence in time & after the demobilization, the progress is not effected adversely. In fact only after the approval from the Client is obtained, any demobilization can be effected though the approval shall not be withheld unreasonably. Control of manpower constitutes in itself a separate mini discipline involving complete procedures from making requirement, forming recruitment strategy, approving the strategy, using agencies, & then interviews, short listing of selections & appointment on contract followed by mobilization to the job site. This is a long process, which must be preplanned to avoid any conflict with the site requirement.
Equipment-
1 Equipment necessary for the inclusion on the project permanently requires considerable input from the Authorization, FEED stages to the performance stage. Technology decision for the project dictates the model & types of the equipment to be installed for the facility. Elaborate & descriptive detailing is extremely necessary during designing, approval & procurement stages. The equipment installed must satisfy the design requirement failing which the facility shall be jeopardized of performance giving any possible halt to the processing & the Client or the operation authority shall make the designer or EPIC Contractor liable to compensate all damages incurred to it by the faulty commissioned equipment.
2 Equipment are too expensive requiring making competent decisions for the inclusion as well as for the election of the vendor.
Decision pertaining the model dictates the foundation designs. This need should also be kept in view while working on the designs to avoid delay on account of providing input to the civil design team.
3 Frequent amendments/modifications have been experienced on the major projects during the day of concreting or one or two days before. This type of bad practice should preferably be avoided. If possible, certain decisions could be taken at the FEED stage & the EPIC Contractor be directed to comply with the vendor of the equipment based on novation of the item.
Procurement-
1 Procurement means to supply to the site all materials & equipment & the process commences from the requirement scheduling, vendor selection, quotation invitations, short listing quotations, specification matches, financial viability, approvability, warranties applications & then the final decisions based on the quotation that fits within the budget & items be the best for the optimum performance according to the requirement of the contract.
2 Every company has established its own procedures meeting the guidelines of the international quality procedures ISO 9001 according to which full corporate management is involved for the procurement management practically effected by the procurement manager or engineer of the corporate part of the company management. This department involves itself for the complete operations front the estimations of the items quantities through the delivery to site & taking up the issues to the insurances in case of transportation damage.
3 During tender stage itself, the expected items are invited for quotations for specialized & important disciplines with negotiations done. Later on subject to the condition that the work is awarded to the tender, further procedure continues & final & confirmed quantities are worked out based on the engineer’s approval of the proposed material or the machine which is separately applied prior to the placement of the procurement order. This is very time consuming process as submission, comments, rejection, incorporation of the comments, re approval etc all are involved. The process involved initially complete package submission meeting defined documentation procedures. A competent & experienced engineer should be involved to carry out all these procedures for technicalities are to be resolved during the whole exercise. Study pertaining each & every requirement should be conducted by the relevant disciplinary engineer & quotations accordingly invited. Based on the quotations, & financial factors, further scrutiny of the quotations regarding conformance to the specification & the project design criteria are done. Then a comparative statement is prepared giving full technical as well as financial with feasibility of timely manufacture & delivery & financial matters such as demand of the letter of credits or other financial support etc. All are reflected to be examined by the management for making a decision promptly.
4 Once the decision is made in favour of one of the suppliers, further submission procedures should be started to obtain engineer & Client approval since procurement order cannot be placed without the Client or the engineer’s approval.
5 After having obtained engineer’s approval, the requirement is processed for a procurement order by the management & all accounting procedures effected & delivery schedule confirmed. That schedule should also be agreed by the engineer & adherence to the agreed dates have to be adhered until unforeseen circumstances irrelevant to the general circumstances play any role.
6 The delivery should be made smoothly all in good condition to the site & the site manager should arrange complete examination by his team as well as approval of the delivery by the engineer concerned so that the delivered material or the equipment is including for the part percentage payment as agreed on the planning schedule.
Physical Construction-Contract management
Construction Project Management
Physical construction
1 After having the mobilization been completed, time comes for the commencement of the permanent works for which the actual contract is meant for. It is definite that the civil construction takes the lead generally on all the projects. This requires the availability of all the approved for construction drawings circulated under control to the relevant supervisors/engineers for the purpose to correctly prosecute the works according to the contract requirement. Sooner the commencement, better the prospective to save the time and money.
2 Every site manager or the project manager should endeavour his plans with the support of the schedule engineer to keep at least in line with the approved programme if not advanced. For this attainment, all necessary resources availability should be properly coordinated. For EPIC case all design matters should also be properly coordinated to keep in line to facilitate the easy construction. There may be a case when due to some unavoidable circumstances, some portion of the contract cannot be prosecuted, the project manager should immediately find an alternative portion to replace the prosecution so as to keep an equivalent proportion of the progress intact. Civil engineering part of the contract is not that easy for it requires basic works on site involving trades persons & semi & unskilled workforce along with the materials in site. Relevant engineers supporting on site should be well experienced & proactive to take up the responsibility for the results orientation. A well coordinated approach is necessary for there could be many instances requiring on site decision to resolve technicalities that must be immediately effected meeting the requirement & properly recorded as a part of field office engineering.
3 Physical construction requires a concentrated as well as diverse attention of the quality assurance & control section or department on site. There should be no delay on this account for the approvals & constant inspection attendance should be ensured whenever necessary on a fast track project.
4 Every activity is inspected according to the Inspection & Test Plans based on a checklist & percentage witness etc. Hold points should be released when the activity is on that status. Most of the jobs are based on the concreting constituting very important element of the contract & quality assurance should take proper attention for this onsite operation. It should also be noted that whilst the civil engineering activities are prosecuted on site, simultaneously, on a foreign station or in a foreign land, other discipline activities for example production of equipment, the pre engineered parts of the structure & other procurable items might be under manufacture demanding factory testing according to the procedures approved. QA & QC should take into consideration proper inspection attendance there as well under the supervision or surveillance or witness of the engineer or the experts for the acceptance of the factory products as level I & completion of the parts in factory or manufacturing place as level II inspection prior to the equipment is shipped to the site location. It is no use should the equipment be rejected after delivery on site.
Contract management
1 It is very wide term on the Industrial contracts. Basically it is the main contract that requires well-established professional management but also covers various sub contracts as well as services contracts. Requirement of complete knowledge of the relevant laws, procedures & coordination correspondence are extremely significant for the performance of Contract management. It is not just one discipline, but from the beginning of the project & until post completion, Contract management shall be required to be applied & represented on site as well as in home office for the resolutions of many complexities. This term also covers a wide part of the documentations to be prepared for forming future arbitration basis as well as proceeding.
2 It may involve costing effects, claims, extras, extension of time claims, additional contractual obligations, contractual correspondences & many more legal affairs requiring resolutions on the contract or the sub contracts as well as services part of the low tier vendors. This term is very complex as its proper implementation necessitates the contracts manager to know & properly understand the engineering, construction, co-ordinations & relevant contractual & general laws applications on the contracts.
Construction project management.
Project site manager or the construction manager or if project engineer be authorized for this responsibility, got very leading & significant obligation to dispose off on a daily & hourly basis. What is going on site is direct responsibility for accountability. Daily, weekly, monthly programmes as well as all discipline coordination is a must for the speeding of the operations. Then also comes the duty to arrange & coordinate the materials as well as the other resources to be utilized on the project. Attendance on the engineering, construction, safety & other meeting is a must. The outcome of the construction depends on the efforts of the construction team. Coordination with all team members as well as the team members of the engineer Client is a must. Co-ordinations with all sections of the site teams & home office teams as well as procurement are very significant. Authorizations of the letters & correspondences produced by the contract as well as other departments for the project is also one of the duties. Reporting all functions to the Client as well as to the home office & resolutions of all possible solutions is also one of the responsibilities. Authority has been invested with him to allow resources promotions & imparting training for the personnel of all categories as on job training. Job requires very dynamic & passionate person who commands all & gets respect from all sections & keeps good working relations with the Client as well as with home office.
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Chapter 5
Testing- Pre Commissioning, commissioning, start up, performance & maintenance
1 The testing is carried out at various stages of given levels. It is conducted in the factory during processing as well as after the finishing of the production. It is then conducted on delivery, prior to the installation & commissioning & during performance & operation.
Factory Acceptance Test, Pre commissioning test, Commissioning Test, Site Acceptance test, Integrated system test, Sustained Performance Test
➢ Factory Acceptance Test FAT
➢ Verify quality & quantity visually according to documents
➢ Demonstration of all system & diagnostic functions
➢ Demonstration of technical parameters
➢ Functional test for all components
➢ Power consumption
➢ Module, communication failure & recovery
➢ Mechanical checks
2 Pre Commissioning Test PCT
Upon completion of system installation, align, adjust & balance the system for pre commissioning performance in order to ensure the conformance of the system to the requirements of the drawings & specifications. Deficiencies to be observed, corrected & if so required, replacement of the malfunctioning of the damaged items with new ones & re-testing until satisfactory performance conditions are achieved. Prepare forms for systematic recording of acceptance test results.
After pre commissioning is complete, provide a letter certifying the installation is complete & fully operable, including the names & titles of the witness to the preliminary tests.
3 Commissioning Test CT
It shall base on FAT & performed on site after the completion of installation & pre commissioning test. Where systems interface between each other, all necessary systems & interfaces shall be operational prior to starting the test.
➢ Verify quality & quantity visually according to documents
➢ Demonstration of all system & diagnostic functions
➢ Demonstration of technical parameters
➢ Functional test for all components
➢ Power consumption
➢ Module, communication failure & recovery
➢ Mechanical checks
4 Site Acceptance test SAT
SAT shall be based on selected tests from the commissioning tests & witnessed by Client & Authority. SAT shall be performed at site after completion of commissioning tests.
5 Integrated System Test IST
To be performed of all sub systems or infrastructure used at physical, network & application level.
Equipment meets the technical & functional specifications
Specified equipment does not interfere with all other systems implemented & all operate without interference from each other in full operation or under fault conditions.
6 Sustained performance test SPT
Long-term stability & reliability of the system under normal operating conditions as well as its ability of automatic diagnosis of defects & alarming any problem in a timely manner. It is done after IST for 30 days or longer
A failure is defined as any occurrence preventing full or partial utilization of the system. Availability shall not be affected & SPT shall be temporarily suspended in case of any failure caused supplied equipment or services.
EPIC Contractor shall design for approval by authority
➢ Design of sustained performance test
➢ Reliability of central equipment
➢ Field equipment reliability
➢ External interface input or output failure
➢ System sustainability as identified by frequency of false alarms
Operations & maintenance O & M
1 Every contract defines a particular duration of post practical or mechanical completion initial operation & maintenance to make sure & evidently prove efficient performance by the equipment / deliveries. During this period training is also imparted to the Client personnel according to the provisions / requirement of the contract so that these personnel get used efficiently for the proper control about operation of new technologies. During initial operation, the contractor shall operate the systems according to the functional requirement complying strictly to the equipment manufacturer’s instructions.
2 Contractor shall deploy his operators for the purpose of initial operation duration & after successful completion of the initial operation, the control of the equipment then shall be taken over by the client.
In case during the period of equipment performance as well as initial operation & maintenance, certain defects are discovered on the deliveries, these are identified, analysed & if so required, replaced or repaired as agreed with the Engineer or Client. The operation & maintenance period recommences until it is evident that no further defects exist on the deliveries.
3 There could be included within the contract modalities any condition of damage compensation to the client applicable because of equipment performance test failure, which case requires the EPIC contractor to make compensation to the Client of the calculated claimable amount for the failure of the required deliveries performance of the technology. This is very significant condition in the sense that compensation may amount to many times the cost of the works. The contractor should be careful during initial operation & maintenance by keeping controlling eyes on all systems & discover any minor or major defects appearing on the operation & if detected any defect, must be brought to the knowledge of the engineer & client for the agreement of the corrective steps to be taken & after correction, re-operation commenced for the successful initial operation completion duration.
Third Party Certifications TPC
1 On many specialists deliveries a clause is included that the product should be certified by a third party independently which shall be approved by the Client or the engineer prior to the commencement of its scope of the works. The third party shall, according to the provisions of the quality systems adopted or approved, inspect the deliverables in the factory as well as on site during procurement; pre-commissioning & commissioning & also during performance & maintenance. No payment shall be made to the Contractor until the third party certifies that the delivered product is according to the project specification requirement as well as meets all defined acceptable requirements.
2 The Contractor shall have to arrange for all proceedings in all respects according to the requirement of the Third party certifying authority, how to effect the item inspection in the factory as well as on site in the presence of the engineer or engineer’s representative. All provisions to be extended to the third party inspector shall be made available in due time so that the inspection be conducted smoothly. Instruction given by the third party shall immediately be implemented to accomplish the job. After having the certification over, the document received shall be processed for presentation & examination by the engineer & the Client for this certificate/s has/have to be included as part of the mechanical completion certification.
3 Third Party Certification services
Contractor is to appoint a Third Party Certification Agency (TPC). The list of approved TPC is to be provided within the FEED documents. The Third Party Certification (TPC) services shall be in accordance with DIN 50049, 3.1C and the certificate to be provided by Third Party Certification Agency shall include the following as a minimum:
➢ Proof of identification of the material
➢ Tests report duly signed by Inspector
➢ Identification symbol of Agency or Inspector
➢ Certificate number and date of issue
➢ The different levels at which involvement of TPC are required shall include, but not be limited to, the following:
Material Traceability Level
Any material under the following categories (Traceability Levels) shall require specific certification or documentation as given below:
Level 1 - Full Material Traceability
The TPC shall review the data books of manufacturers and witness all the tests in accordance with DIN 50049 3.1C or equivalent. These items shall be fully traceable. Level 1 includes Critical System, structures and components where failure could result in:
A significant hazard to personnel. A significant loss of production. A significant environmental hazard.
For example certification of Level I may include: ANSI/ASME B31.3, Generators, Switchgear, Transformer, Craneage and supports
Level 2 - Material Traceability
The TPC shall ensure that the materials supplied to the Project can be traced back to Manufacturer’s Certificates (DIN 50049 3.1B or equivalent), which shall be compiled in a data book and delivered with the equipment package. It is to be ensured that the marked up drawings are supplied to Client for reference and traceability purposes. Level 2 certification is applicable to:
➢ Critical system, structures, components where failure could result in:
➢ A limited loss of production, A limited environmental hazard.
Level 3 - Material Traceability
The material shall have a Certificate of Compliance (DIN 50049 3.1A or 3) Level 3 is applicable to material that is not in level 1 & 2.
Example of system / unit to be included in level 2, Any process system non-process wetted or non-pressure parts which are not in level 1 or 2.
Materials not in levels 1 & 2 e.g. hand rails, floor plate, cable tray.
Minor items e.g. sacrificial spool pieces of low value and non-hydrocarbon duty, etc, Produced water, Lube oil, Instrument air.
Packages
The traceability level for an equipment package can be found by using level 1. The component parts of an equipment package do not warrant the same level of traceability.
The certification type should always be considered consistent with the high criticality and type of equipment / material being designed, procured or fabricated. Consideration needs to be given to the applicable international codes and standards to which the particular equipment is being built.
Project records
All documents in whatever format produced, shall be controlled by master record copy in both hard as well as soft mode. These documents shall be duly numbered for the purpose of efficient traceability. Well established document centre of the Contractor as well as of the Engineer shall affect this requirement for all relevant incoming as well as outgoing documents. All records shall be well maintained & made accessible to the relevant authorities under the direct control of the document controller. All contractual documents, schematic drawings, design drawings, approved for construction documents, specifications, red line mark ups, deliveries, inspections, procedures & others, shall be kept in the centre for an easy reference / review for the authorized personnel. Only controlled copy shall be issued to the designated personnel for reference as well as official use.
Issued for Construction documents-
These documents are meant for the construction purpose having due approval by the engineer & the Client. Without an availability of these documents, no work shall be allowed on site. The site personnel should ensure that the documents under use are approved for construction by making an enquiry from the document control centre. Document control shall immediately affix the superseded seal on the documents not to be used any further. These documents are also given various sequence of revision depending on the changes effected thereto. The document control shall regularly update the register of the documents showing these changes & revision references & circulate to the designated personnel.
Red Lines Mark ups- basis for As Built documents
Every operation on site should go smoothly when all details are available. There shall be instances due to the site requirement of actual conditions, which possibly might not have been included during the original design, that need immediate attention & effects to a certain extent the site for adjustments on the practical execution of the design after the approval by the engineer is granted. These changes on the site shall be recorded on the drawings or the specifications temporarily as red line markings/markups to be used as records for producing as built records. Every red line mark up shall be intimated to the engineer for the purpose of obtaining an approval for as built production. These shall be recorded in the document control as regular documents.
As built-
Every project requires documentation for the works done on site for the final handover dossiers. Those changes recorded as redline markups shall be properly studied by the discipline or the project engineers one by one to decided whether or not these changes should be reflected on the approved for construction documents. All redline mark ups shall be incorporated on to the as built title drawings before the submission to the engineer as project dossiers. Separate documents references shall be used for the se documents for an easy reference as well as traceability.
Operation & maintenance Manuals
All equipment belonging to every discipline procured from any vendor shall be used on operation of the facility permanently under proper maintenance. The responsible facility operators should know explicitly how these machines or the equipment to be used. The respective vendors should provide all operation & maintenance manuals for the reference of the user describing fully to meet all normal as well as emergency requirement. The Contractor shall submit these manuals after processing formally as documents for approval by the engineer. These shall also form part of the handing over dossiers.
Punch List / Snags-
Before the mechanical completion as a part of the pre commissioning stage, joint inspections are carried out to enlist the minor defects as snags for all items one by one according to the approved checklists. These leads are given by the quality assurance & control department jointly with the construction & engineering. These notes of snags are recorded & a time frame agreed to incorporate the correction to items that are correctable. The items that need replacement because of defects shall have to be replaced immediately without any delay so as not to adversely affect the project handover. After conducting the correction to these snags, inspections are made & final list is prepared for minor defects that may not effect the commissioning or the performance of the facility which may be taken up to be repaired during maintenance stage to the agreement of the parties concerned.
Visual defects-
It shall be easier to some extent for which prosecuted items may allow visual inspections for the purpose of full or part acceptance admissible within the quality assurance procedures. Item should then be closely inspected from inside & outside according to the procedures specified on the Inspection & test check list. Whatever observation made, should be recorded & final interpretation punched for further action which shall decide the level of acceptance & suggest the further remedial action applicable. These types of repairs should be immediately carried out to avoid unnecessary inclusion on the punch list.
Technical defects-
Where technical defects have been noted on records pertaining items, amounting to severe nature, that case invites items to be replaced immediately to avoid any delay on the start up. In case defects amount to very minute nature which do not necessarily invite replacement action, touch up repair may be agreed with the engineer & after agreement, according to the procedures the repair be effected for re inspection & acceptance.
Minor non-conformance-
Where a non-conformance has been recorded to repair minor defects, should these defects be repairable, after agreement of the proposal with the engineer, the repair be conducted & approved by re examination.
Snags-
1 Snags have been covered in aforesaid explanation but should be dealt with all according to site requirement & the item concerned. Some snags may require replacement of the item in full that should immediately be effected to avoiding any delay on the performance of the system.
2 Investigations / rectification / remedial measures-
During the inspection many categories of the snags for punch list shall be observed & pointed out. All these should be recorded & some important snags noted which amount to sloppy quality assurance for which investigation must be resorted immediately to establish the responsibility of neglect during supervision.
3 Based on these reports of investigation & punch list reference, Non conformance reports should be constituted, thereafter resolution recorded on these for ‘acceptance & implementation’ following which, the execution of the resolution, re-inspection & approval process repeated. Precautionary measures as revealed by the investigation of the responsibility as established should also be included within the reports & on the close out report for future lessons & references.
Mechanical Completion- Pre commissioning & commissioning-site acceptance test- performance- plant performance-Final documentation
Final Project Dossiers shall be produced as per Engineering Standard compilation of Project Dossiers (Latest revision as on Effective Date Of Contract) and as described below:
Mechanical catalogue-
General
1 Contractor shall prepare the Mechanical Catalogue & make available 3 (three) months prior to being Ready for commissioning for the system / sub system / unit stage as a compilation of ‘engineering and vendor drawings’ and data for use during installation, commissioning, start-up, performance testing, operation and maintenance & include all documents as builts up & others as necessary for installation & operation of the relevant system or sub system or unit .
2 Contractor shall organise all the Mechanical Catalogue by unit and equipment category, which consist of several volumes depending upon from case to case & be submitted in the approved format.
3 Mechanical Catalogue should be bound in hard, durable, binders, with the Job Title and Project Number embossed on the cover. The Table of Contents of each Volume is to appear in all volumes. Contents should be sectionalized and separated by properly labeled dividers. Volume thickness of each book shall not exceed eight (8) centimeters. Book pages are to be A4 size. Drawings should be reduced to A3 size and may be accordion-folded to A4 size. All indices, labels, contents, etc. stated should be in the English language along with electronic media format Data Books.
All drawings and data shall be "as-built"
Mechanical Catalogue Contents
The Mechanical Catalogues shall include items such as given herein:
Lists for items for example - engineering documents, requisitions, general and particular specifications, Development Plan and Design Basis, Design criteria, Specifications and data sheets, PFDs (process flow diagrams), P&Ids (piping & instrumentation diagrams), line lists, Isometrics, ESD (electrical/electronic system diagrams), One line diagrams, Utilities summaries, Plot plans and layout drawings-Approved For Construction (AFC) drawings in all major disciplines (civil, structural, piping, electrical, instrumentation and others), Equipment lists, Load lists, Instrument lists-Major calculation notes for all disciplines, Instrument loop diagrams, Electrical short circuit and load flow diagrams, Electrical trouble shooting diagrams, Electrical relay co-ordination diagrams, Vendor drawings and documents for all equipment and materials, Un-priced purchase orders
Quality assurance record book
General
1 Contractor shall prepare Quality Assurance Record Books consisting of a compilation of quality assurance / quality control documentation representative of the material, manufacturer, fabrication, erection and test history of the equipment ordered and materials installed as appropriate.
2 Contractor to note that some of the requirement stated herein may not be applicable to the Project. The purpose of the Quality Assurance Record Book shall be to ensure that quality assurance and quality control documents originating at the engineering, procurement, fabrication, erection and commissioning stages from multiple sources (Contractor, Subcontractors, Vendors, and their respective sub Contractors and vendors) shall be easily retrievable in order to provide evidence that equipment and materials used and assembled in the FACILITY comply with the Contract requirements at each step of the Work.
3 The content of the Quality Assurance Record Book shall vary depending upon the type, size and complexity of the equipment. Each book shall contain all documentation referenced in the inspection data sheet and all records of testing required.
4 In view of the requirement for full traceability of materials and dimensional control, Contractor shall include drawings such as vessels, tanks and piping shop drawings marked up with welding identification and material certificate numbers.
5 The documents for the quality assurance dossier shall be kept in specific quality assurance files as soon as these are issued, remain easily retrievable and available for consultation at all times during the course of the work.
6 Contractor shall organise the Quality Assurance Record Book by Unit and equipment category. There shall be several Quality Assurance Record Books each consisting of several volumes. The final Quality Assurance Record Book shall be issued together with the other documents to be included in the Final Documentation in required number of copies.
7 Contractor shall submit the details of the format and contents of the Quality Assurance Record Book for approval prior to starting preparation.
The Quality Assurance Records Book shall be bound in hard, durable, binders with the Job Title and Project Number embossed on the cover. The Table of Contents of each Volume is to appear in all volumes. Contents should be sectionalized and separated by properly labeled dividers. Volume thickness of each Volume shall not exceed eight (8) centimetres. Book pages are to be A4 size. Drawings should be reduced to A3 size and may be accordion-folded to A4 size.
8 Contractor shall have all indices, labels, contents etc. stated in the English language. The Project Manager / Engineer shall be consulted as to what arrangement shall be most suitable. Also, Contractor shall prepare electronic media format Data Books. All drawings and data shall be "as-built"
Contents of Quality Assurance Record Book
1 The Quality Assurance Record Book shall include but not be limited to the following items:
Approved dossier index-Signed off copy of quality plan-Technical Certificates of compliance as well as non-conformance technical certificates for the record if any.
2 Where NACE compliance is a requirement, NACE certificates-Typical material certificates-Fully traceable material mill certificates-Weld procedures and qualifications-Weld repair procedures-Welders qualifications-NDE procedures- NDE reports for examination of welds including X-ray films
3 UT test sheets-NDE operative qualifications-Visual examination certificates-Dimensional check report-Heat treatment Procedure-Heat treatment Charts-
As built drawings-Vessel nameplate details-Weight and centre of gravity details-Hydro test certificates-Pneumatic test certificates-Balancing reports-Over speed test reports-String test reports-Hazardous area test reports / certificates-Functional tests, either mechanical, electrical, control system and others as required by national standard or Client specifications, whether witnessed or not (as applicable)-Crane SWL certificate-Electrical continuity / insulation resistance test-Instrument calibration certificates-General electrical / instrument/control/telecommunication-testing.
4 The Pre-commissioning and Commissioning dossiers shall also be included in the Quality Assurance Record Book.
Manuals and data book
Introduction
1 Contractor shall prepare the Operating, Maintenance and Other Manuals for the Client to use for operator training as well as for preparing the detailed operating procedures. Contractor shall organize the Operating, Maintenance, Safety, other manuals and Data Books by unit, System or Sub-System.
For that purpose, a number of manuals shall need to be produced to allow the commissioning team to produce detailed procedures and instruction for operating and maintaining the FACILITY. The manuals are listed here in order that the Contractor may identify any information of an appropriate nature, which should be compiled and handed over to Client.
2 Client shall specify procedure for the coding, format and final completion of documentation, drawing and certification to achieve a smooth hand-over from the Client project task force to the operating staff. It is important that all stages of the Work are properly recorded. The records and documents generated during the Work shall be included in Manuals by Unit, System or Sub-System to be handed over to Client during the transfer of responsibilities from construction to commissioning to operation.
3 Complete document packages for each Unit, System or Sub-System shall be available before transfer of responsibilities for Unit, System or Sub-System takes place. Computerized records shall be utilized where appropriate.
PFD’s, P& ID’s and single line diagrams prepared by Contractor shall be in a format for direct input in Client CAD (Computer Aided Design) system. Also all such documents from Vendors shall be computable to Client CAD format specified in TDMS specification. Manuals shall be written with regard to the overall construction and commissioning program, quality control, operations and maintenance so that they are available at the right time for their proper utilisation.
4 Each Manual shall consist of several volumes. Client might have identified the following manuals to be generated as a minimum:
Each Operating, Maintenance, Safety, Other Manuals shall be available in preliminary form three months prior to ready for commissioning for the relevant system or unit and be issued in the final form together with the other documents to be included in the Final Documentation at the time of applying for Certificate of Completion. The required number of copies of the Operating, Maintenance, Safety and Other Manuals as well as the format is defined somewhere in the documents. Contractor shall submit the details of the format and contents of the Operating, Maintenance and Safety Manuals for Approval prior to starting preparation. The Manuals and Data Books shall be bound in hard, durable, binders, with the Job Title and Project Number embossed on the cover. The Table of Contents of each Volume is to appear in all volumes. Contents should be sectionalized and separated by properly labeled dividers. Volume thickness of each Volume shall not exceed eight (8) centimeters. Book pages are to be A4 size. Drawings should be reduced to A3 size and may be accordion-folded to A4 size, stated in the English language. The Project Manager / Engineer shall be consulted as to what arrangement shall be most suitable. Also, Contractor shall prepare electronic media format Data Books. All drawings and data shall be "as-built"
Facilities Manual
It shall describe the overall FACILITY and contain the basic data which determines the methods of protecting, operating and maintaining the FACILITY. It shall contain the operating parameters including safe working limits for all vessels and pipes. It shall contain plot plans, area classification plans, together with escape routes and other items to be approved by Client.
Access Manual
This manual shall show access and lay-down for maintenance of all items of equipment and be developed by the EPIC Contractor for further review and approval by Client.
Operating Procedures Manual
This shall be the collection of detailed operating procedures relating to each FACILITY or system. Operating manual shall be categorized into Process Units, Utility Units, Auxiliary Facilities, Safety, Control systems, Pipelines, Communications. The manual shall describe the FACILITY in sufficient detail to the level of a competent operator including but not limited to the following:-
FACILITY description, Unit capacities and limitations, start-up and shutdown procedures, emergency shut down procedures, equipment list, PFD, P&ID, operating parameters, cause & effect charts. The draft operating procedure manuals shall be produced well in advance of Equipment and FACILITY commissioning.
Emergency Procedure Manual-
This shall contain all the actions that need be taken in the response to an emergency incident on the site or in its vicinity such as acid spillage, pipe bursting, fire, accidents, etc. It shall describe the organisational response required to deal satisfactorily with such incident, the required liaison with outside authorities & include any special procedures or instruction relating to process / utilities equipment with normal operating procedures.
Engineering Manuals
These are record dossiers of all items of FACILITY and equipment to be supplied by the Contractor. The manual should include Equipment data sheets / vendor documentation, specification, spare part lists, drawings, repair procedures and QA procedures etc.
Maintenance Manuals
These shall provide sufficient information to the Client Maintenance Department and be produced in a form which shall facilitate the setting up of a Maintenance Management System. The final formal and content shall be decided by Client to reflect site policies. The manuals should contain the appropriate data to allow Client Maintenance to perform their function effectively as well as include vendor’s equipment description, detailed drawings, spare lists, references, re-ordering procedures, maintenance and vendor manuals.
Training Manual
This manual shall be produced by Contractor for approval by Client. It shall give a brief description of systems and the associated subsystems. It is intended to be used for training purposes only for which, it shall form the basic of a detailed programme for the operation and maintenance activities of the facility, system and subsystem where appropriate.
Maintenance procedures
Maintenance procedures are to be split per main equipment or main equipment category. General-Detailed description of the equipment and auxiliaries-Detailed instructions for use-Detailed trouble shooting Section and details of self-diagnostic routine-Detailed dismantling instructions-Itemized spare parts lists with reference drawings-Recommended list of consumable-Maintenance schedule
Data book
1 Data Books are intended to provide the information necessary for Client’s resident Technical Department or an outside Contractor or consultant to understand the processes involved, calculate performance capacities, efficiencies and design modifications.Data Book(s) shall in general conform to the following:
2 Basic Engineering Data: General Information. Utility Information, Meteorological Data, Summary report on Soil conditions, Site conditions, Operating and design parameters. Elevations and Coordinate References and government requirements. Drawing Index of all Client, Contractor and Vendor drawings This index shall include: (a) One column wherein all drawings included in the Data Book are clearly indicated and, b) one column wherein all drawings for which electronic format (CAD). Tape / diskette) supplied to the Client are clearly indicated. Also, those included in the Equipment Reference File should be so marked. Refer TDMS specification requirement . Contractor with Client approval, shall provide a database for recording of the index.
Equipment Schedule-
Of all equipment by item number, description and specification number. Group equipment by category, i.e. tower, exchangers, vessels, etc. Also Manufacturer's name.
Process Units
Include Process flows (show oil and utility quantities for specified charge rates), P& IDs by Unit, Block flow diagrams, Process plot plan, Heat and material balances, Process calculations index and Battery limit line Tables for Process and Utility lines, Licensor’s documentation.
Water Systems
Including sources, treating facilities, cooling water, etc., distribution and balances for normal and maximum design conditions; fire water systems design pumps, hydrants, hose and hose reels, fixed spray systems, monitors, etc. systems plot plans, P&IDs, and water treating data sheets.
Air Systems
FACILITY and instrument: Include design basis (quantities, pressure, dew point). Also, systems plot plans, flow sheets and tie-ins when provided.
Air Quality Control
Include design basis for air quality dispersal rates; setting stack heights, and major equipment used in control. Also, flare stack height data related to smoking / non-smoking capabilities; maximum emission allowances for C02, S02, etc. as required by local and other governmental regulations.
Noise-
Include in-plant and community design noise level limit criteria, specifications, where required the local and other governmental noise limit regulation for in-plant and community noise.
Electrical Systems
Including all distribution facilities, design basis abnormal load and peak demand tabulation of significant operating conditions. Systems plot plan (including substation locations), single-line diagrams of ‘generating and main distribution’ system. Design data for switchgear and motor controllers. System description and data on telesignalling system
Communications
Include system description, special requirements (radio, walkie-talkie, etc.) and equipment layouts.-
Buildings-
Include brief description, type of construction, plans, elevations and plot plans.
Safety
Special requirements as related to operating units and equipment.-
Equipment Data
1 Pump information to include pump list data sheets. performance curves, outline and dimensional drawings (including driver), mechanical seal arrangement drawings and auxiliary (vents, drains, lube oil systems) piping drawings. All power System Studies to be submitted as a stand-alone dossier complete with drawings, data, CDs etc.
2 Centrifugal & Reciprocating Compressors and Drivers information to include data sheets, performance curves, general arrangement (outline) and cross-sectional drawings, steam gland and sealing diagrams (when required), lube and seal oil diagrams indicating instrumentation and control and outline drawings, specifications of lube oil and seal oil consoles. Special Equipment such as mixers, filters, etc. to include data sheets, drawings, piping arrangement, electrical.
3 Instrument information to include schedule, listing data by category (temperature. pressure flow, etc.); process information and pertinent mechanical description Maintenance Facilities information to include list (type, size) of permanently mounted shop tools, special portable tools and special inspection equipment; plan and arrangement drawings of simple buildings used for maintenance and bulk materials storage. Also, major platform arrangements, including access for operations and maintenance. Line list information shall be provided as per specification.
Back up of the control / DCS system configuration made for the plant or package shall be provided in CDs or DVDs in 4 (four) numbers.
Technical Data Management System (TDMS)
Contractor shall develop and provide Final Documentation in accordance with TDMS specifications.
Maintenance, Engineering Data Acquisition, Management and Maintenance Strategies for SAP System
1 The supply of the software is not included in the Scope of Work of this Contract. Client shall install the SAP system software. Contractor shall compile the data in accordance with the SAP structure as per the Scope of Work. Contractor’s Scope of Work is to input / entry data into the SAP system in conformance with the Scope of Work and structure as indicated in the SAP document. The operation of SAP is included in the Scope of Work of Contractor. However, the Contractor shall provide hardware and Software interface between SAP System and the DCS. Between the SAP system consisting of SAP modules and the DCS equipment, an Open access module is required. The SAP Open Access module shall extend the functionality of SQL plus to provide direct access to SAP modules from the APIs of DCS equipment. The Open Access module shall be both a Client and server to SAP, so data exchange may be initiated by either SAP or any application program on DCS (like Setcim and Infoplus of Aspentech etc.).
2 This dual functionality shall allow bi-directional event driven information links to be developed between API (setcim) of DCS and SAP applications. This module at a most basic level shall allow standard SAP PP-IP messages to be received and transmitted by SQL Plus. Additionally, in order to accommodate customised SAP systems, the SAP Open Access Module shall also allow user defined messages to be transmitted and received from SAP Advanced Business Application Program (ABAP) which be developed by the Contractor as per the Scope of Work defined. The registration and definition of these messages shall be handled by this module allowing applications to be developed without any changes to any of the already existing SAP configurations.
Final Completion- maintenance & successful performance
Hand Over-
1 Handing over the site refers to mechanical or physical handover to the client at practical completion. The works should have been completed in all respects so that these can be used for the intended purpose & production commences according to the plant designs & technology involved.
2 All documents as explained in the foregoing are compiled according to the QA system to constitute a bunch of documents contractually for an approval by the engineer & the client for permanent use by the client. Immediately after the handover, performance start up, the operations work & the maintenance period commences which continues up to an agreed period or duration according to the provisions within the contract. A list of minor snags not effecting the performance should be prepared for repair in the maintenance period as agreed by the client & the engineer. All punch list items as included within snags should be properly & efficiently attended to so that it does not take much of the maintenance period for the reinstatement conditions. All personnel meant for training the operative of the client should be engaged for imparting to them formal training courses according to the agreed conditions for explaining complete systems demonstrated properly so that no mistake may occur during operations.
Recording the lessons learnt-
1 It should be the endeavour of a professional contractor to record all incidents during the contract execution which obstructed the progress on the contract & all instances evidencing the cooperation by the engineer & his staff. All problems faced or experienced by the contractor should also be recorded on documents giving base for incorporation solutions for future contracts. Contractor should also describe his mistakes or how otherwise the problems could have otherwise be tackled to minimize the loss of time & expenditures. Also a record should be made for the performance of the engineer or the client personnel & any required improvement. These documents are termed as close out report part. The client & the engineer should go through these records to amend its style of working on the future projects.
2 Suggestions-about the sub Contractors- These should also be recorded based on the regular records during the various progress stages.
About the Client engineers-These records should also be based on the regular comments noted on the progress achievement during the contract period giving necessary suggestions about enhancing the client or engineers efficiencies & dealings in the interest of the future projects.
3 Close Out-The close out reporting is very significant in essence as it is a final document speaking all history summary of the project which may be used to learn various lessons for future use by all parties involved & can form an operational research database for supervision analysis
4 Discharge-After obtaining the final completion & maintaining certification, discharge certification should be given by the client & the engineer relieving the contractor of the construction responsibilities provided the contractual warranties as well as liabilities remain in force as secured for the coverage of certain guaranteed items on the scope of work.
Technical safety, operation review & technical audit
1 Contractor shall arrange for technical safety, operability and maintainability reviews which are required to be carried out by Company / Client at specific stages of Engineering, Procurement and Construction during the Project development to check for safety, reliability, operability and maintainability of the FACILITY.
2 In addition, Company / Client at its sole discretion may appoint a third party to carry out such quality / HSE audits of the Work.
Contractor shall make available all records and all aspects of the Work at all times and at all places where Work is performed for detailed auditing by Company / Client or any third party appointed by Company / Client. In particular, Contractor shall make available for reference and Company / Client use at all places where the Work is performed, a good quality copy of the latest issue of all applicable codes, norms, standards, drawings, specifications and qualified Contractor Personnel to assist Company / Client. Contractor shall also provide a suitable venue for such reviews. Additionally, Contractor shall carry out Hazards Analysis, Safety Analysis and Project Health, Safety and Environment Review (PHSER). Contractor shall also prepare Safety Audit and Inspection Manual to submit to Company / Client for approval.
3 Additionally, Contractor shall carry out safety, operability and maintainability reviews and provide copies of Contractor’s findings to Company / Client. Company / Client shall have the right to attend such reviews. Contractor shall implement the review findings into his Scope of Work. Contractor shall also submit Safety Requirement Specification.
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Chapter 6
Project management
Various facilities at Construction Site
Contractor shall be responsible to arrange to acquire all the service logistics required at Plant Industrial City for the performance of the Works. The costs of such services shall be included in the Lump Sum Portion of the Contract Price.
Examples of the required services are:
➢ Land rental for Accommodation / office camp and lay down area.
➢ Gate pass of personnel and vehicles, equipment, plant
➢ H2S, BA Certificate courses.
➢ Fresh water etc
All these facilities shall be managed by the contractor sufficient in advance so as to meet the schedule requirement. It should be noted that the procedure for the lease of the planned land for the camping consumes considerable time by the municipality or the industrial city authorities as well as other authorities. Also, the application procedures for the security gate passes based on its own regulation take certain hours for the issues. All these points should be kept in notice to initiate the application quiet in advance to meet the schedule requirement.
Construction Accommodation Camp and Other Construction Facilities
Contractor shall choose from option 1 or 2 (below) for its accommodation camp.
Option 1 - Accommodation facilities Inside the Fence of Plant Area.
Contractor may utilize accommodation facilities provided by Plant inside the fence of Plant area. Charges and fees to be paid by Contractor to Plant for such accommodation if so preferred & available. Contractor notes that Plant accommodation facilities shall be subject to availability at the time of request and be provided to Contractor or other parties on the basis of first come first served.
In the event that the Plant accommodation facilities are not available, Contractor shall utilize an approved Plant designated area and construct, operate and maintain his own accommodation facilities.
Option 2 - Accommodation facilities Outside the Fence of Plant Area.
Notwithstanding the above, Contractor may elect to have his accommodation facilities outside the Plant area fence. In such case Contractor shall obtain necessary approval from local authorities as mentioned in the foregoing.
Other Construction Temporary Facilities
1 Contractor shall provide, maintain and operate a suitable lay-down area, fabrication area and office camps and obtain permit from Company / Client Plant and / or Government Agencies to build these temporary facilities at Plant Industrial City including permits for all utilities such as power, water, telecommunication, etc. In accordance with the latest Health, Environment and Safety standards for which Company / Client shall assist Contractor by issuing an introductory letter to the Authorities.
2 Contractor shall submit office Accommodation and lay-down area requirements for Company / Client approval after Contract award. Contractor shall utilise these Temporary Facilities for the purpose of the Project only.
3 The approved temporary office camp and lay down areas shall be at no cost to Contractor, provided that these space requirements are considered as reasonable and justified by Company / Client / Plant.
General
1 Contractor shall take over construction preparation for the Temporary Facilities after obtaining approval from local authorities, Plant and / or Company / Client. Contractor shall build, operate and maintain up to Completion the accommodation camp for Contractor Personnel and other related facilities. The camp design and construction is to conform to the design requirements to be developed by Contractor and approved by Company / Client during the engineering phase.
2 Contractor shall provide accommodation, catering and servicing (including safety, medical aid, housing, cleaning, recreational facilities, laundry) in the camp and generally cater to all personnel (no accommodation to be provided to Company / Client personnel) assigned to Construction Site. Contractor shall be responsible for operation, maintenance and housekeeping of the Accommodation Camps and other facilities.
Contractor Personnel are to be accommodated in camp facilities in accordance with the latest Health, Environment and Safety standards.
3 After Completion, Contractor shall close down and re-instate the Accommodation camp to its original state (as a minimum) and other facilities including all facilities provided to Company / Client.
➢ Office Buildings and Other Facilities
➢ Contractor shall build, operate and maintain throughout the duration of the Work all other required Construction Site facilities including but not limited to the following:
4 Office buildings for Contractor and Company / Client Personnel.
➢ Reprography and communications (including phone, fax, radio, etc.)
➢ Pipe fabrication shop.
➢ Warehouses and lay-down area
➢ Warehousing facilities shall include covered storage, air-conditioned storage and outdoor storage as appropriate. Piping must be protected with pipe caps.
➢ Radiography examination room. Toilets, washing facilities, showers and change rooms. Testing laboratories, both civil, mechanical and E &I
5 Concrete batching facility. Roads, paths and car parking for construction requirements. Guard houses, entrance control and fencing. Craft work areas, Fuelling stations for equipment, trucks, buses, adequate storage and handling facilities, Rigging loft, First aid medical stations (minimum three (3) stations), Equipment maintenance facilities, Labour canteen facilities, Explosives storage if required, Lining storage area and work area.
6 Steel fabrication area, Civil prefabrication work areas, Grit blasting, painting shop, Utilities such as power, water, air etc. For the phases of Work up to Completion, any other facilities required for the Work,
7 Contractor shall prepare details and obtain relevant approval of the facilities proposed. The temporary construction facilities provided by Contractor for the Camp, Offices, lay down areas fabrication shops, etc. shall be subjected to the inspection of the State Environmental Supreme Council such as sewage disposal, earth renewal and disposal, dirt transportation disposal, spills, etc. In case, Contractor is not compliant with the minimum requirements, Contractor shall take all necessary remedial actions for proper compliance.
Utilities For Accommodation Camp, Office Buildings and Other facilities at Construction Site
Power- accommodation camp
Contractor shall arrange for power to be provided from Electrical Department through Plant or alternatively to arrange for his own power generation system,
Office buildings and other facilities –
The office buildings and other facilities are to be located close to the Facility to be constructed. Company / Client shall not allow Contractor to utilise existing Company / Client facilities / utilities and Contractor arrange for its own power generation system.
Contractor shall arrange for temporary power and lighting arrangement in all work areas at Construction Site.
Fresh Water - Accommodation Camp
Fresh water at camps at Plant Industrial City shall be provided by Contractor, including what is required for the Work.
Office buildings and other facilities
Contractor shall provide for the collection, storage, transfer and distribution of all water required for office buildings as well as other facilities at Construction Site. Requirements shall also include items such as concrete production, aggregate materials washing, testing of piping, vessels, tanks, drinking water, personnel waste flushing and for compaction of Construction Site fill. Contractor shall provide for adequate water storage facilities for this purpose. Wastes from accommodation camps, offices and other facilities at construction site
Effluents
Contractor shall provide for the collection of all sewage and wastewater from both the accommodation camp and other facilities at the Construction Site to storage tanks and provide for the contents to be treated at the existing Plant Sewage Treatment Plant.
Construction debris
Construction debris may be disposed as follows:
Clean construction rubble and excavated materials hauled elsewhere within Nation to a site approved by Company / Client and / or relevant body.
Garbage and construction unclassified rubbish to be hauled to a Site within Nation approved by Company / Client and / or relevant body.
Scrap steel to be disposed of through local organisations.
Untreated sanitary waste and solid waste to be hauled to a treatment plant located to a site within Nation approved by Company / Client and / or relevant body.
Contractor shall adhere to Environmental Guidelines and Company / Client Environmental Protection Standards and apply to the relevant National public authorities for disposal of such construction debris. Company / Client shall provide a letter of introduction for such application.
Contractor shall adhere to Regulation for Disposal of dredging material given in Contract documents.
Waste disposal
1 All wastes generated from the Contractor’s Temporary Facilities shall be disposed off by Contractor at disposal sites within the Plant Area as approved by Company / Client.
➢ Contractor shall utilize the Plant sewage treatment plant for its domestic waste / sewage treatment for which Contractor shall be charged at the rate of ……. per cubic meter.
➢ Contractor to arrange for transportation of the sewage from his camp to the Plant sewage plant.
2 Communication Systems during Construction,
Telecommunications (TEL), a governmental agency has total jurisdiction on communications for this Project. During Construction Work on the FACILITIES, communications services shall be required for Accommodation Camps, Office buildings and other facilities at Construction site. Construction communications should be considered as a separate stand-alone part of the Project including power supply arrangements. Contractor shall determine the exact requirements. A temporary exchange with sufficient capacity to meet the anticipated heavy demand for telephone and facsimile circuits during this phase shall be provided. Telephone extensions and facsimile machines shall be required throughout duration of the Project for offices of Company / Client, Contractor and Sub-Contractors. Contractor shall seek TEL advice on their requirements to supply telecommunication equipment upon request.
3 For the use of individual groups working at Construction Site with no requirement for access to external circuits, separate hand-portable radio systems with base station repeaters shall be provided. More channels and hand-portable / mobile units are anticipated during the construction phase than during normal operation. The base station repeaters should be installed in the construction office and coverage of the work areas obtained by the use of directional antenna systems. Alternatively, base equipment can be installed in suitable containers and located to provide optimum coverage. Contractor shall co-ordinate Construction Site communication system requirements through Tel. Company / Client may provide a letter of introduction for such applications.
All communications / correspondence with the local tele-communications company (Tel) shall be in coordination with Company / Client. The Communication requirement for Company / Client Personnel is specified.
Import of equipment and materials
1 All materials for the Work shall be subject to customs regulations and inspection. Contractor shall review and understand these regulations. Contractor to note that the Certificate of Origin must be certified by a Chamber of Commerce and ratified (legalised) by a National Embassy / Consulate. National customs shall reject any of these documents not ratified by a National Embassy / Consulate. Contractor to arrange authentication / legalisation of such documents.
2 Contractor shall carry out co-ordination of movement of ships, offloading and handling of equipment and materials delivered to the Construction Site, in accordance with the local regulations and following the requirements in the relevant section of the FEED Design Package.
3 Contractor shall give preference to Plant Port while importing materials. Plant Port is a modern port and has necessary facilities like exclusive heavy load berth, cargo berths etc. To facilitate Project import Material. Alternatively, other Ports can also be considered if necessary. Airfreight shall be through international airport at all stages.
4 Contractor shall clear all materials through National Customs for use at the Construction Site. Contractor shall be responsible for payment of legalisation fees, Custom duty, customs clearance etc.
Disposal of temporary facilities and construction surplus
1 The Temporary Facilities installed, the equipment and tools used and the vehicles are either to be re-exported or disposed of as the case may be, and as directed by the National authorities. Contractor shall be responsible to co-ordinate these activities with National Authorities. Company / Client shall provide a letter of introduction for such applications.
2 Contractor shall be responsible for the disposal of all construction surplus (overbuy) immediately after completion of the Work subject to Company / Client approval.
Guarantee Period
The Guarantee Period for the Work shall be 24 months from the Completion Date.
System Reliability and Water Availability
1 Contractor shall ensure that the Facility is designed, specified, constructed and commissioned to achieve an overall system reliability of not less than 99.7%. Contractor shall ensure that water availability is maintained at 100% at all time to all consumers.
2 Contractor shall perform Reliability Study based on OREDA Reliability Data and statistical data from Plant which shall be requested by Contractor.
3 Contractor shall ensure that the system reliability of 99.7% shall be maintained and proven to Company / Client with the manifold design arrangement. Contractor shall implement in the detailed design the recommendations (e.g: Mean Time Between Failure [MTBF] requirements etc.) Made in the reliability report given in documents
4 It is a part of Contractor’s Scope of Work to monitor and establish design reliability and availability by data collection and analysis for a period of one year from performance test within the contract closure date.
➢ Maintenance, Engineering Data Acquisition, Management and Maintenance Strategies for SAP System
➢ Contractor shall compile input and entry data into the SAP system in conformance with the Scope of Work and structure as indicated in the SAP document.
Project management, control and administration
Project Management
Contractor shall ensure that all parties involved in the Work properly co-ordinate on all interfaces dealing promptly. Accordingly, Contractor shall ‘initiate and implement’ appropriate project management, control and administration procedures. Provision and implementation of Project control procedures for the Work shall be following the guidelines provided in Contract. In particular, Contractor shall give proper attention to the following:
Project Control
1 Contractor responsibility includes the following as a minimum:
Undertaking project management of the design, Engineering, Procurement, Construction, Installation, Testing, Pre-Commissioning, Commissioning start-up, Initial Operation and Maintenance of the FACILITY including the ‘management and supervision’ of all Subcontractors, Vendors and ancillary or temporary services that are necessary for the expeditious completion of the Work in accordance with the Contract.
2 Preparation and submission of organisation charts for Engineering, Procurement, Construction, Installation, Testing, Pre-Commissioning and Commissioning (separately for each phase and location of the Work).
➢ Provision of a project management team/s to manage the implementation of the Work.
➢ Provision of Contractor Personnel to fulfill contractual requirement for timely completion of the Work.
3 Co-ordination and control of work of each work group e.g. Design, engineering, procurement services, project control, contracting, construction, Installation, Testing pre-commissioning and commissioning to ensure the Work is completed within Scheduled Completion Date according to the ‘specifications and drawings’
4 Implementation of a safety program throughout the execution of the work.
Implementation of a Quality Assurance Program throughout the execution of the Work and submission of periodic reports to Company / Client. Carrying out periodic quality, safety, technical and schedule audits with Company / Client attendance and advising Company / Client of the results of such audits together with the appropriate action taken on any recommendation/s. The said audits shall be carried out at 30%, 60% and 90% of the Engineering, Procurement and Construction progress.
5 Preparation of a complete set of Project Administration Instructions / Manual for the Work to obtain approval in line with the requirements of Contract.
6 Contractor shall prepare, finalise and obtain Company / Client’s approval of the project Document Distribution and Approval Matrices which be produced for each work phase i.e. Engineering, Procurement, Construction, Pre-commissioning, Commissioning and Initial Operation and Maintenance. The matrices shall include Contractor’s internal distribution as well as Company / Client’s involved parties, management and discipline engineers.
7 Contractor shall prepare, finalise and obtain Company / Client’s approval of the project Deliverable Register (s) which be produced separately for each work phase i.e. Engineering, Procurement, Construction, Pre-commissioning, Commissioning and ‘Initial Operation and Maintenance’.
8 Management and co-ordination of all external interfaces associated with the Work. These interfaces cover Engineering, Procurement Services (including supply), Construction, Pre-Commissioning, Commissioning,’ Initial Operations & Maintenance’ activities.
9 Attending all management meetings with Company / Client at Contractor’s Design Office, Construction Site and Company / Client offices in Nation in accordance with Contract.
Reporting to Company / Client in accordance with guideline provided in Contract.
Construction Pre-Commissioning / Commissioning / Start-up and Initial Operation and Maintenance Management
Contractor shall provide all Construction Management, supervision and support services including but not limited to the following:
➢ Construction Management and Interface Management
➢ Construction supervision
➢ Safety Management
➢ Quality Control / Quality Assurance Construction engineering and technical control services
➢ Material control and warehousing
➢ Management of Subcontractor and Vendors
➢ TPC and TPI Services
➢ Disposal of construction surplus materials
➢ Dismantling and disposal of construction aids and Temporary Facility except otherwise directed by Company / Client.
➢ Commissioning, start-up, Initial Operation & Maintenance management.
Co-ordination with Vendors and sub-contractors
Contractor shall ensure the following:
Timely supply of AFC drawings and information to be issued to SubContractors. Timely supply of Engineering documents and information to be issued to Vendors. Adequate expediting of Vendors’ drawings / data for incorporation in detailed engineering and timely return of engineering comments and approvals of Vendors drawings /data. Adequate expediting and inspection of Vendors equipment and materials. Timely supply of Pre-Commissioning, Commissioning, Testing, Start up and Initial Operations and Maintenance spare parts to the Construction Site. Expediting Vendors for providing completed SPIR forms within the stipulated period i.e. Within three (3) months of placement of purchase orders. Adequate provision of Vendors assistance for equipment during Construction, Pre-Commissioning, Commissioning, Start-Up, Initial Operation and Maintenance and Performance Test. Timely supply of equipment and materials to be issued to Subcontractors for installation and Construction.
Timely supply of One Year Operational Spare Parts, Capital Spares and Laboratory Equipment when required to do so by Company / Client.
Centralised Document Control
1 Contractor shall provide and maintain the Master Document Control Centre for Contract for documents issued by or to the Contractor at Contractor’s Design Office, Construction Site offices and other operational centres through the life of the Contract. Contractor’s primary responsibility shall include but not limited to the following provisions:
2 Centralised Document control facilities, document control staff, relevant hardware and systems at the above mentioned offices / centres Up to date PC based register of all documents issued by and to the Contractor.
Read / Sort / Print access of Contractor’s Master Document Control Database to Company / Client.
3 Issuing / obtaining Company / Client acceptance to proceed on all Document Transmittals in advance of distribution in accordance with the approved Document Distribution Matrix.
➢ Distribution of all Contractor generated documents duly sorted by function and classification to Company / Client advising due dates for Company / Client comments.
➢ Co-ordination, expediting and collection of Company / Client comments in accordance with due date schedule.
4 Provide dedicated staff to carry out the necessary document control function pertaining to Company / Client specific requirements. Provide additional staff viz. Document clerks as required by Company / Client Project Manager to supplement / support the deputed document control staff.
Project Administration
Contractor shall develop detailed Project Administration Instruction Manual applicable for Engineering, Procurement, Construction, Pre-Commissioning, Commissioning, Testing, Start-up, Initial Operation and Maintenance covering all aspects of planning, scheduling, progress reporting, cost control and project administration. An effective system shall be implemented for planning, scheduling and reporting of progress. Project Administration Instruction Manual shall be submitted for approval within 30 (thirty) calendar days from the Effective Date. Contractor shall develop all Project Administration Instruction Manuals following the guidelines and any other requirement stipulated under the Contract in accordance with good professional practices.
Final Project Documentation
Contractor shall prepare and Handover to Company / Client the Final Project Documentations as per the Guidelines provided in relevant documents. The Final Project Documentations including the following as a minimum shall be approved by Company / Client. Mechanical Completion Manuals, Quality Assurance Record Manual(s), Close-out Report, Project Dossiers
Closeout Report
Contractor shall prepare Closeout Report in accordance with requirements and guidelines provided. Contractor’s Closeout Report development and update shall be done on monthly basis from the Contract Effective Date to ensure authenticity of the report.
Services and facilities to be provided by company / client / contractor
Facilities provided by Company / Client to Contractor
Contractor Personnel shall be required to work at or visit Company / Client facilities at Plant and elsewhere whilst performing the WorK. For this purpose each Contractor Personnel must posses a valid gate pass.
Application for gate passes can be submitted to Company / Client for approval once the person has a valid entry visa stamp of Nation. Contractor shall submit the application for gate passes for Company / Client approval when all requisite formalities are completed in all respects satisfying the requirements of the security authorities and deposit with the concerned department / security office to obtain the passes. Contractor Personnel shall carry the pass at all times when on Worksite. Contractor shall be responsible for all costs relating to Contractor Personnel in obtaining passes, certificates and attending any kind of training training.
Services and Facilities by Contractor to Company / Client
Contractor shall accept the presence of Company / Client’s representatives as well as any third party nominated by Company / Client at Worksite, in his facilities and at Subcontractors / Vendors’ premises for such purpose as Project co-ordination, monitoring, review of drawings, specifications and schedule, inspections, testing etc. all other aspects of the Work.
Services and facilities at Contractor Design Office
1 Contractor shall provide and maintain the following services and facilities for Company / Client personnel at Design Office where Engineering or Procurement Services are performed for their entire service duration:
2 Contractor shall ensure that Company / Client offices within Contractor’s Design Office shall be available for Company / Client access at all times i.e. Company / Client staff have uninterrupted and unhindered access 24 hours a day, seven (7) days a week for the full duration of their stay at Contractors’ Design Office. Contractor to record that Company / Client staff shall not call his security staff to open the doors to Company / Client offices outside normal working hours.
3 Contractor shall ensure that Air Conditioning and heating to Company / Client offices during the hot and cold seasons shall be working efficiently at all times.
Offices and Related Services and Facilities (Indicative)
Sample Only Starts
a. One managerial office of not less than twenty (20) square meters.
b. Three managerial offices of not less than sixteen (16) square meters.
c. Fifteen single occupancy offices of not less than twelve (12) square meters. Common working area would not be acceptable.
d. Secretarial / clerical, administration pool area adequate for at least four persons and locked Document Control Area.
e. One fully furnished and equipped conference room for the exclusive use of Company / Client of not less than forty (40) square meters with conference table for a minimum of twenty (20) persons with all presentation equipment such as overhead projector, writing boards, etc. Contractor shall make available to Company / Client the use of other conference rooms and use of items of equipment such as television, computer projector, video (VCR) and the like for meetings and / or presentation purposes, as required.
f. One fully equipped archive office of not less than twenty-five (25) square meters with filing cabinets, filing drawers, etc.
g. One Prayer Room of not less than thirty (30) square meters.
h. Shaded car parking for twenty (20) cars within the basement of the office building which Company / Client staff shall be accommodated in.
i. One high-speed multi-copy photocopying machine (A4 and A3 plain paper sizes) for the exclusive use of Company/Client. Photocopying machines specification shall include, but not limited to, user friendly console, sorting and stapling facilities with at least twenty (20) trays, dual side copying, enlarging and reducing capabilities, minimum fifty (50) pages feeder, A4 and A3 volume paper trays and speed of not less than sixty (60) pages per minute.
j. One colour photocopier machine for exclusive use of Company/Client.
k. Two (2) paper shredding machines
l. Office scanner suitable for electronic transfer of documentation.
m. The office accommodation shall be supplied with all utilities and services (24 hours a day) such as, but not limited to, electricity, lighting, ventilation, heating and/or air conditioning, fully stocked and maintained dedicated kitchen with hot and cold refreshments, toilet / washing facilities, to the satisfaction of Company / Client. Maintenance and daily cleaning of the offices and common areas shall also be provided.
n. Pantry with a person to serve tea / coffee, etc. Shall be for the exclusive use of Company / Client
o. Toilets with ablution for the exclusive use of Company / Client Muslim staff shall be maintained at EPIC Contractor’s Home Office.
p. Keys shall be provided so that Company / Client office can be accessed at all times.
q. The offices furnishing supplied shall be of good quality and should be sufficient and include, but not limited to, carpeting, lockable desks, chairs, reference tables, meeting tables, lockable filing cabinets, stick files, wall mounted notice boards, white marker boards, drafting boards and telecommunications as described hereinafter.
r. Provision of coat hangers, waste-paper bins and normal office stationery such as, but not limited to, stapling machines, hole punchers, A4 size writing pads, note books.
s. Diaries, Lever arch files, scientific hand calculators, pencils, markers, erasers, scissors, staple extractors, pens, drawing pins, paper clips, stackable paper trays, etc. Are to be provided as required to all Company / Client staff.
t. Stationery and consumables to be used for equipment specified shall be supplied, as required. This shall include, but not be limited to, stationery and consumables for photocopier, facsimile, computer workstations, printers, paper guillotine etc.
u. Offices provided by Contractor for Company / Client shall be in the same building, which Contractor intends to use for the execution of the Work, and shall be segregated from Subcontractors, and other Contractor’s Clients.
v. All managerial and Company / Client staff offices including document control and archive office shall be lockable. Secretarial and Document Controller offices to be of an open space style. Contractor shall be responsible for the security and safety of the office accommodation.
Secretarial/Clerical Assistance
Two (2) secretaries / clerks fluent in English, complete with office space and furniture, as per the specification of those for Company / Client, and equipped and familiar with the telecommunications and computer equipment. Shall be provided. All clerks shall be provided with their own computer workstations, printers, etc. (in addition to those provided to Company / Client elsewhere in the Contract, as per the specification of Company / Client. All Secretaries/clerks shall be subject to Company / Client approval. Contractor shall provide all resumes and arrange for interviews by Company / Client of all secretaries / clerks.
Telecommunication Facilities
a. All offices, administration pool, archive office and conference rooms listed above shall be supplied with telecommunication facilities comprising telephones with speakers and microphones for conference calls with access to domestic and international networks through Contractor’s central switchboard.
b. Two laser facsimile machines with A4 size paper and with at least 100 pages memory connected with two direct lines external to Contractor’s switchboard and with access to domestic and international network.
c. Charges for telephone and, facsimile calls including connection and rental charges shall be to the account of Contractor. Company / Client shall make use of the international calls only for business purpose.
Computing Facilities
a. Contractor shall provide and install the following equipment and shall ensure proper maintenance support (hardware and software) through Contractor’s own computer support group:
b. Fifteen Computer Workstations with minimum 3.0 GHZ processor, 256 MB RAM memory, eighty (80) GB Hard Disk, 512 KB cache memory, 3.5” floppy drive, DVD/ CD ROM drive, 15” SVGA monitor (17” for engineers involved in design review), Windows 98 key board (US Standard), Windows mouse and mouse pad. All Computer Workstations shall be supplied network and Internet ready.
c. Two Notepad Computers with minimum 2.0 GHZ Centrino Processor 3.0 GHZ processor, five hundred twelve (512) MB RAM memory, eighty (80) GB Hard Disk, 512 KB cache memory, DVD / CD ROM drive, 3.5” floppy drive, 15” TFT screen, built-in Windows XP key board (US standard) and built-in-mouse and external mouse, integrated headphone/speakers and microphone jacks, rechargeable battery with average of 3 hours life time plus a carrying case and universal power adapter. All Notebook Computers shall be supplied network and Internet ready.
d. One computer workstation for direct access to Company/Client intranet through the Internet complete with printer.
Common Facilities
a. Common facilities to be shared between as many workstations as listed in (a) & (b) above connected by a local area network and consist of:
b. Two A4 laser printers, 12 pages per minute.
c. One A4 and A3 laser printer, 12 pages per minute
d. One A4 / A3 scanner.
e. Use of A4 / A3 color laser printer and A3 color plotter, as required.
f. Software Back-up facilities.
g. All computer systems should be supplied ready to use.
h. Software, latest English versions for the above Computers (each), as specified here below:
i. Windows and Winzip, Antivirus, Microsoft Professional Office. Adobe Acrobat Writer, Network Software and card , E-mail Software – Lotus Notes
j. Planning Software CONTRACTOR intends to use for the WORK. Scanning Software, Any software related to all engineering disciplines that Contractor intends to use for the WORK through Contractor’s Network. Flash Memory Sticks of at least 2 GB, Contractor shall install all cables, connections, junction boxes and software for the installation of a local area network to service all the above computers (including secretary / clerks and Company / Client Assistant Engineers’ workstations) and common facilities.
k. Contractor shall connect all computers to E-mail and Internet networks to enable communication between Company / Client personnel and Contractor personnel and communication with Company / Client management in National through the Internet Network or telephone modems. Contractor shall endeavour to use the same software applications as shall be used by Company / Client (defined above) for ease of data/reports between Contractor and Company / Client. Contractor shall ensure unlimited e-mail access for Company / Client staff at his Home and Site Offices. Company / Client shall not accept limitation on the size of the “Inbox”. There shall be unlimited megabyte size of the “Inbox”. Contractor shall ensure that remote access by Contractor, of workstations used by Company / Client shall be blocked. However, access may be permitted for short periods following approval by Company / Client.
Messing Facilities
Contractor shall provide access to its home office canteen of senior personnel for Company / Client Personnel and nominated third parties at costs equivalent to those for Contractor’s employees.
Administrative Assistance
a. Contractor shall provide assistance for obtaining (in the country of Contractor Design office where Work is performed) necessary permits, Governmental or administrative authorization visas, residence visas, car rental, domestic and international travel booking services and any other similar administrative matters for Company / Client personnel and their families and any third parties nominated by Company / Client.
b. Contractor shall provide administrative assistance to Company / Client personnel, their family and any third party nominated by Company / Client in relation to, but not limited to the following:
c. Arranging with removal firms for transport of personnel’s belongings.
d. Assisting personnel and their families to find leisure facilities, schools, hospitals, accommodation for leasing and any similar matters. Contractor shall provide the requisite guarantee if required.
e. Cost of the above-referred administrative assistance to Company / Client is included in lump sum Contract Price.
f. In case of the following items, Company / Client representative would issue specific instruction to Contractor authorizing permission and Contractor shall have to bear the cost upfront. Company / Client would reimburse the approved documented cost at actual for all such expenditure through Variation to Contract. However, all costs related to Contractor’s overhead expenses for arranging and assisting with the above would be at Contractor’s account and deemed to be included under the Lump Sum Contract Price. Payments of hospitalization costs (or guaranteeing payment if acceptable to hospital authority) for Company / Client personnel (in the country of Contractor Design office where Work is performed) in case of an emergency hospital admittance and until such time payment is made directly by Company / Client to the hospital. Company / Client would furnish Contractor with a copy of such payment remittance for his record.
g. All fees, charges and costs for visas, permits, residence formalities, etc.
Full and Shot-down Copies of Contract Document
Contractor shall provide thirty (10) shot-down copies of the Contract documents in A5 size for Company / Client use (drawing to be on A4 size folded to A5 size). The shot-down Contract document copies shall be bound with good quality hard covers and shall be subject to Company / Client approval. Shot-down copies of Contract Document exclude the Technical Information Volumes. Additionally, Contractor shall provide (10) full size copies of the Contract documents including Appendix F documents.
Mail and Courier Services
Contractor shall provide to Company / Client mail and courier services through Contractor’s mail office.
Training of Company / Client Personnel
a. Training of Company / Client Assistant Engineers at Contractor’s Home office.
b. Contractor shall provide cost for on-the-job-Training for five (5) Company / Client Assistant Engineers at his Design Office as provisional sum.
c. Contractor shall assign a Lead Engineer as Contractor’s focal point concerning the training of Company / Client Assistant Engineers. The focal point shall provide and be responsible for the following:
d. Preparation and submission of training programs in accordance with the PCP for Company / Client review and approval. Co-ordination of all training activities and matters. Keeping track of training progress for all Company / Client Assistant Engineers. Ensuring that training progress assessment reports are submitted in a timely manner. Liaison with Company / Clientrepresentative or his delegate in all matters regarding the training of Company / Client Assistant Engineers. Providing seminars and classroom courses for Company / Client Assistant Engineers. Arranging vendor factory/shop visits as necessary.
e. Contractor shall assign a Senior Engineer as a mentor for each Company / Client Assistant Engineer in accordance to their specific engineering discipline during the entire Engineering / Procurement phase.
f. The mentors shall be responsible for the following:
g. Familiarization of Company / Client Assistant Engineers with Contractor’s working systems and facilities.
h. Assigning project related activities to Company / Client Assistant Engineers and providing sufficient guidance for them to be able to complete the assigned work at the expected level of competency. Reviewing and evaluations of the activities performed by Company / Client Assistant Engineers.
i. Reviewing the monthly reports prepared by the trainees and forwarding them to Company / Client Representative with their recommendations.
j. Submitting schedule of activities planned for assignment in advance to Company / Client Representative or his delegates.
k. Preparing quarterly progress reports in accordance with the format to be provided by Company / Client.
l. The training of Company / Client Assistant Engineers shall be planned in a way to enable their full appreciation of the overall engineering consideration with respect to their discipline areas during the evolution of the Detailed Engineering and Procurement Services works. This shall include, but not limited to, the following:
m. Applicable engineering standards, codes and practices
n. Engineering design calculations, operating philosophy, process simulations, equipment selection and specifications.
o. Preparation of specifications, data sheets, engineering drawing and engineering document management.
p. Supplier evaluation and selection
q. Quality, safety and environmental
r. Familiarization with applicable computer software
s. Conducting technical meetings, presentations and courses
t. Construction procedures and philosophy
u. Commissioning and start-up procedures and philosophy
Services and Facilities at SUBCONTRACTORS / Vendors Premises
Contractor shall provide the following at Subcontractors & Vendors premises:
Contractor shall provide through Subcontractors and Vendors the following services and facilities for Company / Client personnel assigned permanently and / or temporarily at Subcontractors’/ Vendors’ premises where any part of the Work is performed and/or manufactured:
a. Use of private offices similar in specification to as mentioned above.
b. Use of Subcontractors’ / Vendors telecommunication facilities (telephone, fax, and the like) for all WORK related matters including international line access.
c. Use of Subcontractors’ / Vendors’ Computer workstations and printers.
d. Use of Subcontractors’ / Vendors photocopying machines.
e. Access to Subcontractors’ / Vendors messing facilities.
Contractor shall provide training for Company/Client personnel through Vendors of the following equipment:
a. DCS Equipment, Electrical Switchgear,
b. Main Cooling Pumps including VSDS drives, GRP Piping / Pipelines
c. F&G System, CCTV System (at site), Analysers (at site), Package Control (at site), Laboratory Instruments (at site)
d. The training shall be conducted at Vendors Premises for five (5) Company / Client personnel. Over and above Contractor shall provide training for ten (10) Company / Client Operation staff at Construction Site.
e. The Training At Vendors’ Premises Shall Cover All Areas of design, manufacturing, operating, inspection and testing, QA / QC regulation and packing while the team at the Construction Site shall cover all operation and maintenance of the equipment. Duration of training shall be for a minimum period of three (3) weeks in Vendors’ premises and four (4) weeks for Construction Site.
f. Course venues, equipment, stationery and documents shall be provided by Vendors at Vendors’ premises and Contractor at Construction Site.
g. Services and Facilities at Construction Site
h. Contractor shall provide and maintain the following services and facilities for Company / Client personnel and any third party nominated by Company / Client at Construction Site where Construction, Pre-Commissioning, Commissioning and start-up parts of the Work are performed up to the Contract Completion Date.
Offices and Related Services and Facilities
Contractor shall provide temporary office building at Construction Site for the sole use of Company / Client, which shall accommodate the services and facilities detailed hereunder. Company / Client’s Construction Site office building shall be close to Contractor’s Construction Site office building.
The services and facilities shall include the following:
a. One managerial office of not less than twenty (20) square meters.
b. Three managerial offices of not less than sixteen (16) square meters.
c. Thirty five single occupancy offices of not less than twelve (12) square meters.
d. Secretarial / clerical, administration and document control pool area adequate for at least four persons and their furniture and equipment.
e. Two fully furnished and equipped conference rooms for the exclusive use of Company / Client of not less than forty (40) square meters with conference table for a minimum of twenty (20) persons with all presentation equipment such as overhead projector, writing boards, etc. Contractor shall make available to Company / Client the use of items of equipment such as television, computer projector, video tape player (VHS) and the like for meetings and / or presentation purposes, as required.
f. One fully equipped archive office of not less than forty (40) square meters with filing cabinets, filing drawers, etc.
g. One Prayer Room of not less then forty (40) square meters.h) Shaded car parking for thirty five (35) cars.
h. Two high-speed multi-copy photocopying machine (A4 and A3 plain paper sizes) for the exclusive use of Company / Client. Photocopying machines specification shall include, but not limited to, user friendly console, sorting and stapling facilities with at least twenty (20) trays, dual side copying, enlarging and reducing capabilities, minimum fifty (50) pages feeder, A4 and A3 volume paper trays and speed of not less than sixty (60) pages per minute.
i. Use of Contractor’s colour photocopier machines, as required.
j. Two paper shredding machines
k. One office scanner suitable for the electronic transfer of documents.
l. The office accommodation shall be supplied with all utilities and services such as, but not limited to, electricity, lighting, ventilation, heating and / or air conditioning, fully stocked and maintained kitchen with hot and cold refreshments with a person to serve tea and coffee (full time), toilet / washing facilities (prayer washing facilities shall be provided close to the prayer room), to the satisfaction of Company / Client. Maintenance and daily cleaning of the offices and common areas shall also be provided.
m. The offices furnishing supplied shall be of good quality and should be sufficient and include, but not limited to, carpeting or vinyl tiles, lockable desks, chairs, reference tables, meeting tables, lockable filing cabinets, stick files, wall mounted notice boards and white marker boards, drafting boards, scientific hand calculators and telecommunications as described hereinafter.
n. Provision of coat hangers, waste-paper bins and normal office stationery such as, but not limited to, stapling machines, hole punchers, A4 size writing pads, note books, diaries, Lever arch files, pencils, markers, rubbers, scissors, staple extractors, pens, drawing pins, paper clips, etc. Are to be provided as required.
o. Diaries, Lever arch files, scientific hand calculators, pencils, markers, erasers, scissors, staple extractors, pens, drawing pins, paper clips, stackable paper trays, etc. Are to be provided as required to all Company / Client staff.
p. Stationery and consumables to be used for equipment specified shall be supplied, as required. This shall include but not limited to stationery and consumables for photocopier, facsimile, computer workstations, printers, paper guillotine, etc.
q. All offices and archive office shall be lockable. Contractor shall be responsible for the security and safety of the office accommodation.
r. Roads to Company / Client Site offices shall be paved with asphalt concrete. Construction traffic, trailers and trucks shall not use these paved roads to Company/Client offices
Secretarial/Clerical assistance
Two Secretaries / Clerks fluent in English, complete with office space and furniture, as per the specification of those for Company / Client, and equipped and familiar with the telecommunications and computer equipment. All clerks shall be provided with their own computer workstations, printers, etc. (in addition to those provided to Company / Client elsewhere in the Contract), as per the specification of Company / Client. All Secretaries / clerks shall be subject to Company / Client approval. Contractor shall provide all resumes and arrange for interviews by Company / Client of all secretaries / clerks.
Contractor shall provide one General Helper person for general office routine.
Telecommunication Facilities
a. All offices, administration pool, archive offices and conference rooms listed above shall be supplied with telecommunication facilities comprising telephones with speakers and microphones for conference calls with access to domestic and international networks through Contractor’s central switchboard.
b. Two laser facsimile machines with A4 size paper and with at least 100 pages memory connected with two (2) direct lines external to Contractor’s switchboard and with access to domestic and international network.
c. One office scanner suitable for the electronic transfer of documents.
d. Charges for telephone and facsimile calls including connection and rental charges shall be to the account of Contractor.
Computing Facilities
Contractor shall provide and install the following equipment at the temporary Construction Site office buildings and shall ensure proper maintenance support (hardware and software) through Contractor’s own computer support group:
a. Twenty-five Computer Workstations with minimum 3.0 GHZ processor, two hundred fifty six (256 MB) RAM memory, eighty (80) GB Hard Disk, 512 KB cache memory, 3.5” floppy drive, DVD / CD ROM drive, 15” SVGA monitor (17” for engineers involved in design review), Windows 98 key board (US Standard), Windows mouse and mouse pad. All computer workstations shall be supplied network and Internet ready.
b. One Notepad Computer with minimum 3.0 GHZ processor, five hundred twelve (512) MB RAM memory, eighty (80) GB Hard Disk, 512 KB cache memory, DVD/ CD ROM drive, 3.5” floppy drive, 15” Active matrix colour SVGA, built-in windows 98 key board (US standard) and built-in-mouse and external mouse, integrated headphone / speakers and microphone jacks, rechargeable battery with average of 3 hours life time plus a carrying case and universal power adapter. All Notebook Computers shall be supplied network and Internet ready.
c. Contractor shall ensure that remote access by Contractor, of workstations used by Company / Client hall be blocked. However, access may be permitted for short periods following approval by Company / Client.
Common facilities
Common facilities to be shared between as many workstations as listed above connected by a local area network and consist of :
a. Three A4 laser printers, 12 pages per minute.
b. One A4 colour laser printer, 12 colour pages per minute.
c. One A4 / A3 scanner.
d. Use of Contractor’s A3 colour laser printer, A1 and A3 color plotters, as required.
e. Software Back-up facilities
f. 6 Software, latest English versions in all cases; for the above Computer Workstations and Notebook Computers, as specified here below:
g. Windows XP or the latest (one (1) copy per computer).
h. Microsoft Professional Office (one (1) copy per computer).
i. Network Software and card (one (1) copy per computer).
j. E-mail Software (one (1) copy per computer).
k. Planning Software Contractor intends to use for the Work (two (2) copies).
l. Use of any software related to all engineering disciplines that Contractor intends to use for the Work through Contractor’s Network.
m. Latest English / Arabic software version of Windows and Microsoft Professional Office with a full set of manuals each (2 copies).
n. A full set of manuals for each software application.
o. Anti-virus (One copy per workstation or one multi-user server based copy)
p. All computer systems shall be supplied ready to use.
q. Contractor shall install all cables, connections, junction boxes and software for the installation of a local area network to service all the above computers (including secretary/clerks workstations) and common facilities.
r. Contractor shall connect all computers to E-mail and Internet networks to enable communication between Company / Client personnel and Contractor personnel and communication with Company / Client management in National through the Internet Network or telephone modems.
s. Contractor shall endeavour to use the same software applications as shall be used by Company / Client (defined above) for ease of data/reports between Contractor And Company / Client.
Messing facilities
Contractor shall provide all messing facilities (including food) for Company / Client personnel and Company / Client nominated third parties at the Construction Site as provided for Contractor’s management personnel. The food shall be of good quality and from a variety of international cuisines such as Mediterranean, European, Oriental, vegetarian etc. It is a specific requirement that all meals shall generally be low in oils and fats. Contractor shall allow for a minimum of thirty (30) Company / Client personnel. The menu shall be agreed with Company / Client.
Training of COMPANY / CLIENT Personnel
1. Contractor shall provide On-The-Job-Training for five (5) Company / Client Assistant Engineers.
2. Contractor shall provide all services and facilities to Company / Client Assistant Engineers as per the specification of those for Company / Client. Contractor shall provide offices, computing and telecommunication facilities for each Assistant Engineer. The services provided to Company / Client’s Assistant Engineers shall be in addition to those listed elsewhere for Company / Client.
3. Contractor shall assign a Lead Engineer as Contractor’s focal point concerning the training of Company / Client Assistant Engineers. The focal point shall provide and be responsible for the following.
4. Preparation and submission of training programs for Company / Client review and approval
5. Co-ordination of all training activities and matters.
6. Keeping track of training progress for all Company / Client Assistant Engineers.
7. Ensuring that training progress assessment reports are submitted in a timely manner.
8. Liaison with Company / Client representative or his delegate in all matters regarding the training of Company / Client Assistant Engineers.
9. Contractor Shall Assign A Senior Engineer As A Mentor For Each Company/Client Assistant Engineer in accordance to his specific engineering discipline during the entire Contract duration.
10. The mentors shall be responsible for the following
11. Familiarisation of Company / Client Assistant Engineers with Contractor’s working systems and facilities
12. Assigning project related activities to Company/Client Assistant Engineers and providing sufficient guidance for them to be able to complete the assigned work at the expected level of competency.
13. Reviewing the monthly reports prepared by the trainees and forward them to Company / Client Representative with their recommendations
14. Submitting a schedule of activities planned for assignment in advance to Company / Client Representative or his delegates.
15. Preparing quarterly progress reports in accordance with the format provided by Company / Client.
16. The training of Company / Client Assistant Engineers shall be planned in a way to enable their full appreciation of the overall engineering, construction, pre-commissioning, and commissioning work consideration with respect to their discipline area. This shall include, but not limited to, the following:
17. Applicable Construction, Pre-Commissioning and Commissioning standards, codes and practices
18. Construction Quality, Safety and Environment Control
19. Familiarisation with applicable computer software
20. Equipment Factory Acceptance Test (Travel, lodging - including meal and transportation costs shall be provided by Company / Client)
21. Conducting technical meetings, presentation and courses
22. Welding, Civil and Painting Inspection
23. Material control and traceability
24. Construction and Commissioning operating and safety technical reviews
25. Construction and Pre-Commissioning work
26. Commissioning and start-up preparation work
27. Contractor shall provide On-The-Job-Training for ten (10) Company / Client operating personnel during the Pre-Commissioning and Commissioning, Initial Operation and Maintenance phases of the Work. Contractor shall provide a pool area with adequate furniture (in addition to what is specified for Company / Client elsewhere) to accommodate Company / Client operating personnel for the entire duration of Pre-Commissioning and Commissioning phases. Contractor shall assign a focal point to administer the training of Company / Client operating personnel. Contractor shall submit a detailed training program for Company / Client review and approval three (3) months prior to start of Pre-Commissioning work.
28. Tax Consultancy Services
29. Option Price C calls for a Tax Consultancy Call off Service
30.
31. Detailed below is the Scope of Work for this service:
32. The Engineering and/or Design part of various major projects undertaken by Company / Client in the State of National are carried out by Contractor’s in different countries. Company / Client intends to second its personnel to the offices of the Contractor and these personnel stay overseas for a period that makes them liable to tax in that country.
33. The tax on the individual employees shall be paid by Company / Client. Company / Client wishes to engage the services of a Tax Consultant, managed by Contractor, who has world wide office infrastructure to advise Company / Client on all tax matters related to personal income tax and complete the necessary documentation.
34. The Scope of Work for the Contractor’s tax consultancy work includes, but is not limited, to the following:
35. Pre-assignment/Pre-Departure Tax Services leading to information on pre-assignment tax planning opportunities and procedures that the assignees should be aware of while on assignment.
On Assignment Tax Services in host countries.
Company / Client shall advise Contractor’s Tax Consultant as soon as Company / Client personnel reach the foreign country for Project development and intend to stay for a duration long enough to attract tax liability with details like names of the employee, their Staff Number and the likely period of stay.
1. Upon receipt of above information supplied by Company / Client, the Contractor’s Tax Consultant is required to provide:
2. Current relevant provisions of Personal tax laws of the country.
3. Liabilities of Company / Client towards compliance of tax laws.
4. Further details required, if any, by the Contractor’s Tax Consultant from Company / Client.
5. Based on input / feedback from the Contractor’s Tax Consultant, Company / Client shall issue an ‘Instruction to Proceed’ detailing the Work required from the Contractor’s Tax Consultant.
6. Within 14 days of receipt of an ‘Instruction to Proceed’ the Contractor’s Tax Consultant shall provide to Company / Client:
7. Execution Programme detailing the arrangements and methods which the Contractor’s Tax Consultant proposes to adopt for the execution of the Work including tax planning required, time required, manpower and man-hours required, estimated cost and necessary scheduling.
8. Execution Programme when approved by Company / Client shall become part of the Contract and Contractor’s Tax Consultant shall execute the Work strictly in accordance with the Execution Programme. Contractor’s Tax Consultant shall:
9. Keep Company / Client fully informed of the progress made in the Work. Maintain liaison with local tax authorities.
10.
11. Have regular contact with Company / Client employees in those foreign countries.
12. Scrutinise the requirement of advance tax payments and estimated tax determination thereof and advise Company / Client accordingly.
13. The Contractor’s Tax Consultant shall provide necessary tax returns, ensuring full compliance of tax laws of the country and file the returns with appropriate tax authorities within the specified time. Arrive at the total tax payable and advise Company / Client.
14. Complete the tax assessments within the specified time and endeavour to get:
15. Clean Assessment Orders. Income Tax Clearance certificates for all the employees.
16. The Contractor’s Tax Consultant shall put its best efforts to obtain for the benefit of Company / Client all lawful discounts, tax credits, allowances and refunds from the tax authorities.
17. Repatriation Tax Services involving execution of all tax related matters that are required to be complied with by Company / Client employees while making exit from the host country and re-enter the country of origin.
Post Assessment Tax Services
1. Eliminate / minimize the possibilities of post assessment proceedings like appeals, reassessment, litigation, etc.
2. Keep Company / Client informed from time to time of the potentialities and possibilities of Post Assessment Proceedings and recommend suitable preventive and / or corrective actions that may be required to be taken by Company / Client / its employees in host country. Contractor’s Tax Consultant is required to make every effort to avoid / mitigate such proceedings.
3. Any or all of the Work as mentioned above may be called upon for a particular country or a number of countries either simultaneously or at different points of time through issuance of an ‘Instruction to Proceed’.
4. Payment of tax amount to tax authorities shall be based upon duly receipted acknowledgement of tax authorities in the host country.
5. Payment to Contractor shall be made on a flat rate per person per fiscal year basis against completion / progress made in the tax consultancy work.
6. The flat rate quoted by the Contractor shall include for partners, lead consultants, senior managers, senior consultants, managers/ consultants & support staff.
7. Flat rate quoted is fully inclusive of all associated costs for employment of personnel and all overheads and profit.
Project Soft wares
Contractor shall use the following application software in preparation of the project deliverables:
a. Word processing Microsoft Word 2000, Spreadsheet Micro soft excel 2000, Presentation Mocrosoft powerpoint 2000, Database Microsoft access 2000 or equivalent, Project planning Primavera Latest Revision, Piping Stress Analysis Caesar II, Finite Element Analysis ANSYS, ABAQUS, COSMO or equivqlent, Draughting AUTOCAD 2004, Reliability Study RAMP (Ver 3.4 or latest) or equivalent 3D Modeling, (if chosen by Contractor) PDS / PDMS Pipeline simulation (dynamic / surge analysis) pipenet or internationally validated software, which shall be approved by Company / Client Electrical System Studies CYME software Structural Design STAAD PRO & STAAD -III
b. Company / Client shall not provide any software to the Contractor. The Contractor shall provide pipenet Simulation Programme for Company / Client’s permanent use at the end of the project. Company / Client personnel shall have access to Contractor’s pipenet Programme at any time.
c. Contractor shall specify the software used for sizing Control Valves, Relief Valves, Orifice Plates, Processor Loading etc. If the software used is of proprietary nature and not standard ones, a copy shall be provided to Company / Client for use in future Maintenance, or design modification. Sample Only Ends
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Chapter 7
Detailed Engineering Requirements
Process Engineering
1 The Contractor shall during bid stage verify the process engineering work performed by FEED consultant and provided in the bid documents and satisfy himself that it is a workable design. Contractor shall bid on the design and provide all process guarantee.
2 Should there be any technical deficiencies to prevent Contractor from providing the process guarantees, then these perceived technical deficiencies along with the proposed remedies or solutions should be clearly stated in the Contractor’s bid.
➢ In the event Contractor accepts the process design as proposed by Company / Client, but fails to address it as such in his bid, it shall constitute acceptance of the process design by the Contractor as well as to provide all process guarantees.
3 After contract award and during detailed engineering, Contractor shall not reduce sizes of equipment items or lines nor shall he delete instrumentation or valves from the proposed process design without written approval from Company / Client. Any modifications / revisions to the P& ID’s, equipment data sheets, piping lay out and any 4 Company / Client developed drawing / document shall be subject to review and approval by Company / Client. Any proposed reduction or deletion of equipment items, lines or instrumentation and valves shall be submitted for Company / Client review and approval.
5 Contractor shall be solely responsible for any increase in the size of equipment items, lines, instrumentation and valves and any necessary process modifications after contract award and during the detailed engineering phase. It is therefore, in the Contractor interest to ensure that the Bid Documents comprising the basic process design package is well evaluated and accepted by him.
6 The detail design and engineering shall be based on the design developed during the FEED. However Contractor shall be responsible for confirmation, verification, and validation, update of all process and process related documents and endorsement of all FEED findings. These shall be reviewed, checked, verified and updated by the Contractor as per design criteria, guidelines, codes and standards and acceptable practices. The new system design shall meet 99.7% reliability and 100% availability.
7 Contractor shall start from the Engineering documentation supplied by Company / Client as a result of FEED work or otherwise, and contained in the FEED package. However, the Contractor acknowledges that the FEED package does not define the plant in full detail and needs further development in order to achieve the desired objectives.
8 Contractor as part of the detail design shall optimise all the systems and update as necessary. The relevant process documents included in this tender shall be updated, completed and amended by the Contractor to reflect further design detailing, design development and actual equipment data, performances and characteristics.
➢ Any changes to the PFD, heat and material balance, equipment / instrument data sheet, P&IDs or FEED package in general, as the result of the optimisation, must be approved by Company / Client before implementation by the Contractor.
9 The Contractor shall perform, as a minimum the following process engineering activities as part of scope of services:
➢ Process basis of design and Process Design Philosophy
➢ Contractor shall review and update the process basis of design and Process Design Philosophy to include any other additional data considered for detailed engineering. Contractor shall reconfirm Sea Water Demand figures and other design data with Company / Client before proceeding with the detailed design.
➢ Steady state hydraulic study
10 Contractor shall carry out hydraulic modeling and study based on the final cooling water network for the whole project using latest PIPENET simulation software. Contractor shall demonstrate the routings used in simulations are in agreement with the latest available pipeline / piping layout documents and drawings. In case there are marked differences between routings used in simulations and actual layout during detailed engineering to an extent that they shall invalidate the hydraulic results and conclusions, then Contractor shall carry out new updated simulation. Based on the flow rate defined by Company / Client for individual consumers, Contractor shall optimize pipeline sizing that satisfies all the operating and maintenance scenarios. The soft copy of the model shall be provided to Company / Client during the course of detailed engineering. The
11 Contractor shall provide access to Pipenet Simulation program for the Company / Client process engineers and hand over to Company / Client soft copies of the simulation.
➢ Contractor shall determine the allowable minimum water flow in the network and propose engineering and operation solutions to maintain higher flow in the network piping system. Contractor has to highlight consequences of not adhering to this requirement.
12 Transient Analysis
For the selected and approved cases only, Contractor shall carry out thorough and detailed hydraulic surge analysis of the entire cooling water system to determine any adverse effects on the system, e.g. Water hammer, undue stresses on connected equipment and on pipeline supports etc. Based on the hydraulic transient analysis, Contractor shall determine and provide the required protection measures such as vacuum breakers and specify the required valves closure time.
13 Contractor to note that during FEED, transient analysis of the return cooling water network related to recirculation system has not been done due to non-availability of data for the cooling water pumps of cooling towers. Contractor shall obtain all the necessary data of the pumps and carryout detailed hydraulic surge analysis for the return cooling water network of recirculation system during EPIC phase. If data is not available, same shall be assumed in consultation with Company / Client.
14 Dynamic simulation studies shall be conducted by Contractor for the following objectives:
➢ Verify operability and controllability of the pumps under various transient conditions, such as start up, coast down, emergencies and operational transients.
➢ Confirm the Start-Up procedures.
➢ Confirm the shutdown procedures.
➢ Confirm the design requirement for vacuum breakers.
➢ Confirm the closure time for the valves.
➢ Confirm to restart procedures.
15 The soft copy of the model shall be provided to Company / Client during the course of detailed engineering. The Contractor shall provide access to pipe net simulation program (transient state) for two (2) Company / Client process engineers.
If the Contractor intends to carry out the transient analysis by its own in-house expertise, this must be approved by Company / Client prior to start of work.
16 Electro Chlorination system
Contractor shall carry out a detailed hydraulic analysis and design for the chlorination system including the distribution systems and generate / update all necessary drawings / documents. Contractor shall carry out the aforementioned scope of work suitable for continuous operation and shock dosing modes. The Contractor shall also design for chlorine discharge monitoring system.
Utility System
17 Contractor shall verify the design and capacity of the utility systems such as instrument air, plant air and service water.
➢ Process Flow Diagrams (PFD’s)
➢ Contractor shall perform all work necessary to verify, correct or revise Process Flow Diagrams and heat and material balances to reflect any changes in the design made as a result of Contractor's work.
➢ Utility Flow Diagrams (ufds)
18 Contractor shall perform all work necessary to verify, correct or revise the Utility Flow Diagrams and heat and material balances to reflect the requirements of the process and utility design which shall be approved by Company / Client.
Piping and Instrument Diagrams (P&ID’s)
Contractor shall review, fully update and develop the Process, utilities and electro chlorination P & IDs, provided in the FEED Design Package, during detailed engineering. All the FEED “Holds” on the P & ID’s shall be investigated appropriately & reviewed by the Contractor.
19 Further development of the diagrams shall include, but not limited to, finalising all line sizes, including details of control valves / vacuum breakers etc., adding or correcting mechanical, electrical and instrument details resulting from the detailed engineering and adding vendor details. The Contractor shall implement and action the items identified in FEED HAZOP as a part of Contractor responsibility. Further, the Contractor shall ensure that all HAZOP actions have been closed out. Any auxiliary P& ID’s required, like for the pumps protection or Cooling of the Thyristors of Variable Speed Drives (utilising De-ionised water) etc. Shall be developed by the Contractor or obtained through the equipment supplier / vendor. All valves including manual / gear operated Valves shall be tagged.
The Contractor shall fully develop the detailed P & ID’s for Phase and ultimate Phase and update these drawings during the course of EPIC, as required.
20 Any proposed additions / modifications to the P & ID’s, by the Contractor that may jeopardize or compromise the currently built in operating reliability and or flexibility shall be rejected. Contractor shall then rectify / modify the design and the P& ID’s to Company / Client’s satisfaction and at no cost to Company / Client. Should there be a conflict between the P &IDs as developed and Company / Client specifications, the former shall prevail. It is understood and accepted that P & ID’s may see many revisions during the detailed engineering stage and even during network construction. Every revision shall require Company / Client review and approval. The Contractor shall carry out all changes / revisions requested by Company / Client as part of the contract. Upon successful network commissioning, a full set of as built P & I D’s shall be prepared and submitted to Company / Client for review and final approval and acceptance.
21 Line List
➢ Contractor shall review and fully update the Line List based on the results of detailed engineering.
➢ Contractor shall develop and complete basic line designation tables (LDT’s) in their entirety during the detailed engineering phase. Contractor shall verify all line sizes as depicted on the P & ID’s during the bid stage. No reduction in any line sizes shall be permitted after contract award. Any increase in line size, required as a result of oversight on the part of the Contractor to check and verify during the bid stage, shall be to the Contractor’s account.
➢ Process Data Sheets
22 Contractor shall perform the sizing of all the equipment and instruments and update / generate the process datasheets for all items including but not limited to the packages, equipment and instruments.
Contractor shall provide process guarantees for the satisfactory performance of each equipment item provided in FEED package. Should the Contractor find that certain equipment items need to be modified and/or the size / capacity / duty needs to be increased; he shall clearly state this in the bid and provide the desired design. Failure to do so shall imply that the Contractor accepts the equipment sizes / capacities / duties as depicted by Company / Client on all process data sheets forming part of the bid document and shall provide all process guarantees.
Philosophies
➢ Contractor shall review and update the following philosophy documents as necessary to incorporate the updates during detailed engineering.
➢ Process design philosophy
➢ Operating and control philosophy
➢ The philosophies shall cover as a minimum the valving / isolation, maintenance, operations, blow down, design temperature / pressure and chlorine distribution.
➢ Cause and Effect charts / PSFS
➢ Contractor shall be responsible for modifying / creating all Cause and Effect Charts and PSFS diagrams to include all the new facilities during the detailed design.
➢ Utility / chemical summaries
➢ Contractor shall review and update the utility / chemical summaries and alarm / trip settings documents.
RAM study
➢ Contractor shall carry out a reliability and availability study to confirm that the new system can meet 99.7% reliability and 100% availability. The study shall be carried out on the full system utilizing recognized international standards and practices.
➢ Pre-commissioning, commissioning and start-up manuals
➢ Contractor shall prepare detailed pre-commissioning, commissioning start-up manuals based on the pre-commissioning / commissioning philosophy defined in FEED package.
Operating manual
Contractor shall prepare detailed operation and maintenance manual covering operation procedures, startup, shutdown, maintenance procedures. The format and content of the operating manual shall be discussed and agreed with Company / Client.
Performance test run
1 Contractor shall produce a detailed performance test run procedure and shall be approved by Company / Client. The objective is to demonstrate that the FACILITY is satisfactorily operating in accordance with the design parameters and achieves the product specification and quantity and other performance warranties as specified under the Contract.
2 The performance test shall be carried out within an agreed period between Contractor and Company / Client from the date of hand over of the network to Company / Client. The performance test shall be carried out in accordance with the approved procedure in order to determine whether the network performs in accordance with the design, the performance test shall be carried out by Company / Client. The duration of the test shall be a continuous 72 hrs. Contractor may be present to witness the performance test. Samples of water for chlorine content shall be taken by Company / Client operating personnel and analyzed in Company / Client laboratory. Contractor may choose to carry out his own analysis. In this case, Company / Client shall take another set of samples for the Contractor.
3 The results of the analysis obtained by Company / Client shall then be compared with the analysis results obtained by Company / Client shall then be analyzed once more. Should the difference still remain, then another two sets of samples shall be taken and the procedure repeated again. If at the end the differences still remain and in the event no agreement could be reached then a third party laboratory technician shall be brought to the site to carry out the analysis. This third party technician shall be acceptable to both Company / Client and the Contractor.
Other Requirements
1 Contractor to note that all equipment, instruments and lines have been provided with temporary tag nos. Specific for FEED phase. Contractor shall update all the necessary documents with new identification in line with Company / Client Standard after obtaining the correct sequence numbers from Company / Client.
2 Contractor shall undertake HAZOP using an Independent Third Party Chairman approved by Company / Client. The date (s) for the HAZOP shall be agreed with Company / Client. Contractor shall incorporate the findings of the HAZOP into the detailed design without any cost and / or schedule impact to Company / Client.
3 As part of Phase, Contractor has to provide cooling water supply connection to Power, which is defined in various FEED documents. But in order to meet the immediate requirements of Power, a temporary cooling water supply is being provided by others until such time the permanent supply from Phase development becomes available. This is to highlight to the Contractor the existence of a temporary connection for Power, and Contractor has to note this information before preparation of detailed drawings and to liaise with Company / Client in this regard for any further details.
Contractor shall provide the following:
➢ A DN200 tapping with manual operated Butterfly Valve on the line
➢ A DN200 manual operated Butterfly valve on the same line Upstream of tapping. Tapping and valves shall be near the Pump House area.
➢ The above requirement is as per Company / Client requirement to have interconnection with Phase. The interconnection shall be used in case of emergency and start up of Phase if Chlorination package of Phase is delayed.
➢ As the above requirement is specific and not part of the FEED design, this is not reflected at any of other FEED documents / drawings.
➢ Process Deliverables List
4 The following documents shall be developed by the Contractor as a minimum. The Contractor shall provide a list of deliverables showing the documents and drawings that shall be produced under this Contract. It is the Contractor’s responsibility to develop any other documents that are required to complete the detailed design to Company / Client’s satisfaction.
➢ Updated Process Basis of Design
➢ Steady state Hydraulic calculation report for cooling water system reflecting all updates and amendments made by the Contractor
➢ Transient analysis report for cooling water system reflecting all updates and amendments made by the Contractor
➢ Steady state Hydraulic calculation report for chlorine system reflecting all updating and amendments made by the Contractor
5 Process flow diagrams with heat and material balance diagrams
Utility flow diagrams with heat and material balances, Process System Description, Utilities System Description, Hydrochlorination System Description, P&ids for process, utility and auxiliary systems, PSFS diagrams, Cause and Effects Charts, Process equipment data sheets, Process instruments data sheets, Line list, Operating and control philosophy, Process design philosophy, Alarm and trip settings, Utility and chemical summary, Performance test run procedure, Pre-commissioning and commissioning manuals, Operating manual and the Start-up / Shut-down procedures. Safety Integrity Level
Mechanical Engineering
1 Contractor shall be responsible for but not limited to the following
Contractor shall review / update / upgrade and validate FEED specifications and data sheets for equipment and prepare material requisition documents including Vendor data requirement list & schedule (VDRL) for the equipment in accordance with the Contract equipment list.
2 Contractor shall prepare detail engineering documents for specified modification works of Phase (e.g. Sun shelter at PH for Semi- Portal Cranes current collector and replacement of existing cable reel power line of said crane, etc. As specified in study; Existing Phase crane use as a common crane), and when required prepare specification, data sheets etc. For the equipment not covered specifically in FEED documents.
3 Contractor shall include for RAM Study to confirm requirement of additional EOT Cranes at Pump-house and Semi-portal Crane at Screen-Yard.
Contractor shall witness and approve all documents necessary during major testing such as mechanical run tests and Performance Tests. Also, Company/Client shall witness inspections and tests when required.
4 Contractor shall review and Validate Mechanical Handling Study Report (accessibility and maintainability) of all Project FACILITIES and relevant data sheets shall be updated for procurement.
5 Contractor shall design, supply and install all necessary facilities as recommended in the mechanical handling report such as A-Frame, manual chain Hoist etc. That are not covered in the FEED documents.
Equipment List
6 Contractor shall complete / further develop the equipment list included in FEED.
➢ Equipment Data Sheets
➢ FEED document includes data sheets developed in accordance with process design criteria for all major equipment items. Prepared equipment data sheets identify the minimum design requirements. Contractor is responsible for review and update as required and preparing final detailed equipment data sheets for all equipment.
Civil / Structural Engineering
Contractor shall be responsible for but not limited to the following:
Applicable for all Facilities
1 A preliminary site preparation drawing, along with soil survey report on borehole samples has been included. In addition, rough grades have been established along with a perimeter fence drawing, preliminary grading and drainage drawings, preliminary roadway drawings, road and utility crossing drawings, pipeline drawings, foundation drawings, structural steel drawings and other miscellaneous drawings showing lines only but no details. These drawings / documents are issued for information only.
2 The Contractor has to remove existing pavement in order to place new foundations.
Contractor's work includes, but not limited to, the review and verification of Plot Plans to include any development resulting from supplier information, piping stress analysis, requirements for constructability, plant safety, operation and maintenance to suit completion of the FACILITY.
Surveys
1 A Geo-technical report “Geo-technical Site Investigation” has been provided for Building Area, Outfall Area and on Pipe Corridor's. The purpose of the report is to provide preliminary information on foundation recommendations.
2 Contractor shall be responsible to plan and carry out any supplemental soil survey, to verify the data and to collect additional data at the area(s) where soil data is neither sufficient nor available.
3 At the completion of the site preparation work, Contractor shall carry out site survey for setting out his work and to verify that the Construction Site preparation is done as per Project requirement in terms of extent and elevation of the developed area for all FACILITY.
4 Contractor shall ensure that all existing survey monuments are preserved and properly protected. Survey monuments damaged by Contractor during the performance of the Work shall be repaired or replaced, by the Contractor at his cost.
5 Contractor shall locate and install new permanent monuments at each corner of the facilities Construction Sites and other locations as needed for the Work to mark boundaries and establish additional horizontal and vertical controls for the construction work. Contractor shall record the locations of these monuments and benchmarks on the Contractor's topographical survey drawings together with their National National Grid references and National Height Datum (NHD) elevations.
6 Contractor shall reference the FACILITY grid system for all new co-ordinates, and the National Height Datum for all elevations used for the Work.
As a minimum, the accuracy of horizontal measurements shall meet the requirements of relevant Company / Client standards.
7 The accuracy of running levels for the purpose of establishing grade elevations is expressed as:
Maximum permissible error in mm = 8 times the square root of the distance of level run in kilometres or as specified in Company / Client standards.
8 Topographical Survey
Information and details pertaining to existing roads, storm drainage, etc. Shall be co-ordinated with Company / Client during the execution of the Project. However, Contractor shall survey the existing infrastructure to acquire the actual information and ensure consistency in design and construction. Contractor shall carryout a complete topographical survey of the work site and submit report with drawings to Company / Client.
9 Contractor shall contact the GIS Department for information pertaining to the transformation parameters from grid.
Bathymetric Survey
Bathymetric Survey shall be carried out by the Contractor for the sea bed profiles for the design of the Outfall Structure.
Civil, Structural and Building
1 Contractor shall carry out the following civil design and engineering for the Work included but not limited to the following:
Construction Site preparation, final grading, paving.
Excavation including de-watering.
Foundation works and carrying out soil improvement, soil replacement and / or piling, as required. In the reclaimed land area, soil improvement or piling shall be considered for large equipment foundations, heavily loaded pipe sleepers and / or foundations sensitive to settlement.
2 Roads, paving, culverts, footpaths, road markings, signs, safety barriers and guard posts in compliance with Company / Client and other local Authority Standards, CS and National Traffic Manual, Design guidelines for road pavement and road crossings in Plant Industrial City. Flush kerb stones shall be installed at change of road construction and road direction while crash barriers (guard rails) shall be installed at culverts, ramps and change of road direction as a minimum. Company / Client shall not supply copies of CS standards. Contractor shall have to obtain his own copies from the Ministry of Municipal Affairs and Agriculture.
3 Underground services, such as, sewers, drains, cable trenches, duct banks, pipe trenches, and other civil works associated with underground service installations including underground piping, cathodic protection, electrical cables and grounding, instrument cables, and heating systems. Seawater pipes shall be installed above and under ground. Design, cut and fill shall be for the full width of the pipe corridors, plus the two side maintenance tracks which are part of other corridors adjacent to the Cooling Water Corridors i.e. For Phases while the construction of pipe supports shall be for Phase only.
4 Earth embankment / dikes and related concrete works, if required during construction to be executed by Contractor.
Structures in concrete, steel and masonry block, including but not limited to equipment and pipe supporting structures and foundations, culverts and bridges, pits, manholes, basins, ponds, receiving basin, discharge channel, outfall structure, earth retaining structures, piping anchors and thrust blocks, etc.
Conformance to local law, regulations and practices.
5 Contractor shall design, supply, install and commission impressed current cathodic protection system to protect the reinforcing steel re-bar of the Pump house pit (above and below ground), Receiving Basin, Discharge Channel, Outfall structures and for all structure and foundations within water table or/and below ±0.0m NHD.
➢ Extent and type of the structure of wing wall to PH for the future phases shall be finalised by Contractor during detail design and subject to Company / Client approval. Contractor shall refer to PH walls.
➢ Actual dimensions including buttress walls of Receiving Basin shall be detailed by Contractor and finalised during detail design subject to Company / Client approval. Physical modeling of the Pump pits, Receiving Basin, Discharge Channel and Outfall Structures are to be carried out by the Contractor.
➢ Specialist recommends that the developed design for the intake pumping station be the subject of a physical model test by the Contractor in order to:
➢ Investigate detailed internal flow conditions
➢ Investigate potential vortex action at the pump chambers
➢ Investigate potential pre-swirl at the pump suctions
➢ Optimise required vortex suppression devices.
➢ Investigate performance in the vicinity of the pumps and to confirm pump chamber geometry etc.
6 The proposed overall layout and dimensions for the screen chambers is considered satisfactory for FEED. However, that the required width of each screen chamber element should be subject to further review by Contractor- following identification of the actual screen vendor and actual screen dimensions.
7 Landscaping
Contractor shall carryout design for free bare land beautification including required irrigation pipeline at Common Seawater Facility.
➢ Soft landscaping
The soft landscaping is to be installed around the Building, comprising of grass area, planting beds, plants, trees (palm trees for Operation Building only), shrubs and the like. This landscaping shall cover the following area:
➢ Operation Building - Tag No..
➢ Workshop / Warehouse Building - Tag No.
➢ Workshop Building - Tag No.
The required irrigation pipeline is also to be specified for watering of landscaping. The source of water supply is available from connection to PLANT Landscaping Water Network at CSF Main Road, which is presently under implementation.
➢ Hard landscaping
The area between the buildings and roadways should be kerbed and filled with 100mm depth of 20mm crushed and washed stone (i.e. Pebbles) to the available space between the buildings and road. Earthing pits and cable markers shall be minimum 50mm above the finished levels or shall be reinstalled appropriately. This landscaping shall cover, but not limited to, the following area:
➢ Control Building (Extension) - Tag No.
➢ Electro-chlorination Building - Tag No
➢ Electrical Switch gear building for Chlorination -Tag No.
➢ 33kv Switchgear Building - Tag No.
➢ VSDS Substation for PH - Tag No
➢ VSDS Substation for PH - Tag No.
➢ 220kv Switch Gear Building -Tag No.
Contractor to follow project specifications and Company / Client amendments while designing all Civil Works in addition to the Civil and Structural Design Basis and applicable codes and standards.
Underground Facilities
These shall include all civil work associated with electrical, instrument, telecommunication, fire fighting system and cathodic protection, including cable trenches of all types (concrete wall type, direct buried type, etc.) And duct banks and associated civil work for underground piping, and cables including the required pipe trenches, drainage systems including sewers, drains, catch basins, manholes for various purposes. Contractor shall follow project specifications and Company / Client amendments while designing Underground facilities in addition to applicable codes and standards.
Steel Structure
1 While designing the steel structure, Contractor to follow the Project specifications, Civil and Structural Design Basis, codes and standards Contractor shall be responsible for providing all steel structures. Strict quality control, supervision, inspection and testing during fabrication and erection shall be implemented for the production of steel structures. Only new material certified to the Project Specifications shall be used. Materials conforming to code equivalent to latest ASTM Standards, such as BS or JIS are acceptable for structural materials with prior Company/Client approval. The quality control including material, fabrication, welding, protective coating, transportation, handling and storage is outlined in Project Specifications and shall be strictly followed.
2 With regard to the use of hot-dip galvanised steel structures, Company / Client is concerned with zinc embrittlement of stainless steel and high nickel alloys. Steel structure with a potential to be in contact with equipment containing stainless steel piping or equipment shall not be galvanised but be painted in accordance with Company / Client Painting Spec.
3 In addition, Contractor's design shall make provisions to prevent contamination of these equipment and piping due to dripping of molten zinc from galvanised structural steel due to fire. Thus, wherever there is a potential for contamination due to molten zinc, Contractor shall either paint the overhead structure in-lieu of hot-dip galvanising, provide adequate protection shields or insulate/fireproof the structure.
Operating stages and access on pipe racks, equipment supporting structures, shelters and equipment as well as stages and walkways on ground necessary to facilitate FACILITY operation and maintenance including structural platform shall be provided by Contractor, for Company / Client's approval.
4 Contractor shall be responsible for determining the requirement, developing detail design, and providing small shelters such as those required for local panels and instrumentation, etc. These small shelters are not listed in the Building List. Contractor shall seek Company / Client approval for the scope of small shelters.
5 Miscellaneous pipe racks and pipe supports which shall be required in process, and utility areas are not shown on the plot plans nor in the Building List. Contractor shall be responsible for developing layouts, detail design and providing these pipe racks and supports.
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Chapter 8
Building Design Concept
Design General Specification
Structural Design Basis
Buildings, Process Structures, Pipe Racks, Miscellaneous Plant Structures, Vessels, Exchangers and General Introduction
This specification gives the minimum criteria for structural engineering and design purpose necessary for structural engineering and design for the framework and foundations of all buildings, process structures, pipe racks and for the foundations for vertical vessels, horizontal vessels, heat exchangers, storage tanks, vibrating equipment, grade and elevated slabs and masonry structures. Miscellaneous plant structures such as pits, sumps and retaining walls etc.
Codes And Standards
The following Codes, Standards and Specifications form part of this specification. Only the latest codes shall apply to all requirements. Alternate Codes, Standards and Specifications meeting the requirements of the these Codes, Standards and Specifications may be used with approval by the Company.
Steel grade material S 275 JR to BS EN 10025 and bolts to BS 4190 and BS 4395 may be used upon the Company approval.
Steel grade 43A to BS 4360 may be used for small access platforms without valves, small pipe supports, handrail and ladders, subject to Company approval. American National Standards Institute (ANSI)
ANSI A12.1 Safety Requirements for Floor and Wall Openings, Railings and Toeboards.
ANSI A14.3 Safety Requirement for Fixed Ladders.
ANSI A64.1 Requirements for Fixed Industrial Stairs
American Society Of Civil Engineers (ASCE)
ASCE 7 Minimum Design Loads for Buildings and other Structures
American Institute of Steel Construction (AISC)
AISC Specification for Structural Steel Buildings
AISC Manual of Steel Construction
AISC Code of Standard Practice for Steel Buildings and Bridges
AISC Specification for Structural Joints Using ASTM A 325 or A 490 Bolts
American Concrete Institute (ACI)
ACI 301 Specifications for Structural Concrete for Buildings
ACI 302.1R Guide for Concrete Floor and Slab Construction
ACI 318M Building Code Requirements for Reinforced Concrete Commentary on Building
Code Requirements for Reinforced Concrete
ACI 325.3R Guide for Design of Foundations and Shoulders for Concrete Pavements
ACI 336.2R Suggested Analysis and Design Procedures for Combined Footings and Mats
ACI 350R Environmental Engineering Concrete Structures
ACI 530 Building Code Requirements for Concrete Masonry Structures
American Welding Society (AWS)
AWS D1.1 Structural Welding Code - Steel
AWS D1.4 Structural Welding Reinforcing Steel
American Petroleum Institute (API)
API 650 Appendix E
American Society For Non-Destructive Testing (ASNT)
ASNT-TC-IA Recommended Practice
Portland Cement Association (PCA)
PCA IS 003D Rectangular Concrete Tanks
PCA IS 072D Circular Concrete Tanks without Pre-stressing
National Concrete Masonry Association (NCMA)
NCMA TEK 59 Reinforced Concrete Masonry Construction.
Occupational Safety and Health Administration (OSHA)
OSHA - CR29
American Association Of State Highways And Transportation Official (AASHTO)
Standard Specifications for Highway Bridges
American Society For Testing And Materials (ASTM)
ASTM A6 Specification for General Requirements for Rolled Steel Plates, Shapes, Sheet Piling and Bars for Structural Use
ASTM A36 Specification for Structural Steel
ASTM A53 Specification for Pipe, Steel, Blank and Hot-Dipped Zinc-Coated Welded and Seamless.
ASTM A123 Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
ASTM A143 Recommended Practice for Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedures for Detecting Embrittlement
ASTM A185 Specification for Steel Welded Wire Fabric Plain for Concrete Reinforcement
ASTM A193 Specification for Alloy-Steel Bolting Material for High Temperature Service
ASTM A307 Specification for Carbon Steel Bolts and Studs, 60,000 PSI Tensile Strength
ASTM A325 Specification for High Strength Bolts for Structural Steel Joints (Including Suitable Nuts and Plain Hardened Washers)
ASTM A490 Specification for High-Strength Steel Bolts Classes 10.9 and 10.93 for Structural Steel Joints (Metric)
ASTM A500 Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes
ASTM A569M Specification for Steel with Carbon (0.15 Maximum Percent) Hot-Rolled-Sheet and Strip Commercial Quality
ASTM A786 Specification for Rolled Steel Floor Plates
ASTM A830 Specification for Plates Carbon Steel Structural Quality Furnished to Chemical Composition Requirements
ASTM C90 Specification for Load-Bearing Concrete Masonry Units
ASTM C270 Specification for Mortar for Unit Masonry
ASTM F436 Specification for Hardened Steel Washers
ASTM F959 Specification for Compressible-Washer-Type Direct Tension Indicator for use with Structural Fasteners
Uniform Building Code (UBC)
UBC Latest Edition
BRITISH STANDARDS (BS)
BS 4 Structural Steel Sections Part 1 Specification for Hot Rolled Sections
BS 4190 Black hexagon bolts
BS 4360 Weldable structural steels
BS 4395 High Strength Friction Bolts and Associated Nuts and Washers for Structural Engineering
BS 4449 Carbon Steel Bars for the Reinforcement of Concrete
BS 4483 Steel Fabric for the Reinforcement of Concrete
BS 4592 Grating
BS 4848 Hot-Rolled Structural Steel Sections Part 2: Specification for Hot-Finished Hollow Sections
BS 5950 Structural Use of Steelwork in Buildings
BS 7419 Holding Down Bolts
BS 8004 Foundations
BS 8007 Design of Concrete Structures for Retaining Aqueous Liquids
BS 8110 Structural Use of Concrete
BS EN 20898 Mechanical Properties of Fasteners Part 1: Bolts, Screws and Studs
BS EN 10025 Hot rolled products of now-alloy structural steels and their technical delivery conditions
British Publications
U.K. Concrete Society Technical Report No. 34: Concrete Industrial Ground Floors
Cement and Concrete Association Technical Report 550: Design of Floors on Ground
British Cement Association Interim Note 11: The Design of Ground Supported Concrete
Industrial Ground Floors
CIRIA Special Publication 31: The CIRIA Guide to Concrete Construction in the Gulf Region
CIRIA Report No. 91 Early Age Thermal Crack Control in Concrete
Quality Assurance / Quality Control
Contractor’s proposed quality system shall fully satisfy all the elements of ISO 9001
“Quality Systems - Model for Quality Assurance in Design / Development, Production, Installation and Servicing” and ISO 9004-1987, “Quality Management and Quality System Elements - Guidelines”. The quality system shall provide for the planned and systematic control of all quality related activities performed during design. Implementation of the system shall be carried out in accordance with the Project Contract Agreement, Contractor’s Quality Manual and Project Specific Quality plan. Quality manual as well as project specific quality plan shall be submitted to Company for review, comment and approval.
Design Requirements
1 Reference codes and standards
All structural engineering design shall be within the parameters of the documents listed above and shall constitute part of this design basis.
2 Measurement
All dimensions, quantities and units of measurement shown on drawings or used in specifications and calculations shall be in metric units while pipe size may be in inches.
3 Site Survey and Soils Report
Company accepts no liability for the information contained in the Site Survey and the Soils Report (if any).
Site survey
All design shall be in accordance with the horizontal and vertical controls contained in the survey report prepared by the survey consultant.
Soils report
All design shall be in accordance with the recommendations contained in the soils report prepared by the geotechnical consultant.
4 Basic Design and Drawing Concepts
5 Design and calculations
Prior to starting detailed design, a basic design shall be made consisting of:
➢ Basic sketch
➢ Loading Derivation
➢ Calculation
➢ Stability check
➢ Main Structural members
➢ Basic Sketch
6 The sketch shall show the proposed structure (in perspective and / or a series of cross sections).
7 Structural members may be shown as single lines.
8 The sketch shall include the foundations & all other parts of structures in structural steel or in structural concrete. All applied loads shall be shown on the skethch excluding the dead loads. Calculations The calculations shall give the design philosophy and all loads including the dead loads of the relevant structural components.
9 The calculation shall state the loads in the main structural members (axial loads, bending moments, shear and possibly torsion, reactions, deflections) and shall include the upward reaction loads on the foundation (load per unit of area). The calculation shall take into account the soil investigation report. If any computer programs are to be used for the detailed design, these shall be identified during the basic design stage with all required documentation provided to demonstrate their adequacy & sufficiency.
10 Stability Check
The stability of the structure shall be checked for both factored and non-factored load combinations.
11 Main Structural Members
12 In the assessment of the sizes and dimensions of the main structural members the most critical load combination shall be considered. Structural details, such as connections of steel beams and columns or details of reinforcing steel over the full length of a reinforced concrete beam shall be designed and detailed by the
13 Designer. Standard steel connection details may be designed by the Supplier but must checked by the Designer duly certified by a Professional Engineer. Or equivalent duly registered complying with international standards of EMF.(Engineers Mobility Forum) (In Bharat India, The Institution Of Engineers India represents EMF)
Detailed Design
The detailed design shall be based on the basic criteria as well as FEED.
The calculation shall clearly indicate:
1. The table of contents
2. Design philosophy employed on engineering assumptions
3. Applicable codes, formulas, graphs / tables
4. References to literature etc. for subjects not covered by applicable codes
5. . Loading tables with loads location diagrams
6. If computer programs are used, the following information shall be supplied:
a. Logic and theory used
b. Analytical model of the structure used for computer analysis
c. Users manual
d. A hand calculation to prove the validity of the computer analysis except if validated by QA / QC system.
e. Loads and load combinations
Drawings and related documents
1 Drawings shall be of the standard metric sizes, i.e. A0, A1, A2, A3, A4.
2 The preferred computer aided design system is the software used internationally as well as designer’s in house developed or other software approved by Company. These shall be suitably prepared to facilitate microfilming and incorporate a numbering and indication of revision system. Dimensions on the drawings shall be in the SI system unless otherwise specified. Levels shall be indicated in metres & all other dimensions in millimeters. Layout drawings shall show the highest point of grade as El. 100.00 and the reference of this level to the local datum level for Process Units, in offsites the actual level shall be indicated. All headings and notes shall be in English. Each drawing shall bear the following information in the title block.
3 Order number of the Company, Name of plant , Name of unit , Name of part of the unit , Example: Order number , Catalytic cracking unit , Compressor building
Portal frames
4 Only drawings marked "Released for Construction (RFC)" or “Approved for Construction (AFC)” shall be used for execution of works every where.
This mark "Released for Construction" can be given only by the Designer responsible for design and engineering. Drawings shall be submitted together with the relevant calculations including those required for submission to local authorities. Revisions to drawings shall be identified with symbols adjacent to the alterations, a brief description in tabular form of each revision shall be given and if applicable, the authority and date of the revision shall be listed.
5 The term “Latest Revision” shall not be used. Claim to all drawings prepared by the Contractor under any order placed by the Company shall be vested in the Company and the later shall have the right to use these drawings for any purpose for this project without any obligation to the Contractor.
6 The Contractor shall not disclose or issue to any third parties without obtaining written consent of the Company any documents, drawings, etc. provided at his disposal by the Company or any documents prepared by him in connection with inquiries and orders for purposes other than the preparation of a quotation or carrying out these orders.
Structural concrete
Plan drawing
On this drawing, the general information / data shall be shown as General Notes on the right-hand side or any other suitable location of the drawing.
The general notes shall state that:
a. Levels are expressed in meters with reference to the highest point of grade
b. Dimensions are expressed in millimeters
c. Bar diameters are expressed in millimeters
Furthermore, the general notes shall list:
d. The quality (or qualities) of concrete
e. The quality (or qualities) of steel reinforcing bars
f. The quality (or qualities) of cement to be used
g. Concrete blinding (location, quality and thickness)
h. Polyethylene sheeting, if applicable (location and quality)
i. The concrete cover on bars (type of construction, location and thickness)
j. The list of reference drawings and related documents stating their title and number
k. . The legend of the Contractor’s reinforcing bar call out
Including an indication for which part(s) each quality is to be used.
Detail drawings
On each of the detail drawings, the following information / data shall be listed:
a. a. For general notes, see Drawing No. ......
b. b. This detail drawing refers to Drawing No. ......
c. c. For bar bending list(s), see No. ......, sheet 1 to .......
d. d. For weight list(s), see No. ........, sheet 1 to ........
e. e. Quantity of concrete (for each quality of concrete separately)
f. Bending and weight lists
These lists shall always be made by the Designer unless explicitly stated otherwise. The lists shall be prepared on the detailed drawings or on separate sheets.
Scale of drawings
Plan drawings shall be made to a scale of 1:50 and detail drawings to a scale of 1:20.
Structural steel
Part of the information / data supplied by the Company may be in the form of one or more instruction drawings. If instruction drawings are provided, all the dimensions shown on these drawings shall also appear on the Contractor’s drawings.
1 General arrangement drawings
These drawing shall show the complete structure to be supplied. All main dimensions and the section to be used shall be included. All members to be fireproofed shall be marked with an appropriate symbol or FP designation. A fireproofing legend shall clearly identify the symbols and designations with the work to be performed. For the preparation of the general arrangement drawing, the Contractor may use a reproducible of the instruction drawing(s). For small and simple structures, this drawing may be combined with the base plate drawing.
2 Baseplate drawing
This drawing shall show all dimensions and details of the base plate including anchor bolts which be taken into account in the design of the (concrete) foundation. When the need for a slight adjustment of the anchor bolts during erection is expected, this shall be indicated on the drawing. The scale for details shall be at least 1:10. For small and simple structures, this drawing may be combined with the general arrangement drawing.
3 Construction drawings
These drawings shall clearly show all constructional details of the structure to be supplied. The location of the various parts in the structure shall be indicated.
Scale of drawings Drawings shall be made to an appropriate scale.
4 Bills of material
Bills of material shall show the weights of all large members from the viewpont of transportation and erection at site as well as the total weight of the structure.
Steel structures
1 Structural steel design shall be carried out in accordance with the relevant project, general specifications and international codes. The plastic design method in the AISC Manual shall not be used in steel design. Steel structures shall be designed for the loads and load combinations allowed In this specification. Normally, only pinned column bases shall be used in the design of steel structures. Use of fixed base plates for certain type of pipe racks and buildings may be necessary because of deflection considerations. Where headroom, access or equipment arrangement permit, wind and other lateral loads on a steel structure shall preferably be transferred to the foundations through vertical X-bracing or K-bracing included on the transverse and longitudinal column lines of the structure.
2 As a second choice, wind and other lateral loads on a structure should be transferred to the foundations through moment resistant frames in one direction and vertical X-braced or K-braced frames in the other direction. Structures that resist lateral load with rigid frame systems in two directions should be avoided. The method of bracing selected for a structure should generally be used throughout the structure. Compression bracing for steel structures shall normally be designed with wide flange and structural tee shapes. For tension bracing, single angle or structural tees may be used. Double angle bracing because of maintenance difficulties shall not permitted for either compression or tension locations. When using structural tees in compression, the design shall include bending induced by eccentrically loaded connections. Braces for structures subject to vibration from equipment shall be designed as compression members. Horizontal bracing shall be provided in the plane of a floor, platform or walkway when necessary to resist lateral loads or to increase the lateral stiffness of the unit.
3 Floor grating shall not be allowed to resist lateral loads in diaphragm action without investigated. In a floor system, beam compression flanges should be considered to be fully braced when a concrete slab is cast to match the bottom face of the compression flanges on both sides or when chequered plate is bolted or welded to the compression flanges or when grating or metal deck is welded to the compression flanges. Grating shall normally be clipped or bolted and therefore, shall not be considered as adequate compression flange bracing. In such cases, additional vertical and / or horizontal bracing in the floor system shall be provided. Bar joist floor and roof systems are generally considered to be too light for heavy industrial plant work. However, when approved by the Designer, bar joist systems may be used on a project.
4 Steel Structures shall be designed so that the surfaces of all parts be readily accessible for inspection, cleaning and painting. Pockets for depressions which would hold water shall be provided drain holes or otherwise protected.
5 Connections for steel structures shall conform to the following requirements:
Shop connections may be bolted or welded. Field connections shall normally be bolted however, when approved by the Designer, welded field connections may be used. Bolted connections for primary members shall utilize high-strength bolts conforming to ASTM A325 or A490. A minimum of 2 M20 bolts shall be used for all connections.
6 These connections shall be designed as bearing type. Those connections subject to vibration or stress reversal shall be bearing type. Loads for bearing type connections shall be based on threads excluded from shear plane. Turn of the nut method or load-indicator washers shall be used for tightening all connections. Bolted connections for secondary members (e.g. purlins, girts, stair framing. etc.) shall be made with A307 bolts with the appropriate finish. Connections will normally be designed by the Supplier and checked by the Designer in accordance with the project construction specifications and loads shown on the drawings. Moment connections and special connections, however, shall be worked by the Designer duly shown on the engineering drawings.
7 Moment connections can be bolted or welded type depending on the type of structure and situation. The Designer will determine the type of connection to be used for each structure. All shear connections shall be designed and detailed by the Supplier and checked by the Designer. Reactions shall be shown on the engineering drawings or as per the calculation note provided by Designer. Plant area shall have the primary structural connections continuously seal welded except high strength bolted field connections. Primary structural connections include horizontal and vertical vessel supports, beams and columns on major pipe racks, inaccessible maintenance areas, etc.
8 The forces in truss members and all main bracing shall be shown on the engineering drawings with plus signs indicating tension and minus signs indicating compression or as per the calculation note provided by Designer. The minimum thickness of any structural steel plate or bar shall be 10 mm. Gusset plates shall not be thinner than the members to be connected and shall have a thickness of at least 10 mm. Welded steel grating for platform covering shall be 30 mm x 6 mm bearing bars at 30 mm on center. Cross bars shall be twisted square 6 mm on each side and spaced not over 100 mm center to center, hot-dip galvanized in accordance with ASTM A123 and A143 for corrosive environment. E70xx welding electrodes shall be specified for all shop and field welding of structural steel. All welds shall be continuous. All bracing shall be arranged to minimize torsion and where practicable, be arranged concentrically about the resultant line of force.
9 The connections wherever possible, shall be arranged so that their centroid lies on the resultant of the forces those members intended to resist. When the condition cannot be achieved, the members and connections shall be designed to resist any local bending due to the eccentricity of the force. In practice, it is noticed that corroded steel plates and bolts limit the expected movement which may result in additional stresses. The Designer should consider this point to include sequential additional stresses in their design consideration. Steel structures supporting equipment shall be fireproofed where required by risk & safety analysis.
Reinforced concrete structures and foundations
1 Cast-in-place or situ concrete structures shall be designed in accordance with ACI 318 except as indicated otherwise in this specification.
2 Cast-in-place or situ concrete structures shall be designed for the loads and load combinations required according to codes & description elsewhere in project documents. The working strength or limit state of serviceability design methods shall be used for the structural design of concrete members unless otherwise indicated. Load combinations and load factors for all concrete design shall be adopted in accordance with ACI 318. The design and details of cast-in-place concrete structures shall consider the monolithic nature of hardened concrete.
3 Construction joints in a concrete structure shall be located so as to least impair the integrity and unity of the structure. Construction joints in beams at column or pedestal faces should be avoided. The Designer / Contractor Site Management shall approve the location of all construction joints on site agreement. Moving concentrated loads on elevated concrete beams and slabs shall be treated in accordance with applicable recommendations of the referenced AASHTO specifications.
4 Slabs at grade for buildings and process areas shall be designed in accordance with the publications ‘Concrete pavements for heavy storage areas’
5 Underground structures such as basements, rectangular tanks, sumps, and pits shall be designed in accordance with the latest referenced PCA bulletins and / or BS8007. The design of such structures shall include the effects of ground water pressures and buoyancy. A minimum factor of safety of 1.1 for buoyancy shall be used ignoring soil cohesion. Concrete process treatment structures shall be designed in accordance with ACI 350 R. For all liquid retaining structures, special precautions shall be taken for water tightness.
7 All joints shall be fully detailed by Designer. A corrosion allowance of 3 mm shall be required for all anchor bolts. Bolts shall be hot-dip galvanized in accordance with ASTM A123 and A143. Foundation design in addition to the above applicable criteria shall meet the following requirements:
8 Foundations shall be designed in accordance with the project geotechnical (soils) report. Foundations for structures shall be sized and stability determinations made using service loads only. Load factors shall not be included in these design operations. Unless there is a conflict with the project soils report, individual foundations shall normally be used for major equipment. If combined foundations are appropriate, the centroid of the bearing area should coincide with the resultant of the applied operating load (excluding live load).
9 All foundations shall be placed on sealed blinding concrete on firm, undisturbed soil. Some seal slabs, however, may be placed on well-compacted earth fill, if approved by the Designer. In such cases, the engineering drawings shall specify the kind of fill material and the degree of compaction required for the fill material. Spread footings, combined footings and mats should be designed assuming linear soil pressure distribution.
10 Where the rigidity of the foundation is questionable, an analysis considering the interaction between flexibility of the foundation and the subgrade soil reaction should be considered. For mats particularly, this method of analysis may be in order. ACI 336.2 R contains suggested design procedures. Foundations shall be proportioned so as to minimize general and differential settlements. In order to reduce the overturning moment on individual footings of buildings and process structures, the transfer of column base shears into the concrete grade slab should be considered. The frictional resistance provided by the grade slab shall equal at least 1.15 times the applied column base shears.
11 For design purposes, a coefficient of friction of 0.2 may be assumed between the concrete slab and the membrane. If this design approach is used, the grade slab thickness and joint details shall be properly designed. Where seasonal changes in soil moisture content occur extremely, special details may be required to minimize foundation movements. Control of foundation movements is especially critical for masonry structures. The Designer shall determine design parameters to control such movements.
12 The stability ratio (SR) based on service loads for isolated spread footings shall not be less than 1.5 when determined as follows:
SR = D (P) / 2M = D / 2e Where: D = Diameter or width of footing, P = Minimum gravity load at bottom of footing (exclude equipment and live loads, include buoyancy), M = Maximum overturning moment at bottom of footing, e = Eccentricity = M / P
13 The uplift factor of safety based on service loads shall not be less than 1.25. This factor of safety must be maintained when 70 percent of dead load is combined with no reduction of wind load for uplift.
14 The stability ratio (SR) based on service loads for buildings, process structures and other framed structures shall not be less than 1.5 when determined as follows.
SR = Resisting Moment / Overturning Moment Where Resisting Moment = Moment due to dead load of foundation and structure (include buoyancy), Overturning Moment = Moment due to lateral loads
15 The overturning and resisting moments shall be computed about the most critical axis of rotation of the foundation block at the soil / concrete interface. There may be more than one axis of rotation.
The stability ratio (SR) of retaining walls based on service loads shall not be less than the following.
a. For sustained loading:
SR = Resisting Moment / Overturning Moment
= 3.5 for cohesive soils
= 2.0 for cohesionless material
b. For sustained loading combined with temporary loading:
SR = Resisting Moment / Overturning Moment
= 2.0 for cohesive soils
= 1.5 for cohesionless material
Where:
Resisting Moment = Moment due to dead load of wall and soil overburden (include buoyancy)
Overturning Moment= Moment due to lateral loads
c Resisting moment and overturning moment shall be taken about the toe of the retaining wall and bottom of footing. For all service load conditions, the sliding resistance of foundations especially retaining walls, shall at least be equal to 1.5 times the applied lateral loads. Sliding resistance shall be developed by either friction between the footing and membrane or by passive resistance of shear keys extending below the bottom of the footing in the case of retaining walls.
d In cases where sliding resistance is developed by a combination of friction and passive resistance, it is recommended that a minimum factor of safety of 2.0 shall be provided. Stability calculations shall include the weight of the foundation concrete and the soil immediately above the footing(s). The effects of buoyancy on the concrete and soil weights shall be considered. Passive earth pressures shall not be included in stability calculations except in the design of retaining walls with keys. In this case, only that pressure acting on the key face shall be considered. Foundation bottom level shall be defined taking into consideration geotechnical (soil) report and other factors to be clearly noted on the drawings. Keep standard bottom of footing elevations where possible. Consideration shall be given to interferences with underground soil systems.
General
1 The Region has been defined as being in an Ultra Hot Climate t together with the extremely heavy concentration of chlorides in both the ground and atmosphere together with high humidity that result in the rapid degradation of Reinforced Concrete structures. The degradation of the concrete is principally caused by reinforcement corrosion due to the ingress of chlorides and other aggressive salts, the consequential increased volume of rust produced commonly breaks off the cover on the reinforcement. Failure of the R.C member then becomes imminent. The degradation of concrete arises also from the use of salt contaminated materials.
2 The durability and quality of the concrete itself is of paramount importance. Factors to increase durability while designing shall be considered in concrete such as thermal insulation coating measures as recommended in the “CIRIA Guide to Concrete in The Gulf Region”. Quality of concrete is achieved by good engineering and detailing proper materials and proportioning good construction techniques and concrete curing. One of the main characteristics influencing the durability of concrete is its permeability to the ingress of chlorides, water, oxygen, carbon dioxide, wind blown chloride contaminated dust and other deleterious substances.
3 Coatings shall be applied to all buried and exposed concrete surfaces as an essential protection against attack from chlorides, other harmful elements and to provide the concrete to develop a refined pore structure enhancing impermeability. Coatings shall have crack bridging properties on flexural members. Steel plates shall not be embedded in concrete. The Contractor shall develop a detail that allows attachment of the plates to inserts embedded in the concrete. A detail shall also be developed to ensure an effective seal from exterior moisture is achieved around the perimeter of the plates at the point of intersection between concrete and plate.
Crack prevention
1 Crack widths shall be controlled by an expeditious use of combinations of reinforcement sizes, spacing and cover.
Crack widths shall be calculated using the applicable formula in BS 8007.
2 The calculation shall be based on the long term, steady state loading. For durability it is not necessary to consider peak loadings although this may affect coating selection for the requirement for crack bridging and flexural performance.
Crack widths apply at the surface of the concrete i.e. the full depth of cover shall be utilized in the calculation.
3 Calculation of crack widths shall consider both load (flexural) and restraint (due to thermal and shrinkage effects) induced cracking.
In order to reduce flexural cracking to acceptance limits, it will be necessary to use reduced allowable stresses in the reinforcement.
4 Calculation of crack widths shall not use ‘deemed to satisfy’ options of BS 8007, i.e. do not calculate crack widths on PC and minimum reinforcement ratios.
The minimum external restraint factor (R) shall be 0.5.
5 Methods of calculating crack widths in relation to temperature and moisture effects are given in Appendix A - BS 8007.
6 The minimum fall in temperature between hydration peak and ambient (T1) shall not be less than 31° C for walls and 21° C for ground slabs.
Seasonal temperature fall (T2) shall be considered where continuous construction is used - BS 8007 - Table 5.1 - Option 1. This shall be not less than 30° C.
Crack widths shall be limited as follows.
Crack width shall be = 0.15 mm for all buried, submerged and exposed concrete.
Crack width shall be = 0.30 mm for all concrete located in an air conditioned and sealed environment.
Crack widths shall be = 0.10 for all liquid retaining structures.
Reinforcement
1 Use smaller diameter re-bar at closer centers.
For sections = 500 mm thick and for the outside 300 mm of large sections, reinforcement shall not be less than 0.35% of the applicable gross cross-sectional area of the concrete section.
2 Maximum spacing of reinforcement shall be 150 mm in any direction.
Use fabric reinforcement where possible (‘nested’ where necessary) as this gives better crack control.
Do not bunch reinforcement or use in vertical or horizontal pairs.
Reinforcement shall be adequately detailed to eliminate congested areas i.e. laps to be staggered.
3 Place reinforcement nearest to the surface where it is the greatest restrained length which means horizontal wall reinforcement will be on the outside of the vertical reinforcement.
4 Ensure additional diagonal reinforcement is placed at each re-entrant opening to prevent cracks emanating from corners.
All reinforcement shall be fully detailed by the Designer on bar bending schedules BBS for fabrication.
5 All concrete sections with a thickness of 250 mm or more, reinforcing bars shall be placed on both faces over the full section. In addition, minimum reinforcement shall be placed in the other two faces.
6 Concrete Cover
Adequate cover to the outside of all reinforcement is essential for resistance to corrosion for all types of sections & situations whatsoever..
a. Minimum Concrete Cover (mm) Concrete cast against or permanently exposed to earth (all below grade structures) and all marine facilities over or in contact with water 75
b. Concrete exposed to weather (all above grade structures not enclosed by a temperature and humidity controlled building) 60
c. Concrete not exposed to weather and located within a temperature and humidity controlled building 50
d. Where any individual structural element falls within two or more categories then the most stringent criteria shall apply for the entire element.
e. Horizontal re-bar in walls and faces of large elements shall be on the outside of the vertical reinforcement for more effective crack control.
f. All concrete cover shall conform strictly with values given above unless noted otherwise on design documents or in the applicable standards.
g. Required covers shall not be reduced by provision of protective coatings, membranes or by membrane protective screed.
h. If fire resistance of more than 2 hours is required, cover shall be as determined in Table 3.5 in BS 8110 Part 1 for the particular element under consideration.
i. Concrete Grades
j. Concrete shall have a minimum compressive strength as given in Specification for Concrete
Externals Features
1 Features which collect sand and dust that can form with rain or dew into a corrosive pollutant shall be avoided i.e. decorative patterns with holes and pockets, gutters, ledges and exposed aggregate finishes. Top surfaces shall be designed with falls to encourage run-off drainage.
2 Tops of all pedestal heads shall be sloped 1:20 away from the base plate grout.
Top of pedestal shall project a minimum of 100 mm from the edge of the column base plate grout. Dimensions of the concrete columns or foundations are designed taking into account loads applied to & not by reference to geometric dimensions of base plate.
3 Minimum pedestal heights excluding grout above top of adjacent paving shall be as follows:
a. Structural Steel columns: 150 mm to 200 mm
b. Equipment (general): 100 mm to 300 mm
c. Equipment (pumps): 100 mm to 300 mm
d. Grout is to be sloped 1:1 away from the bottom outside corner of the column base plate grout.
4 Shear keys shall not be used on pedestals / plinths.
5 Stress Raisers
➢ Complicated plan shapes which produce stress shall be avoided.
➢ Large and sudden changes of cross-section i.e. wall junctions and counterforts in the middle of bay lengths shall be avoided. Locate joints adjacent to these stress producers or cast in two separate sections.
➢ Provide appropriate extra reinforcement where stress producers are unavoidable.
➢ Casting-in pipes, box-outs, notches in the middle of bay lengths shall be avoided, Locate joints adjacent to these stress producers if possible.
Anchor Bolts
For small diameters, Chemical type anchors or cast-in anchors are preferred. Where chemical anchors are used, the hole must be properly cleaned according to Manufacturer’s instructions. Anchor bolts shall be designed for combined tension and shear as per BS5950. Minimum edge distance measured to outside of tube shall be 100 mm or 4 times the bolt diameter whichever is greater.
Shear Keys
For standard conventional structures, shear keys shall not be used.
For situations where shear keys are required, back up design calculations and justification shall be given for approval.
Pits and Tanks
1 As a minimum requirement, the recommendations of BS 8007 - Section 5 ‘Design, Detailing and Workmanship of Joints’ shall be adhered to regardless whether or not, the structure is liquid retaining.
2 All construction joints shall be designed, detailed and shown on the drawings by the Designer or Subcontractor for Construction with approval of Contractor.
3 Where continuous construction is necessary, the method of ‘Temporary Open Sections’ as specified in BS 8007 C1.5.5 shall be used. Such open sections shall not be more than 1.0 m containing the “Lapped’ section of reinforcement. The use of sequential bay wall construction shall not be permitted. Unless roofs are insulated, these sections are subject to extremely high daytime temperatures and lower night temperatures. Consideration shall be given to the use of insulation or reflective coatings (e.g. aluminum). All such structures (other than blast resistant structures) shall have an isolated roof slab on a sliding bearing (slip strip or equal approved). Monolithic construction with the supporting wall shall not be considered in such design.
Paving
1 For ground slab paving construction, the method used for design and construction shall be by the alternate ‘long strip method’ using a combination of transverse contraction joints (induced or formed). Adjacent longitudinal strips shall be cast with longitudinal tied joints between each strip.
2 The recommendations for slab design and construction shall be complied with the provisions in the following publications:-
Design of Floors on Ground by Cement and Concrete Assoc. Tech. Report 550.
Concrete Industrial Ground Floors by U.K. Concrete Society Technical Report #34.
The Design of Ground Supported Concrete Industrial Ground Floors by British Cement Assoc. Interim Note 11.
3 Guide for Concrete Floor and Slab Construction by ACI 302.1R.
The location of all joints shall be shown on the drawings with accompanying details of each joint type. Isolation joints are to be provided around all equipment foundations and pedestals.
Concrete Masonry Structures
The design of concrete masonry structures shall conform to ACI 530 and the UBC. Concrete masonry structures shall be designed for the loads and load combinations specified
Grouting
1 All grout materials and application procedures shall be approved by the Designer and the Manufacturer. Sand-cement grout shall not be used for any project. All grouting shall be in accordance with the defined project specifications as well as proprietary standards. Epoxy-based non-shrink grout shall be evaluated by Contractor and the Manufacturer for each application for temperature creep as well as strength and applied in accordance with Manufacturer's specification.
2 Grout material used below base plates for machinery, pipe racks, pumps, pipe supports, etc. shall not be placed higher than the bottom of plate level and sloped outward at a 1:1 slope away from the bottom of the base plate to prevent water accumulation near the base plate as well as to prevent cracking of the grout as a result of corrosion around base plate edge. Contractor shall develop a detail to ensure an effective seal from exterior moisture is achieved around the perimeter of the base plates at the point of intersection between grout and base plates.
Fireproofing
Fireproofing zones
Only specific structures and equipment located within a Fire Proofing Zone (FPZ) shall be fireproofed as described in Specification for Fireproofing
Loads
Buildings, Process Structures, Pipe Racks, Miscellaneous Plant Structures, Vessels, Exchangers and Tanks
The following loads shall be considered:
Dead Load
a. Soil Load (Include as part of Dead Load)
Operating (Product) Load
Test Load
Live Load
a. Sand Load (Include as part of Live Load)
b. Surge Load (Include as part of Live Load)
➢ Truck Load
➢ Wind Load
➢ Earthquake Load
➢ Crane / Impact Load
➢ Dynamic Load
➢ Thermal Load
➢ Erection Dead Load
➢ Maintenance Load
➢ Miscellaneous / Differential Settlement Load
➢ Earth / Hydrostatic Load and Buoyancy
➢ Blast Load
➢ Future Load
➢ The above loads are defined as follows.
➢ Dead Load
Dead load is defined as the weight of all permanent construction including walls, foundations, floors, roofs, ceilings, partitions, stairways and fixed service equipment. For heavy industrial work, this would include equipment, vessels & internals, pipes, valves, accessories; electrical and lighting conduits, switchgear; instrumentation, fireproofing; insulation; ladders; platforms; and all other similar items. Weight of equipment shall be extracted from the Manufacturer’s data sheets and include auxiliary machinery, piping. Equipment and piping should be considered empty of product load when calculating dead load. The gravity weight of soil overburden shall be considered as dead load
a. Soil Load (Dead Load)
Soil loads shall consist of lateral earth pressures. Active and passive coefficients for lateral pressures shall be obtained from the project soils report.
Operating (Product) Load (Live Load)
The load shall be defined as the gravity load imposed by liquid, solid or viscous materials in vessels, tanks, equipment or piping during operation. Unusual loading that occurs during regeneration or upset conditions shall also be considered.
Test Load (Live Load)
The test load shall be defined as the gravity load imposed by any method necessary to test vessels, tanks, equipment or piping. When more than one vessel etc. is supported by one structure, the structure need only be designed on the basis that one vessel will be tested at any one time and that the others will either be empty or still in operation.
Live Load
Live load is defined as the weight superimposed by the use and occupancy of the building or other structure but not permanently attached to it. For industrial design, live load can be defined as the load produced by personnel, moveable equipment, tools and other items placed on the structure but not permanently attached to it. Unless specified otherwise, use the minimum live load values given in the table below. Uniform loads and concentrated loads do not occur simultaneously.
Types of Structures Load (kN/m2)
➢ Walkways (not used as operating) 2.0 (or 3.0 kN point load)
➢ Operating platforms (other than compressor and generator platforms 5.0 (or 5.0 kN point load)
➢ Trench covers (non vehicular) 5.0
➢ Roof (min) 1.0 (or 3.0 kN point load)
➢ Sand on roof (min.) 0.75
➢ Light Storage 6.25
➢ Heavy Storage 12.5
➢ Compressor and generator platforms;
➢ Floor framing (Determine from use but never less than) 5.0
➢ Floor Grating and Slabs 10.0*
➢ For floor grating and slabs being subjected to a concentrated load from either the installation or removal of equipment
➢ Office first aid buildings, guards houses, control room, computer room, electrical
➢ equipment room, laboratory room locker room 3.0
➢ Canteens, Lunchrooms, Stairs, Halls 4.0
➢ Library 5.0
➢ Battery rooms 10.0
➢ Mechanical, electrical, instrument workshop building 20.0
➢ Bulk storage 40.0
➢ Stairs and Ramps 2.0 (or 3.0 kN point load)
➢ Handrailing ** ** 0.75 kN per linear meter applied horizontally at the top of railing, or a horizontal force of 0.9 kN at any one point.
a. Sand Load (Live Load)
Sand load shall be additive to live loads only when the area under consideration is used as a ‘work area’. A 0.75 kN/m2 load shall be used in the design of flat roofs. The effect of sand accumulating behind walls and upstands shall be considered in the design of the walls and roof (treat similar to snow loading).
b. Surge Load (Live Load) Surge loads may occur in some vessels or equipment such as fluid cokers, hydroformers, crackers etc. In such cases, the magnitude and direction of the load will be given in the equipment specification. The project process engineer shall furnish a list of equipment having surge loads and the designer make allowance for such loadings in relevant calculations.
Truck Load (Live Load)
Structures accessible to trucks shall be designed to withstand the gravity, lateral and impact effects of truck loading. Truck loading shall be HS20 or HS20-44 wheel loading as defined by the AASHTO specifications. It shall be checked where applicable whether maintenance and / or construction equipment loads are governing over HS20 wheel loading. At least one road leading to the main process area(s) shall be designated as a heavy equipment route. Bridges, culverts and other underground facilities shall be designed for the maximum expected loading condition caused by transportation of heavy equipment
Wind Load (Live Load) The design wind loads shall be calculated based on a basic wind speed of 145 km per hour at a height of 10 m above the ground for terrain exposure C and a mean recurrence interval of 50 year. For this exposure and recurrence, the value of the importance factor of (I)=1.1. The Designer shall
develop specific wind load calculation criteria and procedures using ASCE 7 for various types of structures and equipment for the project.
For overhead pipe tracks 4m wide or less, the wind load on the three largest pipes shall be taken into account. For overhead pipe tracks of over 4m wide, the wind load on the four largest pipes shall be taken into account.
The following tabulated velocity pressures shall be used for calculating design wind forces for the design of all structures, buildings and equipment and their parts, portions and appurtenances for the project. Pressure coefficient Cf = 0.8.
Pipe racks 4 m wide or less: Wp = 0.8 qh (D1+D2+D3) or pipe racks wider than 4 m: Wp = 0.8 qh (D1+D2+D3+D4) Where
Wp = Unit design wind load on piping
qh = Velocity pressure determined at piping elevation h
Dn = Diameter of pipe
Reference ASCE 7-1993 V - 145 km / hr 50 year mean recurrence, I = 1.1, Exposure C
Height Zone Above Grade (m)
Z Velocity Pressure in Kg/m2
qz Gust Response Factors
Gh and Gz
0-6 107 1.29
6-9 114 1.26
9-12 125 1.25
12-15 134 1.22
15-18 142 1.21
18-24 151 1.18
24-30 164 1.17
30-36 173 1.15
36-45 183 1.14
45-60 198 1.12
60-90 219 1.10
90-120 241 1.08
a. Increase factors may be used to modify the projected areas of vertical and horizontal vessels (including insulation if any) to allow for attachments such as manholes, nozzles, piping, ladders and platforms.
b. The ‘shape increase factors’ may be used to modify the projected areas of vertical and horizontal vessels (including insulation if any) to allow for attachments such as manholes, nozzles, piping, ladders and platforms. Use Cf = 0.8.
c. Wind loads shall be separately computed for all supported equipment, ladders, and stairs except for vessels where ‘projected area increase factors’ have already been accounted for these items. Gust response factors G for main wind resisting systems of flexible buildings, structures and vertical vessels having a height exceeding five times the least horizontal dimension or a fundamental natural frequency less than 1.0 hertz shall be calculated. Calculations shall be based on a rational analysis that incorporates the dynamic properties of the main wind force resisting system. One such procedure for determining gust response factor is described in ASCE
d. No reduction shall be made for the shielding effect of vessels or structures adjacent to the structure being designed.
e. For main wind force resisting systems and walls, use Gh evaluated at the height h (top) of the structure. An exception is in the various structural specifications for equipment, the variable gust response factor Gz is used. For components and cladding, use Gz evaluated at centroid height z above ground.
f. Earthquake Load (Live Load)
g. Earthquake load shall be applicable according to project Location & in conformance to Uniform Building Code (U.B.C.) 1997-Division III-Seimic zone Tabulation Section 1653.
h. Crane / Impact Load (Live Load)
i. For structures carrying live loads that induce impact, the live load shall be increased sufficiently. If not otherwise specified, the live load increase shall be following:
j. Category
k. Vertical Load Horizontal Load
l. For supports of elevators (dead and live load) 100%
m. Cab operated traveling crane support girders & and their connections
n. 25% 20% 1 10%2
o. Pendant operated traveling crane support girders & and their connections 10%
p. Monorails, trolley beams, davits 50%
q. Light machinery, shaft or motor driven 20%
r. Reciprocating machinery or power driven units 50%
s. Hangers supporting floors and balconies 33%
a. 1. Increase the sum of the weights of the rated capacity of hoist, crane trolley, cab and hooks.
t. Apply one-half of the load at the top of each rail acting in either direction normal to the runway rails.
a. 2. The longitudinal force shall if not otherwise specified be taken as 10% of the maximum wheel loads of the crane applied at the top of the rail.
b. 3. Live load on crane support girders shall be taken as the maximum wheel loads.
u. Dynamic Loads (Live Load)
Each structure shall be designed to withstand the effects of vibration and impact to which it may be subjected. Each structure and foundation supporting a compressor, turbine, pump or other machinery having significant dynamic unbalance shall be designed to resist the peak loads specified by the manufacturer. Vibration amplitudes of the supporting structure or foundation shall
v. be kept within acceptable limits for dynamic forces that occur during normal machine operation. In the case of a tall and slender structure, there may be a need to investigate the dynamic effects of wind gusts.
w. Centrifugal pump foundations for pumps less than 750 kW do not require a dynamic analysis. However, the foundation to pump assembly weight ratio shall not be less than 3 to 1.
x. Foundations for reciprocating machinery, centrifugal machinery and centrifugal pumps over 750 kW require a three dimensional dynamic analysis.
y. Thermal Load (Live Load)
z. ASCE 7 mentions thermal loads however, the ASCE thermal comments are not geared to heavy industrial work. Thermal loads shall be defined as forces caused by changes in temperature. The primary source of thermal loads in an industrial plant is the expansion or contraction of vessels and piping. Another source of thermal loads in a redundant structure is the expansion or contraction of the entire structure or individual structural components. Provisions shall be made for thermal forces arising from assumed differential settlements of foundations and from restrained dimensional changes due to temperature changes.
aa. Thermal loads and displacements caused by operating conditions shall be based on the design temperature of the item of equipment rather than the operating temperature. Design atmospheric temperature ranges from a minimum of 5 deg C to a maximum of 58 deg C. Low friction slide plates (Fluorogold, Teflon / PTFE or an approved equal) shall be used if the vessel operating condition weight is greater than 45 kN at the sliding end. For preliminary design, the temperature drop of 1.9 deg C / mm from the bottom of shell to bottom of saddle may be assumed. The following friction coefficients shall be used for calculating frictional restraint due to temperature change or lateral loading on sliding surfaces:
ab. Surface Friction Coefficient
ac. Steel-to-steel (corroded) 0.35
ad. Steel-to-concrete 0.50
ae. Teflon-to-teflon
af. A straight line variation of 0.17 to 0.08 for bearing Stresses from 0.0 N/mm2 to 0.7 N/mm2, respectively Bearing stress greater than 0.7 N/mm2 0.17 to 0.08
ag. 0.08
ah. Graphite-to-graphite 0.15
ai. For computing friction loads due to the effects of pipe expansion in pipe racks, use the following friction coefficients:
aj. Number of Lines on Support
ak. Friction Coefficient
al. 1 – 3 0.3
am. 4 - 6 0.2
an. 7 or more 0.1
ao. For a given support, if considering only larger lines and ignoring smaller lines results in greater loads. These forces and associated friction coefficients shall be used instead of considering all the lines.
ap. A concrete pipe rack beam shall be designed for an arbitrary horizontal pipe anchor force of 15 kN acting at midspan unless design calculations dictate a higher force and more locations. The pipe anchor force shall not be distributed to the foundations.
aq. For pipe anchor forces transferred by longitudinal girders to structural anchors (bracing) an arbitrary force of 5% of the total pipe load per layer shall be taken into account unless design calculations dictate a higher force. These forces shall be distributed to the foundations.
ar. Foundations and structures which are subject to temperature effects shall be designed for the various loading conditions and also for any temperature difference which may occur in parts of structural members.
a. a. Anchor and guide forces shall be obtained from the Designers Piping Engineering Department.
b. b. Structural Steel Pipe Supports shall be designed in accordance with Industry
Standard Structural Design Methods.
Erection Dead Load
a. The erection dead load is the weight of the equipment at time of erection plus the weight of the foundation. The foundation weight is the combined weight of the footing, pedestal, and overburden soil.
b. All possible loading conditions during erection shall be considered and for any member of a structure, the most unfavorable be considered.
c. Heavy equipment lowered onto a supporting structure can introduce extreme point loads on structural members exceeding any operating or test load. After placing of equipment, the exact positioning (lining out and leveling) can also introduce extreme point loads. The above should be interpreted on the basis of contractor’s practical experience, manufacturer’s information and allowed for in the design calculations accordingly.
d. Beams and floor slabs in multistory structures e.g. fire decks shall be designed to carry the full construction loads imposed by the props supporting the structure immediately above. A note shall be added on the relevant construction drawings to inform the field engineer of the adopted design philosophy.
Maintenance Loads (Live Load)
a. Maintenance loads are temporary forces caused by the dismantling, repair or painting of equipment.
b. The force required to remove the tube bundle from a shell and tube heat exchanger shall be assumed to act along the horizontal centerline of the exchanger with a value of 2 times the weight of the bundle but not less than 10 kN.
Miscellaneous Loads (Live Load)
a. Miscellaneous loads shall be defined as loads that do not fit into the categories listed in this section.
Earth / Hydrostatic Load and Buoyancy (Live Load)
b. Earth and hydrostatic water pressures on retaining walls and underground structures shall be determined. Outward pressures on liquid retaining structures shall also be considered. The buoyancy load is equal to the weight of the volume of displaced water.
Blast Load (Live Load)
Negligible Blast
Buildings located more than 610 m away from the potential explosive sources do not require special provisions with regard to explosion resistance.
Blast Resilient
Buildings within the 200 m to 610 m distance from potential explosive sources shall be designed to the same loading conditions as specified for buildings beyond the 610 m zone and in accordance with the following design concepts:
1. The building structural frame, roof, walls, bracing and connections shall be designed in such a manner that large plastic deformations of the major frame members as well as external wall panels will be allowed to occur without causing partial or total building collapse. Blast resilient buildings shall be designed and detailed in accordance with ACI 318, Chapter 21, “Special Provisions for Seismic Design”.
2. The building frame shall comprise of reinforced concrete or structural steel.
3. The building walls shall be constructed as reinforced concrete, reinforced masonry with concrete filled cells or properly designed carbon steel cladding system. Walls for these buildings shall not be used as mainframe members or to provide structural stability and / or structural strength.
4. The building roofs shall be constructed of monolithic reinforced concrete or a properly designed carbon steel roofing system. Loose lightweight concrete roof slabs or asbestos cement sheeting shall not be used. Gravel as a protection of roofing finish or loose tiles for walkways on top of the roof finish shall not be used.
5. For steel structures, structural steel bracing in roof and walls shall be provided.
6. Materials with a brittle behavior such as masonry shall not be used in such a way that provides strength.
7. For additional architectural construction requirements, refer to Specification for Architectural Design Basis (Not included)
Blast Resistant
Buildings within 200 m distance from the potential explosive sources may be designed to withstand the anticipated blast effect. The blast loads or pressures to be used for the design of various structural elements shall be calculated in accordance with an acceptable method taking into account the dynamic response. The calculated blast loads shall not be less than the following equivalent static loads acting inward or outward perpendicular to the surface:
1. External Walls 100 kN/m2 except loads on doors and windows which may be assumed to be 30 kN/m2.
2. Blast loads on the roof slab is dependent on the span between supports.
➢ 50 kN/m2 for span of 3m
➢ 45 kN/m2 for span of 4m
➢ 40 N/m2 for span of 5m
➢ 35 kN/m2 for span of 6m
➢ 30 kN/m2 for span of 7m
➢ 25 kN/m2 for span of 8m and over
It is to be assumed that the blast loads will act simultaneously on and over one wall and the roof. These loads act with applicable dead loads. Suction on walls and roof shall be 50% of the above-mentioned static loads and it is to be assumed that these loads will act simultaneously on one wall, the roof and not in combination with above-mentioned loads.
Structures shall be detailed in accordance to ACI 318, Chapter 21 “Special Provisions for Seismic Design”. Pre-stressed concrete shall not be used. In general, special attention shall be paid to ensure continuity and a minimum of local stress concentration. Adequate lapping of reinforcement is required. The following provisions shall supersede ACI 318, Chapter 21 for Blast Resistant structures:
The concrete walls and slabs shall be reinforced each side in the main direction with a minimum of 0.6% in the case of steel bars with a yield strength of 410 N/mm2 and a minimum elongation of 14%. In the other direction on both sides, a distribution reinforcement of at least 20% of that in the main direction shall be applied. Maximum spacing of bars shall be 150 mm center to center. It is preferable for the wall and roof thicknesses to be between the limits of 250 and 400 mm in order to facilitate the placing of the required reinforcing bars. Shear reinforcement shall be applied in beams only being a combination of stirrups and horizontal sidebars: web reinforcement.
When the actual shear stress (V) is less than 1.3 N/mm 2 (Vc1): no web reinforcement is required.
When the actual shear stress (V) is more than 1.3 N/mm 2 (Vc1) but less than 4.5 N/mm2 (Vc2): web reinforcement shall be required for (V-Vc1) N/mm 2.
Where:
V = Actual shear stress
Vc1 = Concrete shear stress lower limit
Vc2 = Concrete shear stress upper limit
At least 50% of the bottom main reinforcement shall extend over the face of the support providing a good anchorage between the supports.
Wind or earthquake loads shall not be combined with blast loads.
Future Load (Dead or Live Loads)
Future loads including pipe rack extensions and building expansions shall be considered when so directed by the Company.
Load Combinations
Piles, structures and members of structures as well as their support and fixing points shall be designed for various loading combinations given in the following tables:
Load Description Abbr.
Weight of Structure DL
Empty Weight of Vessels and Equipment DLempty
Operating Load LLop
Hydrostatic Test Load Test
Live Load LL
Moving / Truck Load LLmove
Wind Load WL
Earthquake Load EQ N/A
Crane / Impact Load CR
Dynamic Load DY
Thermal Load TL
Erection Load ER
Maintenance Load ML
Differential Settlement DS
Earth / Water Pressure HY
Blast Load BL
Loads shall be combined as specified below. Concrete bund walls shall be designed for accidental load condition when the bund is completely filled with water to the crest. Only the hydrostatic fluid acting in the outward direction and gravity loading need to be considered. The factor of safety shall not be less than 1.3 for this loading condition.
Load Combinations A through G:
Primary Operation Test Erection Earthquake Maintenance Blast
Loads without wind with wind
A B C D E F G
DL x x x x x X x
DLempty x x1 x x x X x
Test x
LL x x x x x X
Crane x x x X
LLop x x 1 x
LLmove x x x X
WL x x 3,4 x 4
EQ N/A
DY x x x2 X
TL x x X
ER x
ML x
DS x x x X x
HY x x x x X x
BL x
1. The most unfavorable load combination shall be taken into account.
2. Only if the structure supports rotating equipment that will be in operation while a vessel is being tested with water.
3. Only 50% wind load shall be taken into account.
4. The effect of wind forces acting on temporary scaffolding erected during construction or later for maintenance which will be transferred to the vessel or column shall be considered.
When considering these effects, the actual projected area of the scaffold members together with the correct shape factor and drag coefficient should be used. As an initial approximation, the overall width of the scaffolding itself can be taken as 1.5 m on each side of the vessel or column with 50% closed surface and shape factor 1.0.
5. Blast condition shall be taken into account for the blast resistant design of buildings where applicable.
6. In the ultimate limit state design, due regard shall be given to the different load factors for the various load combinations and the adverse or beneficial effects of the basic load cases.
Where imposed loads (live loads) have a beneficial effect, they shall be zero.
Structural Materials
The general types of material to be used are defined below :
➢ Structural Steel
➢ The furnishing, fabricating and erecting structural steel and miscellaneous steel shall be in accordance with Design General Specifications. Structural steel shapes and plates shall conform to ASTM A36 or to BS 4 or BS 4848 or BS EN 10025.
Cast-in-Place or situ Concrete
Cast-in-Place or situ Concrete shall have a minimum compressive strength in accordance with Specification for Concrete Supply. Upon the approval of Company, higher strength concrete may be used.
Precast concrete shall be carried out only with approval of Company.
Reinforcing Steel
Requirement to prevent ‘stray current corrosion’ of steel in concrete (due to implementation of impressed current Cathodic Protection to the nearby underground installation) is to be in accordance with Specification– Material Selection and Corrosion Monitoring Philosophy
➢ Reinforcing steel shall conform to BS 4449 Grade 460. Epoxy coating shall not be applicable where Cathodic Protection CP is provided.
➢ Welded wire fabric shall conform to BS 4848. Epoxy coatings shall not be used.
➢ Reinforcing is not required to be electrically continuous for any future cathodic protection of concrete structures.
Concrete Masonry
Mortar shall be Type M mortar (f’c = 17.3 N / mm2) conforming to ASTM C270. When determining allowable mortar stress, assume no inspection.
➢ Concrete blocks shall be Grade A, hollow-unit concrete blocks (f’c = 9.3 N/mm2) conforming to ASTM C9O.
➢ Reinforcing steel shall conform to BS 4449 Grade 460.
Anchor Bolts
Anchor bolts shall conform to ASTM A36. Minimum size bolts for structural columns and typical equipment shall be 20 mm, 16 mm bolts may be used for small pumps and handrails. Anchor bolts shall be galvanized in accordance with ASTM A123 and ASTM 143. In special cases where A36 anchor bolts are not sufficient, ASTM A193 Grade B-7 shall be used.
➢ Paint (only) for these high strength bolts may be used upon approval of the Designer.
➢ Handrail
➢ All handrail shall conform to ASTM A36.
➢ Welding shall conform to the AWS D1.1. All welding electrodes shall meet filler metal requirements given in AWS D1.1. The electrode material shall be E70XX.
Grating
Grating shall conform to ASTM A569 or BS 4592. The grating size and method of attachment shall be indicated in the project specifications. Grating and fixing material (clips) shall be hot-dip galvanized in accordance with ASTM A123 and A143.
Floor Plate
Chequered floor plate shall be four-way raised pattern steel plate with a thickness of 10 mm. Plate material shall conform to ASTM A36.
Bolts
The following bolts shall be used for all connections unless higher strength bolts are required and noted on the drawings: Bolts 20 mm and larger shall be high strength ASTM A325M or A490M; Bolts 16 mm and smaller shall be in accordance with ASTM A307. Anchorage of low temperature equipment (-50C) on steel structures shall use ASTM A320.L7 bolts.
Unless noted otherwise on the drawing, bolt size shall be as follows:
➢ For main members: 20 mm (min)
➢ For railings and ladders: 16 mm (refer to applicable standards)
➢ For ladder cages: 12 mm (refer to applicable standards)
➢ For stair treads: 8 mm (refer to applicable standards)
➢ High strength bolts shall be installed in accordance with AISC.
Grouting
All grout materials and application procedures shall be used in accordance with Specification for Grouting.
Embedded Items
All embedded items shall be ASTM A36 material and be hot-dip galvanized.
Contractor is to develop a detail which effectively seals the junction of embedded items and concrete for Company approval.
Allowable Stresses
Structural Steel
Allowable stresses specified in AISC specifications shall be used for the design of structural steel.
Cast-in-Place Concrete
The allowable stresses specified in ACI 318M shall be used in the design of concrete.
Masonry
The allowable stresses specified in ACI 530 and UBC shall be used for masonry design.
Anchor Bolts and Base Plate Bearing
1. The allowable stress for anchor bolt shall conform to AISC and ACI Specifications. Neither probability factors nor allowable stress increases shall be used for anchor bolt design. The calculated bolt diameter required to resist specified design loads shall be increased 3 mm to provide an allowance for corrosion.
2. Permissible bearing stress under base plates shall be as given in ACI 318 Code.
Stress Increase
The allowable stresses specified in the applicable codes given above for structural steel, concrete and masonry shall apply for all design with the following exceptions:
The increase in allowable stresses for all structural elements and their connections:
20% - Test without Wind Load
33% - Including Wind
Test Load Factor for Concrete Design
Deflection and Vibration
Allowable Deflections
The following sections give normally permissible deflection limits for steel and concrete structures.
The functional requirements of the structure may impose stricter limits. Systems should be reviewed for possible incompatible deflection behavior in piping, equipment or building components and support deflections.
Beam Deflections (Based on Live Loads Only)
Maximum allowable deflection for beams supporting floor systems and equipment shall be as follows:
Max deflection = L / 500 L = Span
Maximum allowable deflection for beams supporting brittle finishes such as plaster ceilings shall be as follows:
Max deflection = L / 360 L = Span
Maximum allowable deflection for purlins supporting roof system shall be as follows
Max deflection = L / 400 L = Span
Maximum allowable deflection for cantilever beams shall be as follows:
Max deflection = L / 400 L = Overhang Length
Maximum allowable deflection for beams supporting steel platforms, staircases, pipe racks, etc.
Max deflection = L / 300 L = Span
Crane Runways
Max deflection = L / 300 L = Span
Overhead Traveling
Max deflection = L / 600 L = Span
Monorails
Max deflection = L / 400 L = Span
Lateral Sway
Maximum allowable sway of buildings or structures shall be as follows:
Max deflection = H / 300 H = Height - if equipment supported
H / 200 H = Height - If equipment not supported
Maximum allowable sway for pipe racks shall be as follows:
Max deflection = H / 200 H = Height
Maximum allowable deflection for wall stanchions shall be as follows:
Max deflection = H / 300 H = Height
h = height of story or height of structure
These limits apply to sway between stories and to the structure as a whole.
Grating = L / 250 (Maximum span 1.6 meter)
Vibration
Superstructure Vibration
1 The primary source of vibration in superstructures is harmonic unbalanced forces generated by rotating or reciprocating equipment. The final design should be such that vibrations will be neither intolerable nor troublesome to personnel and not cause damage to the machine or structure or adjacent foundations, structures or services.
2 As a general rule, none of the natural frequencies of the structure should be within a band of the operating frequency of the supported machinery. The band recommended to be avoided is 1.414 above operating frequency and 0.707 below operating frequency. To find structural natural frequencies, a computer analysis shall be required.
3 All natural frequencies below 2 times the operating frequency for reciprocating equipment and below 1.5 times the operating frequency for rotating equipment shall be calculated.
4 It shall be demonstrated that the amplitudes at the natural frequencies between 0.35 and 1.5 times the operating frequency are within the allowable values even assuming that, due to differences between the actual structure and the assumed model, resonance does occur. In this case a reasonable amount of damping should be estimated.
5 Resonance condition requires a detailed three dimensional dynamic analysis. Once a model analysis has been conducted, a harmonic response analysis shall be performed. The response analysis will indicate anticipated amplitudes of vibration, velocity, and acceleration as well as magnitudes of forces in structural members. From the above information, the adequacy of the design can be evaluated and if necessary, modifications may be made.
6 The maximum vibration amplitude of the equipment shall not exceed the lower of the following values:
a. The maximum allowable values stated by the manufacturer of the equipment.
b. The amplitude (single amplitude) which causes the effective velocity of vibration to exceed:
2 mm / s at the location of the machine bearing housings
2.5 mm / s at any location of the structure
c. The dynamic amplitude of any part of the foundation including any reciprocating compressor shall be less than 80 µm single amplitude (80 x 10^-3mm).
The effective velocity is defined as the square root of the average of the square of the velocity, velocity being a function of time. In the case of a pure sinusoidal function the effective velocity is 0.71 times the peak value of the velocity.
The depth of a steel beam supporting large open floor areas free of partitions or other sources of damping should not be less than 1/20 of the span to minimize perceptible transient vibration due to pedestrian traffic.
Foundation Vibration
The Designer shall determine which vibrating equipment is to be analyzed by dynamic analysis.
Dynamic Analysis
1 For foundations for reciprocating machinery, centrifugal machinery and centrifugal pumps 750 kW or over, a three dimensional dynamic analysis must be performed. Foundation vibration generally involves a grade foundation designed to support one or more reciprocating or rotating machines.
2 Generally the same considerations for superstructure vibration also apply to foundation vibration.
3 The primary differences are that these foundations are often rigid blocks and that soil behavior must be considered. Rigid foundations supporting only one major machine can readily be analyzed using hand calculations and the concept of elastic half-space theory. For flexible foundations or foundations with many machines, a computer analysis should be utilized along with the concept of elastic half-space theory. The Designer shall prepare an instruction for foundation vibration analysis which contains current state-of-the-art approaches, soil information, machine information, dynamic analysis aids, published response criteria, example solutions, and a comprehensive list of references.
4 The dynamic amplitudes of any part of the foundation including any reciprocating compressor shall be less than 80 µm (80 x 10^-3 mm) single amplitude.
For the dynamic analysis, the exciting forces shall be taken as the maximum values that according to the Manufacturer of the equipment will occur during the lifetime of the equipment. When the exciting force is not given by the Manufacturer, it shall be determined from
Q(kN) = [Rotor Speed (rpm)/6000] x Rotor Weight (kN)
5 The dynamic calculations shall be based on a mechanical model wherein the weights and elasticity of both structure as well as foundation and the weight of the equipment to be represented in an appropriate way.
6 All natural frequencies below 2 times the operating frequency for reciprocating equipment and below 1.5 times the operating frequency for rotating equipment shall be calculated.
7 It shall be demonstrated that the amplitude of the natural frequencies between 0.35 and 1.5 times the operating frequency are within the allowable values even assuming that, due to differences between the actual structure and the assumed model, resonance does occur. In this case, a reasonable amount of damping should be estimated.
8 The natural frequency of the supporting structure shall not coincide with any resonant frequency of the equipment.
9 The static deformation for rotating equipment foundations shall be calculated and shown to be within the limits stated by the Manufacturer of the equipment. The calculations shall include but not be limited to the following causes of deformation.
10 Shrinkage and creep of concrete.
Temperature effects caused by radiation and convection of heat or cold generated by machinery, piping, and ducting.
Elastic deformation caused by changing vapor pressure in condensers.
Elastic deformation caused by soil settlement.
Non-Dynamic Analysis
For installations that do not warrant a dynamic analysis, (equipment weight less than 5000 kN), the mass ratio concept is commonly used. In the design of equipment foundations subject to vibratory loading where dynamic analysis is not performed, foundations shall be proportioned as indicated below:
Rotating equipment mass ratio = weight of concrete / weight of machine > 3
Reciprocating equipment mass ratio = weight of concrete / weight of machine > 6
Miscellaneous Design Data
Clearances and accessibility
Minimum clearances for Equipment, Structures, Platforms and Supports shall be in a accordance with the table in Specification for Design, Layout and Drawing
Coefficients of Static Friction
Coefficients of static friction for various material combinations are listed as follows:
Steel to steel Smooth, dry surfaced 0.3
Oxidizing steel 0.5
Steel to concrete or grout 0.5
Fluorogold, Teflon / PTFE and other similar materials as per Manufacturer's recommendations
Concrete to foundation materials
Clean sound rock 0.7
Clean gravel, gravel-sand mixtures, coarse sand 0.55
Clean fine to medium sand, silty medium to coarse sand, silty or clay gravel 0.45
Clean fine sand, silty or clayey, fine to medium sand 0.35
Fine sandy silt, nonplastic silt 0.30
Very stiff and hard residual or pre-consolidated clay 0.40
Medium stiff and stiff clay and silty clay 0.30
Membrane sheet 0.20
Engineering Maintenance Manual
The Designer shall prepare a detailed maintenance manual for use by the operators. The manual shall contain the following information:
Design Basis
A brief description of the basis of design of all foundations, structures and buildings, including reference to the detailed calculations for each to enable them to be retrieved if necessary.
Inspection
Recommendations for the routine inspection of works to enable the early detection of potentially dangerous deterioration including guidelines regarding the symptoms to be looked for such as locations and types of cracking which could be found in reinforced concrete structures etc.
Routine forms for inspection are to be established.
Materials
A detailed listing of all materials used (both generic types and Manufacturers' details) in the works including concrete mix constituents, concrete surface coatings, steel grades, painting details etc. to enable the Company to obtain compatible materials for future maintenance.
Maintenance and Repair Procedures
Details of recommended repair procedures for common types of failure such as breakdown or mechanical damage to concrete surface coatings, cracking of small foundations plinths due to reinforcement corrosion etc.
Finishing Material Manual
Additional list of all finishing materials used in the project buildings including material catalogs and sources to enable the Company to obtain such material or equal for future maintenance.
Operational Requirements
Concrete asset management system (CAMS)
In view of the continuous deterioration of reinforced concrete structures in plants, a computerized database system shall be developed by the Company to carry out periodical inspections and monitor the evaluation of disorder, if any.
Data related to new structures / foundations is required to be entered by the Contractor in the system in accordance with the existing procedure.
Existing settlement check survey program
An existing computerized monitoring system for tanks and critical foundations carrying large loads, rotating equipment foundations etc, shall be developed by the Company.
As a result of this ongoing program, new tanks and critical foundations shall be required to be monitored for future maintenance.
The Contractor is required to provide the following:
1. Permanent bench marks to allow for future check surveys.
2. List of tanks and critical foundations / structures proposed for monitoring.
3. Monitoring devices (non-corrosive material) embedded in the concrete foundations and fixed on the tanks as required.
4. Plot plans showing locations of the monitoring points and the permanent bench marks.
5. A computerized form filled with the first readings of the monitoring points surveyed at the completion of the Project.
Corrosion monitoring system for critical concrete structures
Some critical concrete structures due to operational requirements cannot be shut down for inspection. A new technology exists which allows for installation of metal sensors into concrete structures in order to monitor the corrosion risk at regular intervals. In this way protective measures can be taken before excessive damage occurs and without the need of a shutdown for inspection.
The following structures are given as an example of the types of structures to consider for installation of the sensors:
1. Below ground culverts
2. Outfall structures
3. Brine tanks
4. Below ground tanks such as sulfur pits
5. Reinforced concrete or pre-stressed pipes
Contractor is required to propose to Company the corrosion monitoring system to be used and to propose to Company the critical structures which should be equipped with the system. Contractor then is responsible to install the agreed system to structures.
Units Of Measurement
All dimensions, quantities and units of measurement shown on drawings or used in specifications and calculation sketches shall be given in metric units except pipe size which shall be given in the English units of inches. Refer to “Basic Engineering Design Data”.
Contractor shall design all buildings to adequate dimensions (lengths, widths and heights) to accommodate the necessary requirements inside. However the following minimum criteria shall be followed.
The corridors connecting the rooms within the buildings shall be wide enough to allow possible movement of equipment. The clear height of room from finished floor level to finished ceiling levels shall be minimum 3500mm. The space between equipment and walls shall be wide enough for a technician to walk around with tools, instruments, etc. (Refer to Company / Client Electrical Specification) and carry out the necessary inspection/maintenance works.
The external doors of the building shall be minimum 2400mm wide x 3000mm high plus a 300mm transom. The internal doors shall be 1100mm wide x 2100mm high. The HVAC system shall be Direct Expansion (DX) Split System ducted and adequately sized for the heat load inside the buildings. Contractor shall follow the requirement of space between equipment and walls as per Company / Client Electrical Specification All Civil/Buildings works shall be of construction type as indicated below;
Pump Pits (Sub-Structure) shall be of reinforced concrete complete with impressed current cathodic protection
Receiving Basin shall be of reinforced concrete complete with impressed current cathodic protection
Outfall Structure shall be of reinforced concrete complete with impressed current cathodic protection
Discharge Channel shall be of reinforced concrete complete with impressed current cathodic protection. Bottom slab of discharge channel shall be constructed with reinforced concrete.
Pump Houses -steel frames with profiled metal sheet cladding with hot rolled steel section for all structural members. Metal sheeting shall be protected with lightning protection rods to avoid puncturing.
Electro-chlorination and Electrical Switchgear Building -Reinforced concrete with block work panel and storage area shall be structural steel framing and metallic roofing and siding complete with protection against lightning. Electro chlorination building shall be fully covered structure steel building with metal sheeting and provided with transulent sheet for lighting.
33kv Electrical Switch Gear Building for PH- Reinforced concrete frames with block work panels.
VSDS Substation for PH- Reinforced concrete frame with block work panels.
VSDS Substation for PH- Reinforced concrete frame with block work panels.
Operation Building - Reinforced concrete frame with block work panels.
Local Lot Control Buildings - Reinforced concrete frame with block work panels. Contractor to design all LLCC’s for Phases and to construct only Phase LLCC’s.
Gate Houses - Reinforced concrete frame with block work panels.
Workshop Building - Structural framing with metallic roofing, complete with translucent sheets and lightning protection. Contractor shall allow for 3m high perimeter block wall and panels for offices and other rooms.
Warehouse/Workshop Building - Structural framing with metallic roofing complete with translucent sheets and lightning protection. Contractor shall allow for 3m high perimeter block wall and panels for offices and other rooms.
Control Building (Extension) - Reinforced concrete frame with block work panels.
220 kv GIS Building – Reinforced concrete frame with block work panels.
Transformer Pens – Transformers shall be supported on reinforced concrete foundations in a room having two sides as a minimum covered with firewalls and front side with fence provided with gates. Top of transformer pen has to be covered with metal sheeting.
Foundation for Analyser houses.
All concrete exposed to seawater or saline ground water shall be provided with additional protection as appropriate, including cathodic protection to the reinforcement, water proofing system, extra cover to the reinforcement, use of admixtures in the concrete and protective paint on the surface of the concrete. Corrosion Inhibitor shall be added to the structural concrete mix at the minimum rate of 10 lt / m3 for Pump Pits, Receiving Basins, discharge channel, outfall structure and to all structure foundations within water table or and below ± 0.0m NHD.
The list of required buildings and their conceptual drawings with finishing material schedule are provided. These building drawings are conceptual and have been developed based on preliminary building requirements and equipment sizing developed during the Front End Engineering Design. Contractor shall examine the drawings in detail and shall modify the drawings as necessary to accommodate final equipment selection and operational requirement.
Material Specifications
The selection of material is based on Project Specifications and any deviations shall be subject to Company / Client's approval.
Contractor shall import rock for outfall structure. The quarry shall be subject to Company / Client approval.
Concrete as Specified in project specification shall have fly ash, microsilica, corrosion inhibitor and the course aggregate shall be of Gabro type.
HVAC and Plumbing
HVAC Sample Only
HVAC system design and sizing shall be by Contractor in accordance with Project Specifications and all auxiliary systems and equipment shall be provided by Contractor.
Operation building HVAC System
The operation building shall be air conditioned by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on operation building roof. The specification for DX Condensing Units / AHU's shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with back draft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s.
Twin duty / standby auto changeover fans shall be used for toilets, pantry and Battery room exhaust. Battery room twin fans shall be eexcl IIC, T6, non sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries. All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver.VSDS Substation building PH, PH and 33 Kv switchgear Building HVAC system. The VSDS Substation Building PH, VSDS Substation Building PH and 33 kv Electrical Switchgear building shall be air conditioned by independent HVAC system for each building.
Each building shall be air conditioned by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on respective building roof. The specification for DX Condensing Units / AHU’s shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with back draft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each.
Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s. Twin duty / standby auto-change over fans shall be used for Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries. All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver. Electro Chlorination Building HVAC System.
The chlorination cells building and electrical substation building within Electro Chlorination Building shall be air conditioned by independent HVAC systems. Each sub building shall be air conditioned by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on electro chlorination building roof.
The specification for DX Condensing Units / AHUSs shall be as per the Company/Client specification and other standards. Each AHU shall have a centrifugal fan chamber with back draft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s.
Twin duty / standby auto-change over fans shall be used for Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries.
All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver.
Control building (extension) HVAC System.
The control building (extension) shall be air conditioned independently by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on control building (extension) roof.
The specification for DX Condensing Units / AHU’s shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with back draft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s. Twin duty / standby auto-change over fans shall be used for toilets, pantry and Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries.
All fresh air intakes shall have sand trap louvers / Pre-filters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver.
The conversion of existing two rooms in to Laboratory in existing control room is foreseen during the FEED design. Contractor shall re-balance the complete Existing HVAC system for Ground Floor to accommodate the ventilation and cooling requirement of laboratories. For Construction of the Control Room Extension, the existing HVAC condensing units shall be either relocated and connected to Ground floor existing AHU’s or secured to allow the construction of First floor works without any disturbance to the function of ground floor HVAC system.
Upon completion of first floor construction the new condensing units for existing ground floor along with first floor shall be installed on the first floor roof and connected to the respective AHU’s. Local Lot Control centres HVAC System. The Local Lot Control Centres Buildings shall be air conditioned independently by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on respective building roof.
The specification for DX Condensing Units / AHU’s shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with backdraft and volume control / shut off dampers. The AHU fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each.
Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s.
Twin duty / standby auto-change over fan shall be used for Battery room exhaust.
Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries.
All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers.
The exhaust air outlet shall be fitted with weather louver.
Workshop / Warehouse building HVAC System
All Offices and Electrical room in workshop / warehouse building shall be treated with wall mounted split units. Air-cooled condensing units shall be located on external walls. Vendors’ standard Indoor units shall be suitable for wall mounting.
Chemical / sensitive materials store (s) within warehouse shall be air conditioned independently by duty / standby Direct Expansion (DX) Package units to ensure 100% redundancy. Total 100 % treated fresh air shall be supplied by 100 % capacity duty / standby Package units. The duty / standby Package units shall be located outside workshop / warehouse building on ground.
The specification for Package Units / AHU’s shall be as per the Company / Client specification and other standards. Each Package unit shall have a centrifugal fan chamber with backdraft and volume control / shut off dampers. The Package unit supply air fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the Package unit. Electric heating coils and steam humidification sections shall be provided in the Package units air handling section.
Twin duty / standby auto-change over fans shall be used for Chemical / sensitive materials store (s) Pantry and Toilets room exhaust. Chemical / sensitive materials store (s) twin fans shall be eexd IIC, T6, non-sparking type.
Warehouse storage area for Mechanical items and Electrical Cables shall be ventilated by 100 % capacity duty / standby exhaust fans installed on roof and air intake through wall opening at low levels. Wall opening at low level shall be with sand trap louvers and G4 pre filters.
Workshop area shall be ventilated by 100 % capacity duty / standby exhaust fans installed on roof and air intake through wall opening at low levels. Wall opening at low level shall be with sand trap louvers and G4 pre filters.
Workshop building HVAC System
Offices area within workshop building including electrical room, electrical workshop, instrument workshop, tool room, spares parts room, HVAC room and corridor shall be air conditioned independently by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located outside workshop building on ground.
The specification for DX Condensing Units / AHU’s shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with backdraft and volume control / shut off dampers. The AHU fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each.
Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s.
Twin duty / standby auto-change over fan shall be used for Toilets, Pantry rooms and Locker rooms exhaust.
All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers.
The exhaust air outlet shall be fitted with weather louver.
Workshop area shall be ventilated by 100 % capacity duty / standby exhaust fans (i.e Four 50 % capacity fans) installed on roof and air intake through wall opening at low levels. Wall opening at low level shall be with sand trap louvers and G4 pre filters.
Gate house HVAC System
Gate House Building (s) offices shall be air conditioned with cassette type ceiling mounted split units. Air-cooled condensing units shall be located on external walls or on gate house roof. Vendors’ standard Indoor units shall be suitable for wall mounting.
Twin duty / standby auto-change over fans shall be used for Toilet exhaust.
220 kv switchgear and control buildings HVAC System
The 220 kv Switchgear and Control building shall be air conditioned by independent HVAC system for each building. Each building shall be air conditioned by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on respective building roof.
The specification for DX Condensing Units / AHU’s shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with backdraft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each.
Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s.
Twin duty / standby auto-change over fans shall be used for Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries.
All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers.
The exhaust air outlet shall be fitted with weather louver.
Plumbing
For all Buildings
Contractor shall design, furnish, install and place in satisfactory operation a chemical waste sewer system with utilities for wash down of the Battery room. The Battery room chemical waste sewer shall be provided with floor drain and be piped to a local storage system for truck removal.
Plumbing facilities including number of equipment and fixtures, and their capacities shall be developed by Contractor in accordance with Project Specification.
Contractor shall allow for the design, supply and installation of eyewash, complete with plumbing and drainage works for all Battery rooms and electro-chlorination area.
The list of required buildings and their conceptual drawings with plumbing arrangement are provided. These plumbing drawings are conceptual and have been developed based on preliminary building requirements and sizing developed during the Front End Engineering Design. Contractor shall examine the drawings in detail and modify the drawings as necessary to accommodate final sanitary equipment selection and operational requirement.
Roads
In principle no road cutting is allowed in the State. However, cutting for road / utility crossings for cooling water pipe work, identified within the Scope of Work, is acceptable to Company / Client. For these crossings, Contractor to design, procure and construct approved road diversions, so as not to disrupt traffic at any time. Contractor shall reinstate roads / tracks / ground to its original specification / condition. For all other crossings, Contractor shall design and construct road crossings by way of horizontal drilling without cutting the main asphalted road and without disturbing the traffic.
All pipe crossings for existing roads and corridors shall be made through micro tunneling or cut & cover method depending on the availability of the micro tunneling equipment. Road design and construction shall be according to National Highway Design.
Road markings / road signs to be provided in both local language and English.
Crash barriers along culvert, bridges, change of road direction and along embankments such as ramps.
Overhead steel pipe to be painted with sign warning and clearance.
Marking road edges.
Flush kerb-stones shall be allowed for at change of road construction and change of road direction.
Considerations for final grading and surface drainage shall allow excess water to flow into open drainage and shall include the following:
The open ditch system should be connected to the storm water basin. The water can be re-routed to the sea.
Roads, other areas as necessary to be paved.
In case of heavy rainfall, all building and equipment areas should be accessible.
Road levels shall be higher than the adjacent graded level (as a minimum 500mm above FGL)
Detailed engineering should be developed by the Contractor for the following:
Construction lay down; including temporary facilities; warehouse area; construction camp; site offices for Company / Client and Contractor. Access road to Company/Client site offices shall be asphalted.
Parking, road marking, traffic signs & information in both local language and English
Handling Devices Structures.
Rising pipes should be installed on structural steel pipe racks. Road and utility crossing by indicated approximate sizes and elevation to NHD shall be prepared by Contractor. Minimum requirement of clearance between walls, bottom slab and sofit of top slab and pipe shall be 600mm. Also note that 5.5m minimum clearance is required between roads whether existing or / and new and bottom of structures supporting pipes in utility crossings.
For consumer utility crossing involving any combination shall be designed and built by Contractor. Contractor shall design all the pipe bridges and utility crossings required for Phase and construct only Phase bridges. Minimum clearance shall be as indicated on FEED drawings (6m).
Pipe Bridge Crossing Over Existing and New Discharge Channel
Contractor shall design and construct series of concrete support frames to support pipelines over the new and existing discharge channels. The corridor crossing occurs just up stream of the road bridge. Contractor to construct the foundation for the Pipe Bridges, each end user shall construct their own steel truss bridges for carrying pipes.
The required conceptual drawings Pipe Bridge are provided. These drawings are conceptual and have been developed based on preliminary requirements and sizing developed during the Front End Engineering Design. Contractor shall examine the drawings in detail and shall modify the drawings as necessary to accommodate final pipe sizes and routing.
Oil Spill Control Equipment
Contractor to design and construct Oil Spill Control Equipment based on the SOW (Scope of work) provided, however the SOW provided is based on the preliminary requirement of Company / Client, and the same to be modified based on the one constructed at Phase for Pump House
Electrical Engineering
The Phase of the project shall derive power at 220kv from a new 220kv substation, as further detailed below.
Power Supply for Local Lot Control Centers located at the Consumer premises receive and distribute Power at 415V. At intermediate locations, power supplies for Local Lot Control Centers shall be derived from the existing 11kv network, by providing 11kv RMU units and 11kv / 433V Package substations and distributed at 415V. At Receiving basin and Outfall areas, the existing 11kv network shall be augmented by providing 11kv RMU units and 11kv / 433V Package substations and power supplies to llccs shall be distributed at 415V. The Contractor shall provide the following systems / facilities as a minimum.
220 kv System
Two 220kv / 34.5kv, 165/220 MVA transformers (located near the new 33kv switchgear building) shall be provided.
A 220kv Substation consisting of double bus switchgear shall be provided. Existing two circuits of 220kv cables shall be cut and terminated to the 220kv switchgear as incoming cables. New 220kv cables shall be provided from the 220kv switchgear to feed the two existing 220 / 33kv transformers. Also, new 220kv cables shall be provided for the two new 220 / 34.5kv transformers. The GIS shall have provision for additional two 220kv feeder bays to receive power from a future Electrical department substation.
33kv System
New 33kv double bus switchgear with Gas Insulated bus bars and vacuum circuit breakers shall be provided and located in 33kv Switchgear building. This shall include 33kv gas insulated bus ducts connecting the transformers to the 33kv switchgear.
Expansion of existing double bus Siemens make 33kv switchgear (gas insulated) located in existing 33kv Electrical Switchgear building-1 to cater to Phase loads located in Phase area.
One 33kv, 1250A rated tie feeder connecting existing 33 kv switchgear (feeder allotted from the expansion portion) to the new 33kv switchgear.
Two 33kv / 6.9kv Transformers (located near VSDS Substation for PH area.
Two 33kv / 6.9kv Transformers (located near Electro Chlorination building).
Replacement of two existing 33kv / 6.9kv Transformers with higher MVA capacity transformers (located near existing 33kv Electrical Switchgear building-2).
33kv XLPE Cables along with termination kits and associated items for feeding vsds transformers and various other loads.
Harmonic filters connected to new 33kv switchgear and to existing 33kv switchgear.
11kv System
11kv / 433V Package substations (consisting of RMU’s, 11kv / 433V transformers, LV Switchboard, etc.) For deriving Power supply for llccs in MOV corridor area, Receiving basin and Outfall area.
11kv XLPE Cables with their termination kits and associated items for modifications / additions in the 11KV network.
6.6kv System
New 6.6kv metal clad draw-out type switchgear with insulated (solid insulation) bus bars and vacuum circuit breakers shall be provided and located in VSDS Substation for PH building. This shall include 6.6 kv bus ducts connecting the transformers to the 6.6kv switchgear.
New 6.6kv metal clad draw-out type switchgear with insulated (solid insulation) bus bars and vacuum circuit breakers shall be provided and located in new Electro Chlorination building. This shall include 6.6 kv bus ducts connecting the transformers to the 6.6kv switchgear.
Expansion of existing 6.6kv switchgear (Schneider make) located in existing 33kv Electrical Switchgear building-2 to cater to Phase loads located in Phase area.
Four 6.6kv / 433V Transformers (located near VSDS Substation for PH building).
Two 6.6kv / 433V Transformers (located near 220kv GIS Building)
Two 6.6kv / 433V Transformers (located near new Electro-Chlorination building).
Two 6.6kv / 433V Transformers (located at operation building).
Two 6.6kv / 433V Transformers (located near VSDS Substation for PH building).
6.6kv XLPE Cables with their termination kits and associated items for feeding various loads.
415 V System
New 415V Switchgear–MCC assembly located in VSDS Substation for PH building. This shall consist of an emergency section fed from an emergency diesel generator and shall also include 415V bus ducts connecting the transformers to the 415V switchgear.
New 415V Switchgear–MCC assembly located in VSDS Substation for PH building. This shall also include 415V bus ducts connecting the transformers to the 415V switchgear.
New 415V Switchgear–MCC located in new Electro Chlorination building. This shall consist of an emergency section for feeding emergency loads and shall include 415V bus ducts connecting the transformers to the 415V switchgear.
New 415V Switchgear–MCC located in vsds building for PH. This shall consist of an emergency section fed from an emergency diesel generator and shall include 415V bus ducts connecting the transformers to the 415V switchgear.
New 415V Switchgear–MCC assembly located in 220kv GIS Building. This shall consist of an emergency section for feeding emergency loads and shall include 415V bus ducts connecting the transformers to the 415V switchgear.
New 415V Switchgear–MCC assembly located in Operation Building. This shall consist of an emergency section for feeding emergency loads and shall include 415 bus ducts connecting transformers to 415 V switchgear.
Modifications to existing 415V Switchgear–MCC located in 33kv Electrical Switchgear building No-2 to add manual synchronizing for Load testing of the existing emergency generator.
New 415V Switchgear–MCC assembly located at existing Electro chlorination building to feed the loads of Power consumer. This shall consist of an emergency section feeding emergency loads.
Modifications to existing 415V Switchgear–MCC located in Electro chlorination building to provide power feeders to Power – MCC indicated above.
New 415V Power distribution centres for sub-distribution of 415V Power supply (Normal and emergency as applicable) at various load centres.
New 415V Switchgear–MCC located in each.
230V AC UPS System
New 230V, 50Hz, UPS system shall be provided at the following locations:
UPS with battery banks for Phase equipment located in Phase-I area and located at extension portion of Control Building.
UPS with battery banks for Phase located in VSDS Substation for PH building.
UPS with battery banks for each LLCC building located in End-User premises, MOV Corridor, Receiving basin and Outfall area.
UPS with battery banks for 220kv GIS located in 220kv GIS building.
110V DC System
New 110V DC UPS system shall be provided at the following locations:
UPS with battery banks for Phase located in VSDS Substation for PH building.
UPS with battery banks for Phase located in 33kv switchgear building.
UPS with battery banks for Phase located in Electro Chlorination building.
UPS with battery banks for 220kv GIS located in 220kv GIS building.
Control, Protection and Alarm Systems
The Contractor shall provide control, protection, interlocking and alarm systems for Phase-II equipment as detailed below:
220kv System
Separate Relay panels, Control and annunciator panels shall be provided and located in 220kv GIS building.
33kv System
Separate Relay, Control and annunciator panels shall be provided for new switchgear and located in new 33kv Electrical Switchgear building.
Separate Relay, Control and annunciator panels for extension of existing 33kv switchgear shall be provided and located in existing 33kv Electrical Switchgear building.
6.6kv System
Relays control and annunciation system shall be mounted on the 6.6kv switchgear LV Compartment for new and modified switchgear.
11kv / 433V Package substations
Relays, control and annunciation system shall be mounted on the 11kv rmus LV Compartment / 415V switchgear compartment as applicable.
415V System
Relays, control and annunciation system shall be mounted on the 415V switchgear LV Compartment as applicable.
Substation Control and Monitoring Systems (SCMS) and Power Management Systems (PMS)
The Contractor shall provide the following:
SCMS System FOR 220kv System
Separate SCMS system shall be provided for 220kv GIS. This shall include all necessary Control, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis.
One Human machine interface (HMI) with necessary software and graphical interface shall be provided for the 220kv GIS. This shall have necessary gateways for Electrical department, 33kv SCMS and Power Management system (PMS).
SCMS System FOR NEW 33kv System
Separate SCMS system shall be provided for the new 33kv GIS. This shall include all necessary Control, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis.
One Human machine interface (HMI) with necessary software and graphical interface shall be provided for the 33kv GIS. This shall have necessary gateways for Electrical department and PMS.
Transformer Monitoring System
Separate transformer monitoring system (equivalent to GE Faraday TMCS) shall be provided. This shall log all transformer signals from transformer monitoring devices.
PMS System
PMS shall be provided for overall control and monitoring of the Phase electrical system
The PMS shall be linked to Gateways of the SCMS of 220kv and 33kv systems.
The PMS shall be linked to the data acquisition and control system of the new VSDS and all control, signals shall be enabled in the PMS.
The PMS shall be linked to the data acquisition and control system of the existing VSDS and all control, signals shall be enabled in the PMS.
The PMS shall be linked to the existing PMS and all control signals shall be enabled in the new PMS.
The PMS shall be linked to the Transformer monitoring system and all signals and data shall be available at the PMS.
For 6.6kv, all necessary Control, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis, shall be provided.
For 415V system, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis, shall be provided. Control shall be provided for Incomers, bus ties and feeders ties.
One (1) Human machine interface (HMI) with necessary software and graphical interface shall be provided for the PMS. This shall be located in the Control building. This shall have a gateway facility to DCS.
Tariff Metering Systems
Tariff metering system shall be provided on the Incoming feeders of new 33kv switchgear.
The metering scheme shall be subject to approval by Electrical department.
Existing as well as new metering signals are to be transmitted to NCC
Lighting Systems
The Contractor shall provide lighting systems as detailed below:
Indoor lighting systems for all buildings in Phase. Building external lighting (Photo-cell controlled) shall also be provided.
Outdoor Areas Lighting systems (Photo-cell controlled) for the intake area of Phase.
Stilling basin. Additional lighting to be provided to enhance the lighting (Photo cell controlled) to 150 lux at the Outer edge of Stilling basin.
Security Lighting (Photo cell controlled) system shall be provided for the intake plant overall perimeter fence. This shall consist of pole-mounted floodlights. The poles shall be located inside the perimeter fence. The floodlights shall be with high pressure (HPSV) lamps. The lighting level at the fence shall be 150 lux.
Earthing Systems
The Contractor shall provide earthing system for all installations in Phase. This shall consist of insulated earthing cables and stainless steel earth rods.
Earthing studies and calculations shall be carried out to establish the parameters of the earthing system design.
Contractor shall perform the studies using CYME software to plot ground potential contours for 33kv and 220kv GIS installations to substantiate that the touch and step voltages are within tolerable limits. Both electronic and hard copies shall be submitted to Company / Client as a part of final documentation.
Lightning Protection System
Lightning protection shall be provided for all the buildings and tanks associated with Phase. This shall also include the Control building extension.
The Contractor shall provide calculations to establish the design of the system.
Both electronic and hard copies shall be submitted to Company / Client a part of the final documentation.
Power System Studies
Following studies covering the entire plant network shall be conducted. The studies shall be conducted in accordance to Company / Client specification and harmonic requirements.
The studies shall be contracted to a Company / Client approved study Consultant. All the studies shall be carried out on Windows based CYME package except Insulation co-ordination study, which shall be on PSCD EMTP software. The VSDS vendor documentation shall also the CYME software package for analysis and reporting.
Other Specialized software may be used for insulation co-ordination studies but this shall be subject to prior approval of Company / Client.
Load flow studies
Load Flow studies shall be performed to validate the chosen equipment ratings (continuous). This shall include motor starting studies.
Short circuit studies
Short circuit studies shall be performed to validate the chosen equipment (short time) ratings.
The actual fault levels at the 220kv + PLANT substation shall be made available during detail design. Fault level details shall be co-ordinated with Company / Client during detail design.
Harmonic studies
As harmonic levels are in excess of the stipulation mentioned in the specifications, the Contractor shall install necessary filters to mitigate the harmonic levels to the specified limits. Following successful plant completion, Contractor shall perform extensive site verification tests to prove that limits imposed have not been exceeded.
Protection co-ordination studies.
Establish the relay settings for all protection relays. These shall include protection settings at all llccs.
Insulation co-ordination studies
The studies shall establish that the insulation levels of equipment are adequate for probable surges in the system with a safety margin. The studies shall also establish the location, number and rating of surge arresters/surge suppressors in the system.
Both electronic and hard copies shall be submitted to Company / Client as part of the final documentation.
Motor Starting
Substation Earthing
LV Power and Control Cables
XLPE insulated Copper Cables shall be provided as required to distribute LV Power, and for Control, protection and annunciation requirements.
The Contractor shall route the cables in concrete troughs, trays, conduits, raceways, under ground trenches, etc. As detailed in the cable layout drawings.
Emergency Diesel Generator
An emergency diesel engine driven generator with a minimum rating of 630kva shall be provided to cater to the loads of Phase emergency loads and located in VSDS Sub-station for PH. The Contractor shall size and verify the rating based on various loads connected to the emergency bus.
An emergency diesel engine driven generator with a minimum rating of 350kva shall be provided to cater to the loads of Phase-II emergency loads located in Phase area. This shall be located in VSDS Sub-station for PH. The Contractor shall size and verify the rating based on various loads connected to the emergency bus.
Bulk Materials
The Contractor shall provide as required Push button stations, receptacles (415V and 230V), local control panels, junction boxes, etc. As required for each system.
Scope at Remote PLANT Substation and NCC
The Contractor shall provide the necessary facilities at the remote end for tele-signalling.
Co-Ordination with PLANT and Electrical Department
The design, installation and commissioning of all 220kv equipment (including control and signalling to PLANT substation) shall require co-ordination/approval of Company / Client, PLANT and Electrical department.
Contractor shall take the responsibility / lead in obtaining approval for the interface facilities with PLANT and Electrical department. Company / Client shall facilitate the co-ordination and interface by a letter of introduction.
Contractor shall engineer, connect and configure the signals for monitoring and controlling the FACILITY pertaining to this Project only. Twenty percent (20%) of the spares shall be connected and configured as spares as detailed in the specification provided. Provision for expansion shall be made for connecting any additional signals (future).
Harmonic Filters
Harmonic filters shall be provided based on the power system study requirements. This shall consist of :
One set to cater to the requirements of existing 33kv network and connected to the existing 33kv switchgear (in the modified portion). This shall be further split into two groups. Each group shall be connected to individual bus-section.
One set to cater to the requirements of new 33kv network and connected to the new 33kv switchgear. This shall be further split into two groups. Each group shall be connected to individual bus-section.
The filters shall require a minimum of manual intervention and shall be designed for minimum energy losses. The harmonic filter package shall be for the Phase (existing).
Tele-protection System and RTU
The existing tele-protection system (SWT-3000), in the existing 33 kv switchgear room, shall be expanded to be made dual redundant.
The existing tele-protection system in PLANT shall be expanded to be made dual redundant.
A new dual redundant tele-protection system shall be provided for the new incoming cables in the new 33 kv switchgear room and the new 220 kv switchgear room.
The existing RTU and existing C30 Controller located in existing 33kv switchgear room shall be expanded to cater for additional feeders.
The tele-protection systems at PLANT, existing 33kv, new 33 kv and the new 220kv are to be integrated into a network via redundant, dedicated optical fibre cables. The network shall be configured such that the functions of any one redundant tele-protection unit that has failed shall by automatically assumed by another tele-protection unit within the network.
Tele-signal Transfer
The existing communications system shall be extended and expanded in order to provide voice and data links from the new 220 kv substation to the NCC.
A new SDH node, PDH and PCM multiplex and supervisory system at the new 220 kv substation connected to PLANT via redundant optical fiber cables shall be provided.
Telephone and hotline telephone facility at the new 220 kv substation shall be provided.
The existing SDH and associated equipment at PLANT and NCC shall be expanded, including software upgrades, to cater for the new and expansion of the tele-signaling and telecommunication requirements or a new SDH equipment shall be provided.
Necessary software and hardware modifications, including map work, network display, etc., and additions shall be provided at NCC for the new substation.
Miscellaneous Requirements
Reactive Power compensation equipment shall be provided if necessary based on the power system study requirements.
The design shall be based on a design life of 30 years for all equipment.
Fibre Optic cables for all networked equipment.
In order to coordinate with others, Contractor shall provide the following:
Estimated annual load build-up for the Project based on available data on flow requirements and utilities. This estimate shall be in tabular as well as graphical format. The first submission shall be within four months of award date and tabulation shall be regularly revised every six months with the development of the Project.
Priority shall be given to finalising the load Schedules / load Data for all end-user llccs so that early coordination of LV power supplies can be undertaken with the respective end users.
Where new roads or maintenance tracks cross-buried cables, Contractor shall install duct banks to safeguard the buried assets. The design of duct banks shall be suitable for a 30-Ton axle load.
Pipelines and Distribution
Contractor to note that the terminology ‘Piping’ or ‘Pipelines’ anywhere in this document refers to complete piping systems (both ‘on plot’ and ‘off-plot’) including Pumping Station piping, Manifolds, package piping, fire water piping, utility piping, cooling water supply and return headers, piping from / to end users battery limits, etc.
General Requirements
Contractor shall check, validate and endorse all FEED documents, drawings and data during detail engineering as a part of his scope of work.
Contractor shall bring to the notice of Company / Client in writing any contradictions / conflicts in the FEED documentation provided.
All detail engineering deliverables shall fully comply with the requirements of all relevant Company / Client standards / specifications and FEED documents.
Survey Requirements
Topographic and Geotechnical Survey for all cooling water corridors have been performed as part of FEED engineering and the survey report is included. Contractor shall perform additional survey as required for detailed engineering to confirm the pipeline routings, tie-ins, fouling/interface with other facilities, collection of data for detailed engineering, installation of piping, road and utility crossings and pipe supports.
Detailed Engineering
Contractor shall perform detailed engineering for piping including but not limited to the following activities:
Basis of Design
The FEED Basis of Design for Piping shall be expanded as required for detailed engineering. Any change in the Basis of Design shall be specifically highlighted and shall be subject to Company / Client approval.
Specifications
All FEED specifications shall be developed to detailed engineering status. Any modifications from the FEED specification shall be specifically highlighted and shall be subject to Company / Client approval.
Additional specifications, as required during detail engineering, shall be prepared by the Contractor. These shall be stand alone, self contained and Project specific.
Drawings
Review the piping drawings included in APPENDIX and produce complete piping General Arrangement Drawings (GAD’s), Equipment Layouts / Plot Plans, Sections, Piping standards, etc. For engineering and construction covering all pipe work.
Verify that pipe routings indicated in FEED documentation have not been compromised or fouling with by on going works / projects.
Prepare Key Plans, which shall show the facilities subdivided into geographic construction areas and sectors and their corresponding documentation.
Develop piping general arrangement drawings for the entire facilities. All drawings shall be produced from 3D CAD model and in AUTOCAD electronic format and shall conform to Company / Client draughting standard requirements.
Plot Plans, Key & Area Plot plans. Overall Pipe Routing Plans. Fire Water / Fresh Water Routing & gads. Prepare a list and drawings on special supports. Prepare Piping Isometrics for all piping having the following information as a minimum: Complete line from start to end with all components with full dimensions. Complete Bill of Materials. Information on type and thickness of insulation. Information on Process conditions and parameters. Information on whether line is stress analysed, stress relieved, etc. Information on pipe supports. Pipe supports to be shown on the Isometric drawings only for DN 50 and above piping. Information on reference drawing
Studies,
Perform Mechanical Handling studies and prepare a report for Company / Client review. Incorporate any changes required as a result of maintainability and operability study. Calculations. Contractor shall reconfirm selected material and wall thickness for all piping as part of detailed engineering activities. Review and update all existing piping engineering calculations that have impact on the Project as appropriate and carry out new calculations wherever required. Contractor shall perform detailed flexibility analysis of all relevant piping based on final pipe routing and design conditions. CAESAR-II latest version shall be used for flexibility analysis. Stress analysis of FRP piping shall be carried out by the FRP pipe supplier utilizing specific properties of the supplied pipes. Contractor shall perform detailed support design and develop new project specific support standard / drawings and lists based on detailed engineering for all piping. Carryout Surge Analysis for the Fire Water (Fresh Water) System GRE Piping.
Finite Element analysis for Critical Components, supports, and manifold Tees, reducers etc. Using COSMO, ABAQUS or ANSYS Soft wares.
3-D Model
Prepare a 3D PDS model for the entire facilities. Piping of all sizes shall be modeled. The 3D model shall further include modeling of pipe supports for DN 50 and above piping, electrical and instrumentation items / cable trays, civil and structural information, all equipment, etc. Intelligent model to be submitted to Company / Client, updated to include as-built status of installed facilities. This shall be used by Company / Client for further engineering during ultimate phase or future phase
Vendor Data Review. Review, check and comment on all applicable Vendor calculations, drawings and data and incorporate requirements in design and engineering. Construction. Prepare all documentation for fabrication, erection, installation, inspection and testing of piping. Tie-ins, Prepare Piping Tie-in schedule and details as per P& I D’s and other Project documents. MTO and Requisitions. Perform and prepare Material Take-offs and summaries for piping and support materials including bulk material. Prepare material / purchase requisitions (RFQ’s) for all piping and support materials.
Prepare Technical Evaluation Summary reports for all piping items. GRP Piping. Coordinate between different GRP Vendors. As Built Documentation
Prepare and submit final “As-Built” documentation.
Piping / Pipeline Deliverables
Electronic copies in native format (generic) and hard copies shall be supplied in final documentation for all disciplines. Piping Basis of Design. Piping Material Specification (Piping Classes). Piping Wall Thickness calculations Reports. Technical Specifications for Pipes, Flanges, Fittings, Valves, Rubber Expansion Joints, Bolts & Nuts, gaskets, etc. Process / Piping specialties specifications and data sheets. Valve Data sheets. Valve Schedule. Specification for flexibility/stress analysis. Specification for Pipe Supports.
Specification for Fabrication, Erection, Installation, Inspection and Testing of Piping. Specification for Hydrostatic Pressure Testing of Piping. MTO for piping and support materials. Requisitions for all piping bulk items, valves, specialities, etc. Technical Bid Evaluation Reports. Mechanical Handling study report. Surge Analysis report for the Fire Water (Fresh Water) System GRE Piping. (Plot Plans / gads / Pipe Routings) Key Plans. Plot Plans (Overall & Unit). Piping General Arrangement Drawings (key Plan & Plans & Sections / details). Piping Isometrics (AFC). Tie-in schedule and details. Critical Line List for Piping Stress analysis. Piping Stress Analysis calculation reports. Standard Pipe Support drawings. Special Pipe Support Drawings. Support Schedule. 3D – PDS Model (Generic and Intelligent). Overall Pipe Routings
Reports / Calculations notes etc. As listed. As-built drawings (for all above referenced drawings / documents)
Specific Requirements
Design, Fabrication and Installation of FRP Piping. Detailed design and supply for FRP (GRE / GRP / GRV) Piping are of specialist nature and hence shall be subcontracted to the Specialist GRP and FRP pipe manufacturer respectively.
Detailed Design shall include, but not limited to the following: All thickness calculations for pipes and piping components. Update and issue of design and installation drawings. Flow / Surge calculations for the system as may be appropriate. Static and Dynamic stress calculations and analysis. Design of jointing system based on the design. Design and location of supports, anchors, and design data for anchor blocks. Review of all proposed field design changes, which may affect FRP pipework or support throughout construction. Supply of FRP Piping and spool fabrication. Supply of piping components such as pipes, fittings, flanges, etc. For FRP piping system.
Supply of pipe supports such as saddles etc. Supply of fabricated spools.
Further, the FRP vendor shall furnish Installation, inspection and testing procedures for FRP piping and shall supervise the site installation activities in order to ensure single point responsibility of design, supply and installation.
Instrumentation & Controls
Contractor shall be responsible for but not limited to the following:
General
Contractor shall be fully responsible for the design and provision of instrumentation, and associated control systems for the Project. Responsibility extends to all required detailed design, material supply, engineering, factory inspection and testing, packaging, logistics, calibration at site, installation, hook-up and field verification. All systems shall be supplied, configured and tested in accordance with the relevant Project Specifications.
Refer Instrumentation & Control Basis of Design, General Instrumentation Specification, Specification for package Instrument Installation Contractor shall make a detailed site visit to study and familiarize the existing Instrumentation & Control system already implemented for Phase
Site visit report shall be submitted to Company / Client.
The Instrumentation and Control system to be implemented for Phase shall only be considered for the Project. Phase related items would be a separate project in future.
Instrument scope shall include, but not be limited to the items listed below:
Instrumentation Data base
Contractor shall develop a Master database of Instruments in ‘intools’. This database shall cover the details of all the tagged instruments and their signals as per the Company / Client Drafting & Numbering system. The basis for this list shall be P&ID. This database shall be dynamic until the ‘As built’ stage of the project. All the features of the intools e.g. Index module, Data sheet module, Calculations, wiring, Instrument Loop diagrams, hook-ups etc. Shall be utilized.
As a minimum, one license of ‘INTOOLS’ shall be made available for Company / Client use during project stage and the same license, complete database with associated information shall be handed over to Company / Client at the end of the project.
Instrument specifications & Data sheets
Contractor shall generate a stand-alone specification and / or data sheet for every Instrument and Control system. These documents shall be regularly updated until the “As built” stage.
The Specification shall cover minimum requirements such as the selection of type, Material, requirements pertaining to Manufacturing, QA / QC, Inspection, Painting, Storage, Handling, Transportation and Maintenance & Operations etc. The data sheets shall cover complete details of individual instruments.
Installation drawings and Documents
Contractor shall develop detailed instrumentation installation related drawings to facilitate the easy construction of the Instrument & Control System. These drawings shall include but not limited to the instrument equipment layout in building, location layouts, cable block diagrams, cable routing layouts, cable schedule, Hook-up Diagrams, Bill of Materials, MCT schedules, Air supply distribution, Termination diagrams, Loop diagrams etc.
Contractor shall develop a detailed Specification for the Installation of Instrumentation & Control System.
Input to various disciplines / participation in various studies
Instrumentation shall provide inputs to the various disciplines associated with the Project. Proper co-ordination among all the Project team members is expected. Instrumentation shall participate in various studies (e.g. Hazop, Constructability review etc.) During course of the detail engineering.
Procurement
Contractor shall prepare detailed Scope of supply (which includes Documentation requirement etc.), Material Requisitions for each type of Instrument and Control system. The enquiries shall be floated to the Company / Client approved Suppliers only. A detailed Technical evaluation shall be carried out and the Technical Bid Analysis shall be submitted to Company / Client. All the relevant documents shall be updated to reflect the make, model number of the individual instrument and submitted along with the technical section of the Purchase Order.
Vendor Drawing approval
Contractor shall carry out detailed review and approval of all the Vendor drawings and documents. Vendor Data Books shall be submitted in format explained in the relevant Project specification.
Inspection & Testing
Inspection and testing shall be conducted as defined in the relevant Project specification.
Distributed Control System (DCS)
The Control system for Phase is EMERSON make Delta – V system. There are two options for Phase. Either this system can be extended to cater for the expansions including phase or an independent third party Distributed Control System integrated with the existing DCS through ‘OPC’ open system connectivity. It is intended that the Operator stations implemented for Phase shall be continued to be in use for Phase and all the future phases of the Project including Phase. Presently only one additional operator station is planned to be added.
Contractor shall develop Control philosophy and all relevant documents for the System Supplier like Functional Design Specification, Control / Logic Narratives, I / O lists (Hardwired & softwired), Loop typicals, Graphic specification, Layout of individual Graphic pages, Logic Diagrams etc.
Contractor shall finalize the hardware required for the Project and ensure smooth integration. It should be noted that the plant would continue to run during implementation of this Project. Contractor shall submit detailed Method statement for proper and uninterrupted transition of the new system.
A separate method statement shall be prepared for the pre-commissioning of the Control system. Depending on the final architecture and the routing of the Fiber Optic cable, a sequential start-up is expected.
Due care shall be taken to define and implement the communication links to various subsystems like HVAC, Machine Monitoring systems, VSDS, Switchgears, F&G Systems, End users’ systems, and various packages etc. The DCS shall have redundant F.O. network.
Refer Specification for Control system, Specification for Machine Monitoring system, Control System architecture and various equipment layouts of the buildings.
Fire & Gas System
The Fire and Gas System to be used for Phase shall work on a F.O. redundant network of single mode fibres. Also the fire panel at each location shall communicate serially to the DCS over redundant link. The Master Fire panel shall be located in the CCR. Repeat signals shall be connected to the panels in PLANT Control at existing main gate house and Fire station within the PLANT .
The Phase seawater pumping & distribution project has a ‘Cerberus’ make Fire & Gas system having one operator station in CCR and one in PLANT control in existing main gate house. The system has hardwired contacts to the respective DCS subcontrollers. Also this system is communicating over multi-mode fibers and not on Single mode fibers. In order to integrate Phase systems, following two options are envisaged:
1. Communicate all the Phase alarms and signals to the existing F&G Operator stations located in CCR and PLANT control at main Gate House.
2. Replace the Phase system completely and bring Phase and Phase systems on to a single platform.
In this option, for the F&G panels in Phase building, either existing telecommunication F.O. network (single mode) shall be used or new connections shall be made to the F&G panels at nearest building that is being built in Phase of the project.
Every unmanned Building shall have HSSD System. The manned building shall have smoke detection and other associated detection system specified in the relevant Project specification. The Fire & Gas detection and alarm systems for each building shall have a F&G panel. All such F&G panels shall be connected to a new Master F&G control panel to be located in the existing Control room, the PLANT Control located at the Main Gate House (known in Phase as Fire / Incident Control Room) and Fire Station, which shall communicate with the Operator station.
Two new Gatehouses are planned in the Project, which shall also have alarm panels as defined in the relevant specification.
The Fire and Gas system shall provide a fast, comprehensive and automatic means of detecting, alarming and indicating the presence of fire and combustible gas hazards. The system shall also be connected to activate deluge of 220 kv / 33 kv transformers on detection of fire. The system shall close the inlet dampers in the control room and other buildings when toxic gas is detected. Refer Specification for F&G System and F&G System block diagram Instrumentation on Package Equipment.
Contractor shall develop Control strategy for individual packages where instrumentation and Control system shall be involved. All the interfaces between the various systems shall be properly defined.
Refer Specification for Package Equipment Instrumentation.
Flowmeters
Contractor shall implement water Metering System at discharge main header and each consumer’s intake.
Dual beam multi-path ultrasonic flow meters shall be used in line and shall have accuracy equal to or less than 0.5%. The ultra-sonic meters shall be clamp-on type. The mounting arrangement shall be such that there shall not be any loss of signals.
Analyzers
Analysers installed in Analyser House / shelter shall be utilised for environmental monitoring at the intake, outfall and at every consumer.
Control and On-Off Valves
All the Control and On-Off valves for the Project shall have Motorized actuators (with the exception of any pneumatic valves having independent Instrument Air system for Electro chlorination package). The actuators shall be intelligent type and shall communicate on single pair cable forming a network. A master station shall be located in the CCR / LLCC for certain number of movs based on Manufacturer’s recommendation. The output signal from DCS to the Control valves (fvs and ccvs) shall be hardwired. The Combined Check Valves (ccvs) shall have electro-hydraulic actuators. Each CCV shall have an independent hydraulic system and control panel.
Contractor shall develop the network and implement for the Project.
Other Field Instrumentation
Contractor shall ensure that all the field instruments are procured from the Suppliers listed in Company / Client supplier’s list. Also all the Instruments shall completely comply with all the Project documents.
There is a special requirement to measure the seawater temperature one meter below the surface at outfall. The temperature points shall be distributed in a semi-circular fashion at a distance of 100 meter from the discharge point. A sensor attached to a floating buoy is a preferred arrangement. Contractor may suggest any other alternatives for consideration by Company / Client. The cables for these temperature sensors shall be sleeved with a pipe and precast concrete blocks. Alternatively, remote wireless sensors and transmitters can be considered. Access shall be provided for sensors inspection / replacement.
Laboratory
Contractor shall design a laboratory, design, supply, install, test and commission the laboratory instruments as per the specification for Laboratory Instrumentation Doc. and Laboratory Layout Drg. The laboratory layout shows only indicative minimum requirements and Contractor shall suggest any requirement of additional equipment, space, etc.
Instrument air required for the laboratory shall be tapped and arranged from the existing Instrument Air compressor located near Electro chlorination package of Phase
F. O. Network
It is intended that a complete redundant Fiber Optic Network shall be utilised for the following:
DCS;-F&G;-MOV;-Telecommunication;
The F.O. Cables shall run on either side of the Cooling Water Pipelines. The cable shall be supported over the cable trays laid over the Pipe sleepers on the above ground portion. The cables shall be buried where the Pipeline is also buried.
In case, all the pipes are not laid in the defined Pipeline corridor and second route of the F.O. cable is not available due to this, Contractor shall be allowed to commission the system on non-redundant F.O. network temporarily as a special case. However Company / Client approval shall be taken in advance and shall be properly reflected in all the documents. Once the second route is available, the ‘redundancy’ shall be implemented.
Instrumentation Deliverables
All documents and drawings shall be continuously updated until “as-built” revisions.
Following is a minimum list of Instrumentation documents to be generated by Contractor or enhance the FEED documents where applicable for the implementation of Phase
Site Visit report, -Instrumentation and Control Basis of Design.-Specification of Individual Instrument;-Data sheet of Every Instrument;-Material Requisitions;-Technical Bid Evaluation and Recommendation;-Vendor Data Manual;-System Specifications (DCS, F&G, etc);-Functional Design Specification / Control Narrative;-Loop diagrams showing terminal numbers and all elements of the loop.-Logic Description;-Flow chart derived from the Cause and Effect Matrix (developed under Process discipline) or the narratives for trip, shutdown or operation of equipment.-Instrumentation Index (Database);-I / O Lists;-System Architecture Diagrams;-Logic Diagrams and sequence charts;-Instrument Cable Block Diagrams;-Cable Routing Layouts;-Instrument Location Layouts;-F&G Detector Layout,-Laboratory Layout,-Instrument Junction Box wiring diagrams;-Instrument Hook-ups;-Installation MTO;-Instrument Cable Schedule;-MCT Layouts for CCR and llccs;-MCT Schedule,-Interface wiring diagrams;-Equipment Layouts in the Buildings;-Instrument Loop Diagrams;-MODBUS address mapping details;-Instrument Grounding Layout;-Calculation of Instrument Air Consumption, wherever applicable;-Power Requirement Calculations and distribution drawings; -I/O allocations, Controller allocations;-Sizing Calculations for Valves, Orifice Plates, Power supplies, Instrument Air consumption;-Noise Calculations;-Following documents shall be generated by individual suppliers. These shall be duly approved by Contractor and submitted to Company / Client.-Panel GA Drawings;-Panel Dimensional Drawings;-Panel Wiring Diagrams;-Calibration Procedure;-Calibration reports;-Operation Manual;-Maintenance Manual;-Spare Part Manual (The manual shall include the complete Bill of Materials. All the parts that have individual part numbers shall be listed in the manual);-FAT and SAT procedures and completed dossier where applicable, for systems and packages.-Contractor shall detail the FAT and SAT already included in the Instrument Specification documents.
Instrumentation softwares required
Contractor shall specify all the proposed software to be used for the Project. Following is the list of preferred software: Database – intools; Flow Orifice Sizing – instrucalc / intools; Control Valve / Safety Relief Valve Sizing – instucalc / conval / intools; Drawings – autocad.
Telecommunication System
The Contractor shall be responsible for the complete design and provision of telecommunication facilities for the project. The responsibility extends to all required detailed design, material supply, engineering, factory inspection and testing, packaging, logistics, installation, hook-up, Integration and field verification. All systems shall be supplied, configured and tested in accordance with all the relevant Project Documents.
General
The Contractor shall provide telecommunication facilities for the existing Central Control Room (CCR), other new buildings in the Intake Area and Local Lot Control Centres (llccs) being covered in Phase of the Project. Refer: Telecommunication Basis of Design, Document No., System Diagram - Overall Telecommunication System, Drawing No., Block Diagram – Overall Telecommunication System, Drawing No and Equipment List – Telecommunication System, Document No. The Contractor shall interface with existing telecommunication facilities in the existing buildings as stated in the relevant documents.
The Contractor is required to make himself fully aware of all relevant standards and regulations, such as the following, on which the design and installation of the Telecommunication System shall be based:
Tel Publications.
IEEE wire regulations for Electrical Installations, ITU International Telecommunication Union, C Electromagnetic Radiations Compatibility, Company / Client Standards, Project Documentation.
The Contractor shall note that the Company / Client Standard, SD-ITN-001, Cable Infrastructure Standards of the IT Department is vendor limited, in some cases, and therefore shall not be issued to vendors.
The Contractor shall ensure that the entire Telecommunication Works shall be carried out through a qualified Telecommunication Systems Integrator. The Contractor and Systems Integrator shall attend liaison, review and progress meetings, in National, on a monthly basis during the design phase and weekly site meetings during the construction phase. The monthly meetings during the design phase to be for a period of 3 days and shall include site visits. Company / Client, at it’s discretion, may choose to conduct certain monthly meetings via teleconference. The weekly meeting during the construction phase to be for a limited period, as required, and shall include a joint inspection of the work taking place at that time.
The Contractor shall study and revalidate the FEED both as a desktop exercise and via a number of site visits to be conducted during the initial stage of the Project to familiarize and study the Telecommunication System implemented, as well as the changes being implemented, within PLANT. The Contractor shall make four (4) site visits for a period of two (2) full days each visit.
The Contractor shall suggest any enhancements, with rational, to the FEED following the FEED verification, in the form of a report, for the approval of company / client. The Contractor shall submit, for the approval of Company / Client, Site Visit Reports for each site visit.
The Contractor shall provide load analysis on any of the existing power supplies that shall be directly utilised as a part of this project and provide a report with rational and recommendations, having considered all alternatives.
All systems shall be provided fully assembled, supplied, configured and tested in accordance with the relevant project specifications. Also, the Contractor shall be responsible for interfacing the new systems with existing telecommunication systems; any upgrade work required on the hardware / software of the existing system for this purpose shall be carried out by the Contractor.
The Contractor shall obtain prior approval from Company / Client of his detailed design before proceeding with any purchase of equipment and any installation work. The Contractor shall participate in a formal design review, in National, six (6) weeks prior to purchase of equipment and include appropriate Company / Client comments in the design.
The Contractor shall obtain Tel “Type” approval as required.
The Contractor shall ensure adequate co-ordination between the Telecommunications System Integrator and all other disciplines / activities on site takes place in order to ensure an efficient installation.
The Contractor shall make provision and ensure common infrastructure like the routing of the Fiber Optic cables shall include the llccs / Buildings planned to be implemented in the future phases e.g. By provisioning a coiled FOC length near Phase llccs.
The Contractor shall be aware that there is telecommunications effort associated with the new and existing electrical sub-stations and the existing Electrical department network by virtue of tele-signalling transferring systems and tele-protection systems and that this effort is detailed in Clause Electrical Engineering.
The Contractor shall be aware that at the present time the Optical Transmission System in the Plant Industrial City Telecommunication network comprises redundant SDH nodes at STM-1 (Alcatel SDH 1650 SMC) configured in a single ring on main and standby cables and that other interfacing contracts, being performed by others, shall initially retain the single ring, identified as PAB, POB, NTB, MGH, E2, RB, LNG 2, Fire Station # 3, IPP, W6, CB and PAB and then reconfigure the single ring into three (3) rings of STM-1 namely Port Ring, Eastern Ring and Western Ring. The Scope of Work in Phase is to implement a spur link from Fire Station # to LLCC MOV Corridor H and integrate with the Western Ring and also provide telecommunication system facilities and connectivity to various llccs as stated in the Telecommunication Facility Requirements and Connectivity Table – Document No
The Contractor shall make him self aware of the status of the various concurrent interfacing contracts and establish any impact to the Scope of Work. The following interfacing contracts are identified at this time:
(i) add a SDH/PDH node at the Fire Station # 3. This new node shall be connected to the network via 2 x 24 core Single Mode Fibre Optic cable routed to the existing LNG 2 LLCC which is the closest node to Fire Station # and to LLCC in order to form a logical ring i.e the Western Ring.
(ii) add a PDH node at the metering station located close to the IPP LLCC. This PDH node is being connected to the network with a copper cable to the IPP node.
(iii) move the SDH STM-1 from the Port Administration Building (PAB) to the new control building for Berth 1A and 1B
(LPB-1). A new SDH STM-4 node Alcatel 1660, shall be installed in PAB together with additional Cross Connect Alcatel 1515 CXC and PDH multiplexer 1511 BA This shall form another logical ring, the Port Ring.
(iv) provide telecommunications facilities for LNG 1 from the existing sub plant (S) and for W 4 from Fire station.
The Contractor shall perform the following Scope of Work:
Interfacing to existing Telecommunication Systems at various levels including linking through fiber optic network and upgrading / re-configuring (re-programming) of the existing ALCATEL system for the additional facilities.
Supply of a compatible telecommunication system which shall interface, tie-in to the existing system / network and continue to have a closed loop configuration or multiple loop configuration for the existing STM-1 ring network and two new spur link locations, Fire Station # and MOV Corridor H.
Supply of hardware and the software upgrades, as required, for the existing SDH system in order that the new terminal equipment shall be interfaced with the existing equipment.
Supply of two (2) redundant Plesiochronous Digital Hierarchy (PDH) equipments with multiplexers and associated Network Management System (NMS).
Supply of Fibre Optic cable and accessories up to subscriber connectivity and software configuration and upgrade.
Supply of a Telephone System comprising a copper cable distribution and necessary IDF, junction boxes, patch panels etc; excluding the PABX which shall be supplied by others, together with a number of Telephones, Fax Machines, Audio Multiplexers etc. And a Hotline Telephone System operating between the CCR and the Consumer Control Rooms.
Expansion of, and reconfiguration of, an existing Public Address / General Alarm System including supply of all necessary hardware and software.
Connectivity to any other required utilities.
Providing technical input required to support other disciplines.
Providing documents and drawings, including “as-built” revisions.
Interface with, and obtain approvals from, Tel. This shall include the design for the Telephone System infrastructure as well as any “Type” approvals as necessary.
Provision of all data sheets for telecommunication systems, subsystems and equipment.
Evaluate and confirm the adequacy of all the existing systems to accommodate the new systems, sub systems and equipment.
Upgrade the PC based Telecommunication Supervisory System to include the new PDH nodes.
Upgrade the Network Management System to include the new telecommunication equipments.
Commission and Hand Over all systems, sub systems and equipment fully integrated.
Telecommunication System Specifications & Data sheets
The Contractor shall generate a stand-alone detailed specification and / or data sheet for each telecommunication system, sub system and equipment, These documents shall be regularly be updated until the “as built” stage.
The specification shall cover complete details of the selection of type, material, requirements pertaining to manufacturing, QA / QC, inspection, painting, storage, handling, transportation and Operations & Maintenance etc.
The Contractor shall use the telecommunications specifications in Appendix as an initial basis to develop the detailed engineering and the specifications. The design and specifications shall be submitted to Company / Client for approval.
The Contractor shall ensure that every element in the system shall have an associated Mean Time Between Failure (MTBF) of better than 20,000 hours and that each sub-system shall have a Mean Time To Repair (MTTR) of better than two (2) hours, assuming the appropriate spare part is available.
The Availability of the system shall be 99.999 %
Scope of Work and Supply
Fibre Optic Cable & Accessories
For details of the guideline specification, refer Specification for Fibre Optic Cable and Accessories, Doc. No., Main Cable Routing Drawing, Doc. No. and Fibre Optic Cable Allocation Drawing, Doc. No.
A duplicated (main and standby) Single Mode Fibre Optic Fire Retardant Armoured Cable Network with Accessories shall be laid in order to provide the transmission medium to facilitate Instrumentation, Telecommunication, Fire & Gas, Electrical and Security systems as indicated below:
2 x 36 core cables shall be laid in two (2) separate physical routes for embracing all llccs to be constructed to/from the CCR in CB in a loop configuration.
2 x 12 core cables shall be laid within the Intake Area to accommodate Instrumentation requirements e.g DCS at various buildings and Pump houses to/from the CCR in CB.
2 x 24 core cables shall be laid between substations in the Intake Area to accommodate Electrical requirements e.g Tele-protection and Tele-signal transferring.
4 x 6 core non-duplicated cables shall be laid to / from the Telecom Room in CB and the four (4) hubs situated within the Intake Area to cater for the CCTV system. The cables shall also be laid between the hub and it’s associated CCTV cameras.
Optical Patch Cords / Connectors and Fibre Patch Panels shall be supplied to support the above.
Optical Transmission System
For details of the guideline specification, refer Specification for Optical Transmission System, Doc. No. and System Diagram - Optical Transmission System Doc..
A redundant PDH spur optical link is to be implemented between Fire Station and MOV Corridor H. Each of the FO transmitting stations shall be equipped with at least two (2) optical receivers and two (2) optical transmall necessary hardware and software modifications shall be made in the existing SDH STM-1 Western Ring in order to ensure that phase II telecommunications facilities are seamlessly connected.
The existing SDH equipment shall be upgraded to provide CCTV Camera(s) signal transport from the Intake Area, LNG 2 and RB to CCTV monitors at CCR CB and to monitors and system management and recording facilities at CR Plant situated at the Main Gate House (MGH).
An independent dual optical fibre single audio channel based telephone connection shall be provided to four (4) llccs from a PABX, to be implanted by others, in the Telecom Equipment Room at CB on audio multiplexer systems.
PCM Multiplexes and Channel Interface
PCM Multiplexers shall be provided in order to provide the required telecommunication facilities associated with Corridor H and shall be equipped with common equipment DC-DC converter (from -48VDC), equipment controller board, alarm board, 25Hz generator with the following user interfaces:
2W FXO channels, -2W FXS channels,
The terminal equipment shall be of Alcatel make, type PCM 1511BA.
Cross Connect Equipment
The existing equipment (duplicated Alcatel 1515 CXC connected in series) shall be reconfigured, as necessary, in order to complete the system requirements.
Network Management System (NMS)
The existing Alcatel 1320/1353 CT/CX Network Management System (NMS) for control and monitoring of all PDH / SDH nodes shall be upgraded with hardware for the new sites and the latest version software and reconfigured as necessary to include the new PDH nodes and other routing channels to provide connectivity across the new llccs. In addition the software shall be made available on two existing desktop personal computers in CCR CB and PAB and additionally on two laptop personal computers, to be provided, for maintenance personnel at site(s).
Telecommunication Equipment Supervisory System
For details of the guideline specification, refer Specifications for Telecommunication Supervisory System, Doc No
The existing Hitachi make Telecommunication Equipment Supervisory System which operates on a separate LAN and provides alarm monitoring of the entire Telecommunication System shall be upgraded with hardware for the new sites and the latest version software and reconfigured as necessary to include the new PDH nodes. Further a Laptop PC shall be provided, equipped with the appropriate software and hardware accessories for programming fault detection and engineering purposes.
The Remote Supervisory Unit(s) shall be modular consisting of one or more modules. Each module shall include 32 x volts less contact shall be poared from the 48V DC supply.
PA / GA System
For details of the guideline specification, refer Specification for Public Address and General Alarm System, Doc. No. and PAGA Field Location Layout Drawing No.
The existing PA / GA equipment is NOVA 2001 and manufactured by GAI-TRONICS of Italy.
In order to ensure adequate acoustical coverage shall be available in the Intake Area an acoustical analysis shall be conducted including site investigation and measurement, together with desktop calculations. The analysis shall take into account existing and future ambient noise levels. The analysis shall be performed, utilising a procedure to be approved by Company / Client, within three (3) months of the Effective Date. The results of the analysis shall be used to optimize the quantities and locations which shall to be included in a report to included coverage drawings, with rational and recommendations, to be submitted for the approval of Company / Client. The report shall also contain recommendations with rational on the existing Phase coverage.
The coverage in the Intake Area shall be verified, by measurement, as conforming to the acoustic analysis as part of the commissioning procedure.
The existing system shall be extended and upgraded as necessary, both hardware and software, in order to provide coverage at the new llccs and buildings in the Intake Area. The system shall be re-configured and re-zoned for the new and existing sites to meet the operational needs of Company / Client. Further a Laptop PC shall be provided, equipped with the appropriate software and hardware accessories for programming fault detection and engineering purposes.
Hotline Telephone System
For details of the guideline specification, refer Specification for Hotline Telephone System Doc. No. and System Diagram - Hotline System Drawing No.
Hotline Telephones shall be installed between the CCR in the CB to two (2) new customer sites associated with llccs LNG-1 and LNG-2. Provision of the Hotline Telephone service shall include the telephones and the PCM FXO / FXS circuits. The existing Hotline Console at CCR shall be upgraded to accommodate the new handsets and indicators, refer Hotline Console Layout Drawing No.
In the event that the customers sites are not available at the time of commissioning then commissioning shall take place in the applicable LLCC.
Telephone & Data System
For details of the guideline specification, refer Specification for Telephone System Doc. No..
A PABX, Ericsson model MD 110, exists at PAB and all telephone users at existing llccs and in the Intake Area operate as remote subscribers via FXS/FXO circuits on the SDH Optical Transmission System. In 2nd quarter 2006 a PABX shall be provided, by others, at CB therefore all new llccs shall operate as remote subscribers from the PABX at CB and all users in the Intake Area shall operate as direct subscribers. The PABX at CB shall have sufficient capacity and be equipped for all new subscribers in the Intake Area and remote subscribers at llccs
The active components of the Data Network shall be supplied by others and the LAN shall be commissioned by others.
All cables, structured cabling, idfs, junction boxes, interfaces, interconnections etc to effect a comprehensive infrastructure shall form part of this Scope of Work.
Telephones, Fax Machines and Audio Mux
For details of the guideline specification, refer Specification for Telephones and Fax Machines Doc. No..
All telephone shall have RJ-45 connectors and the types of telephones installed shall be different for different areas and functions, as tentatively defined on drawings and relevant documents. Refer: Equipment List – Telecommunication Equipment, Document No. for quantities.
All Fax Machines shall have RJ-45 connectors and be installed in locations tentatively defined on drawings and documents and shall be model L-360 or later version from Canon or equivalent.
Four (4) Audio Mux with FXO / FSX capability are required to provide individual telephone communications, over dual optical fibre, between the PABX at CB and llccs.
Earthing
All telecommunication equipment shall be connected to the telecom earth at existing stations and a separate telecom clean earth of less than one (1) ohm at each new location.
Power Supplies
A fully redundant nominal - 48VDC battery / charger system with 8 hours autonomy shall be provided and used to supply all telecommunications related equipment at LLCC MOV Corridor H. The battery / charger system shall be designed in accordance with Data Sheet, DC UPS, Document No. in order to supply power to the telecommunication equipment and shall have 50% spare capacity.
A fully redundant nominal -48VDC battery / charger system with nominal 8 hours autonomy shall be provided, by others, and used to supply all telecommunications related equipment at Fire Station. The PDH and associated equipment at Fire Station shall connect to this existing supply.
A fully redundant nominal -48VDC battery / charger system with nominal 8 hours autonomy exists at each node in the SDH / PDH Optical Transmission System and can be utilized for like equipment.
Each new site shall contain a 230 V AC UPS which shall be utilised for any new PA / GA equipment.
Testing
Testing shall take place in order to demonstrate the specifications of the equipment, sub system and system have been achieved and as stated in the applicable system specifications.
Training
Training shall be provided as stated in the applicable system specifications in Appendix and is to take place at site. The training shall be as per manufacturer’s standard syllabus and shall be conducted by the manufacturer.
Documentation
Documentation shall be provided for the design, purchase, installation, “as built” and O&M phases and as stated in the applicable system specifications in Appendix.
Security System
The Contractor shall be responsible for the complete design and provision of the Security System for the project. The responsibility extends to all required detailed design, material supply, engineering, factory inspection and testing, packaging, logistics, installation, hook-up, Integration and field verification.
General
The Security System for the Plant Industrial City shall be highly confidential. The details shall not be reproduced or / and copied.
The Contractor shall provide a Security System for the Intake Area, along the Pipeline Corridor and at the Receiving Basin (RB). Refer Specification for Security Control System, Document No., Closed Circuit Television System Diagram, Drawing No., Card Access Control System Diagram, Drawing No., Field Location Layout Security System, Drawing No. and Equipment Layout Security System, Drawing No..
The Contractor is required to make himself fully aware of all relevant standards and regulations, including Company / Client standards, base his design and installation on those standards and regulations.
The Contractor shall note that the Company / Client Standard, Cable Infrastructure Standards of the IT Department is vendor limited, in some cases, and therefore shall not be issued to vendors.
The Contractor shall ensure that the entire Security Works shall be carried out through a qualified Security & Telecommunications Systems Integrator. The Contractor and Systems Integrator shall attend liaison, review and progress meetings, in National, on a monthly basis during the design phase and weekly site meetings during the construction phase. The monthly meetings during the design phase to be for a period of 3 days and shall include site visits. Company / Client, at it’s discretion, may choose to conduct certain monthly meetings via teleconference. The weekly meeting during the construction phase to be for a limited period, as required, and shall include a joint inspection of the work taking place at that time. Company / Client shall agree to combine the Telecommunications meetings with those of Security in the event the same System Integrator is chosen.
The Contractor shall study and revalidate the FEED both as a desktop exercise and via a number of site visits to be conducted during the initial stage of the Project to familiarize and study the Telecommunication System implemented, as well as the changes being implemented, within Plant city. The Contractor shall make four (4) site visits for a period of two (2) full days each visit. Company / Client shall agree to combine the Telecommunications site visits with those of Security in the event the same System Integrator is chosen.
The Contractor shall suggest any enhancements, with rational, to the FEED following the FEED verification, in the form of a report, for the approval of Company / Client. The Contractor shall submit, for the approval of Company / Client, Site Visit Reports for each site visit.
The Contractor shall provide load analysis on any of the existing power supplies that shall be directly utilised as part this project and provide a report with rational and recommendations, having considered all alternatives.
The Contractor shall be aware that the existing CCTV System at Plant is in the process of being upgraded to a an IP Ethernet based network and this is due for completion. The coverage of the existing and upgraded system does not include the location areas that form part of this Scope of Work.
All systems shall be provided fully assembled, supplied, configured and tested in accordance with the relevant project specifications. Also, the Contractor shall be responsible for interfacing the new systems with existing telecommunication systems; any upgrade work required on the hardware / software of the existing system for this purpose shall be carried out by the Contractor.
The Contractor shall obtain prior approval from Company / Client of his detailed design before proceeding with any purchase of equipment and any installation work. The Contractor shall participate in a formal design review, in National, six (6) weeks prior to purchase of equipment and include appropriate Company / Client comments in the design.
The Contractor shall ensure adequate co-ordination between the Security System Integrator and all other disciplines / activities on site takes place in order to ensure an efficient installation.
The Contractor shall perform the following Scope of Work:
Provide a new CCTV system consisting of cameras, hubs/switches and monitors interfacing to an upgraded existing CCTV System.
Provide a Card Access Control System (CACS) at Gate House # and Gate House # to automate inbound / outbound vehicle & personnel movements.
Provide security fencing and lighting around the intake facility.
Security System Specifications & Data sheets
The Contractor shall generate a stand-alone detailed specification and / or data sheet for each of the security system, sub system and equipment. These documents shall be regularly updated until the “as built” stage.
The specification shall cover complete details of the selection of type, material, requirements pertaining to manufacturing, QA / QC, inspection, painting, storage, handling, transportation and Operations & Maintenance etc.
The Contractor shall use the Specification for Security Control System, Document No. as an initial basis of the specifications to be developed. The specifications shall be submitted to Company / Client for approval.
The Contractor shall ensure that every element in the system shall have an associated Mean Time Between Failure (MTBF) of better than 20,000 hours and that each sub-system shall have a Mean Time To Repair (MTTR) of better than two (2) hours, assuming the appropriate spare part is available.
The Availability of the system shall be 99.999 %
Scope of Work and Supply
Closed Circuit Television (CCTV) System
The CCTV System shall include PTZ (Pan / Tilt / Zoom) cameras at the Intake Area, Pipeline Corridor and Receiving Basin (RB) together with fixed cameras, with alarm capability, to accommodate the provision of motion detection facilities around the perimeter of the Intake Area. All cameras shall be IP.
Company / Client is in the process of evaluating whether to proceed with motion detection or not in the Intake Area and consequently Security Field Layout Drawing No. show layouts with and without motion detection.
There shall be a combination of fixed focus cameras and PTZ dome type cameras around the fence of the Intake Area to provide a system capable of motion detection. Only PTZ dome type cameras shall be utilised for a system with no motion detection. In both systems additional PTZ cameras for enhanced monitoring within the Intake Area shall be installed. Refer Equipment List – Telecommunication Equipment, Document No. for quantities.
The Contractor shall state in Appendix B the price reduction should motion detection not be implemented.
There shall be two (2) PTZ dome type cameras installed at each the Pipeline Corridor and RB.
Three (3) new monitors shall be installed in the CCR in the existing CB. Signals from all the cameras in the Intake area shall be available on these monitors. These signals shall also be monitored at the four (4) new monitors located in the PLANT CR at Main Gate House (MGH) via the existing upgraded CCTV network. System control shall be from the existing upgraded CCTV system.
The signals from the CCTV cameras at the Pipeline Corridor and the Receiving Basin (RB) shall be monitored / controlled by the existing upgraded CCTV system from PLANT CR at MGH.
The existing SDH Optical Transmission System shall be upgraded with Ethernet Modules to provide CCTV Camera(s) signal transport from the Intake area, LNG2 and Receiving Basin (RB) to CCTV monitors at CCR CB and CR PLANT at the Main Gate House and to the existing Network Video Recording System at PLANT CR at MGH which shall be upgraded to accommodate the additional data to be received.
The existing upgraded CCTV System Management shall be further upgraded, including software configuration, in order to connect and activate the peripherals e.g cameras and monitors, as required to ensure a seamless integration of the CCTV System at the Intake Area, Pipeline Corridor and RB.
Card Access Control System (CACS).
The CACS shall be a stand-alone system installed in Gate Houses of the Intake area. Separate controllers shall be installed in each Gate House, integrated together in order to provide redundancy for each Gate House.
The Access Control system shall have following facilities:
Card Readers to enable in-bound and out-bound vehicle and personnel traffic.
Vehicle gates; Turnstile gates; Automatic opening and closure of vehicle gates and turnstiles,
Controlled access by pre-programmed access card(s) or by security personnel access control.
Recording of time and date of in-bound and out-bound movement.
The card readers shall be compatible to the existing CACS being used at the Main Gate.
Security Lighting
A photocell controlled, security lighting system shall be provided for the Intake Area perimeter fence. This shall consist of pole mounted floodlights. The poles shall be located inside the perimeter fence. The flood lights with high pressure HPSV lamps shall be used for the same. The illumination level at the fence shall be 150 Lux with overlapping fields facing towards the fence so that failure of one lamp shall not create any dark area on the fence. Refer: Perimeter Security Lighting Layout, Document No.
Testing
Testing shall take place in order to demonstrate the specifications of the equipment, sub system and system have been achieved
Training
Training shall be provided as stated in the applicable system Specification for Security Control and is to take place at site. The training shall be as per manufacturer’s standard syllabus and shall be conducted by the manufacturer.
Documentation
Documentation shall be provided for the design, purchase, installation, “as built” and O&M phases and as stated in Specification for Security Control,
Safety, Fire Protection and Loss Prevention
General
Contractor shall be responsible for but not limited to the following:
The Scope of Work includes the design, fabrication, procurement, installation testing and commissioning of the Fire Protection, Fire & Gas and Safety Systems described in the project specifications, Loss Control Philosophies and Drawings in the EPIC package, Appendix and Company / Client Corporate Philosophy for Fire and Safety Company / Client-PHL-S-001 and other related documents.
Firewater Systems
The existing firewater (seawater) system is to be extended to all end user plots at Plant Industrial City. Drawing
A new firewater (fresh water) system is to be provided at the intake area. The power transformers (220 / 33 kv) located at the intake area, both existing and new (to be installed) are to be provided with deluge protection. The existing collection pit shall therefore have to be enlarged.
Contractor shall verify the project Specifications and drawings for the following systems and develop as required and implement them.
Fire protection system including:
Fire water (Fresh Water) supply, storage. And Fire pumps (electric motor driven, diesel engine driven and jockey pumps).
Fire water distribution layouts (seawater & fresh water network systems) including the deluge system.
Fixed and portable, manual and mobile fire fighting equipment (including hydrants, hose reels, water spray nozzles and other specialised fire protection systems).
Fire protection of Analyser Houses
Fire and gas detection and alarm system
Fire and Gas cause & Effect Charts
Contractor shall verify the project specifications on Fire and Safety System and Fire Alarm and Gas Detection System and develop them as required and utilise HSSD (High Sensitivity Smoke Detection) system. The individual smoke detectors shall be ionisation type. Contractor shall obtain the necessary permits from Supreme Council and obtain import licence for these detectors Company / Client shall issue recommendation letter to concerned authorities if requested by Contractor
Interface these fire alarm systems with the DCS system to alarm at the Main Control Room, existing PLANT Fire / Incident Control Room at the Main Gatehouse and a Fire Station # .
All the buildings, Main Control Room, LLCC’s, Sub-stations, chlorination units etc. Shall have fire and smoke detection and alarm systems which shall be interfaced to the DCS at respective locations and eventually to CCR.
All the information from Phase system shall be available on the operator desk in the existing control room, existing gate house and in the new Fire Station #3. Presently all the existing data & displays of Phase are made available at PLANT Fire / Incident Control room at the main gatehouse through Telephone link.
Location of this PLANT Fire / Incident Control Room is within the Security building located at the main entrance of the Plant Industrial City.
Fixed and portable personnel safety equipment, including safety showers and face/eye wash stations are to be located at the electro chlorination plant and 33 kv Switchgear Building, while self contained eye wash stations are to be located at all battery rooms and analyser houses.
Safety studies and calculation reports performed during FEED, including Operational Safety Study, and FMEA / FTA Study shall be updated by the Contractor.
Contractor shall carry out, in consultation with Company / Client, a complete and detailed HAZOP Study during detailed engineering phase. A third party independent chairman shall be the team leader and the HAZOP shall be carried out as per Company / Client. HAZOP review shall also be carried out for Vendor Packages.
Contractor in a report issued to Company / Client for review and approval shall detail the findings and the actions of the study. Contractor shall incorporate, as part of the detailed engineering work any / all modifications in the network design as requested and required by Company / Client, to comply with any portion of the study actions.
Contractor shall verify storm water sewer systems, taking into account appropriate firewater disposal in the event of a fire in accordance with project Specification. Contractor shall develop escape route drawings for the buildings.
Fire Protection, Detection and Safety System
Contractor shall update, design and provide the Fire Protection, Detection and Safety Systems as developed during FEED.
Contractor shall be responsible for developing and establishing the fire protection system, avoiding interference with underground facilities. Guidelines on the number and types of fire fighting equipment are given in the Company / Client Corporate Philosophy for Fire & Safety (Company / Client) and its references. Contractor shall verify, finalise and provide the number and types of fire protection, detection and safety items shown as a minimum.
Mechanical Equipment
Contractor shall be responsible for but not limited to the following.
The Scope of Work includes the review and update of FEED specification and data sheets (as required for detail engineering development), fabrication, installation, testing and commissioning of the equipment installed at:
Mechanical Cleaning Plant, Main Cooling Water Pump Packages (Novated items), Utility Services, Electro Chlorination Plant, Lifting Equipment (for maintenance service),
Equipments installed at plant facilities are listed in Equipment List of Project Phase. All activities of procurement shall be carried out during detail engineering including development of Material Requisition / VDRL dossier.
Contractor shall verify the FEED Specifications, data sheets and drawings and update / develop as required to implement them.
Contractor shall include in his work scope for development of equipment specification and procurement engineering documentation, as required, when not included (missing or detail engineering development) in Equipment List of Project Phase.
Main Cooling Water Pump Packages
Contractor shall take full responsibility of owning novated Main Cooling Seawater Pump Packages (including electrical motor and VSDS system items) for Phase in accordance with Contract and ensuring guaranteed pump performance.
The items included in above pumps package shall be as per Purchase Order dossier, further procurement engineering up to commissioning shall be the Contractor’s responsibility and scope shall include the following:
Expedite, review and approve Vendor’s data sheets and drawings.
Participate and witness all required Factory and / or site inspection and testing; ensure TPC is made available for the items of these packages.
Organizing / conducting pump physical model tests at Pump Vendor works to demonstrate pump selection / performance,
Organizing / conducting sump (pit) model tests at specified sub-Contractor works to demonstrate pump hydraulic performance with all required functional flexibility, considering intake screening equipment, to verify the intake sump and consequently the screening equipment, to finalize the intake sump (and consequently the pumps house dimensions). The sump model tests shall be carried out in the presence of Company / Client and Pump Vendor. Contractor shall take full responsibility to design and construct the sump pit in accordance with above results. Findings of Sump model test report conducted by sub-Contractor shall be endorsed and implemented by the Contractor.
This may include provision for additional splitter, flow stabilizing device, a weir, etc. as recommended in sump model test report.
Carry out the String test at Vendor’s shop for the first two Main Cooling Water Pump Packages including pumps, drivers, vsdss and associated auxiliaries. For other identical pump models, required performance tests shall be carried out at pump vendor works using electrical test setup established for previous string test.
All necessary co-ordination with Vendors and/or Sub- Contractors for timely delivery of contracted scope.
Prepare all “as-built” data sheets and drawings.
Carry out pre-commissioning, commissioning and start-up of pumps.
Deionised Water for VSDS
The first fill of deionised water used for the VSDS cooling system shall be provided by Pump Packages supplier. Any further topping up requirements shall be accomplished by supply of deionised water by Contractor till Contract Completion.
Electro-Chlorination Plant
Verify and confirm Chlorination package sizing and selection.
Prepare and update the package data sheets and specifications.
Prepare material requisition packages.
Carry out bid evaluation and vendor recommendation.
Expedite review and approve Vendor’s data sheets and drawings.
Participate and witness all required inspection and testing.
Prepare all “as-built” data sheets and drawings.
Carry out pre-commissioning, commissioning and start-up of the packages.
Co-ordination with Vendors and Subcontractors.
Mechanical Cleaning Plant
Contractor shall procure these items in accordance with project specifications / data sheet included in FEED dossier (and covered in Equipment List) after review, verification and detailed engineering and design.
Coarse screening shall be performed at Fixed Bar Screens installed at Screen Yard upstream of pumps houses. Common traversing trash rake (grab bucket cleaner) and debris collection system shall be installed as covered in applicable specifications / data sheets. Screen bar material shall be to accomplish detachment / retarding of marine shells clinging to bars.
Rotary Drum Screens are to be installed for finer (mesh opening 3 x 3 mm) screening before seawater (service fluid) is fed for further pumping and construction materials requirements are covered in applicable specifications / data sheets. Contractor shall provide the falling object protection for drum screens. Design approval of Company / Client shall be required.
Utility Services
Contractor shall procure these items in accordance with project specifications / data sheets included in FEED dossier (and covered in Equipment List) after review, verification and detailed engineering and design.
Utility services include Instrument Air Compressor – Dryer Packages, Portable Submersible Pumps (for emptying compartments of Pump Sump Pits, Receiving Basin) and pumps for draining of piping sections / manifolds.
Lifting Equipment
Pump Houses and Screen-Yard Cranes (Common crane and additional cranes):
In Phase of the project extending of existing 60T / 40T capacity EOT Crane at pump-house and 10T capacity Semi-Portal Crane at screen-yard is envisaged. Common crane study report included in FEED dossier provides details of modification to be implemented. Besides this, an additional crane requirement at above two locations is subject to RAM study recommendation. Contractor shall carryout RAM study and confirm requirement of additional Cranes at pump house and Screen Yard.
Contractor shall procure these items in accordance with project specifications / data sheets included in FEED dossier after review, verification and detailed engineering and design.
Manifold Area Cranes:
Phase II of project facilities envisages Craneage to handle ccvs and Isolation Valves installed at manifold area. This new facility requirement is addressed in Material Handling Study Report and FEED dossier Equipment List covers the required equipment to be installed for servicing of manifold area items.
Other Handling / Lifting Facility:
Contractor shall procure and supply all material handling items covered in Equipment List as stated in Material Handling Study Report, which shall be updated during detailed engineering stage after review and verification.
Contractor shall prepare procurement-engineering dossier when required for procurement of off-the-shelf items such as manual chain-hoist with trolley on monorail beam etc. And supply the same.
Mobile equipment viz. Mobile Crane, Fork Lifts etc. To assist transportation and handling of materials are not covered in equipment list / material handling studies. Being construction / operation aids these mobile facilities are envisaged to be directly purchased by Company / Client, only guiding specification / data shall be provided by Contractor as per detail engineering developments.
Noise Control
Contractor shall be responsible for but not limited to the following:
General Requirements (Refer to Company / Client Corporate Philosophy for Fire & Safety Company / Client-Environment Protection Law National)
Contractor shall comply with all rules, guidelines, regulations, procedures, programmes and policies in the “Environmental Guidelines & Environmental Protection Criteria for Plant Industrial City during the execution of the WORK.
The “Environmental Guidelines & Environmental Protection Criteria for Plant Industrial City
The initial calculation shall be based on equipment meeting the sound level and sound power level limits of Company / Client Specification. The final calculation shall be based on the vendor quoted and tested equipment sound levels. These calculations shall be included in an initial and final report, which shall be submitted for Company / Client approval. These reports shall contain the following:
Equipment list. Equipment physical data such as size, speed, and power.
Equipment location. Estimated industrial community sound level at Company / Client determined locations. Estimated sound level contours including in-plant areas, at fence line, and at inner edge of perimeter infrastructure road in 2.5-decibel (dba) increments. Equipment sound power levels used in the model. Equipment sound levels at one meter. Noise control treatments proposed. Vendor sound level reports. Vendor’s shop test reports. The final report shall be called the "Noise Control Design Basis - Summary Report".
Contractor shall conduct a co-ordinated overall noise control program, including cost effectiveness comparisons. In addition, Contractor shall recommend such alternative or additional acoustical design features or treatment as needed to meet the requirements.
Contractor shall ensure that the sound pressure level of cooling water pumps shall not exceed the values specified in Contract by applying any attenuation devices.
Contractor shall be responsible for identifying any necessary reduction of equipment sound level limits specified in Company / Client specification, to ensure compliance with the FACILITY sound level provisions.
Environmental Control
Contractor shall be responsible for but not limited to the following:
General Design Requirements
Contractor shall finalise the design documents incorporating design data including emission data obtained from the Vendor’s. Contractor shall be responsible for compliance with the local Environmental Control Regulation and Project Specifications provided in the Contract. In general, the FACILITY should be designed to meet the ambient air quality and water quality guidelines of the National regulations as specified in the Project Specifications.
Engineering Evaluations
Contractor shall verify or finalise the engineering evaluations to ensure that the environmental control systems as designed shall comply with the required regulations.
Cathodic Protection System
Contractor shall be responsible for the pre-design survey, design, detail engineering, supply of material, installation supervision, commissioning and start up of cathodic protection systems.
An impressed current cathodic protection technique shall be utilized / applied to provide the corrosion protection for seawater screen equipments, earthing system, concrete re-bars of facility foundations and pipe support foundations adjacent to the Intake Area. Sacrificial anode cathodic protection technique shall be utilized / applied for the protection of pipe support foundations in areas remote from Intake Are.
Cathodic Protection Systems shall cover the following:
Seawater screen equipments-Bar screens-Drum screens-Stop log guides-Stop logs-Facility Foundations-Pump house pit concrete re-bars-Receiving basin concrete re-bars-Outfall structure concrete re-bars including discharge channels-All building foundations-All structure pipe supports/ foundations within the water table or / and below + /- 0.0 m -Earthing Systems -Pump houses-Building area at Intake-Receiving basin-Manifold areas-LLCCs-Detail Design Specifics
Contractor shall incorporate the specific following requirements into the detailed design Scope of Work.
Contractor shall engineer, connect and configure the signals for monitoring and controlling the FACILITY pertaining to this Project only. Twenty percent (20%) of the spares shall be connected and configured as spares as detailed in the specification provided under Appendix. Provision for expansion shall be made for connecting any additional signals (future). Contractor to co-ordinate with PLANT and Electrical authority through Company / Client.
Due to the marine / dusty / humid environment at Plant area, all transformers shall be designed with suitable bushing / terminal enclosures or bus-ducts, to avoid pollution and random tripping.
Contractor shall submit to Company / Client Hydraulic Models of Phase along with licensed Software programme, spreadsheets & Manuals used for the analysis. Company / Client shall have access to the simulation models while the simulation work is being done by the Contractor.
Contractor shall undertake Hydraulic Model studies and submit results during the detail design stage. Contractor shall comply with the following when preparing the hydraulic model:
“Marine Works” in particular “Physical model requirement”
Ensure that minimum flow of seawater is 300000. m3/hr.
Allow to clean up the beach twice at start and at completion of works (at intake and outfall areas) for a distance of 500m extending both sides of intake and outfall areas, i.e. Total distance of 3000m.
Allow for cut and fill complete with compaction to 100% of Maximum Dry Density (MDD) as specified for the full widths and lengths of pipe corridors. Excavation may require blasting. Excavation in rock & varying materials and backfilling shall be carried out in Phase. All pipes shall be installed above finished grade on pipe supports / saddles (complete with inserts) as the design shall dictate.
Contractor shall develop and optimise pipe corridors to take all Phase pipes, mainly pipeline routing / layout.
Contractor shall carry out site grading of pipe corridors to allow the flow of rain, surface and spill water to the surface water drainage.
Allow for grading area completely around intake structure by cut / fill and compact to receive Phase structures.
Allow for the design and construction of surface water drainage to cater for rain and spill water. Water shall be collected by a network of concrete paved ditches and discharged into the sea. “V” or trapezoid concrete paved ditches shall be designed and constructed. Protection to ditches and warning signs shall be allowed for.
Design and install chain link fences around building and local Control room areas as a minimum. Covered car parking is required for the operation building and as shown on the drawing attached in Appendix
Contractor is to allow for the design and construction of 10% extra for each building, e.g. Building “X” has to be minimum 500m2 to accommodate all personnel and equipment in accordance with the best international standards. Therefore, Contractor shall have to design and construct building “X” to be 550 m2.
Allow for temporary access roads during construction such as diversion roads. Such roads shall be subject to Company / Client formal approval.
Allow for seismic loading, where appropriate, in accordance with the Uniform Building Code for Zone 1.
Allow for the design and installation of access over Cooling Water Piping. Number, type and location are subject to Company / Client formal approval.
Allow for all concrete, whether mixed and placed in Marine works and/or other structures to comply with project specifications.
Design and construct roads as access to substations, chlorination building, control building, pump house and other buildings as shown in the Plot Plan.
Allow for surveying and relocating sand dunes within the pipe corridors, intake and outfall areas.
All the local Control Rooms at the consumer lot interface as well as other electrical installations shall have separate battery rooms and space for telecommunication equipment.
At the Consumer Lots / Interfaces, existing consumers have generally agreed to provide the required LV power supplies up to the battery limit.
The Contractor shall carry out a complete study on ‘Material’ for the entire Phase project and produce a report for Company / Client’s approval during the early stages of the project. The work shall be carried out by a third party consultant or by the Contractor itself provided it has the in-house capability to the satisfaction of Company / Client.
The Contractor shall implement any approved recommendation or findings of studies carried out during FEED such as RAM, FMEA, Hydraulic Studies by HRW, SYSOP, SAFOP, OPTAN etc.
Design of elevated floor slabs of substations shall be as per Drg.
The PLANT 11kv network is not part of the CCWP Phase I installation, therefore all works involving tapping into the existing 11kv network of PLANT shall involve the following:
Collection of ‘As-Builts” drawings and CYME calculations if any, from PLANT and verify that they are suitable for the proposed modifications i.e. Perform load survey, check protection settings etc.
Verify that the new loads when added shall not affect operations. Calculations (using CYME) & report of load flow, protection settings, etc. Shall be submitted to Company / Client for review. Protection settings shall include 11kv source circuit breaker upto down stream LV circuits of LLCCS.
On completion of the proposed works, existing ‘As-Built’ drawings shall be updated to reflect the new works, as performed by Contractor. Also, soft copy of CYME calculations shall be handed over as part of final documentation. Sample Only Ends
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Chapter 9
Procurement
General
Contractor shall perform the procurement and expediting of all materials and equipment necessary for the performance of the WORK in a timely manner and in accordance with the Execution Programme.
For the purpose of this Contract, the terms “seller”, “Vendor”, “Supplier” and “Sub-Contractor” shall be interchangeable in meaning and context.
Contractor shall be responsible for the performance of the following activities.
1 Identification of material procurement requirements and preparation of a procedure for Company / Client approval.
2 Preparation of all materials take off.
3 Preparation of requisitions
4 Preparation of Purchase Orders
5 Purchasing and Expediting
6 All vendors selection / evaluation, taking due account of Company / Client list of approved Vendor
7 Consideration of minimum maintenance philosophy.
8 Adherence to any standardisation requirements from Company / Client.
9 Consideration of quality related to Contractor’s warranties and guarantees.
10 Provision of the best possible warranties and guarantees from vendors for Company / Client’s benefit
11 Inspection and testing of all procured materials by TPC.
12 Transportation of all materials to Site including packing to sea freight/air freight standard as required.
13 Storage, preservation and handling at Site.
14 Identification of spare parts requirements.
15 Preparation and issue to Company / Client of completed spare parts interchange ability record (SPIR) forms within 3 months of placement of Purchase Orders.
16 Procurement of pre-commissioning, commissioning and start-up spare parts.
17 Procurement of insurance spares (If specified to do so by Company / Client).
18 Procurement of 1-year operations spare parts (If required to do so by Company / Client).
19 Customs clearance including payment of customs duty and payment of legalisation fees.
20 Payment to Vendors
Efficient use of materials.
1 Vendor support and assistance during construction, pre-commissioning, commissioning, start-up and performance testing (as necessary).
2 Obtaining all necessary certification and “as built” drawings and data from vendors including Quality Assurance Record Manuals, Operations & Maintenance Manuals etc.
3 Issue closeout report highlighting vendor performance.
Long Lead Items Novated to Contractor Sample Only
1 During the FEED Phase of the Project, equipment, packages and systems that have a longer delivery time are identified as under:
➢ Main Cooling Seawater Pumps
➢ Main Seawater GRP Piping
2 The main cooling seawater pump scope of supply includes pumps, variable speed motors, variable speed system, transformers etc.
3 Scope of supply for main seawater GRP piping includes GRP pipes, GRP fittings, GRP flanges, etc. GRP piping is split into 11 packages, which shall be supplied by multiple Vendors.
4 Complete purchase requisitions including specifications have been developed and issued to potential suppliers. Quotations when received shall be reviewed for technical compliance with the enquiry and requisitions.
5 Company / Client intends to award the purchase orders for the above critical long lead items prior to Contract award, in order to maintain the project schedule.
6 A copy of the Material Requisition package for both the above long lead items is enclosed with this tender document in Appendix. The Contractor shall consider that the items listed in the Material Requisition shall be ordered by Company / Client on Ex-Works packed and loaded on truck / trailer basis.
7 Upon award of Contract Company / Client shall assign the purchase orders to the Contractor through a novation agreement. The Contractor shall take over full responsibility for the successful design and supply of the long lead items to meet the project engineering design requirements and schedule. Contractor shall be the single point responsible party for the long lead items in all respects.
8 cContractor shall endorse the purchase order requisitions and specifications.
9 Contractor shall review and verify the purchase order requisitions in all aspects and if necessary shall carry out all required additions or amendments to purchase order requisitions to cover up any omissions / errors / shortcomings/deficiencies as deemed necessary for the successful design, supply and commissioning of all long lead items with prior approval of Company / Client.
Purchasing
Contractor shall be responsible for the following purchasing activities as a minimum:
1 Prepare RFQ specifications and documents for all equipment and materials in accordance with the Project specifications. Ensure that the terms and conditions of purchase, requirement of Pre-Commissioning, Commissioning, One Year Operational Spare Parts, SPIR forms, Vendor site support services and Final Documentation have been reviewed by Company / Client and included properly in the enquiry document. Rfqs shall be subjected to Company / Client Approval.
2 RFQ shall specify the Quality Program of Vendor(s) which shall comply with the requirements of ISO 9000 series, 2001 edition and requirement of Company / Client QA/QC procedure
3 Conduct purchasing in accordance with Company / Client approved vendors, and Subcontractor List. Procurement of those items which are not listed in approved List shall be subject to Company / Client approval and shall be carried out on a world-wide competitive basis except when technical regulations or specifications require otherwise. Contractor shall abide by the National regulations regarding the countries of origin.
4 Review bids received from vendors and prepare technical and non-priced bid tabulations advising the selected vendor and the ranking of the others. Company / Client review and approval shall be sought prior to placement of purchase orders for all major / critical equipment/items. Review all equipment/ material selection and verify their suitability and operability for the service intended. Before placement of purchase orders, assess and ensure that the financial status, availability of Vendors’ recommended Pre-Commissioning, Commissioning, One Year Operational Spare Parts, including quantity and unit prices thereof, present work load and suitability of the vendors are satisfactory to meet project objectives. Technical bid tabulation and Vendor’s technical proposals / clarifications shall also be provided to Company / Client for approval if Vendor is technically acceptable.
5 Contractor shall submit to Company / Client lists and prices of 1 Year Operational Spare Parts with the technical and non-priced bid tabulation.
6 Prepare purchase orders, complete with all attachments (i.e. Purchase requisitions, specifications, drawings, shop inspection and testing requirements), spare parts requirements, Vendors’ and Suppliers’ assistance requirements. Provide copies of non-priced purchase orders or any revision thereto to Company / Client.
7 Purchase all project equipment and materials as per the specifications and in accordance with the requirements of Execution Programme.
8 Contractor shall ensure that Purchase Orders are placed with only reliable Vendors/Suppliers approved by Company / Client.
9 Contractor shall ensure that Critical Equipment such as Main Cooling Water Pumps, VSDS, Chlorination Plant, Mechanical Cleaning Equipment, Switchgears, Motor Operated Valves, Control Valves etc. Shall be of proven type equipment, not prototype.
10 Issue status reports on purchasing activities to Company / Client in accordance with Appendix D.
11 Review and approval of Vendor’s drawings and documents (core drawings / specification to be submitted to Company / Client prior to approval by Contractor).
12 All Vendor’s drawings and documentation shall be in accordance with Company / Client Engineering Standard for draughting
13 Contractor shall engage the services of Glass Reinforced Polyester (GRP) pipeline manufacturer / designer, as a single point responsible party, to carry out detail pipeline engineering, manufacturing, fabrication, jointing, installation, QA / QC, inspection and commissioning for the piping system supplied by the particular manufacturer.
14 All the activities related to novated items as per item 5.2 above.
Expediting
1 In accordance with execution program, Contractor shall perform expediting of equipment, materials, Vendor’s data, technical assistance, personnel and documentation from RFQ to delivery at Construction Site for Vendors’ items including the materials on suborders. Contractor shall maintain a system to monitor progress on all the purchase orders and prepare and issue a detailed schedule to Company / Client in accordance with Appendix. The system shall be able to identify those items of the equipment and materials which are critical or are potentially critical from Execution Programme point of view and require special attention to ensure timely delivery, along with an action plan to achieve it.
2 Contractor shall not limit his expediting activities to only the progress reporting. Contractor shall take appropriate remedial action with Vendors who are behind schedule. Contractor shall promptly recommend appropriate alternative remedial action to Company / Client and implement the same.
3 All expediting efforts shall be directed towards achieving or improving the equipment and material delivery dates while maintaining the purchase order design specification, conditions and Schedule Completion Date. Any actual or potential deviations or slippage from these requirements shall be immediately transmitted to Company / Client in writing. Contractor’s expediting activities shall include, but not be limited to, the following:
4 Contractor shall expedite and take all appropriate actions to obtain all technical data and other documentation, including completed SPIR forms and Final Documentation, from the vendors and their sub-vendors in a timely manner.
5 During the Guarantee Period, Contractor shall expedite all the replacement materials, associated documents and vendors’ assistance.
6 Contractor shall submit weekly Material Status Report to Company / Client.
Inspection and Testing
1 Contractor shall execute inspection activities for all equipment and materials in accordance with the following requirements:
2 Contractor shall carry out all inspection and testing required for all equipment and materials, and shall be responsible for ensuring that all equipment and materials are strictly in accordance with the specifications as defined in the Purchase Order.
3 Contractor shall specify identifiable requirements based on Company / Client' class of inspection' for each material requisition, or alternative procedures designed to ensure an equally high standard of inspection. The minimum requirement of Company / Client is specified in Exhibit of Appendix. Contractor shall prepare a document establishing criticality rating system of all equipment and identify the level of surveillance inspection required for Company / Client’s review and approval and shall form part of its overall quality management system and plan. Full load tests, reduced load tests and / or no load string tests shall be as specified in the Contract. The minimum Company / Client’s requirements are listed below:
4 Inspection shall be performed by qualified Third Party inspectors employed by Contractor.
5 Shop inspection shall be carried out by Contractor at both the point of manufacture and, where necessary at the source of Vendor(s) and / or sub-vendors materials.
6 Contractor shall be responsible for all quality assurance activities including Vendor(s) and / or sub-vendors inspection.
7 Provision shall be made at all times for Company / Client to have the option of participating in pre-inspection meetings, inspection visits and test witnessing. Contractor shall prepare anticipated weekly testing programs providing Company / Client sufficient advance notice for their participation (at least fourteen (14) days). Contractor shall note that FAT shall be witnessed by Company / Client Engineers and all the services and facilities to Company / Client Engineers shall be provided by Contractor in accordance with relevant Section of Appendix (not included). Contractor shall provide twenty-one (21) days notice to Company / Client for FAT.
8 Contractor shall submit to Company / Client written reports on expediting and inspection carried out in sufficient detail for Company / Client to monitor the effectiveness of inspection. Inspection reports shall be issued to Company / Client within three (3) calendar days of the inspection visit. Contractor shall prepare and provide to Company / Client an inspection co-ordination procedure to be developed in accordance with the Contract.
9 Contractor shall compile all fabrication and manufacturing data folders containing mill test certificates, machinery test certificates, performance test Certificates, type Test Certificate where required, and all other relevant inspection data and submit the same upon delivery of equipment and /or material to Construction Site.
10 Contractor shall be responsible for checking all material on arrival at site and the issuance of any Overage, Storage and Damage Reports (OS & DRS) may be required.
Certification
Contractor shall be responsible for arranging and co-ordinating the use of TPC services where required for equipment and materials in the country of origin, for statutory, insurance, or any other reasons. Minimum requirement of TPC services is provided in Exhibit of Appendix Such requirement shall in no way relieve Contractor of his responsibilities under the Contract. The TPC shall function independently and report simultaneously to Company / Client and Contractor. The list of Company / Client approved TPC Subcontractors is provided in Exhibit of Appendix. Contractor shall prepare a Certification Matrix in accordance with the requirement of Exhibit of Appendix for Company / Client Review / approval.
The TPC scope shall include but not limited to the following:
1 Checking Project equipment and bulk material list.
2 Attending kick-off meetings and pre-inspection meetings to specify and ensure that the entire Quality requirements have been met.
3 Reviewing the high criticality rating of equipment and packages before the placement of purchase orders.
4 Ensuring that type of certification required by Company / Client is compliant with the requirements.
5 Reviewing Vendor’s data requirements lists and identifying those documents required for certification purpose.
6 Checking that the standards requested by Company / Client have been implemented for a wide range of products and the minimal approach has been adopted.
7 Reviewing and certifying Vendors quality plans and specifications for the procurement certification level.
8 Conducting monitoring visits to Vendors to review procedures for generating certification.
9 Reviewing the documentation prepared by Vendors as part of the Final Documentation.
10 Insuring that all special requirements for equipment in sour service have been complied with.
Shipment and Freight forwarding
1 Contractor shall be responsible for sanctioning the release of completed equipment and materials for shipment after satisfactory completion of final inspections and certification and shall execute forwarding activities for all equipment / material (including long lead equipment items).
2 Contractor shall be responsible for organising and co-ordinating packing, marking and transport of equipment from the source of supply determined in the purchase order to the Construction Site. Such work shall include:
3 Preparation of seaworthy / airworthy packing, marking, shipping and documentation specifications.
4 Inspection and certification as the case may be of packing, marking and loading.
5 Taking responsibility for authentication of shipping documents (including Certificate of Origin) by National Embassy / Consulate.
6 Develop plans and procedures for freight forwarding, handling and customs clearance of equipment and materials to ensure that all freight is consigned to arrive at the Construction Site on time.
7 Organise and ensure timely shipment of materials and equipment to Construction Site. Prepare, maintain and issue a monthly shipping progress report and monthly shipping forecast in a format approved by Company / Client.
8 Arrange for the importation of all materials and equipment purchased, for receiving and off-loading at Construction Site including organizing and securing approval from relevant authorities for shipment and transportation of heavy and bulky equipments and materials.
9 cContractor shall give preference to Plant Port while importing materials. Plant Port is a modern port and has necessary FACILITY like exclusive heavy load berth, cargo berths etc. To facilitate Project import materials.
10 Contractor shall provide its own craneage facilities for all loading and offloading operations at the heavy load and dry dock berths at Plant Port.
11 Contractor shall be charged by PLANT for the use of the port facilities at Ras Laffan. Details of these charges are given in Appendix.
12 Contractor shall comply with Plant Port Regulations given in Appendix.
Sea / Air shipment, Inland Transportation and Customs clearance
Contractor is fully responsible for arranging inland transportation, sea/air freight, legalising/authorisation of Certificate of origin and other shipping documents, voyage insurance, customs clearance including payment of customs duty, legalisation fees and transportation of all equipment / material to the Construction Site
Storing and Material traceability
1 All equipment and materials shall be carefully handled and stored in adesignated area at Construction Site.
2 Fragile equipment sensitive to the weather conditions (such as instruments) shall be stored in totally enclosed, heated and/or air-conditioned rooms. When installed, they shall be protected from the sun or from sand ingress by temporary shelters or plastic sheets.
3 Handling, preservation and storage of equipment and materials shall be carried out in conformance with Vendors' instructions and Company / Client specifications.
4 All Materials including spare parts shall be subjected to an appropriate traceability procedure so as to ensure easy retrieval of materials and related documentation for each item in all circumstances. For this purpose, Contractor shall provide experienced personnel for warehouse management and goods inward / outward control utilising PC based software allowing status progress at all times.
Spare Parts
1 While floating RFQ, Contractor shall instruct the Vendors to indicate the requirement of Spare Parts as shown below:
2 Commissioning Spare Parts – spares for pre-commissioning and commissioning.
Initial Spare Parts – spare parts to safe guard the operation of equipment during the start up / running –in and first year of operation.
Spare Parts for Normal Operation – spares for day-to-day maintenance for the period of one year following the initial operation.
3 Contractor to ensure that while submitting their quotation, Vendors shall provide description of the Spare Part items, number of Units recommended, ex-work Unit Price including seaworthy packing. Company / Client shall not approve any purchase order to be placed unless accompanied by One Year Operational Spare Parts and Capital spares list and prices.
Pre-Commissioning, Commissioning and Initial Operation &Maintenance Spare Parts and others
1 Contractor shall procure and supply Pre-Commissioning, Commissioning and Initial Operation and Maintenance spare parts, chemicals and lubricants, special tools and handling gear for each equipment as necessary up to Completion.
2 Contractor shall develop a procedure for the proper receipt, stacking, storage and handling of the spare parts and provide all the supplies and services in accordance with the same.
3 The Contractor shall provide list of all spares prior to their usage for site activities. The Contractor shall record all spares used during the site activities and update the list on a monthly basis.
4 The Contractor shall be responsible for ensuring that the spares provided (type and quantity) match with the requirements of the equipment.
Spare Parts for Normal Operation
One Year Operational Spare Parts as such do not form part of Contractor supplied items under the Lump Sum Contract Price. Company / Client may procure One Year Operational Spare Parts and Capital Spares through Contractor for which Contractor shall be reimbursed in accordance with the provisions of Appendix of the Contract. The Prices quoted by Vendors are to be kept firm throughout the duration of the Contract and no escalation in this regard shall be entertained by Company / Client.
SPIR Forms
SPIR procedure and a sample SPIR form are enclosed in Appendix. Contractor shall obtain through the successful Vendors a completed SPIR form duly filled in within three (3) months of placement of Purchase Orders. Following review of the SPIR, Company / Client may instruct Contractor to procure the One Year Operational Spare Parts.
It shall be noted that One year Operational spare parts are required to maintain the FACILITY immediately after Completion Date. Consequently completion of the SPIR form with all related drawings, etc. Shall be undertaken expeditiously by Contractor.
Company / Client approved vendors and Sub-Cont
1 Contractor shall ensure that it procures equipment and materials only from Company / Client approved Vendors (Ref Exhibit of Appendix not included).
2 For procurement of equipment and material for which no vendor list has been provided by Company / Client, Contractor shall propose suitable Vendors. Contractor shall establish that the Vendors / Suppliers proposed have previous experience of supplying similar type of equipment / materials to such projects. Contractor shall provide all relevant information for the vendor proposed for Company / Client to determine the suitability of vendor and its ability to comply with the pertinent requirements of the Contract.
3 Any deviation to the Company / Client approved vendor list shall be avoided.
4 When specifications call for a particular brand or type, any proposed substitutions shall be subject to prior approval by Company / Client.
5 Notwithstanding the foregoing, Contractor shall be fully responsible for the procurement, timely delivery and performance of the vendors’ equipment, materials and services.
6 Should Contractor propose the use of non-recommended vendors, it shall present the following information to Company / Client in the form of Pre-qualification document for review and approval prior to placing related Purchase Order(s):
7 Financial records demonstrating the commercial stability of the proposed vendor for the last three (3) years.
Records demonstrating that the vendor has appropriate and relevant industry experience and in particular experience for supplying similar item.
Records demonstrating that the vendor has services support for its products or services in National (preferred) or in the Middle East.
Records in the form of correspondence / confirmation from vendor demonstrating inability of the listed Company / Client approved vendors to supply the equipment / materials.
8 Once the pre-qualification documents have been reviewed, Company / Client may instruct Contractor to undertake registration of some Vendor’s / Supplier’s with Company / Client Materials Department before approval of Vendor / Supplier.
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Chapter 10
Construction
Introduction
1. Contractor shall carry out all construction work in accordance with procedures and methods prepared during detail engineering for all construction trades in accordance with the Project specifications.
2. All details of the FACILITY shall comply with Approved For Construction drawings, specifications, and all applicable engineering and technical standards and codes. Contractor shall plan construction in such a way that the FACILITY can be built, Pre-Commissioned, Commissioned and Started-Up in sequence. In particular, Contractor shall Commission the utilities well in advance for the purpose of Start-Up of the FACILITY.
General Construction Requirements
The FACILITY for the Project shall be provided and constructed in a safe, timely and reliable manner. The latest construction techniques and equipment shall be used to provide an effective construction approach, to achieve the Scheduled Completion Date.
During construction of the FACILITY, Contractor shall comply with Company / Client safety and work permit procedures, and shall enforce a set of Approved safety rules and precautions for Work at Construction Sites.
Contractor construction work shall include, but not limited to, the following:
1. Obtaining all approvals, and permits for the Work as per Company / Client regulations.
2. Establishing Construction Site safety rules and providing a Safety Manager, Officers and staff for the Work.
3. Providing construction personnel, temporary works, Temporary Facilities and other facilities required for construction:
4. In order to ensure the proper performance of the Work in accordance with the Subcontract Schedule, from the commencement of the Work to its completion, Subcontractor shall fully adapt his organisation for each specific phase of the Work to fulfil all Subcontract requirements and accordingly shall mobilise, develop and maintain the overall functional organisation and corresponding resources, including when, where and as necessary by providing additional means.
5. All construction equipment, scaffolding, tools, protection, testing and control equipment, auxiliaries, consumables, etc., and personnel (including management and supervision), necessary for the performance of the Work in particular for handling, transportation, warehousing, prefabrication, erection, testing. These include, but are not limited to:
6. Provision of maintenance and running of construction equipment
7. Provision of safety equipment and tools for personnel and works
8. Provision of personnel small tools
9. Provision of mechanical equipment and material necessary for working in water free conditions, whatever the volume or flow
10. Provision, storage, distribution and disposal of consumables (oil, lubricants, gas, etc.) And auxiliary materials (planks, timbers, tarpaulins etc.)
11. Provision of scaffolding and protection material
12. Provision of materials and apparatus for the technological laboratory to test materials, welders and provision of materials and apparatus to test all completed works
13. Safety equipment
14. Providing accommodation, lodging and transportation for construction personnel from Contractor, Subcontractors and Vendors.
15. Preparing construction procedures for the Work, which shall be submitted for Company / Client approval. In addition Contractor shall ensure:
16. Preparation of the Inspection and Test Plan (ITP) in compliance with the above and the Contract conditions, to be submitted for approval to Company / Client
17. Execution and recording of all test and inspection for equipment / materials and Work
18. Verification / checking the conformity of the Work and provide records
19. Issuance of construction method statement as per Company / Client request (for critical works)
20. Contractor must be able to prove at all times that the quality of the Supply incorporated in the Work complies with the quality specified in the Contract.
21. Managing and co-ordinating and supervising the work of Subcontractors and Vendors to ensure Work is performed on schedule and in accordance with the quality and safety requirements.
22. Preparing detailed schedules for the Work in accordance with the Execution
23. Programme, regular monitoring of this schedule and making appropriate adjustments to obtain most efficient usage, taking into account the interfaces with TEL, Electrical authorirty, MMAA and other parties involved.
24. Providing detailed manpower and construction facilities deployment charts.
Providing schedule and progress reporting in accordance with the requirements of the Contract:
1. Progress reports (daily, weekly, monthly, flash)
2. HSE report
3. Work schedules
4. Physical progress reports
5. Construction equipment status reports
6. Supplies status reports, unpriced copy of purchase orders, certificate of origin of all equipment and materials to be provided by the Contractor.
7. Monthly status of material taken over by Contractor
8. Updating of the list of work items drawings
9. Providing a quality assurance plan and developing quality control procedures.
10. Providing all Temporary Facilities required for the Work:
Erection, maintenance, dismantling and removal of all temporary Site facilities, including all complementary works, civil, electrical, etc. Inside the allocated areas. It includes, but is not limited to:
Contractor and Subcontractor’s site facilities such as office, workshop, warehouse, shelter, sanitary building, storage area, concrete or bituminous mix production plant, etc. Including all complementary works, civil, raw and potable water and sewer networks, power supply, etc. Inside the allocated areas,
Lighting of the works areas
Temporary works to prevent personnel from injuries and/or properties from damage
Scaffolding and safety equipment necessary for the Works. Such scaffolding and safety equipment must be left in place as long as necessary to allow inspection, tests and control
Contractor and Subcontractor office facilities
Company / Client office facilities
Contractor and Subcontractor warehouse
All site utilities for Contractor needs to include, but not limited to:
1. Power supply
2. Power supply cost (for Contractor use)
3. Water supply (Potable, Raw)
4. Potable water Supply cost (for Contractor use)
5. Potable or raw water supply cost (for construction works use except for piping hydro test)
6. Raw water supply cost (for piping or equipment hydro test)
7. Treatment of the raw water for hydro tests
8. Nitrogen supply for pre-commissioning works
9. Nitrogen supply for Works including cost (for Contractor use)
10. Air supply
11. Air supply costs (for Contractor use)
12. Disposal of all sewer and wastewater, rubbish and trash
13. Fuels and lubricants for the temporary facilities and construction equipment
14. Maintaining construction records in formats to be submitted for Company / Client approval.
15. Ensuring timely mobilisation of Vendors' representatives and/or any specialists, and their retention at Construction Site for the required duration.
16. Providing QA / QC and inspection services for the Work. This shall include, but not limited to civil, structural, welding, piping, mechanical, electrical, instrument and painting inspectors.
17. Contractor shall mobilise a Third Party Inspection Agency (TPI) to perform the following: NDT and interpretation-Civil Lab Testing-Load Tests
18. Any other required Personnel and QA / QC Inspectors shall be provided by Contractor. Contractor shall mobilise adequate level of Inspectors. QA / QC Procedures and Equipment shall be subject to Company / Client’s approval.
19. Maintaining and operating an adequate system of control of availability of drawings and specifications at their latest revision at all places where the Work is performed.
20. Maintaining and operating an adequate material control procedure at all places where the Work is performed.
21. Assisting Company / Client with technical safety reviews to confirm that the FACILITY can be operated, maintained, shutdown and started up in a satisfactory manner.
22. Managing field queries, field changes and revision of drawings.
23. Preparing a complete set of data sheets, specifications and as-built drawings.
24. Preparing rigging studies as required.
Mobilize in a timely manner the construction management team to Construction Site in National. Contractor should in particular submit:
1. Detailed construction execution plan, taking into account the Site constraints
2. Mobilisation plan
3. Scaffolding plan, including resources, technical solution proposed material specification and scaffolding management (HSE) procedure
4. The nominative organisation charts down to but excluding Foremen level and corresponding CV's
5. The list of resources assigned to the Work:
6. Personnel per category and nationality and split between the different disciplines and significant activities within each discipline as required in the Particular Exhibits
7. Construction equipment (type and quantity)
8. Allocation of Site temporary facilities and storage areas to Contractor
9. The Site temporary facilities detailed layout drawing and description
10. The Site storage areas (raw materials, finished materials) detailed layout
11. Provide housekeeping personnel for the Work on the basis of one cleaner per 25 persons.
12. Reinstate existing roads, track, channels and secondary roads to original conditions and specification.
13. Arrange for protection of turtle eggs during construction.
14. Contractor shall do whatever is necessary to take care of rock, obstructions or/and unsuitable materials present within the Construction Site.
15. Contractor shall dismantle and remove X nos. Temporary Cofferdam and take ownership of sheet piles and deliver the pre-cast units to Plant Port as directed by Company / Client.
16. Contractor shall within 30 calendar days from Contract Effective Date supply and install its own dewatering system in the cofferdam constructed by other Contractor.
17. Contractor is aware that there are buried services (pipe, cable, and duct) within the battery limits, and that co-ordination with Company / Client / Plant (for as-built drawings) shall be required during detail design, and that hand excavation shall be required in certain areas during construction unless confirmed in writing by Company / Client.
18. Protection and preventive maintenance of the Material handed over to or supply by Contractor as per the state of art and the supplier’s recommendations.
Contractor shall be responsible for the following:
1. Respect of Site constraints (safety, units in operation, site layout, location and set-up of temporary Site facilities etc.)
2. Protection of all tracks and roads used by Contractor and subcontractor and located in the vicinity of the Site
3. Make good to the original condition at Contractor's cost of the parts damaged by
4. Contractor or his representatives (Concrete, steel structures, piping, instruments, painting, etc.)
5. Installation, dismantling and removal of all temporary protection devices used by
6. Contractor to protect personnel, structures, piping, facilities and equipment on the Site
7. Any precaution and measure to avoid damage caused by traffic, dust, noise and any other cause that may affect the personnel, buildings, equipment or goods located nearby
8. Contractor shall be responsible for the following:
9. Daily collecting and removal of any materials used within the works areas such as iron scrap, debris etc
10. Disposal of refuse and debris in the relevant authorised dumps
11. Housekeeping of the areas allocated to Contractor
12. Daily cleaning of Site and of all tracks and roads used by Contractor and located in the vicinity of the Site. This also includes spraying of water, if required, for stabilising the dust. Destruction of temporary paving and concrete works including removal, transportation to an authorised dump and levelling of the concerned areas
13. Returning the Site to a suitable condition at Completion of the Work
Work Permits Procedures and Regulations
Contractor shall comply with Company / Client Work Permit Procedures and Regulations appended in Appendix and with Electrical Authority / Plant Work Procedures, when working at Plant and at NCC.
The following Company / Client Regulations shall also apply:
1. Electrical Safety Instructions
2. Plant Security guidelines
3. Consolidated Permit to Work system in PlantIndustrial City.
4. Company / Client Lifting Equipment regulations
5. Plant Mutual Aid programme
6. Regulations for disposal of Dredged Materials within Plant Industrial City
7. Health, Safety and Environment Plan in conformance with Company / Client requirements
Construction Site Preparation and Construction Site Access
1. Contractor shall accept the Construction Site work "as it is", and shall complete the excavation work as required, dispose of ground and rain water, provide the complete required infrastructure, including additional temporary fencing, security gates for the FACILITY, roads, ditching, sewers, and more generally, be ultimately responsible for finalization of any Construction Site preparation work required.
2. The Construction Site preparation shall include Construction Site clearance, rough grading, general earth works, leveling to grade selected, temporary boundary fencing, opening of roads on Construction Site, excavation and blasting, if required. Contours are provided, but the ultimate responsibility for the final contours shall be with Contractor.
3. Site preparations and transport of quarried construction materials shall be carried out in an environmentally acceptable manner so as not to impact the surroundings.
Construction Facilities
1. Contractor shall obtain permission from Plant for access to areas close to Construction Sites for offices, lay down, fabrication yard etc.
2. Contractor shall provide office facilities to Company / Client as specified in Appendix.
3. All utilities required in all areas during the execution of Work shall be the responsibility of Contractor.
Safety and Security
Contractor shall take sole responsibility for safety (including fire prevention) of the Work. The scope of safety shall include, but not limited to, the following:
1. Providing safety and fire prevention procedures at Construction Site.
2. Providing evacuation and first aid facilities in accordance with the local regulations, for all personnel assigned to the Construction Site.
3. Providing adequate safety management and personnel, safety procedures, safety plans, safety organization charts, safety instructions and safety talks, and ensuring that these procedures together with Company / Client's requirements are promulgated and enforced.
4. Supervising all personnel assigned at Construction Site to ensure that they abide by the safety program. Generally, providing one safety officer for every 50 persons.
5. Regularly verifying adequacy of Subcontractors' craneage, rigging and scaffolding to function safely and reliably.
6. Ensuring safety regulations and keeping safety records.
7. Reporting to Company / Client on status of planning and implementation of activities to ensure safe construction and operation installations.
8. Issuing safety reports to Company / Client as specified in Appendix .
9. Providing security gates and surveillance at various Sites.`
Extent Of Construction Scope Of Work
1. The construction work includes but is not limited to the activities described here after. Those descriptions are not exhaustive and are given solely for Contractor guidance and shall be read and continued within the context of present scope of work document.
2. Above Ground Piping Work Prefabrication and Erection including material management, prefabrication and erection works including all tests and control and flushing operation.
3. Instrumentation Work including the installation, connection, testing of all material and equipment in units and in technical rooms / control rooms including loop testing from control systems such as DCS, PLC, to each local instrument.
4. Electrical Work including the installation, connection, testing of all material and equipment in units and in substations including testing and energisation.
5. Site Preparation and Road, Piling, Underground Piping, Civil works and Building Works including earthworks, road, site preparation including fencing works, drainage, pressurized underground piping erection, gravity pipe networks, all concrete works such as foundation, structure, paving building construction including detailed design and supply / erection of secondary works and HVAC systems and all related test and control.
6. Steel Structure Fabrication and Erection Works including detailed design, supply, fabrication, transportation, erection and all associated tests and controls.
7. Insulation Works of piping and equipment including supply and erection of all type of insulation and associated tests and controls.
8. Painting Works of piping, steel structure and equipment including supply and application on field (or on shop for piping elementary components) of paint on but not limited to steel structure, piping and equipment.
9. GRP Piping Prefabrication and erection including material management, prefabrication and erection work including all test and control and flushing operation.
10. Hoisting, mechanical assembly of all equipment and material including erection work, alignment, test and control.
11. Heating, ventilation and air conditioning including installation, connection testing of all material and equipment.
12. Storage facilities including detailed design, supply, fabrication, transportation, erection and all associated tests and control.
13. Fire water tank, erection of fabrication tank, site construction, assembly and all associated field tests.
14. Pipeline construction-pipeline routing
15. Introduction
16. Pipeline construction scope shall compose of all works in relation to Piping / Pipeline construction as outlined below and as defined by the FEED Specifications, drawings, documents.
Contractor shall be responsible for identifying all disciplines in the extent of work requested for piping / pipeline construction activities. Pipeline construction activities shall include, but not limited to the following activities.
➢ Installation of GRP piping manifolds at Pump Houses.
➢ Installation of all Pump House Piping for Pump Houses.
➢ Installation of all utility Piping in Intake Area.
➢ Installation of all Piping for packages including electro chlorination unit.
➢ Installation of Piping (above ground / buried) for fresh water firewater system.
➢ Installation of the extension of seawater, firewater system (above ground / buried) to cover all new plots / facilities.
➢ Installation of cooling water supply pipelines (above ground / buried) from Pump House to end user battery limits.
➢ Installation of cooling water return pipelines (above ground / buried) from end user battery limits to receiving basin.
Note that ‘Installation’ includes all pipe, joints, valves, fittings, flanges, spectacles, supports, anchors, manholes, inspection holes, vents, drains, sumps, pits, welding, jointing, non-destructive / destructive testing, inspection & repair, trenching, lowering, backfilling, crossings of pipelines / utilities / roads, ROW preparation, hydrostatic testing, any temporary supports, etc.
1. Contractor shall make due allowance in its schedule and management of its Construction activities for other ongoing Third Party activities at Construction Site and the surrounding area.
2. Contractor shall be responsible for contacting and obtaining necessary permissions from all relevant Governmental Authorities and Third Parties before construction works commence. Contractor shall obtain all necessary permits and consents in compliance with the requirements. Contractor shall verify the location of any existing installations and services to the satisfaction of Company / Client and applicable service owners.
3. Contractor shall allow the Governmental Authorities and Third Party service owners all possible access to inspect and witness Works execution in the vicinity of their installation(s) and shall conduct such works in accordance with their requirements.
4. Contractor shall meet all its obligations in this respect in a timely manner such that there is no delay in the Works.
5. Contractor shall utilize only approved certified testing laboratories for all destructive testing to be carried out on the Works under construction.
6. If Contractor wishes to provide testing facilities on Construction Site to carry out such destructive testing, the facilities shall be certified in accordance with relevant international standards and also approved.
7. Contractor shall note that Works include at least the receipt, transportation, handling and storage (in addition to all other construction activities) of all items included in the novated purchase orders by Company / Client to Contractor. Contractor shall comply with all Company / Client instructions with respect to these particular items and its delivery to Site.
The following drawings form part of Appendix of this document.
1. Plot Plan.
2. Pipeline Routing Plans including sections and details.
3. Survey Drawings for the cooling water and firewater route corridors.
4. Contractor shall be responsible for verification and confirmation of all FEED deliverables.
5. Contractor shall initially locate existing pipelines and other facilities and shall place barriers to prevent his personnel or equipment from working over and damaging existing pipelines and other utilities.
General
Contractor’s scope of work shall include but not limited to the following:
Installation of the piping systems generally indicated on the P&ID’s, preliminary plot plans and preliminary main routing plans included in the Contract.
1. All material handling, craneage and scaffolding
2. All prefabrication of piping systems
3. All erection of piping systems, including tie-ins and crossings
4. All prefabrication and installation of supports including material supply
5. All welding
6. All heat treatment, if applicable
7. All non destructive testing
8. All hydro testing, construction cleaning, draining and drying of piping systems.
9. All chemical cleaning, if applicable.
10. All reinstatement
11. All nitrogen or air testing
12. Performing all inspections and tests
13. Providing all weather protection measures when and as required
14. Bolt tensioning
15. Provide all pipe spools and pipe fittings necessary for hydro test
16. Provision and installation of locking devices, to lock open certain valves where necessary
Scope of Modification Works
1. All works necessary for implementation of the modifications at the various sites or, alternatively, in workshops or other designated locations.
2. Scope of installation works
3. Installation at a definite location of equipment for the project, the activities to include setting, first alignment and tightening and tensioning of equipment foundation bolts.
4. Installation of all Equipments / Packages / etc.
5. Provide support structure
6. Second alignment after final connection of piping
7. Provision and installation of services items such as temporary blinds, caps, grease, etc.
8. Provision of protection against mechanical damage and damage from weather conditions.
9. Performing initial fill of lube oil, grease, etc.
Prefabrication of Piping
Contractor shall perform a site survey and ensure spooling of correct dimensions suitable for erection at site and determination of field welds. Contractor shall prefabricate piping in quality controlled conditions (offsite) to the maximum extent possible.
The scope of prefabrication work shall include but not be limited to :
1. Transport, receipt inspection, storage, conservation, handling and administration of all materials at Contractor’s prefabrication shop location.
2. All prefabrication, hydro test (including supply and disposal of test water) and NDT works and send it to painting yard for blasting and painting.
3. Transport (incl. Loading and off-loading) of prefabricated elements from the prefabrication shop to the worksites.
4. Tagging of all spools with isometric number and storage it in a safe designated area at erection site.
5. Erection of piping
6. Access to existing facilities shall not be interrupted. Future corridors reserved for other facilities shall not be encroached. Temporary access to existing facilities/roads shall always be maintained.
7. Prepare workpacks and identify piping spools for erection.
8. Erect rack structure, supports etc and align
9. All erecting, testing and re-instating of the piping systems, including supporting (both temporary & permanent).
10. All bolt tensioning required according to pipe specifications.
11. Installation of temporary strainers and removal after flushing.
12. Arrange and provide all testing and drying facilities
13. Supply, installation and dismantling of temporary supports.
14. All other necessary activities such as marking, re-stamping, inspections, documenting, establishing procedures, obtaining approvals from Company / Client, etc.
15. Surface protection, priming, painting, touch up etc.
16. Fabrication, erection and installation of U-bolts, pipe clamps, and / or other restraining devices necessary for the Work.
Pipe protection
At each location where pipes cross roadways at an elevated level inside the plant areas, permanent bunting poles with warning signs shall be erected.
1. At all locations where pipes are located adjacent to plant roadways and at all locations where new facilities are being constructed or modified, permanent ‘armco’ type barrier protection shall be provided.
2. Installation of GRE / GRP piping
3. Construction Supervision
4. Coordination with all GRP vendors / suppliers at site
5. Arrange meetings with other Contractors (interface) to avoid fouling with existing facilities.
6. Access to existing facilities shall not be interrupted. Future corridors reserved for other facilities shall not be encroached. Temporary access to existing facilities/roads shall always be maintained.
7. On/off loading and storage
8. Installation of piping system
9. Insertion of all sealing rings, gaskets and locking devices
10. Make up of all laminated / bonded joints and coupled connections
11. Acceptance of anchor bolts
12. Acceptance of trenching backfill and compaction
13. Acceptance of each system as ready for hydro test
14. Hydro test of spools / joints and double bell couplers prior to system hydro test.
15. Guarantee of successful hydro test
16. The above acceptance shall be signed by the Site Representative of the GRE / GRP Manufacturer prior to Contractor proceeding with the subsequent stage of construction in each case.
Trenching
Contractor shall carry out pipe trenching in accordance with the following:
1. Contractor shall perform all required trenching and excavation by machine or by hand, including rock hammer and blasting where required and provide all necessary shoring, sheeting, dewatering, protection, stabilization and maintenance of the trenches, including the supply and installation of temporary crossings over the excavation if required.
2. Contractor shall take all necessary precautions to protect any existing facilities encountered during the performance of his Work. Where excavation is required within three (3) meters of any gas, oil, water, sewer, electrical, telephone or power lines, Contractor shall give Company / Client ample notice (at least two weeks in advance) for each work permit and follow Company / Client standard practice. Contractor shall also arrange for permits from the various local authorities.
3. Contractor shall take special precautions when working parallel and within five meters of any existing pipes or below overhead lines. All Work in the existing facilities areas shall be carried out adhering to the Company / Client Work Permit Procedures.
Welding and Radiographic Inspection
Contractor shall carry out welding and radiography inspection in accordance with the following:
1. Contractor shall provide all services, materials, and equipment necessary to develop and submit to Company / Client for approval all required welding procedure qualifications, welder qualifications, for production welding for the mainline, installation of the scraper traps, installation of the mainline valves and all other welding activities.
2. Contractor shall check all controlling dimensions and pipe roundness prior to installation, to avoid any delay. If discrepancies exist, Contractor shall notify Company / Client immediately in a timely manner of its corrective action for approval.
3. Ten percent (10%) radiographic examination of all welds shall be performed using X-Rays. Weld maps shall be prepared and maintained by Contractor and turned over to Company / Client at the completion of the Work.
4. 10% Radiography shall be taken as basis; however detailed NDT requirements shall be reviewed during the execution of the Work on case by case basis depending upon criticality and nature of services.
5. All radiograph films and test results shall be protected and stored by Contractor in a dry, secure place, until they are handed-over to the Company / Client at the completion of the Work, packed in good condition for permanent storage.
Road, Track and Existing Pipeline Crossings
Contractor shall carry out pipe, road, track and existing pipelines crossings according to the following:
1. Contractor shall construct all roads, tracks, and crossings on existing pipeline and other facilities as required in accordance with approved drawings and in full compliance of all local road requirements and regulations in National.
2. Contractor shall maintain traffic flow and movement of personnel during installation of the road crossings.
3. Where road crossings are performed by ‘open-cut’ method, detours shall be provided. Contractor shall obtain Company / Client approval for the design of detours. All detours shall be paved. After completion of the crossing, Contractor shall re-instate the roads and the surrounding area including detours to their original condition and to the satisfaction of Company / Client
4. Pipeline Cleaning
5. Contractor shall ensure that internals of pipeline are thoroughly cleaned and inspected prior to hydrostatic testing in accordance with approved project procedures.
Hydrostatic Pressure Testing
Contractor shall perform hydrostatic pressure testing of all piping in accordance with approved project specifications and procedures.
Tie-Ins
General Requirements-
1. Preparation of a detailed tie-in index and schedule
2. Obtaining approval from Company / Client for all tie-in locations.
3. Marking of tie-in locations at site for Company / Client Approval.
4. Provisions of all spades, gaskets and bolts for the tie-in Works.
5. Removal of piping, if necessary
6. Prefabrication of tie-in piping
7. Connection of tie-in piping, including cutting and beveling.
8. Non-destructive testing (NDT) of the tie-in location prior to and on completion of the works.
9. Hydrotesting and drying of the relevant part of the existing and new piping system.
10. Repair of coating on the existing system.
Tie-Ins during Shutdowns
1. Contractor shall furnish all equipment, materials, personnel, supplies, and consumables necessary for performing all tie-ins. Contractor shall confirm the adequacy of these tie-ins.
2. Contractor shall plan and schedule tie-in activities to take place during planned plant shutdown periods or, where there is not possible, to minimise any plant shutdown required.
3. Contractor shall submit a procedure and method statement for each of the tie-in activities, for Company / Client review and approval, including but not limited to:
4. Procedure-Method Statement-Work execution plan-Material for permanent incorporation-Consumable requirement-Safety consideration-Hazard identification-Operational Impact
5. Contractor shall tag (physically mark on site) each tie-in location after it is confirmed.
6. Contractor shall produce an isometric drawing with complete material list for each tie-in. Contractor shall ensure all materials are available for the tie-in Work prior to submission of the request to commence the tie-in works.
Final Cleanup
1. The Project area and all other areas affected during construction shall be maintained clean and free of environmental pollutants. Daily cleaning of the Construction Site shall be performed.
2. At the completion of the Work, the construction areas shall be restored as close as possible to their original condition. This includes Construction Site, staging and storage areas, excavated material stockpiles, existing structures affected, as well as any other areas disturbed by Contractor during construction.
Cathodic Protection
Contractor shall install cathodic protection system where necessary as indicated in Cathodic Protection Specification and Scope of Work document and provide post installation testing, interference testing, and preparation of as-built drawings and final report.
Mechanical Completion
Contractor shall plan, in conjunction with Company / Client, to achieve the Mechanical Completion in accordance with the Execution Programme in readiness for the Pre-commissioning activities. Mechanical completion activities are linked in Exhibit of Appendix .
Navigation
1. Without in any way limiting or detracting from the effect of any other Clause hereof, Contractor shall conform to the Byelaws and Regulations concerning navigation and shall obey the orders of any authorized and competent officer or agent of the Government or the Port Authority in reference thereof.
2. Contractor’s operations must be conducted in such a manner that they do not interfere with nor endanger either the use of working of the waterways, anchorage wharves, jetties, causeways, dolphins and approaches there to, whether belonging to Company / Client or to persons or any water borne traffic except by prior arrangements with Company / Client representative and the Port Authority.
3. Contractor is to subject full details of any of his operations that may cause any interference to shipping to Company / Client’s representative for approval at least 7 days before the event and is to make such modifications as Company / Client’s representative may require in order keeping such interference to the minimum. Normal movement of craft within the harbour shall be notified to Marine Operations. All crafts shall be fitted with VHF radios.
HRW Hydraulic Study Notes Conclusions
Contractor shall consider HRW studies conclusions as given below.
1. This Technical Note has described a design review and a computational fluid dynamic model study of the proposed Plant CCWS pumping stations
2. The study has considered the most recent estimates of the design flow rates, comprising -------m3 / hr from Pumping Station ------- m3 / hr from Pumping Station and ------------ m3 / hr from Pumping Station .
3. Design flow conditions at the entrance / inlet to the pumping station
4. The water levels at the pumping station entrance and the approach flow patterns considered in the analysis took account of the flow into Pumping Station. The minimum water level of -0.95m NHD corresponds to a head loss of only 0.07m in the channel. Approach flow patterns are direct and well-behaved.
5. Review of layout in relation to design guidelines, etc.
6. The typical maximum approach flow velocities to the bar screens are considered to be within acceptable limits in relation to potential turbulence levels at the bar screens.
7. In the worst case (i.e for PH-) at maximum flow, the velocity in the double-entry channels at the drum screens shall be typically 0.86m / s. This is a little high relative to HR Wallingford's experience of other installations and it would be appropriate to confirm with relevant screen vendors that a maximum approach velocity of some 0.8-0.9m / s is acceptable in the channels approaching the drum screens.
8. In the worst case (when one screen train is out-of-service), the maximum velocity leaving the screen units shall be approximately 0.8m / s. This is considered a little high in relation to the size of the forebay area, as confirmed by the CFD model. Flow modification measures (e.g. Baffles or columns) are likely to be required in the forebay to ensure satisfactory flow patterns under adverse combinations of screens and pumps in operation.
9. Submergence of pumps
10. The available submergence and proposed elevation for the pump bay invert (-9.50m NHD) are considered satisfactory in relation to the required submergence conditions for minimisation of free-surface vortices.
11. Overall dimensions and internal structures
12. The proposed overall layout and dimensions for the screen chambers is considered satisfactory for FEED. It would be recommended, however, that the required width of each screen chamber element should be subject to further review / detailed design during EPC - following identification of the actual screen vendor and actual screen dimensions.
13. In the case of PH#, the initially designed pump chamber width of 5.0m is smaller than standard guidelines would suggest. Preliminary enquiries with pump manufacturers have indicated that a pump chamber width of 5m would be acceptable (even based upon a bell mouth diameter of 2.7m). Taking this into account, the proposed 5m width for each pump chamber is considered satisfactory for FEED. It would be recommended, however, that the required width of each pump bay should be subject to further review / detailed design during EPC - following final confirmation of the actual pump vendor and actual bell mouth diameters.
14. The Initial Design for the pump bays provides for a “standardised” pump bay length of 10m, which is satisfactory with respect to the pumps for PH and PH but short relative to standard guidelines in the case of PH#.
15. The proposed “standardised” distance from the rear wall of a pump bay to the pump centre line of 2.2m is in accordance with standard guidelines.
16. In general terms, the splitter / benching, corner fillets and curtain wall arrangements are considered appropriate vortex suppression devices / methods. On the basis of "standard best practice", it is considered that these features should be included in the pump bays, as they shall help serve to inhibit severe surface and sub-surface vortex formations.
17. Free passage of air must be allowed at the top of the pump bays and other semi-enclosed areas of the pumping stations.
18. The roof slab is expected to be clear of the water surface even for extreme water level/wave conditions (notwithstanding possible transient water levels in the Intake Channel that might result from pump start-up or trip scenarios).
19. The possible improvements identified for testing in the CFD model resulted from the short pump chambers in PH and the restricted distance between the drum screen chambers and the pump chambers.
20. Computational fluid dynamics (CFD) model tests
21. Simulations have been undertaken for a variety of operational conditions in the planned Plant CCWS pumping station.
22. The calculated water level at the entrance to the pumping station takes account of the flow into the Phase I pumping station (PH, and the intake channel model demonstrated well-behaved approach flow to PH and PH. Therefore, although the pumping station computational model does not explicitly simulate PH, the simulations take account of the effect of the flow into PH.
23. With the original design, and under adverse combinations of pumps and screens in operation, significant oblique flow with local velocities approaching 1m / s was observed in the pump forebays. Flow in the pump chambers under these conditions was asymmetric, locally approaching 0.8m / s and there was rotation at the pumps.
24. Revisions to the design have been proposed, in which columns are introduced at the entrance to the pump chambers to dissipate the asymmetric jets. Further simulations have been carried out to show the effects on the flow patterns. These show significantly improved flow patterns in the pump chambers, but there is scope for further improvement in the forebays.
25. The CFD model studies indicate that the overall pumping station dimensions are adequate, subject to provision of the dissipating structures described above and optimised during EPC.
26. Physical model study
27. To confirm and extend the conclusions of the CFD model study, it is recommended that a physical model study be carried out during the EPC phase. This would enable final optimisation of the internal layout, and confirmation of satisfactory performance under the final design operating conditions. For Physical modelling scope of work Refer to Appendix- (Hydraulic Study Report)
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Chapter 11
Pre-commissioning (PC)
Introduction
1. Pre-commissioning shall generally include the following and should be defined and followed up by PC status Index:
2. Systematic conformity checks in accordance with check list, carried out on each part or item of equipment or component, such as pressure gauges, motors, cables, to visually verify the condition of the equipment, the quality of installation, the compliance with project drawings and specifications, manufacturers instructions, safety rules, codes, recognised industry standards and good practice.
3. Static, de-energized tests and test start of specific equipment, to ensure the quality of a number of critical components. This cold testing work shall concern all disciplines, and cover activities such as calibration of instruments, machinery alignment, setting of safety valves, pressure testing of piping systems, testing of cable continuity.
4. Piping and vessels flushing, cleaning, hydro testing and de-watering shall be supported by specific reports.
5. Leak testing (at 1.1 times the design pressure) is required to ensure that all inline components / isolated portions of piping during hydro testing are installed.
6. Dynamic verifications that each elementary electrical and instrument function in the FACILITY is designed to achieve and shall perform properly. Typical examples of such tests are: electrical motor uncoupled runs, instrument loop tests, and electrical breakers operation. Energising of the electrical networks shall be part of this activity.
7. Pre-commissioning shall be organised by sub-system following an approved sequence to be prepared by Contractor.
8. Pre-commissioning preparation shall start at the engineering stage together with Commissioning and Start-Up preparation, and shall include the preparation of the documentation, mentioned hereafter, together with the preparation of the FACILITY breakdown in Systems and sub-systems and the FACILITY start up sequence mentioned under the Work Unit description for commissioning.
Contractor responsibility of Pre-Commissioning consists of, but not limited to the following:
Prepare plans, procedures-Prepare safety audit-Provide PC spares-Provide PC tools, equipment-Co-ordinate activities of Vendor(s)-Maintain all documents, records-Carry out PC activities, e.g. Conformity check-Main activities of PC are: -Flushing/air blowing, -Hydrotesting, and-No-load motor runs-PC documents as follows:
Check list-Test sheet-Status index-Punch list-Dossier
Pre-Commissioning Check Lists
1. The conformity checks defined above shall be carried out in accordance with, and reported on Pre-Commissioning Check Lists.
2. Pre-Commissioning Check Lists shall define the Scope of Work that must be systematically performed on each selected item of equipment and shall also be used as a log to record the checks made. A typical sample of such Pre-Commissioning Check Lists is attached in Exhibit 03 to this Appendix A.
3. One Pre-Commissioning Check List shall be filled in for each sub-system and type of equipment or package.
Pre-Commissioning Test Sheets
1. The Pre-Commissioning tests shall be carried out in accordance with the relevant specifications and reported on Pre-Commissioning Test Sheets.
2. A typical sample of such Pre-Commissioning Test Sheets is attached in Exhibit to this Appendix .
3. One Pre-Commissioning Test Sheet shall be filled in for each test performed. Specific reports and drawings shall support all other Pre-Commissioning activities such as piping and vessels flushing and cleaning.
Pre-Commissioning Status Index
1. The Pre-Commissioning methods and procedures shall be defined and followed up in a reference document entitled Pre-Commissioning Status Index.
2. The Pre-Commissioning Status Index shall be an exhaustive list, arranged per sub-system, discipline and type of equipment, for all equipment and materials subject to Pre-Commissioning operations.
3. The Pre-Commissioning Status Index shall summarise for each subsystem the corresponding pre-commissioning checks and tests to be performed for each item of equipment or materials (i.e. Pressure gauges, electrical cables, pumps and the like).
4. Each Pre-Commissioning task shall be recorded on the Pre-Commissioning Status Index.
Pre-Commissioning Punch Lists
1. Pre-Commissioning punch lists shall be established for each sub-system being Pre-Commissioned, for the purpose of recording all discrepancies, damaged or missing equipment, malfunctions, missing documents and any deviation from the design drawings and specifications.
2. Pre-Commissioning punch lists shall be attached to the Ready for Commissioning Certificate for each sub-system.
Pre-Commissioning Dossiers
Contractor shall compile documentation pertaining to the Pre-Commissioning activities in a dossier arranged by sub-system, which shall contain all information required to demonstrate that a sub-system has reached the Ready for Commissioning status.
The Pre-Commissioning dossiers shall include the following:
Ready For Commissioning Certificates-Punch lists-Systems descriptions and marked up drawings-Specific procedures-Pre-Commissioning Status Index-Pre-Commissioning Check Lists-Pre-Commissioning Test Sheets-Marked up AFC drawings latest status-Vendors’' shop test reports-Vendors' documentation needed for commissioning.
Commissioning
Introduction
1. This section deals primarily with Commissioning. However, in view of the required continuity of the completion activities, i.e. Pre-Commissioning, Commissioning and Start-Up, this section also deals with interfaces between such activities.
2. Contractor shall execute all activities required for Commissioning the FACILITY, i.e. Checking, putting in operation and operating the utilities Systems required for Commissioning the process and other facilities, and all verifications required to demonstrate that the process facilities are in the Ready for Start Up.
General
Commissioning shall generally include the following
1. Pipelines and Piping system: Operational Tests and leak tests
2. Instrumentation: Loop check, Logic check and Operational Tests of DCS / F&G systems.
3. Electrical: Operational Tests on all power system equipment, all motor runs, tests on lighting system, tests on earthing system, tests on cathodic protection system etc
4. Telecommunication: Functional tests.
5. Chemical loading / filling.
6. Actual run in and on line tests during a significant period of the main process equipment in closed loop wherever applicable, and of the utilities systems.
7. Checking, startup, operation and maintenance of the utility systems.
8. Equipment packages shall be subject to Commissioning operations at Construction Site, irrespective of the amount of testing that may have taken place at manufacturers' shops.
9. Contractor shall execute all activities required to Commission the FACILITY and shall ensure that before each functional system of the FACILITY is started that the common activities have been performed in accordance with the requirement of the Contract.
10. All operations shall be organised by sub-system and reported on that basis.
Contractor's responsibilities for Commissioning shall include but not limited to the following:
1. Providing a team of suitable experienced and qualified personnel for Commissioning as per approved plans, schedules and procedures.
2. Preparing interface and Commissioning coordination procedure
3. Preparing safety audits and maintaining record of all approved safety audit items
4. Providing necessary Commissioning spare parts and ensuring their availability at Construction Site at least three (3) months prior to Commissioning of each relevant facility
5. Coordinating activities of vendors and any Subcontractors participating in the work
6. Developing all required software items
7. Maintaining all documentation and records of Completion Activities on microcomputer
8. Maintaining records of all changes for updating the operating manual towards the end of Work
9. Providing fresh clean water suitable for testing
10. Providing mechanical, electrical and instrumentation test gear and small tools necessary to carry out calibration and testing.
11. Gathering and completing the Commissioning dossier of the complete systems
Operational Tests
1. Wherever applicable and as approved at the Commissioning preparation stage, each sub-system shall be the subject of an Operational Test, provided the Basic Functions of the sub-system have been successfully functionally tested.
2. Operational Tests shall consist of bringing a given system into operation under conditions as close as possible to normal. Included shall be testing the automated devices, controls, normal and shutdown sequences in operation, with a view to revealing mechanical or electrical faults likely to occur during prolonged normal operation of equipment. Such faults may be due to watertight performance defects, vibrations, overheating, overloading and the like.
3. Wherever applicable, the Vendors' performance guarantees shall be verified during such Operational Tests.
4. Typical sub-systems to be subjected to an Operational Test are: fire water pumps, air compressors, DCS system, and process pumps in recycle mode (under air or nitrogen whenever possible).
5. Each Operational Test shall be conducted in accordance with a specific Operational Test procedure to be established and approved at the Commissioning preparation stage.
6. Following successful Operational Test for any System or Sub-System, Contractor shall issue for Company / Client approval Ready for Start-Up Certificate for such System or Sub-System. Upon Company / Client approval of all Systems and Sub-System in the FACILITY, Contractor shall Start-Up the FACILITY.
Vendor’s Assistance
Contractor shall provide all required Vendors’ support and assistance by mobilizing Vendors’ representative and specialists to Construction Site.
Vendor support and assistance shall be required as necessary for the following.
Rotary Equipment:
Main Cooling Water Pumps-Fire Fighting Pumps
Mechanical Packages:
Chlorination System-Fire Fighting System -Hoisting / Lifting Equipment-Pipeline Metering Packages-Drum Screens and Trash Rake Machines.
Instrument Air Compressor / Drier Package.-Stoplog guide ways installation
Process Items:
FRP Piping Systems-Cooling Water System Valves
Electrical:
HV switchgear-220kv Cables-LV Switchgear and MCC-Transformers
Variable speed drives and Motors-UPS / Battery system-Emergency Diesel Generator-Cathodic Protection-Substation Control and supervisory system.
Control and Instrumentation:
DCS systems-Pipeline / Piping-GRP Vendor Support / Supervision-F&G systems-Cooling Water Pumps control systems-Flow metering stations-Telecommunication systems-Process Stream Analyzers-Laboratory Instruments.
Commissioning Dossiers
The Commissioning Dossiers shall include the following:
Ready for Commissioning Certificate-Punch lists-All Functional Test Sheets-All calibration sheets and records-Vendor factory tests reports.-Set points of relays, protective devices-Record of site modifications in drawings-Statutory authority reports / certificates-Marked-up drawings-System Description-Commissioning Procedures
Completion Activities
Start-Up all Facility
1. Upon completion of all remaining commissioning activities of the FACILITY, Contractor shall carry out the Start-Up of the entire FACILITY in accordance with procedures to be developed by Contractor and approved by Company / Client. The Start-up activities shall be planned in accordance with the Execution Programme and shall confirm the design intent of the Project in terms of all design parameters, specification and Cooling Water quality.
2. Contractor shall provide all Personnel, Equipment, Tools, Rigging, Temporary Facilities, Consumables and any other utilities as required to undertake the FACILITY Start-up.
3. Contractor shall liaise with and mobilize any Vendor and work in close coordination with Company / Client to assure a timely successful Start-up of the FACILITY.
72-Hour Performance Test
1. Upon completion of FACILITY Start-up, Contractor shall assure that the FACILITY is operating at steady and stable conditions, whilst maintaining flow rate to all consumers including IPP.
2. Contractor to note that not all consumers are available at the time of the test to receive their designated flow rate, as such Contractor shall produce / develop a 72-Hour Performance Test Procedure approved by Company / Client to cater for this situation and demonstrate that the performance test can be carried out with the absence of certain consumers.
3. When ready for the 72-Hour Performance Test, Contractor shall give Company / Client 48 hours prior notice to carry out the 72-Hour Performance Test. Upon Company / Client approval, Contractor shall carry out the Performance Test in accordance with the approved Procedure for a continuous 72 hours.
4. Contractor shall present all results of the test to Company / Client after the Test for Company / Client approval.
5. Once satisfied of the 72-Hour Performance Test results, Company / Client shall issue Contractor a successful 72-Hour Performance Test certificate. Contractor to ensure that the water supply to PLANT and other consumers is in no way disturbed or interrupted during the test.
6. In case not all consumers are available to receive their nominated flow Rate, Contractor Shall Design, Supply and Install Any Temporary Facilities to simulate that particular consumer in terms of flow rate, pressure drop, temperature increase, as if all consumers are actually there for the purpose to carry out and to demonstrate the 72-hour performance test.
7. All flow rates to consumers shall be measured including those needing Temporary Facilities for the 72-hour performance test.
8. Contractor shall design, procure and install Temporary Facilities, which shall be subject to Company / Client approval. Such Temporary Facilities can be based on plain Carbon Steel.
9.
10. Contractor shall have the consumer interface system connections to all consumers, inlet & outlet, Mechanically Completed and ready to be connected to each consumer.
11. The 72- hour Performance Test shall be carried out satisfactorily by Contractor on or before the date stated in Appendix H.
Initial Operation and Maintenance
1. Contractor shall mobilize all operating and maintenance personnel and Vendor representatives as required for the operation and maintenance of all the FACILITY on 24 hour basis. The Initial Operation and Maintenance shall start after the 72 hour Performance Test and up to and including the Completion Date. The Operation and Maintenance of the FACILITY shall be undertaken by Contractor in accordance with the operation manuals and Vendor’s Instructions.
2. Contractor shall set-up a procedure and an Operation management system for the operation and maintenance of all project equipment with a view to record, and log all interventions, operating parameters related to each equipment for the purpose of good records. These control systems shall be co-ordinated with Company / Client Operations. All spares, consumables, fills, lubricants, chemical shall be provided by Contractor during the Initial Operation and Maintenance of the FACILITY.
3. Contractor shall study and define the optimum manpower requirement to operate and maintain the Plant FACILITY. This study shall be based on the various equipment manufacturers’ data, information and specific details of the FACILITY such as a FACILITY layout, consumer interface, criticality of consumer needs should also be considered. This study shall be the basis for Company / Client to set up its own operation and maintenance team.
4. Contractor shall maintain a continuous steady flow to PLANT and other consumers during the entire Initial Operation and Maintenance period.
Project Completion / Handover
1. Contractor shall complete all remaining Works under the Contract such as, Punch List Items clearance, Material reconciliation, Final Documentation, Training and any other Works as specified in the Contract.
2. Contractor shall ensure that Project is completed on or before the scheduled completion date.
3. Contractor shall proceed with the FACILITY Hand-Over to Company / Client Operation in a progressive and co-ordinated manner so as to allow a smooth hand-over by the scheduled completion date after all training has been conducted by Contractor to Company / Client personnel.
4.
5. Upon Completion the Facility shall be considered as Handed over to Company/Client in accordance with the Contract.
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Chapter 12
The following statements have been included exactly as are produced during job by me for certain international bids to support technically as a part of Technical Bid
EXECUTION PLAN
(PROJECT IMPLEMENTATION STRATEGY)
Process Buildings Package
Sample Only
Engineering Design
a) Building Engineering Design Management necessitates an integrated approach to formulate an overall philosophy, able to achieve an intellectual product covering & incorporating a wide range of performance & serviceability requirements that shall completely meet intended functions of the proposed building adequately satisfying architectural, structural & allied services requirements. The target achievement of this fast track EPC project shall be kept in consideration by all discipline designers to release the necessary documents on planned line.
1. To accomplish this part of the package to the best possible standards, AJESCONTRACTOR shall invite certain (possibly 3) reputed & leading architectural engineering Firms as Engineering Services sub contractor. Based on the merits of each offer as well as applying the competency criteria, a preliminary selection shall be made. After obtaining Bechtel approval respecting this Firm, a formal appointment shall be made by executing an engineering services agreement.
2. Engineering Services Sub Contractor hereinafter called ‘Firm’
b) The scope of the Firm shall include but not be limited to carrying out the following engineering services’ operations for all buildings included within Process Buildings Package
1. Undertaking additional surveys, intrusive surveys and investigations as may be necessary for the engineering designs. Soil Investigations as required accomplishing the design
2. (Topographic survey shall be performed by AJESCONTRACTOR)
3. Production of all architectural, structural & allied services schematic designs
4. Perform all studies, design calculations etc.
5. Secure all governmental and local Authority permits and approvals if so necessary Compilation of any outstanding data deemed necessary for the completion of the detailed engineering design
6. Compilation of any outstanding data deemed necessary for the completion of the detailed engineering design
7. Production of all architectural & structural detailed designs for Bechtel approval according to contract & sub contract requirement.
8. Act as AJESCONTRACTOR Design & Engineering representative for the relevant Buildings contract scope
9. Civil & Architectural scope from its inception to completion as & when required
c) Building services : conceptual drawings only for plumbing & sanitary, small power & lighting, HVAC, Fire Fighting & Fire & Gas Detection/Loss prevention, Structured Cabling System
1. Liaison, co-ordinate & lead AJESCONTRACTOR services subcontractors’ design & engineering efforts
2. (AJESCONTRACTOR services subcontractors shall be responsible for the detailed designs and engineering for their relevant scope based on the conceptual drawings and other basic documents issued by Firm) to obtain necessarily approvals from Bechtel
3. Firm shall issue its whole drawings / documents production schedule immediately after the award & commence its design work keeping in line to the programme
4. Represent AJESCONTRACTOR at Bechtel offices / officials at UK, Abu Dhabi and / or Habshan as AJESCONTRACTOR’s Design & Engineering representative during the course of the contract from its inception to completion as & when required
5. Engineering coordination with the Firm shall be conducted from AJESCONTRACTOR head office. All field interfaces shall be conducted from site offices in collaboration with AJESCONTRACTOR field engineers
6. All other remaining functional descriptions shall be conducted by AJESCONTRACTOR personnel both in the head office as well as on site office depending on function wise technical nature
7. All engineering design products shall be managed conforming international standards included on the contract documents for the technicalities as well as document controls.
8. Firm shall comply with the agreed documentation system & conduct its operation in all respects accordingly. All the design documents shall be given appropriate numbering reference to meet traceability requirement. AJESCONTRACTOR operates its own system of centralized document control, which shall be used fully complying in accordance to Bechtel & Client Company Procedures by reformation, if so required
9. Firm shall produce & issue the scheduled documents at various stages of works for reviewing, approval & AFC etc efficiently keeping in line with the project construction plan on various phases. Any delay on this account shall not be acceptable to AJESCONTRACTOR management
10. Immediately, after the issue of the control documents to the site team, field/design engineers shall conduct over review of design & construction ability & consequently relevant design engineer raise technical queries to remedy any discrepancies among these documents if so discovered, which should immediately be resolved by the Firm & duly informed to Bechtel. All such documents shall be processed through the documentation system facilitating most convenient trace ability for consultancy & reference
11. Consequent upon the resolution of discrepancies, the effected design drawings shall be revised & reissued for construction duly incorporated with the solutions & circulated through documents control regularly to all concerned personnel.
12. Buildings services schematic drawings shall be issued to sub contractors for further development of shop & working drawings for Bechtel approval & issued to the concerned parties after getting duly approved for construction
13. Necessary structural shop drawings shall be produced by AJESCONTRACTOR own engineering personnel in head as well as on site offices, which shall also be processed into document control system for Bechtel & issued to the concerned parties after getting duly approved for construction
14. Preparation of requisitions for enquiry and award, technically evaluate bids and review of vendor / lower tier subcontractor documentation shall be done by purchase manager in collaboration with project manager. All these procedures have been incorporated on the company procurement procedures document.
d) Detailed Engineering Design:
Preparation, issue and control of calculations, specifications, drawings, material requisitions and bills of material. Extent of computer application for these activities. At the very first stage of the commencement of the detailed designs, Firm shall formulate positioning of all framing members vertically & horizontally befitting coordinates as well as level controls, meeting the architectural requirement maintaining the basic design principles that the whole structural skeleton behaves as an integral unit with its centre of gravity passing through or within the permissible vicinity of the resultant of all the applied forces considered avoiding any eccentricity and that settlement of the soil is within permissible limits. After considering all direct & indirect imposed loadings according to the relevant codes, design model shall be generated using Firm software. Loadings shall include, direct loads such as dead load, live load, seismic shear (though not applicable in Abu Dhabi geographical location) / wind load, blast load / effect, test load/application & also considering various analysis, a most critical case of resulting stresses shall be considered to be adopted for the dimensioning & further details of various vertical & horizontal members forming the framing skeleton. Generated model in 3D may be made available for the presentation to Bechtel & Company to explain & justify the adopted philosophy if so required. Calculations shall be done trying various options of loadings in 2D & 3 D & included with the design proposal for approval. These calculations shall be done & certified by a Chartered Engineer of Firm for structural adequacy & structural intended performance.
e) Services Designs
Designs of the services shall be carried out discipline wise.
Electrical - In accordance to the provision of electrical loadings design criteria as indicated on the Bechtel/Company documents, loadings, distribution of loading & all other parameters shall be adopted & calculated adhering to the international standards, IEE as well as UAE authorities regulations & schematic drawings produced meeting the architectural schematic drawings requirement
Similarly all loads from the HVAC disciplines as well as from the other remaining disciplines shall be included. This shall be done in close interface with all disciplines coordinated by the Services design coordinator / Design Project Engineer or Manager. All these details shall be included on the drawings documents for approval
All designs shall be generated using appropriate computer software package
f) Specialised discipline- Loss Prevention & others
On the similar pattern as described in the foregoing, detailed designs shall be calculated meeting all requirements of the contract specification, disciplinary performance as well as meeting international & conventional standards, complying local bodies statutory provisions.
From the foregoing approved documents, Bill of Quantities shall be generated discipline wise & building wise which document should be utilised for the purpose of Material Approval Proposal, Issue of requisitions of the approved materials to the procurement manager. The bill of quantities shall not constitute part of contract documents but serve guidance. All bills shall be generated using appropriate computer software package.
g) Specifications / Supplement Specifications
It is intended to adhere to Company specifications provided by Bechtel within the documents to every extent possible, however, to meet some particular requirement, supplement specifications shall be drawn & proposed for approval wherever necessary for producing better product or the materials for which no specification is defined. These shall be drawn in collaboration with Firm & AJESCONTRACTOR design team keeping in view an overall approach to documented specification criteria as well as conventional engineering & construction practice in similar circumstances.
h) Co-ordination Procedure
The following entitled co-ordinations shall be conducted during various stages of the design & execution that have been outlined below
Coordination between AJESCONTRACTOR & Bechtel head office
This part shall be conducted by regular interaction among AJESCONTRACTOR representatives Head Office based in Musaffa & Bechtel UK office to help resolve all pre & post award issue of Engineering services & monitoring project controls
Coordination between AJESCONTRACTOR & Bechtel site office
This part shall be conducted by regular interaction among AJESCONTRACTOR & Bechtel site representatives to help resolve all pre & post award issue of Engineering services & monitoring project controls
Coordination between AJESCONTRACTOR & Firm
This part shall be conducted by frequent interaction between AJESCONTRACTOR & Firm representatives of all disciplines for the resolution of all designs issues, issue of all documents, approval of all documents & resolution of all engineering issues on site
Coordination between AJESCONTRACTOR / Firm & Bechtel
This shall resolve all issues respecting engineering designs particularly during design stage as well as generally during construction phases for efficient decisions making to help smooth execution of all activities
Coordination between AJESCONTRACTOR / Firm & Bechtel on site
This shall resolve all issues respecting engineering designs during construction phases on site for efficient decisions making to help smooth execution of involved activities
Coordination between AJESCONTRACTOR Site & Firm
This is essential to keep on fast track the availability of complete design information for all ongoing as well as planned activities & should the information be pending, it shall be identified, coordinated & made available on site prior to its requirement to avoid any problem of execution
AJESCONTRACTOR internal Coordination among various sections
AJESCONTRACTOR in Head office organized with all corporate sections necessary to meet the requirement of this project shall operate as an integral functional team keeping on resolving regularly & as required all issues of project designs & follow up in all respects. This coordination is ongoing on daily basis & frequent interaction among all corporate managers as well as supporting professionals help the resolutions of all current & forthcoming issues. Management meetings are conducted regularly for making decisions to avoid any pending identified problems
AJESCONTRACTOR internal Coordination among various sections on site
Similarly on site all project sections managers & supporting professionals shall coordinate to resolve all types of problems to avoid any pending identified problems & notify to corporate management for immediate resolutions should the solution not be possible from site.
i) Review and Approval of Documents
This requires effecting an instant action on the part of AJESCONTRACTOR that, whenever any document is received, it must be reviewed by its design team located at Head Office/Site office as the case may be prior to formally submitting to Bechtel. After its submission to Bechtel, Bechtel shall process it through its system & after obtaining company approval, return approved or commented original to AJESCONTRACTOR for further necessary AJESCONTRACTOR action. All documentation shall be carried out adhering to the AJESCONTRACTOR documentation system after tuning that in line to Bechtel & Company requirement
j) CAD Procedure
It is intended to use standard CAD software for the production of design & drawings. All standard system of designing shall be adopted at every workstation available in Firm offices. The details of all available software & hardware have been given in attachment. Also included the hardware & software details which are functional in proposed Engineering sub contractor/Firm office
k) Engineering Reporting and Change Control
The status of design progress shall be submitted to Bechtel on a weekly basis during progress meeting. Should any change be required, that shall be affirmatively considered subject to cost impact resolution & then the change incorporation request issued by AJESCONTRACTOR to Firm. The Firm shall then work on the revision, its calculations & advise to AJESCONTRACTOR & Bechtel of any adverse effect on the structural adequacy / performance or if any amendment to be applied to already worked element / member. Should there be no such adverse consideration, the design shall be revised & revised document issued following the documentation & approval procedures.
l) Document Control Procedure
AJESCONTRACTOR operates its centralized DCC in head office that shall be tuned to Bechtel / Company documentation system & extended to site office to meet the project requirement. AJESCONTRACTOR document control system is enclosed for reference.
m) Vendor Print Numbering, Review and Distribution Procedure
All vendors shall be issued schedule of document numbers to be printed on the documents adequately in advance of documents preparation. All approved procedures of documents shall also apply to vendors' designs.
n) As-built Drawings
As built drawings serve the purpose of telling the user about the building records that should be used for the purpose of maintenance / or for whatever purpose possible. It is therefore, an important & significant part of documentation as well as also a contractual obligation on the part of AJESCONTRACTOR & Bechtel which should be affected smoothly & regularly throughout the duration of project. Should there be no change on the Released for construction drawings i.e. the construction has been carried out all in accordance with the approved documents provisions, there shall be no purpose of As - built drawings. But in practice, to produce physical structures, some changes are imminent due to arising of new requirement, changes, effects of disciplinary interfaces to bring the work to proper use functions etc. During the whole currency of the contract, it should be an endeavour of the AJESCONTRACTOR that all changes are recorded on contract documents as Red Lines mark up & issued to Bechtel for approval. These Red Lines mark up shall form the basis of producing all As Built documents on the project. It is not the drawings only that are to be recorded but also all changes whatsoever for any document on record. All these As Built shall form part of hand over dossiers. Should as built records be maintained regularly, this part of the dossiers shall be comfortably produced. The site design engineers shall keep an eye on this activity & record changes regularly as red line mark up & process the documentation to fulfil the contractual obligation to this extent possible. It is expected of the site engineers, the design engineers as well as land surveyors to coordinate on site to comply with this obligation efficiently. All survey changes or variations shall also be recorded on the drawings based on the pre pour & post pour records taken from survey section. Surveyor shall present all such changes on the corresponding documents to be recorded as Red Line Mark ups.
Inspection & Test Plans
All necessary Inspection & Test Plans shall be originated by the Quality Engineer in collaboration with Engineering in head office & Engineering in site team. These ITPs formats shall be issued for Bechtel & Company approval according to the procedures laid down on Project Quality plan. Production of all these documents shall be the responsibility of AJESCONTRACTOR Quality Manager / Engineer. Complete details about the quality management system have been included on the respective Quality Procedures document. Generally, ITPs for all disciplinary activities shall be produced for Bechtel & Company approval from site office in due course. All defined tests shall be conducted by Bechtel/Company approved laboratory located on site. For those items the tests shall be conducted by any Bechtel / Company nominated laboratory, for which facilities are not available on site. The details of these plans shall be submitted separately. Every ITP shall be allotted a document number along with a numbered checklist. Check list shall form the basis of inspection requirements.
Project Controls
Project Control management requires the formation of strategies those can be utilized optimally to achieve the target in minimum cost with best quality product
1. To achieve as aforesaid, it is extremely important that complete project should be analyzed from whole to one & all necessary resources to be used should be known prior to commencement of physical works.
2. Based on the project design, construction, commissioning and maintenance durations, Analysis, planning & charting out at various levels shall be carried out by the Planning Engineer. Further based on these periods, all necessary resources shall be arranged & mobilized by human resources, materials, and technical managers in collaboration with Project Manager.
3. The plans shall be monitored regularly, as the project construction progresses, on a weekly basis, monthly bases & no delay allowed & if any, immediate recovery shall be planed. The relevant reporting shall project the real quantum of planned & actual physical works, resources available, deficiency of resources, material procurement status, materials delivered & expected time of arrival etc & all necessary measures required to keep the construction on line & valuation worked accordingly. Every effort should be made to keep the progress in line with plan.
Procurement
Note-The term Material herein includes equipment also
1. According to the site requirement & provisions made on the plan, for temporary materials & consumables, requisitions shall be raised from site by the relevant engineer, checked, numbered & coded by the material controller & approved by the construction manager for transmission to head office procurement manager for further action. Cost controller shall further check the budgetary provision applicable & give clearance to the purchase manager for procurement. Purchase manager shall then invite the inquiries from various sources of material, negotiate & prepare a comparative statement & based on the merits of responses / quotations, record his comments based on the comparative statement as well as recommendations for the considerations by the Management. After reviewing the proposal, the management shall approve or reject the proposal. Purchase order shall be made on the approved proposal. An alternative source shall be located for the rejected proposal. A copy of the approval shall be provided to the project manager for follow up the delivery.
2. For permanent works, proposed material shall be submitted for Bechtel/Company approval on requisite Material Approval request form along with brochures, samples if applicable, processed through the document centre after Project manager approval. After obtaining Bechtel / Company approval on the request, procurement manager shall process the requisitioned approved item based on the budget quantities following in line the procedures applicable for temporary materials.
3. After the material is delivered to site, material controller & relevant engineer shall check the quality & quantity of the delivery. Any deficiency in quantity, quality or any damage observed, shall immediately be notified to the procurement manager through construction manager. Delivery information shall be circulated to the concerned personnel & quality manager himself shall or delegate an inspector or the relevant inspector shall check the adequacy of quality & if necessary according to ITP provision, shall invite the Bechtel/Company engineer to inspect / examine the delivery. The selected samples of delivered materials shall be sent to an approved laboratory for technical tests for the purpose of certification of compliance. After inspections & approvals, delivered materials shall be recorded in stores receipt documents, an issue to site may be undertaken thereafter.
4. Post placement of purchase order, Procurement Manager shall track various stages of material production & transportation or shipment to the site/delivery & if so noticed that an expectation exists for the delay in delivery, shall apply all efforts to expedite the delivery on appointed date.
5. Materials shall be stored in proper designated areas complying with the manufacturer’s instructions. Separate area shall be located for the materials requiring certain temperature of storage. Stores shall be well constructed & shaded. Generally, all consumables shall be stored in shade provided with proper lock & key arrangement. Materials which remain unaffected by exposition to weather may be stored open duly protected under proper watch & ward.
6. Proper protection shall be made for all stored materials inside covered area or out side. Necessary protection by removable membranes such as polythene or tarpaulins shall be used to protect material from the ingress of moistures or from effect of dust.
7. Storage of all materials delivered shall be done complying to the set & approved procedures making sure that all inventories can be verified any time & that any material can be traced any time easily.
8. All entries of the incoming deliveries shall be recorded into the register & verified by the store keeper & material controller that it complies with the details on deliveries documents. Any deficiency noticed shall be immediately reported to the procurement manager.
9. After the acceptance of the material by the concerned authority only, a store issue shall be affected & recorded on the required issue documentation. Regularly the status of all receipts, issues & balance in stores shall be reported to the construction & project manager who shall act further depending on the project requirement.
10. Elaborate details have been given on the AJESCONTRACTOR procurement procedures document
International and local transportation and customs clearance
11. Materials & equipment that have to be imported from overseas, shall also follow the foregoing procedures with the addition that necessary Letter of credits shall be opened by AJESCONTRACTOR adequately in advance of the required date of delivery adhering to schedule date, so that the delivery is shipped in time from original source. AJESCONTRACTOR procurement manager shall arrange all port clearances immediately of shipment arrival & material shipped to work site. Tests & Examinations shall be conducted similarly as aforesaid. Any claims of insurances for the damaged material shall be made immediately after inspections. Process to replace the damaged material shall be carried out at once to avoid any delay. If so required, AJESCONTRACTOR shall apply in time for any statutory road permit for the efficient transportation of the material by suitable vehicles. Elaborate details have been given on the AJESCONTRACTOR procurement procedures document.
Procurement and provision of construction spares, commissioning spares, insurance spares and special tools
12. These shall be processed applying the same methods of procurement & delivery received by AJESCONTRACTOR / its services or specialist sub contractors. Most probably, the spares shall form part of the order package. Elaborate details have been given on the AJESCONTRACTOR procurement procedures document
Recommendation for two-year operating spares for approval by Company in accordance with the G-SPIR format requirements
13. This provision shall be followed & spares delivered according to contract & Company requirement by AJESCONTRACTOR / its services sub contractors. Elaborate details have been given on the AJESCONTRACTOR procurement procedures document
Procurement and provision of two-years operating spares, (at cost and extra over Lump Sum Subcontract Price)
14. Similarly this provision shall be effected & spares delivered according to Bechtel/Company instruction to AJESCONTRACTOR subject to the approval of the procurement cost prior to the purchase order placement by AJESCONTRACTOR
Source inspection
15. If so required by Bechtel / Company, arrangement shall be made by AJESCONTRACTOR after meeting with the vendor or manufacturer, a date & time appointed for the inspection to the convenience of all parties concerned & required inspection at source conducted to the satisfaction of Bechtel or Company. Representatives from Bechtel and/or Company, AJESCONTRACTOR, services sub contractor & vendor shall constitute an inspection at source team. Proper record of inspection shall be made.
Compliance with Company’s criteria and procedures for selection of vendors including but not limited to compliance with local registration requirements and approval of purchase requisitions, bidders lists, technical bid summaries and award recommendations
16. We shall adhere to Company requirements.
Involvement by the UAE in particular and GCC in general with respect to the provision of local materials and services shall be encouraged
17. AJESCONTRACTOR honor & respect with due regards to the provisions of UAE & GCC policies for the materials & professional services which need be availed out of the local & GCC sources subject to the compliance with the quality requirement. Every effort shall be attempted by Procurement Manager to chart out the available ‘local & GCC sources’ & prepare a database to be used whenever any applicable procurement arises. This procedure is already followed by AJESCONTRACTOR. AJESCONTRACTOR vendors shall also comply with this requirement.
Pre Mobilization Planning
A thorough and logical mobilization plan is essential for the successful start-up of construction activities. This plan must detail all planning, preparation and pre-construction activities necessary to ensure the timely availability of drawings, personnel, construction equipment, temporary facilities and materials at the job site to properly support the construction efforts.
1. This plan is already under preparation at this stage.
2. This preliminary mobilization plan shall be further developed after contract award and concluded within a week of the contract award. The mobilization plan shall be closely coordinated with the construction plan to ensure mobilization activities properly lead into and provide a smooth transition into initial construction activities.
3. A time scale bar chart diagram shall be prepared with early and late activity bars detailing the main activities to achieve full mobilization of staff, labour, construction equipment and camp/site facilities shall be prepared at the commencement of the contract.
4. Mobilization plans for staff & labour, accommodation and temporary facilities established during the bid stage (as conceived in pre-mobilization planning) would be studied and re-evaluated in the light of any changes, which may have occurred since the day of preparation. All necessary adjustment measures shall be implemented.
Additional site visits shall be conducted immediately after the project kick off to confirm data collected during bidding stage, reconfirm assumptions and establish additional information required to permit smooth and timely mobilization. The following items shall be reviewed and confirmed.
➢ Access to the job site
➢ Locations of temporary facilities
➢ Company requirements for properly validated licenses and certificates to be held by construction personnel
➢ Transport plans
➢ Loss prevention and safety requirements
➢ Arrangements for first-aid facilities
➢ Arrangements for drinking water and construction water
➢ Arrangements for electricity supply
➢ Arrangements for storage fuels and lubricants
➢ Arrangements for sanitary & its disposal facilities
➢ Final arrangements for security interface with Bechtel & Company
Work Centres
AjesContractor Head Office
Upon notification of contract award, the key personnel to the site Management Team shall be assigned. Construction personnel shall be mobilized to the project site office to provide input and direction to the project team. Successful project execution requires construction experts to be active from the onset of the project. The only activity to continue from Head Office after mobilization period is procurement. All procurement for the project shall be done from the corporate procurement section located in AJESCONTRACTOR Head Office at Mussaffa, Abu Dhabi.
The following specific activities must be addressed early to be fully effective:
1. Finalize construction schedule requirements and subsequent approval from Contractor
2. Review manpower requirements for both non-manual and manual personnel; update these requirements by means of staffing schedules, histograms and craft mixes; and ensure subcontractors manning levels are compatible.
3. Review construction equipment needs and ensure that timely subcontractors mobilization plans are in place.
4. Review field procedures and method statements defining standards, policies and procedures required for the execution of the works and ensure they constitute “Project Specific” status.
5. Review environmental, safety and Health (ES&H) and site security plans to ensure compliance with the client’s specifications and guidelines.
6. Review Construction Quality plan in line with the guidelines of ISO 9000 and check Established QC parameters by discipline.
7. Overview temporary facility requirements, including indirects such as tools, consumables, gases and the like and check subcontractors compliance.
8. Actively pursue preliminary site activities such as approvals, permits, establishing contracts.
9. Ensure Lessons Learned & Practices from previous projects are well understood & should be applied effectively from the onset of the works itself to achieve professional products.
AJESCONTRACTOR Site Office
Actual ‘on site management’ would be from offices based on the site next to Contractor and Company’s office. AJESCONTRACTOR Site Office is fully supported by AJESCONTRACTOR Head Office at Musaffa.
The following major activities shall be carried out at site offices.
➢ Safety Regulation Enforcement
➢ Quality Assurance Enforcement and Procedures
➢ Construction Method Statements
➢ Construction Planning
➢ Site Documents Control
➢ Field Engineering & Design Controls
➢ Material Requisitions
➢ Materials Control and Tracking
➢ Materials Storage
➢ Work Procedures
➢ Physical Construction
➢ Site Administration
Mobilization
Mobilization shall be coordinated from the AJESCONTRACTOR Head Office at Abu Dhabi with input from AJESCONTRACTOR personnel already mobilized for the execution of Site Preparation Package and Temporary Facilities for Contractor and Company. Existing teams responsible for the execution of the those two mentioned packages already have substantial cadre of experienced professional well versed in mobilization of temporary facilities, project execution, QA / QC planning, Safety and security operations etc.
➢ Mobilization shall commence with the following activities:
➢ Kick off meeting to commence the sub contract
➢ Commencement of the required land surveys to establish various horizontal & vertical controls bench marks
➢ Incept of the engineering designs at the Firm office
➢ Soil Investigation by an approved laboratory
➢ Construction of temporary facilities
➢ Obtaining various permits from Authorities and conclusion of arrangements with local committees where necessary.
➢ Third party independent concrete testing laboratory credentials submission for approval.
1. Shortly after contract award, site surveying shall begin utilizing the Total Station System to establish accurate control points for the performance of the work.
2. As soon as practicable, the plans and specification for the site temporary construction facilities shall be finalized and released for installation.
3. During the installation of the temporary facilities existing AJESCONTRACTOR site offices shall be utilized to supervise the site activities required for the temporary facilities installation.
4. On completion of the site offices at Habshan, balance of the AJESCONTRACTOR construction staff shall be mobilized to the site along with construction equipment, tools, consumables, warehousing, storage and other items necessary to commence the work in accordance with the construction schedule. Temporary facilities at the job site shall include Generator Yard and Construction water storage tank, carpentry yard, re-bar fabrication, lay-down area, warehouse and workshop facilities at location A4.
5. At the start of the construction, an emphasis shall be given on the critical requirements of the construction schedule. Work shall be carried out under continual supervision and inspection over performance. Progress shall be monitored on the basis of actual installed quantities compared to scheduled quantities.
6. For construction areas, dedicated work crews shall be allocated for each discipline supervised by foremen and general foremen who in turn shall report to the discipline supervisors / site engineers. Based on the construction schedule requirements, necessary operational crews shall be formed and controlled over to meet the planned progress target to be physically achieved satisfactorily.
7. It is the responsibility of the supervisor / site engineer to ensure the efficient utilization of his material, workforce, tools and equipment.
8. For ‘construction operation water’ requirement, unless an alternative arrangement is made available, water shall be trucked from nearby Desalination plant.
9. Site ‘construction and temporary facilities electricity requirements’ shall be met by installing suitable size and suitable numbers of generators.
Subcontract Strategy
1. Building Engineering services shall be utilized by appointing a consulting firm, to be responsible for the complete architectural, structural design drawings & documents productions as well as for the services schematic designs drawings production. Firm shall also represent AJESCONTRACTOR regularly during the project currency
2. Detailed services designs shall be prepared by AJESCONTRACTOR services sub contractors
3. AJESCONTRACTOR shall carry out broadly all civil engineering works employing its own resources of manpower, machines, equipment etc.
4. Lower tier sub contracts shall be allowed for the execution of single operations such as supply of ready mix concrete, roofing finishes etc
5. Ready Mixed Concrete is envisaged supplied from an established RMC supplier, an establishment with proven track record duly approved for supplying concrete by GASCO, within 10 kms of the site. However, in the mean time, without reservations, we are also seriously considering installing our own concrete batching plant.
6. In case any minor or specialized work is necessary to be sub contracted on lower tier, Company procedures shall be apply for prequalification and award of the subcontracts.
Testing And Inspection
1. A field inspection and testing program shall be organized to be in line with AJESCONTRACTOR Quality manual & Approved Project plan under overall responsibility of the QA / QC Manager.
2. Prior to conduct any testing, Contractor and Company (as required by QC Plan and ITP) shall be advised of the tests for witness.
3. Wherever required vendor specialist shall be made available for conduct of testing and inspections.
Material Management
Once material has arrived at site, material management shall come under the purview and custody of the site store staff. The storekeeper, supported by his store assistant shall be responsible for the custody of the material prior to issue. Material tracking from source to the place of installation shall be conducted by the computerized system. The construction manager shall be responsible to provide the technical oversight and direction for the control of materials at the construction site area. More information has already been elaborated in the foregoing.
Procurement
The Central procurement department located at the Al Jaber Energy Services, Musafa, Abu Dhabi, UAE office shall be responsible for all purchases adhering to the following procedure.
Preparation of Purchase Requisition shall be made based on take-offs quantities calculated from the approved drawings documents. Purchase requisition shall completely, identify all applicable drawings, data sheets, specifications, vendor documentation requirements etc. with the inclusion of following information.
➢ Quantity of each item required with comprehensive breakdown
➢ Adequate information concerning nomenclature description, Material approvals, Quality required, applicable specifications, design & other drawings, etc / or detailed outline of the material required.
➢ Required delivery dates for all major items.
➢ Delivery points of major items
➢ Inspection of the goods at the point of origin issue
➢ Certification of test data and/or compliance / warranty
➢ Method of shipment (if goods imported), conditions/packing
➢ Instruction of holding, kitting consolidation, marking
➢ Drawings, manuals etc
➢ Spare parts requirements
➢ Special Instructions to vendors
1. A technical evaluation shall be done in house to verify the conformity with specifications.
2. Samples and technical information shall be submitted to Contractor. Once the final approval from the client is obtained, purchase order shall be raised.
3. Upon receipt of Purchase Requisition, a purchase order shall be raised and entered in the computer register system, indicating cost and budget allocation.
4. The procurement department shall maintain a follow-up system so that contact suppliers and / or manufactures may be made on continuous basis.
5. All questionable delivery commitments shall be expedited on a daily, weekly and monthly basis as required to ensure prompt delivery in accordance with the requirements.
Organization
Corporate Organization
1. Al Jaber Establishment formally known as Al Jaber transport & General Contracting EstablishmentThe Contractor is an umbrella organization which has got numerous divisions within in itself and which is also the parent company for various subsidiaries. Al Jaber Energy Services (AJES) is a The Contractor is aseparately registered company specifically set-up to target the energy sectors and its clients. AJESCONTRACTOR has been operating under the Al Jaber Establishment umbrella since 1995.
2. Broadly all the activities of the above divisions and companies can be divided into:
➢ General Construction
➢ Heavy Lifting and Transport Services.
➢ Trading
➢ Industrial
➢ Plant Construction.
Site Organization
Proposed site organisation and responsibilities of the key personnel are enclosed. All supervisory staff shall be highly experienced and qualified drawn from on-going projects wherever possible.
Manpower Resourcing And Mobilization
1. All the personnel on site shall be employees of Al Jaber Energy ServicesContractor. All of the required personnel to execute the work are already in UAE and working on other sites. These sites are due for demobilisation in the coming months.
2. The planning department shall produce a histogram schedule of the resources by category. These schedules shall define the monthly manpower levels. The scheduled shall also be indicative of manpower mobilization.
3. The standard Contractor Al Jaber Energy Services site supervision is based upon the principle of training. A charge hand shall be trained and supervised by a foreman. In normal cases a foreman shall supervise four charge hands. The charge hand shall then supervise approximately ten labours. Where a special process is conducted, this ratio may be revised accordingly.
4. Training is a requirement of the Contractor Al Jaber Energy Services quality management system and foreman and charge hands shall conduct training of the manpower in their respective roles and functions. The recruitment of manpower shall ensure that background in the relevant job skill has been achieved. The training in quality awareness shall be an ongoing process through the quality department and the foreman.
5. Sufficient numbers of site supporting staffs which consists of Mechanics, Electricians, Auto Electricians, Guards, Water boys etc and other ancillary staff shall be deployed for the unhindered progress of the work.
6. The Contractor Al Jaber Group contains at all times a vast pool of manpower in all Disciplines. These workforces are at all times working on various projects in multi discipline fields.
Equipment Resourcing And Mobilization
7. Based on the project schedule the planning department shall generate the construction equipment schedules.
8. The Contractor Al Jaber Group is one of the largest equipment rental companies in the GCC with over 5000 fleet where modern repair and machine facilities enable them to maintain a first class fleet of equipment.
9. It has been our company policy to weed out the old equipment on a periodical basis and keep the equipment fleet very young. We have one of the youngest fleets of equipment in the GCC based on size.
Construction Method Statement– Process Buildings
Following the award of the project, a detailed contract scope works programme for the whole project shall be developed including all disciplines separately based on already approved outline preliminary programme appended under the coordination of our Construction Manager and Planning Engineer
The Method Statements related to various project activities shall be submitted for contractor’s approval prior to commencement of any activity during the execution stage.
Subcontracting
Develop and manage a lower tier subcontracting plan and subcontractor list AJESCONTRACTOR plans to carry out most of the civil activities itself but selected items shall be sub contracted on the lower tier such as ready mix concrete, roofing application, doors & windows manufacturing, painting application, raised flooring application, suspended ceiling installation etc.
Perform all lower tier subcontracting activities including specification of packages of Work to be subcontracted, pre-qualification of bidders, issue of ITBs, bid evaluation, recommendation and award. All relevant information shall be provided by the Project Manager to the purchase manager who should act immediately to conduct the required functions & the lower tier deal finalized after obtaining Company recommendation by the Project manager
a) Management of lower tier subcontractors and their activities
1. These operations shall be manager & controlled by the Construction Manager on site & reported to the Project manager
2. Monitoring and reporting of all lower tier-subcontracting activities. This activity shall be affected by the project manager based on the construction manager report. The report shall be regularly provided to the planning engineer, head office & Company.
3. Involvement by the UAE in particular and GCC in general with respect to the provision of local services shall be encouraged. As included earlier somewhere else that UAE national policy shall fully be honored subject to making no compromise to the quality requirement
4. Construction including providing labour, supervision, safety and quality management, inspection, vendor support, temporary facilities and services, and construction equipment, tools, utilities and consumables. All these issues have been elaborated earlier somewhere else
b) Provision of Construction Camp, messing, transport to Jobsite, sanitation, utilities etc. for SUBCONTRACTOR’s personnel.
1. All these shall be fully undertaken by AJESCONTRACTOR based on the site requirement. Already a camp exists on site & further extension shall be made to meet the contract requirement. Messing shall be resolved by employing catering sub contractors so that all personnel & workers take good food. All utilities shall be provided to maintain the good house keeping of the camp. All safety & emergency precautionary measures shall be undertaken to the contract requirement. AJESCONTRACTOR operates its own system of transport, which shall be extended for the use of workers transportation. Similarly, the arrangements shall be made for the employed high tier & low tier sub contractors on this package
All activities necessary for Mechanical Completion, Pre commissioning, commissioning, and Provisional Acceptance.
2. All activities for the buildings part have been described on the method statement appended
All testing facilities required at Jobsite
3. AJESCONTRACTOR shall supply an independent testing laboratory equipped with all equipment necessary for involved tests for this package properly managed by qualified personnel meeting all QA testing & certification requirement.
Full responsibility for co-ordination with any Third Party Inspectorate
4. AJESCONTRACTOR aggress to extend its full cooperation to meet any Third Party Inspections. Project manager & Construction manager shall be responsible to affect this part of the contract.
Supply and coordination of lower tier subcontractor and vendor representatives as necessary
AJESCONTRACTOR shall supply & coordinate with all lower tier sub contractors & vendors or their respective representatives to the requirement. Supply of these shall be managed by the Purchase Manager while the Project manager shall manage on site. Coordination shall be conducted by the Construction Manager
Provision of waste management at all Jobsite locations, including disinvestments of all temporary works, upon completion of Work
Waste management shall be fully operational on a day to day basis both for garbage & sewage according to the planned arrangements. Safety manager shall be responsible for the operations of all such activities & report to the Construction/Project Manager regularly
Provision of medical and fire-fighting services at Jobsite and for temporary works
Medical male nurse shall be employed on job site First Aid centre. Male nurse shall take care of providing First Aid treatment to injured workmen immediately & then the worker if so necessary in the opinion of the male nurse, shall be sent to Contractor site clinic for further treatment. Safety manager shall be responsible for the operations of all such activities & report to the Construction/Project Manager regularly
SPECIFIC CONSTRUCTION METHOD STATEMENT– BUILDINGS PACKAGE
Sample Only
1. It is known from the contract documents that 15 buildings for various intending use as Sub station+Bottle Store, New Control Building, Instrument Equipment Shelter+Bottle Store and Operator Shelter have been defined to be constructed
2. Keeping in view the nature of contract being EPC, AJESCONTRACTOR have decided to apply RCC in situ construction for all intended buildings accepting the Company direction on drawings for which a confirmation was communicated to Company on May 7, 2005. RCC framings shall meet the design criteria of blast resistant & resilient structure productions meaningfully. Sub Structurse shall also be constructed of RCC in situ.
3. Soil report bore holes log direct to employing spread footings in isolation, which shall be integrated by grade beams/walls to form an unit for compaction settlement & long-term consolidation controls. However, to verify the validity of the soil report, AJESCONTRACTOR shall further conduct investigations based on the Engineering Services sub contracting firm recommendations, utilizing the services of an approved laboratory. Foundations shall be designed based on the laboratory recommendations.
4. The phases of the construction shall be adhered to meeting the set out milestones, which are very tight for the purpose of physically executing the buildings package. The construction teams shall be constituted to meet the requirement as exhibited on the organization chart. One project site manager shall be an overall responsible for all on site execution operations & conduct interface with the head office duly supported by safety, construction, quality, technical & administration sections all to be well established on site. Project & Construction manager shall in collaboration constitute six independent dedicated teams for six working divisions/areas lead by each site engineer directly reporting to construction manager as shown on the organization chart. Each team shall comprise of one site engineer, required number of site foreman & further supported by charge hand from each trade. For each team one quality assurance/control engineer shall be deployed to conduct QA / QC procedures for the relevant area. One General foreman shall be deployed for the labour engagement responsibilities on various day-to-day activities. For all other organization details please refer to Project organization plan.
5. A surveying team shall be constituted lead by a chief / senior surveyor to carry out all site setting works from the stage of preliminary site survey to the point of recording redlines for the purpose of ‘as built’. Survey team shall coordinate with each site engineer to meet site requirement. It shall be the responsibility of each team to set out, inspect & record all layouts, pre & post concrete data for the purpose of approval & handover dossiers. All horizontal & vertical controls shall be established & monitored by the leader.
6. All approved controlled drawings shall be issued to surveying team to commence the setting out operations. After ensuring proper safety arrangements are in, survey barricading shall be established & necessary grids control fixed & inspected by QA / QC. Excavation shall commence after the clearance is obtained & continue according to the plan. Proper safety shoring shall be arranged during this activity when it crosses 1.5 m depth & arrangement for suitable access into pit made to the satisfaction of the safety inspector & company. All unsuitable excavated material shall continuously be removed from site & suitable material tip off to designated area. All environment controls shall be taken care off during this operation. A surveyor shall continuously ensure the depth of excavation does not exceed the design requirement. When the excavation reaches the formation level, dressing shall be started followed by compaction of the soil so that area is ready for inspections.
7. AJESCONTRACTOR QA / QC shall inspect the formation. After required clearance, arrangement shall be made for blinding all released area according to the approved method statements. Area shall be blinded to the design thickness minimum 75 mm properly levelled & trowel applied to make it suitable for the purpose to receive heavy duty concrete protection layer membrane. Then curing shall be carried out for 3 days. Application of the protection membrane shall commence thereafter over whole area of the blinding.
8. Foundations shall be set out to design details to permit formwork erection & rebar placement. All starter rebar shall also be fixed supported by plastic spacer. On sides also plastic spacers shall be fixed to keep all rebar in proper position. Foundation top levels shall be fixed using 25 mm plastic triangular chamfers horizontally. Chamfer shall also be fixed on the vertical edges of the forms. Inspection shall be conducted followed by concrete pouring supplied by an approved ready mix plant. All ready mix record shall be maintained according to QA approved procedures. After concreting is finished, proper curing arrangements shall be made for the required number of specified days. Setting outs for further stub columns shall be done & preparatory works continued.
9. In parallel, all works regarding grade beams/walls shall continue complying with all the approved procedures. Fabrication of rebars shall be done in a designated area while fabrication of forms too in another designated area all according to approved procedures. After completing the preparatory works for the stub columns, inspections & pouring shall be carried out following all procedures. Operations of grade beams/walls shall be taken up on similar principle as other activities.
10. For sub stations where cable cellar floor slab is to be built, shall be prepared together with surrounding sub structures. After curing is done for the specified period, protection membrane shall be applied on both horizontal & vertical surfaces followed by inspection & backfill in compacted layers to specified requirement. Field density tests shall be conducted to monitor the requirement of density & water content etc. Backfill shall continue up to the formation level below the grade slabs blinding in buildings & where cellar suspended floor slab is to be built, backfill shall be done around the grade structures.
11. Preparations shall be carried out for the cellar suspended slabs by erecting required supporting system, forms fixed, rebars placed, all services inserts provided & inspections conducted from all disciplines followed by the concrete pouring observing all QA procedures.
12. Similarly, on the areas where grade slab is to be built, after the completion of the backfill up to the bottom of blinding concrete i.e. formation level, plastic sheet shall be laid after compaction & leveling & all necessary under ground services completion, blinding concrete shall be poured, leveled & wood floated well to make it sufficient enough to receive the grade slab. After three days of curing on blinding, preparation for the grade slab works shall commence & re-bars placed either by site fabrication or using pre fabricated mesh to design requirement. All necessary services shall be inserted, inspections conducted & concrete poured. At this stage of the building, major sub structural elements have been completed giving a way to commence the super structural works.
13. All preparatory works of superstructure elements shall come into full swing by the fabrication of the forms & steel rebar fabrication to the BBS details. Scaffolding shall be erected for the fixing & placing vertical rebars of columns & walls in all required areas. Steel rebars shall be fixed placed with spaces & inspections conducted. Any inserts necessary for the electrical conduit or earthing, shall be installed immediately & inspection conducted. Work of vertical forms shall commence for sides of columns as well as walls fixed using removable tie bolts with cones/boss at tie rod ends. Forms shall be made of fair face ply to produce specified texture to the elevation requirement. All exposed vertical edges shall be chamfered using plastic chamfer 25 x 25 mm triangular section nailed to the forms. Inspections shall be conducted for the elements ready for pouring. Pouring shall commence keeping the height of pour not more than 2 m using vertical pipe chute of the pump reaching up to necessary level. Curing shall follow adhering to the agreed or approved procedures. Similarly walls of transformer areas shall be built adhering to all QA procedures.
14. Next operation of erection of the propriety scaffolding to support the superstructure roof slab shall commence strictly complying with the scaffolding drawings. On parallel, operations of fabrication of forms & rebar shall be taken up. All vertical & grid controls shall be established by surveyor to keep in line & level all forms of beams alignment & soffits. Level of slab shall be established & then work of form fixing shall commence followed by placing of beams reinforcement. Services inserts such as electrical conduits, HVAC inserts or block outs if necessary & other inserts shall be marked for establishment. Works of steel rebar placement shall continue in parallel to speed up the preparatory works. An inspection of the preparatory works shall be conducted by all involved disciplines. After obtaining approval for the pour, pouring shall be carried out adhering to pouring method statement compliance. Curing shall be started immediately after finishing the surface as required by the curing compound manufacturer’s instruction for the application of compound & also by using water in combination all to agreed procedures.
15. Intermediate slabs on the Battery rooms shall be constructed following the foregoing procedure.
16. Erection of the scaffolding around shall extend to cover the parapet portion followed by formwork & rebar fixing. On the similar pattern as defined earlier, all inserts shall be fixed followed by all relevant inspections & pour. All aforesaid concreting operations shall be supported by necessary number of transit mixers, concrete pumps, nozzle vibrators conforming to perform 10000 oscillation per minute & all other necessary arrangements necessary to perform the best task. Well-trained teams shall be engaged for such operations. All necessary safety measures shall be installed. If necessary during hot weather, rest pauses shall be allowed to workers with the provision of liquid or salt water. Forms shall be struck form the elements carefully ensuring full safety intact. Concrete surface shall be inspected immediately after removing form, cleaned & surface treatment to the project specification applied to produce specified class of surface texture i.e. smooth finish or sandy or rough or grouted.
17. Any defective concrete shall be applied remedial measures as agreed with the Company or Client. On New Control Building, special forms shall be erected for dome portion, followed by the steel rebar fixing & pour. Wherever special openings have been provided in designs within the structural framing, those shall be provided within the formwork itself. Now the structural framing works have been completed giving way to attack on internal walls & other items such as dry wall lining & preparation for the roofing item. All preparations shall commence for the remaining works.
18. Block work shall be carried out wherever required for walls followed by services fix 1 items & then plastered over as specified.
19. Roofing shall commence by scabbling the slab surface, laying of light weight foam concrete in grade minimum % to receive water proofing membrane, membrane application followed by water leak test for 72 hours & then polystyrene boards laid over to be protected by concrete pavers. Seperation geotextile shall be provided according to applicator direction. Over concrete protection paint on parapet, Aluminum flashing shall be fixed to design details.
20. Services site team shall be inducted in full swing for carrying out all disciplinary operations.
21. Suspended ceiling fixers shall also enter in to commence the work. Where there is no ceiling, work on the slab finishes shall continue.
22. Wall lining work shall be carried out in accordance to design details after ensuring complete inspections of services conduits etc. are over.
23. Fixing of cable terminations framing steel as well as framing steel for the floor openings shall be carried out according to details.
24. Flooring shall be carried out in according to design details. Tiling shall be followed on required areas schedules to receive floor or wall tiles.
25. Concrete surfaces requiring protection shall be applied accordingly with 3 coat system or any other approved.
26. Operations of constructing transformer foundations shall be carried out & protection applied to that. Sums shall be constructed to details in floor. Gravel filling shall be done around the transformer oil containments/enclosures.
27. All finishing items shall be carried out in wet areas & concealed piping shall be carried out prior to that. Services operations shall be completed in all areas followed by finishing works. Services inspections shall be conducted prior to commence the finishing works.
28. When the works are ready involving the scope of telecommunication routes, an entry shall be allowed to the related other sub contractor from other scopes provided with full cooperation in all respects.
29. Similarly, car park shed shall be worked by constructing its foundations with anchor bolts inserts. The engineered structure shall be erected on the foundations.
30. Works for the planter beds shall also be completed accordingly to the plan requirement. Works of all ramps shall be constructed according to details.
31. Works of external services within 5 m of building shall be completed & tested. All surrounding or backfills shall be completed to the specification provisions. Walkways works shall commence by filling & leveling around the building excluding the instrumentation room on the plant side portions. Walkway Kerb shall be fixed to the profile over the blinding concrete with haunch concrete over. Sand shall be filled over the compacted & profiled area of the walkways whereon the interlocking concrete blocks are to be fixed in to design pattern.
32. Around new control building, work of embankment shall be carried out to the profile shown & back fill done in layers to retain the walkway. This embankment shall be used for grass growing. All internal & external light fixtures shall be installed. New control building requires complete furnishing excepting personal computers.
33. All furniture shall be procured, inspected & installed accordingly to the relevant details.
34. Necessary directional signs to be installed in buildings shall be fixed to approvals. All other furniture within scope shall be inspected & installed accordingly.
35. Foundation works for a 100 m mast to support radio antenna shall be carried out at New Control Building which activities include setting out, excavation, blinding, rcc block, concrete protection.
36. External landscape items such as gravel spreading, grass growing shall be undertaken accoding to layout shown on drawing.
37. Pre commissioning, Commissioning, Provisional Acceptance and Final Acceptance All services individual items integrity & tests shall be conducted by related sub contractors & record maintained. After ensuring that each installation is efficient in performance, release for commissioning shall be given. Details are included within the technical literature/datasheet
38. Supply and coordination of lower tier subcontractor and vendor representatives as necessary All necessary lowers tier sub contractor & vendor representatives shall be provided to the scope requirement
39. All activities necessary to achieve Pre commissioning, commissioning and Provisional Acceptance. Services disciplines such as electrical, fire alarm, & gas detection system, fire suppression system, internal sanitary & drainage, infrastructure of all other included services require pre commissioning, commissioning & provisional acceptance. All fix 1 & fix 2 procedures shall be conducted according to ITPs & approved procedures.
40. All utilities, fuels, lubricants, chemicals and catalysts required up to issuance of the Provisional Acceptance Certificate. Within Contractor scope
41. All required operating and maintenance documentation. All operating & maintenance manuals shall be submitted covering work scope items
Warranty Obligations through to Final Acceptance SHALL be submitted for the work scope items
42. For further details on the services method statements for the package, please refer to the CCTC documentation (not attached within this proposal).
EXECUTION PLAN Method statement
(PROJECT IMPLEMENTATION STRATEGY)
Civil Works/Site Preparations
Construction Method Statements
Sample Only
Civil Works & site preparations shall be executed according to Company & Contractor requirement depending upon the priorities. It is expected that all the design & relevant details pertaining all involved structures shall be issued for construction by the Contractor in time according to the agreed schedule of construction. It is also expected that the site shall also be made available in time to meet the schedule requirement. It is proposed to commence the works from all available areas respecting which designs are available immediately after mobilization & upon the receipt of the ‘Permits to Work’ if so required. Areas belonging to the standalone scopes may also be taken upon one by one depending upon the Company priority.
1. Smooth execution of the construction works necessitates the organization of certain competent teams constituted of capable members fully trained in their respective callings. The team members should upon receipt of the project documents should not waste any day but immediately commence with the practical works with the resolutions of all technicalities issues. Surveyor should efficiently establish all setting outs & its controls with prompt approval according to the guidance of the site engineer. Site engineer in conjunction with the site management should arrange all equipment necessary for the smooth excavation & other following activities. It is also advised that feed back & homework planning has also been under charting process at the pre mobilization stage as envisaged somewhere else in this document.
2. Since our organization works adhering to the set standards of execution in compliance with the quality manual & the project quality plan, all our staffing level shall affirmatively follow the guidance & the direction provided to, optimally utilize for the discharge of their functional responsibilities entrusted by the management, for product quality assurance as well as customer satisfaction.
3. Our efforts shall be to organize the works in such a way that trained teams are established on site for important activities such as steel fixing, formwork, concreting, concrete protection etc. The team members shall be proficiently skilled in the respective trades & group shall be rotated on the project various locations in sequence to perform the jobs on various work elements following the guidance & direction of the trade foreman & general foreman, adhering to the instructions by the site engineer and/or construction manager. Quality team shall monitor fully these operations of the construction teams.
4. These teams shall be extended full technical & administrative support from the engineering as well as procurement & all other controllers based on site as well as in head office immediately, whenever required.
This document gives an overall strategy of proposed performance pertaining the site preparation & civil works keeping in view the quantities of various items/descriptions involved & the construction duration according to the defined milestones.
5. Company major policies have already been incorporated within the Execution plan of the New Buildings Package which is an EPC forming a part of overall subcontract scopes.
6. This document should be considered as an extension of that, since the main purpose herein is to serve on the communication of specifically significant procedures that may be adopted on the project based on our past experience of construct able competency which has been exhibited by outlining the procedures & definitions that should be adopted for the proficient prosecution/ execution respecting various preparatory works items involved on the project under works code groups entitling Site Preparations & Civil Works
7. The scope involves the sub titles & their description of constructions as follows, which cover major portions of the Preparation & Civil Works for the project.
8. Site protection & preparation- Surface levelling-Area for this activity shall be selected according to the scope indicated on the IFC drawings. Inspection of the available surface shall be done first visually & then ascertained by spot levelling & undulations noted. Undulation means certain types of ridges & valleys generally of irregular profile. Ridges shall be chipped out & filled into valleys to form a balance throughout the area under consideration. All unsuitable material shall be removed to the specified thickness using heavy equipment such as shovels or bulldozers & selected good material filled. Dressing of whole area shall be conducted to form an acceptable level line profile. Surface Compaction using water shall be carried out to maintain the required profile. Dry & wet compaction shall be carried out to a suitable state of acceptance. Similar procedure shall be applied to the sloping surfaces. Areas covered around obstacles for both flat as well as sloping shall be dressed manually & compacted by plate compactors or light rollers.
9. Checking procedure- Profile should be within acceptable limits. Soft spots should be removed.
10. The survey team shall locate and mark, all services that are present upon the site (This includes above ground services as well as buried services). These services, (Electric, telephone, gas, oil, chemical, water etc), shall be clearly marked using stakes and warning tapes. These existing services shall be marked upon a site drawing and the issues raised with the client for reaching a practical resolution.
11. The survey team shall also mark upon the site plan, all obstructions, structures and developments. Any obstruction encountered during excavation activities shall be plotted and recorded.
Site Preparation & Earthwork Typical
1. Where hazardous material is encountered, it shall be identified and isolated. Technip & client shall be informed. The hazardous material shall be collected and removed to a licensed tipping place. The details of the material and tipping arrangements shall be documented for review by the client as appropriate.
2. Wherever within the subcontract scope, existing structures, fences and developments, shall be demolished in a safe manner, as site-stripping activities proceed. The necessary permits, approvals and permission shall be obtained from the concerned authorities, prior to the commencement of the activity. The method of removal of these existing elements shall usually be conducted by dozer or breaker. Where necessary, discussions on site shall be conducted concerning alternate methods of removal, when the full extent of these structures is exposed.
3. The removal of the topsoil shall include all vegetation, and rubbish material, from the work site.
4. Prior to the start of topsoil removal, the surveyor shall peg out the haul roads that shall be used by the construction equipment for all the site preparation activities. These roads shall be constructed by levelling of the existing terrain. Grade pegs shall be set to an agreed grid, to indicate existing grade and reduced grade. Dependant upon the quality of the existing soil where the roads shall be built, suitable compactable fill may be imported or re-located from other parts of the site.
5. These roads shall be maintained as the work proceeds.
6. Where required water shall be spayed for dust control.
7. For general removal of the topsoil activities, using appropriate equipment, the areas concerned shall be excavated and graded to levels that shall ensure adequate surface water drainage. The Geotechnical Engineer shall monitor the activity, to ensure that the topsoil material is removed. Sampling and testing of the resultant material shall commence and be conducted for specification verification and compaction data.
8. Upon completion of the topsoil removal activities, where appropriate, the exposed surface shall be scarified, moistened and compacted, to achieve the required density criteria. The areas shall be divided into manageable sections that shall be defined upon sketches. The Geotechnical Engineer shall monitor and test all sections. The results of the tests shall be recorded upon the relevant QC format. The number of tests conducted shall reflect the specification requirement. QC Engineer shall monitor activities regularly.
9. In excavation areas, the Geotechnical Engineer shall review the material to be excavated, to ascertain its suitability for re-use as fill material. This excavated material shall be transported to areas that require filling. The material shall be deposited onto the areas to receive filling, levelled, moisture conditioned and compacted. If necessary, stockpiling may be required.
10. The excavated areas shall be divided into manageable sections, which have to be defined upon sketches. The excavated areas shall be monitored by the Geotechnical Engineer to ensure that any unsuitable material does not appear. Where unsuitable material appears, it shall be removed.
11. The excavated formation surface shall be treated by scarification, moistened and compacted, according to the specification criteria. All areas shall be tested and the results recorded.
12. Where areas are to receive fill, the material that has been excavated shall be transported to the fill area, tipped, leveled, moisture conditioned and compacted. The material shall be spread and leveled in 200mm layers. The areas to be filled shall be divided into manageable sections that shall be defined upon a sketch. The fill layer shall be moistened and compacted to achieve the required specification criteria. No further fill activity shall be conducted upon an area that has not been approved and released by the Geotechnical Engineer. Attention shall be observed at edges and slopes, to ensure that compaction criteria are achieved. Additional layers of fill material, shall be placed in the same method as described above, until the desired elevation has been achieved.
Production procedure.
1. Verification exercise for fill activity on record has been conducted to establish the economical and effective method for the fill activity.
2. Import and place fill to controlled areas of approximately 25m wide by 100 - 150m long.
3. Spread and level the imported fill.
4. Add water to the fill layer by passing the water tanker over the fill layer. The water tanker should pass over the layer twice. A time gap of approximately two hours is allowed for the water to soak into the fill material.
5. The layer is now mixed with the grader until a uniform blend of moist material is achieved.
6. Additional water is added by passing the water tanker over the layer in a uniform sequence. A time period of approximately one-hour is allowed for this water to soak into the fill layer.
7. The fill layer is mixed again with the grader, leaving the fill level to the correct grade.
8. Vibrating rollers shall now compact the fill layer in a logical sequence that densifies the layer uniformly.
9. Field Density Testing of the layer shall be conducted to the ITP requirement.
Gravel Finishing- Installation of gravel crushed or natural shall be carried out by spreading to the specified thickness of 100 mm or 50 mm as the case may be over the prepared surface uniformly to site feasibility. Mechanical or manual adjustment shall be carried out to the spread gravel followed by mechanical compaction to bring the material to undisturbed acceptable profile. Work shall be done to the area indicated on IFC drawings.
Vegetal Soil Surface - Landscaping- Humus for the grass shall be spread over the IFC drawing indicated area on flat as well as sloped surface to specified thickness & leveled roughly by mechanical means. Irrigation network piping & fittings shall be carried out to the indicated areas on IFC drawings. Supply, laying & pipe connection shall be carried out accordingly to the sub contract scope.
Protection of Existing Services
1. From the provision of existing site drawings, provided by the relevant authorities within ASAB, existing services shall be located, and exposed by hand excavation.
2. The Survey Team shall check and accurately record these existing services. A line of pegs shall be positioned to indicate the route of the existing services. The use of warning tape, and/or nylon cord, to indicate and protect the route of the service shall be conducted. The Survey Team shall inform the Infrastructure Engineer of the exact location of the service relative to the warning flags.
3. Should an existing service be disbanded or redundant, that service shall be exposed, to allow confirmation of the status of the service. The Infrastructure Engineer, through the Technip representative, shall ask the relevant authority within ASAB, to review the excavated service and confirm the status and action he requires for the removal of the service. The redundant service shall be removed under the supervision of the Infrastructure Engineer according to the agreed criteria of that relevant authority.
4. Where an existing live service remains during the site preparation activity, such as the 33KVA electric cable, that existing live service shall be protected.
5. The Survey Team shall locate the live service upon the ground using spray paint or small pegs. At periodic locations along the route of the existing live service, defined by the Survey Team, small hand dug pits shall be excavated, to identify the service. The purpose of this exercise is to ensure that the location of the live service is accurate.
6. Ten meters (10m) either side of the route of the existing live service shall be erected posts. A nylon cord, with warning tape streamers, shall be strung between the posts. This shall clearly indicate the service and its route. The posts shall fixed be at suitable & sustainable centres.
7. Signboards indicating what the live service within the marked corridor exactly is, shall be displayed at sufficient locations along the route.
8. Where temporary roads cross-existing cables, sufficient suitable fill material shall be placed on top of the cables to afford adequate protection to by distributing the vehicle axle loadings safely minimising stress concentration.
9. The Safety Officer shall periodically check the condition of the barriers, where necessary refurbishment shall be conducted
10. Galvanized fence-Galvanized mesh shall be installed according to the IFC indicated location. Supply shall be affected according to the requirement. Excavation shall be carried out for the post embedment constructed to the manufacturer instructions by using RCC plug in to the holes to support the post of the fence.
11. Reinforced concrete fence- Pre-cast RCC fence panels shall be erected & connected to the already carried out foundations & inserts to the fence requirement. Individual elements shall be stocked properly.
12. Prefabricated reinforced concrete fence- Pre fabricated elements of the fence shall be procured from the market to the IFC indication & erected on site & connected to the already carried out foundations & connected to the structural requirement.
13. Vehicle gate- gates in complete package shall be supplied to the IFC & specification requirement as approved & installation be carried out accordingly to the manufacturer instructions & details.
14. Pedestrian gate- pedestrian gates in complete package shall be supplied to the IFC & specification requirement as approved & installation be carried out accordingly.
15. Road barrier- road barriers in complete package shall be supplied to the IFC & specification requirement as approved & installation be carried out accordingly.
Fence Erection.
1. The final grade level of the area shall be the commencement point for the fence construction.
2. A level survey shall demonstrate the accuracy of the site grading activity.
3. The Survey Team shall set out the line and level of the fence, including post locations for all elements.
4. Using a machine-mounted auger, 300 and 450mm diameter holes as appropriate, shall be drilled for the fence post foundations.
5. The drilled holes shall be cleaned and bedded to the correct base level.
6. The fence post foundation shall be placed in the drilled hole to the correct line and level.
7. Dune sand shall be compacted around the foundation.
8. The fence fabric shall be strung and tensioned as per the drawing details and manufacturers recommendations
9. Using hand tools, a trench shall be excavated for the ground beam.
10. The ground beam shall be placed to the correct line and level.
11. Suitable fill material shall be used to compact around the ground beam.
12. The fence fabric tie staple shall be grouted in position once the fence fabric is tensioned.
13. The gap between the ground beams at the location of the fence post shall be concreted to form a continuous beam.
14. QC procedures shall be closed out on an on-going basis.
Excavation
1. The engineer shall ensure that the current drawings relating to the excavation activity are approved for construction. The engineer shall ensure that there are no conflicts with existing services or other discipline issues. Constructability from the drawing shall be ensured.
2. The surveyor shall provide line and level engineering that shall enable the excavation of the structure.
3. A system for quick reference shall be established.
4. The surveyor shall inform the excavation foreman of these lines and levels.
5. The excavation foreman shall direct the excavation equipment in an agreed sequence. Excavated material shall be classified by laboratory test. Unsuitable material shall be removed off site to the tip area. Where material is classified as suitable, the required volume shall be stockpiled on site in an agreed location.
6. Safety barriers shall be erected as the work proceeds.
7. Where applicable, the sides of the excavation shall be sloped.
8. There is no requirement for ground de-watering equipment.
9. Should restrictions be imposed by adjacent structures etc that would make sloping of the sides un practical, shoring or support of the excavation sidewalls shall be agreed with Technip on site.
10. The surveyor and site engineer shall check the excavation to confirm compliance with his levels and lines. A survey shall be conducted of formation level upon completion of the excavation.
11. The formation shall be visually inspected for unsuitable material. Any such material shall be removed.
12. The formation shall be scarified and compacted to the required specification criteria. The laboratory test results shall be provided. Upon acceptance of these results, the area shall be released for consequent activities.
Backfill to structures
1. The engineer shall ensure that all subsequent activities are passed and completed. Cleaning shall be done.
2. Upon approval to backfill, the engineer shall instruct the foreman to carry out this activity.
3. The backfill material shall be sourced from the suitable material stockpile. The backfill material shall be placed in layers according to the specification. The layer shall be moisturized and compacted to the agreed criteria.
4. Each backfill layer shall be field density tested by the laboratory. An acceptable test result shall allow the next layer of backfill to be placed and compacted. This process shall continue until the whole fill is completed.
5. Upon completion of the backfill activity, the area shall be cleaned of waste materials and left tidy for the next activity to follow.
6. Any safety barriers shall be removed to the safety store.
Ignore if not applicable
Piling Typical - Equipment mobilization, Piling rig moving- shall be done accordingly & pile location set out by the surveyor. In case of pre cast piles, the rig shall drill the pile bore to specified dia vertically using steel insert protection at pipe toe. Pre cast/stressed piles shall be inserted into the bore with compression impact hammer gradually till the whole pile is driven into the strata.
1. It shall be ensured that the pile remains vertical & in its set out location.
2. After the pile is driven, sonic test, dynamic auscultation & load test shall be conducted to specified requirement. Load test shall be conducted by reaction truck loading or the actual load applied in cycles. Dynamic auscultation test shall be conducted to the code requirement. All records shall be maintained. After piles have been driven, demobilization of equipment shall be effected
3. Pile head preparation shall be carried out by cutting pile heads to expose the rebar for connection to pile head or cap rebars. After proper placement of the rebars of the pile cap & the pile head, formwork shall be erected & concrete poured for the pile head or cap. Curing shall follow to agreed procedures.
Cast in place concrete piles-
1. Driven cast in place concrete piles with permanent casing- Location of the piles shall be set out.
2. Casing shall be driven truly vertical into the location using the rig & continued until the design depth is reached. Soil column shall be taken out by pressurised water. Casing base shall be cleared & inspection for the plumb & profile conducted. Reinforcement cage provided with concrete spacers shall be placed into the casing properly fixed. After inspections, concrete shall be poured into the casing keeping a maximum drop of concrete not more than 2 m. Concrete vibrator shall be kept working into the poured concrete & gradually withdrawn progressively as the concrete moves up. In case casing is to be withdrawn, it shall also be gradually withdrawn following the gradual & progressive pour. While withdrawing, care has to be exercised that verticality is not disturbed. Pouring shall be completed up to the head of the pile. All accumulated water shall be removed by pumping continuously & piling area kept dry. Pile shall be poured continuously avoiding any construction joint. All excavated earth shall be removed from site.
Pile load test shall be conducted after lapse of specified duration. Engineer shall select the piles to be load tested. Cyclic load testing shall be applied for 72 hours loading & unloading & reloading. Test record shall be maintained according to ITP & procedural requirement. To ascertain the pile integrity, sonic test shall be conducted by a hammer impact & the transmission of the sonic waves recorded using the standard equipment.
1. This test shall be conducted for all piles for it ascertains the integrity & transparency of the material used.
2. After the piles have been tested successfully, preparation of the pile head shall commence. Extra portion of the concrete shall be cut to the pile cap base level. All reinforcement effected by concrete shall be cleaned, new reinforcement for the pile cap & column starter bars installed. Preparatory form shall be erected for the pile cap. Concrete spacer shall be fixed properly. Any tie up beams preparatory works shall be carried out. After the inspections are conducted, concrete pouring shall be carried out & the unformed surface finished smooth enough to receive concrete protection.
3. Ensure the side are truly aligned as well as in plumb. Ensure dimensions are correct within tolerable limits. Ensure reinforcement placed to the design details. Ensure the spacers are properly fixed & all steel bar in its design locations. Ensure concrete level at top is fixed properly using 25 x 25 mm plastic chamfers. Ensure the vertical corners edges have been fixed with plastic chamfer.
4. Since, most of the pile caps shall be thick sections, special arrangement shall be made for curing using saturated Hessian, polythene sheets and clean sand fill below the coverings so that no heat transmission is permitted from the concrete surface. This type of curing is called thermal curing. During high temperatures, water shall be sprinkled on the forms from the sides to ensue minimum heat loss in early days of concreting.
5. Bored Continuous flight auger (CFA) Piles, reinforcement for Continuous Flight auger (CFA) piles-
6. Similarly, CFA piles shall be continuously augur bored into any soil, reinforcement place in & concrete poured. All tests shall be conducted according to previous explanations.
7. After the piles have been cast, location survey shall be conducted for 5% of the poured piles.
8. Micro Piles, Drilled micro piles, reinforcement for Micro piles,
9. Jet Grouting soil Improvement system- For the proposed piles, locations shall be set out. Rotary mast shall be utilized to drill a bore into the strata without removing the soil & high pressure cement grouting applied into the bore. Curing shall be carried out to the requirement. All debris shall be removed from site.
10. Pile test- Sonic test by hammering for construction uniformity & homogeneity, Dynamic auscultation test by impedance, Load testing (compression), Load testing tensile test, Load testing horizontal loading test, pile location survey,
Earthwork-
1. Grubbing - According to the scope included on the IFC drawings, trees, plants, bushes, roots shall all be removed completely from the soil ensuring that the soil is not effected adversely. These uprooted green materials shall be collected at one place for suitable disposal to a designated area.
2. Scrubbing- According to the scope included on the IFC drawings, vegetation topsoil shall be removed irrespective of its consistency & water content.
General Excavation-
1. In the controlled plant area, prior to commence with the excavation, legal ‘permit to work’ shall be obtained from the ‘operating authority’
2. It shall be made sure that no existing services run under the proposed area from the concerned authorities record. Necessary benchmarks shall be established for surveying controls & monitoring purpose. Where it is feasible to excavate the whole unit area involving all foundations & beams etc. using heavy excavation equipment, general excavation should be carried out which allows saving in excavation time keeping the area tidy. Such area shall be set out to the IFC details, grids marked on the timber rails around the area periphery. Additional marking shall be set for the general area limits & proposed convenient ramp to allow easy access & egress to & from the area. Proper safety warning signs shall be erected around proposed general area. Signs shall include KEEP AWAY DEEP EXCAVATION, HARD HATS ZONE etc
3. In case of any mishap caused to the existing services, immediate information shall be notified to the concerned authority so that corrective action can be undertaken.
4. Excavation shall be started by excavator directly loading the material into a dumper truck which shall remove the excavated material from the location to stock pile areas in case the material is suitable for re use as backfill or to a designated dumping area otherwise. A surveyor shall constantly monitor excavation formation level. Environment protection arrangements shall be charted out to keep the site tidy. During excavation in case of loose soils such as sand whose angle of repose does not permit, shoring shall be arranged around the periphery to prevent soil subsidence. Excavation & soil removal shall continue to reach the formation level. No further excavation shall be carried out. All debris shall be removed from area, dressing conducted on the rough formation to bring it to required profile. The surface shall be watered & compaction carried out using heavy road roller of at least 8 T capacity, which work in strips in parallel overlapping the previous strip. Compaction shall be conducted until rebound occurs. Field density test shall be conducted to ensure the correct formation density has been achieved, atterberg’s limit & moisture content are within acceptable limits.
5. In case, soil improvement is to be applied, further excavation shall be carried out to the design thickness of the improved strata. After preparing the formation for the engineered fill, selected granular material shall be placed into the prepared formation in layers, watered & compacted. Field density test shall be conducted for each layer of fill. Plate bearing test may also be carried out to know the ultimate & safe bearing capacity of the improved strata. Now the formation is ready to receive the foundations on it. Formation levels shall be recorded.
6. In case water level is high & dewatering is necessary, proper plan shall be made to install the dewatering system until the whole of area is constructed up to the ground level. Water shall be pumped out & disposed to a suitable agreed discharge point keeping the location tidy. But in this case, according to investigation report, soil is free of water. No dewatering is required.
Sectional Excavation-
1. In the controlled plant area, prior to commence with the excavation, legal ‘permit to work’ shall be obtained from the ‘operating authority’
2. Where particular foundation or trench for a cable or an isolated or combined footing or vessel base etc is to be excavated, excavation shall be carried out only for that particular area. Necessary benchmarks shall be established. Setting out shall be done accordingly for the extent of the area & grid control established. Safety signs shall be established. All arrangement for the necessary shoring resorted in advance. Excavation shall start by mechanical equipment removing the excavated soil into a dumper truck for disposal to stockpile or to a designated area. In case manual excavation is to be carried out for the protection of the existing services, no machine shall be used until specially permitted after the exposure of all existing services. In case of fibre optic cable exposure, only water jetting should be used to excavate the area. In case of any mishap caused to the existing services, immediate information shall be notified to the concerned authority so that corrective action can be taken.
3. In case water level is high & dewatering is necessary, proper plan shall be made to install the dewatering system until the whole of area is constructed up to the ground level. Water shall be pumped out & disposed to a suitable agreed discharge point keeping the location tidy. But in this case, according to investigation report, soil is free of water. No dewatering is required.
Embankment- Typical
Profile shall be set for the proposed embankment base. Centreline of the embankment shall be marked. Loose soil from the base shall be removed. Embankment template shall be fixed at various spacing longitudinally. Backfill shall be carried out in layers 250 mm loose thick, watered & compacted using heavy roller. Whole layer shall be compacted to achieve non-structural fill density. Field tests shall be conducted according to the specification requirement. The quantity of samples to be taken for test shall depend on the extent of area under compaction. Filling shall continue in layers until the whole section is completely backfilled. Every layer shall be tested accordingly. Structural backfill compaction density test shall be ensured for the embankment to receive heavy loading such as tanks, roads, foundations etc.
Earthwork for Storage facility-
1. Excavated material from the other excavation areas shall be stockpiled at designated areas. Reusable material for filling shall be screened out regularly from the stockpiles. Compliance of this material shall be ascertained by conducting classification tests & if necessary, additional deficient materials of required grading be added to bring the stock to acceptable plasticity index or non-plastic standard.
2. This material shall be used for the formation of the storage facility foundation fill works.
3. Tank foundation area shall be set out to IFC details. Design profile shall be established & fill layers commenced with. Every layer shall be filled 250 mm thick watered & compacted down to 200 mm. Field density test shall be conducted after the compaction to allow the commencement of the upper layer. All forthcoming layers shall be filled adhering to same procedure & tested.
4. The top layer to receive the bituminous surface finish shall be prepared suitable accordingly. Surface shall be cleaned, levelled properly & top of surface finish level established. Surface shall be primed with approved material. Conglomerate of 10 to 20 mm size, closed with 5 mm aggregates & bituminous emulsion @ 1 kg/m^2 or in accordance with Contractor standard to from a total compacted thickness 100 mm.
5. Surface shall be inspected & density test conducted by taking out the compacted cores.
6. Similar operations shall be carried out on the sloping areas.
Earth dikes- To retain the basins
1. Similarly, the filling works for the earth dike shall be carried out as stated in the foregoing from excavated material & also if required from the supplied material as the case may be.
2. Body of the dyke shall be covered by application of an approved material to give acceptable finish to the body of the dyke per provisions on the IFC drawings.
Soil Improvement- By Soil Substitution
1. Wherever shown on the IFC drawings, the scope of replacement of the existing soil from the plant area, existing soil shall be excavated out in specified thickness & removed to dumping areas.
2. Suitable backfill material shall be procured from an approved source including the site stockpiles & backfilling carried out to replace the excavated portion of the plant area.
3. Watering & compaction shall be carried out all according to approved procedures. Testing shall be conducted to ascertain the field density achievement.
Soil Treatment-
Wherever shown on IFC drawings, the scope to treat the soil belonging to an area, the soil shall be stripped out from the area & transported to stockpiles for the purpose to add into this material cement or lime, water & mix mechanically. After the mixing of the soil, re-transport to the original location shall be carried out, spread on to the area, levelled & compacted in acceptable thickness & bring the profile to the defined levels. Whole area in the scope shall be applied treatment accordingly.
Walkways kerb-
Wherever shown on IFC drawings, the scope of laying & fixing the walkway kerbs, proper preparation of the formation duly compacted shall be carried out. Blinding shall be laid to the required profile in gradient. Kerb shall be placed on the blinding using defined cement mortar mix sealing the base of kerb & end to end joints perfectly. Alignment of the kerb, gradient, verticality & joint thickness shall all be controlled. Any deviation in the alignment shall be within acceptable limits.
Walkways Foundation-
Granular material shall be filled below the walkway finishes given required gradient. This fill shall be compacted to the non-structural requirement.
Walkways Finishes-
1. Finishing over the walkway foundation shall be applied according to IFC drawings & specification requirement
2. Wherever shown on IFC drawings, 30 mm thick rolled thickness of bituminous conglomerate shall be applied.
3. Wherever shown on IFC drawings, 100 mm thick RC concrete with prefab mesh paving given float finish shall be applied with required number of joints properly spaced.
4. All loose soil shall be cleared and formation level made up and well compacted & pesticide treatment applied if so specified.
Laying Kerb stones Typical Sample
1. Setting out kerb excavation lines according to drawing
2. Excavation up to the formation level i.e. 450mm from the kerb top level
3. Form work fixing and pouring grade 20 concrete 450mm wide and 150 mm thick
4. Formwork fixing and pouring grade 20 concrete 150mm wide and 150 mm thick high
5. Pouring grade 20 concrete all according to approved procedures
6. Fixing 12 T re-bars @ 200 c/c vertically supported to forms
7. Bedding in cement mortar 1:3, 25mm thick for kerb stones grade 20
8. Fixing kerb on the mortar to the true lines and levels with chamfer facing pavement & jointing with mortar. Alignment tolerance shall be 3 mm in 75 mm both ways vertically as well horizontally. End to end butting mortar thickness shall be 3 mm
9. Placing haunch back fillet concrete grade 20, as shown in (triangular fillet section)
10. Filling up to top of vertical concrete with earth fill & compaction
11. All areas below proposed interlocking course to be filled with 100 mm thick sand screed all according to conventional procedures
12. QC inspection shall be conducted for kerb laying approval and ITP requested to be signed off by QC
(Laying Paving Interlocking blocks)
1. Thickness of the interlocking blocks 60mm
2. Thickness of the sand screed bedding 100mm
3. Plank runs shall be used to allow barrows to move on to avoid level disturbance
4. First surveyor shall set out the pattern borders all according to shop drawing as well as design drawings
5. First Grey or other approved colour interlock blocks shall be laid to position & profiled to form the border pattern.
6. The blocks shall be laid in full but at the edges of the obstacles such as inspection covers where cut blocks may be required, whole blocks shall be laid first wherever possible and the trim able blocks exactly marked & cut to the required size.
7. After profile is well formed to the approval, the fill in course to the border areas shall be carried out by laying Red or as approved colour blocks
8. After sufficient blocks have been laid, sand bedding shall be carried out using a plate vibrator pressing the blocks to the required level in 2 passes covering entire area with each pass to make the bedding even
9. Sand screed shall be spread on the surface of the blocks with 2 more vibrator passes applied & brushed under the leading edge of the vibrator to allow the joints vibrated
10. QC inspection shall be conducted & QP requested to approve the paving
Ignore if not applicable
Roads, Yards, Paving (Asphalt)
Road Works Typical Sample
The following sequences shall be involved to do the roadwork
1. Clearing all services according to the project drawings and inspections/Approvals
2. Preparation of the area to be structured by removing topsoil, placing in imported fill material, profiling levels to the project drawing & compaction.
3. Applying pesticide treatment if required
4. Application of all pre work items such as construction of kerbstone to complete sectional details shown on project drawing miscellaneous details.
5. Inspection of the surface
6. Sub base class B material shall be spread on the area in strips of required thickness keeping more than design thickness by 25mm i.e. 150+25 mm
7. Sub base approved fill material to interlock the class B material shall be spread on the spread material & dry rolling carried out to produce correct profile of the section
8. Water shall be sprayed on the surface to make it penetrate in to & around all the voids of the spread material & compaction by heavy roller carried out to densify the whole course.
9. After required number of passes probably 6 given by 18 to 12 tonne rollers bringing the laid material to the required thickness 150 mm & exhibiting rebound on the surface, the compaction by rolling shall cease.
10. Density test shall be conducted all according to approved ITPs requirement
11. Compacted course shall be left for drying in due course allowing it to be ready to receive Prime Coat MC1. Drying time shall not be less than 48 hours.
12. Prior to the start of the Prime course spreading, any defect is observed during visible inspection shall be repaired in rectangular or square shape or as agreed with.
Asphalt concrete
1. Asphalt concrete shall be laid in widths of driveway roads according to the project drawings.
2. Wearing course thickness being 40mm & that of dense bitumen binder course 80mm
3. Paving works shall be carried out in 2 stages
4. Stage 1
5. Laying & compacting bottom bituminous binder course
6. Stage 2
7. Laying & compacting top wearing carriageway
Surface preparation
1. Prior to the application of the dense bitumen binder course, already laid & compacted aggregate base course shall be prepared suitable for this purpose
2. Base course shall be corrected of any deviation more than 13mm from the designed profile at any point & not more than 9mm in 3m on the longitudinal grade at any location by either adding to or removing from the surface the deficient or redundant material respectively to bring the surface to the design shape, watered & compacted in accordance to the specification all as stated above
Main Operations
The following main operations are involved
1. Re-preparation of aggregate base course surface with water & compaction by pneumatic roller
2. Application of Priming coat & drying out
3. Application of 60mm thick dense binder course
4. Power brooming the completed dense binder course
5. Application of Tack coat & drying out
6. Application of 40mm thick bitumen concrete wearing course
Mixing
1. All materials shall be mixed at an approved calibrated & approved Asphalt plant
2. All trucks and other equipment as included shall be readily available for inspection
Transportation
1. Material shall be transported from the plant to the planned location in good condition by trucks cleaned of all foreign material & covered with tarpaulin to prevent dust invasion in inclement/adverse weather conditions
2. It shall be ensured by obtaining observations using thermometer that the material when laid is within 130 to 165 degree Celsius
Application
➢ Coverage
➢ Primer coat 0.8 to 1.4 litre/ m^2
➢ Tack coat 0.4 to 0.7 litre / m^2
Primer
1. QC inspections shall be conducted to ascertain the true profile of the aggregate base course & corrections applied if so required
2. All surfaces planned to be primed shall be barricaded & cleaned of all dirt & any objectionable material
3. Bituminous material shall be applied evenly on the dry surface by means of a pressure distributor spray tanker within a temperature 30 deg to 70 deg C
Surfacing Binder Course
1. QC inspection shall be conducted prior to the commencement of binder course laying to make sure that the surface is satisfactorily clean, well dried & even to the specified priming conditions as well as to receive binder course.
2. The material upon arrival at the location shall be spread & struck off to the prepared profile by means of self-poared spreading & finishing equipment attached with a strike off assembly distributing the mixture to a strip 3 m wide
Rolling Steel Roller’s # of passes 6 to 8 depending on the surface condition Steel rollers 10 T capacity equipped with adjustable wheel scrapes, water tanks & sprinkling apparatus to keep the wheel sufficiently wet to prevent the bituminous mixture from sticking to the steel surface shall be employed to roll the profiled material immediately after the material is laid to the acceptable profile to prevent the formation of undue displacement or hair cracking
1. The roller wheels shall be kept properly moistened without excess water or oil
2. Rolling shall be commenced from the side and proceed towards the centre each trip overlapping the previous by at least 300 mm with keeping alternate trip not more than 5 km/h & it shall continue until the surface is impression free.
3. Mechanical compactors shall be engaged to compact the roll inaccessible area layers.
4. Pneumatic tyres rollers shall be engaged only after the compaction by wheel roller is over.
5. It is significant to make sure that the asphalt temperature does not fall below 80 deg C prior to full compaction is achieved
6. Roller shall not pass over the edges of the freshly laid material generally except when the edge is located at a discontinuation for that day
7. QC inspection shall be conducted throughout the above operations to make sure that the material is compacted to the standards and the temperature remains within limits mentioned as well as levels are maintained within specification tolerances particularly over the areas involving shoulders
8. At the commencement of the work on the area involving the compacted & chilled edge, a bevel shall be cut out, cleaned & tack coat applied to receive adjoining material
9. No traffic shall be permitted until 12 hours lapse post-rolling completion
Wearing Course
1. The planned surface shall be cleared of all dust & dirt using power broom or blowing
2. Tack coat shall be applied to the specification requirement
3. Immediately upon arrival, the material shall be spread & rolled similarly as described in the foregoing.
4. QC inspection shall be conducted throughout the above operations to make sure that the material is compacted to the standards and the temperature remains within limits mentioned as well as levels are maintained within specification tolerances
Reinforcement Fabrication
1. When reinforcement is to be “cut and bent,” the foreman shall be issued with a current rebar schedule. The foreman shall review the schedule and allocate the fabrication process to the relevant fabricator/steel fixer. Material required shall be sourced from the yard storage facilities.
2. The correct bar diameter shall be cropped into the specified length as given on the bar schedule. The cropper operator shall crop the required bars of each diameter.
3. Upon bending of the first of each bar type, it shall be checked by the foreman for correctness. This bar if correct, shall be utilized as a check sample for all concurrent bars of that type. The bending operator shall fabricate the required number of bars of each shape code checking against the check sample when each bar is completed. Any error in bending of the bars shall be corrected prior to placement in storage.
4. The correct bent bars shall be stored in bundles & protected against ingress of moisture.
5. The bundles shall be tagged with a suitable label that indicate the relevant bar reference and BBS document reference from which these have been fabricated.
6. The completed bundles shall be stored within the reinforcement yard until such time as those are required upon site. Storage shall be in accordance with the procedure for store control.
Reinforcement Placement Typical
1. The relevant reinforcement bars, spacer blocks, chairs, stirrups and tie wire, shall be collected from the stores as well as fabrication yard and made available at the work site. The material shall be stored at the worksite, in accordance with the storage procedure pertaining fabricated & non-fabricated re-bars.
2. The current revision of the reinforcement drawing that applies to the structure being constructed shall be checked by the Project Engineer, Site Engineer, Q A for validity.
3. The steel fixers shall place and tie, reinforcement bars and accessories, in accordance with the current reinforcement drawing under direct supervision of re-bar charge hand or foreman.
4. Particular attention to the following items shall be monitored by the charge hand steel fixer and foreman:
5. Lap length of bars.
6. Tie wire protrusions into cover areas.
7. Appropriate concrete cover to formwork and outside faces.
8. Placement of adequate support chairs and stirrups.
9. Spacing of bars.
10. The Site Engineer & charge hand steel fixer/foreman shall check the fabricated reinforcement when all the placement of the reinforcement bars is complete. The result of this inspection shall be recorded upon Pre concrete inspection checklist by Site Engineer & QC.
11. The foreman steel fixer shall ensure that the reinforcement has been correctly placed prior to informing the Site Engineer & QC.
12. QC shall check all items of different shapes, spacing & numbers, spacer blocks, additional chairs if required.
13. Should any inserts, conduits, pipes, bolts etc, require fixing within the structure according to design details or shop drawings, the steel fixer foreman shall arrange for the placement of these items according to directions by Project Engineer/Site Engineer. Where a reinforcement bar clashes with such items, based on the decision of Engineer, Project or Site Engineer, the steel fixer shall move the relevant bar. An additional bar may be required to offset this moved bar. Should any doubt arise about moving bars, the charge hand shall inform the foreman & Site Engineer to resolve the issue with the engineer.
14.
15. The foreman shall inform the Site Engineer when these activities are complete.
16. The QC shall inspect the re-bars placed in the structure for compliance with the design drawings and details as well as other working and shop drawings.
Formwork Erection Typical
1. Based on site engineer’s instruction, the formwork foreman shall review the drawing of the structure to be formed & shall decide together with the site engineer, the most suitable method of formwork erection.
2. Where pre-fabricated formwork can be assembled in the carpentry workshop, fabrication shall be carried out.
3. The surveyor shall establish the lines and levels for the erection of the formwork. These lines and levels shall be explained to the foreman and supervisor in charge/charge hand of the formwork activity.
4. The foreman shall check that the preceding activities have been approved, so that this activity may commence. The sections of formwork required to form the structure, shall be taken to the work site.
5. The form carpenters shall ensure that the formwork faces are clean, in good condition for the type of finish required & applied over with shutter form oil.
6. The form carpenters shall assemble and fix the formwork in accordance with the current drawing.
7. The charge hand of carpenters shall monitor particular issues such as:
8. Sealing of joints between formwork has been applied properly
9. Verticality of formwork is according to requirement. Tie bolts are in proper positions & snug tight.
10. Adequate bracing and supports are in tact
11. Provision where applicable for box outs and inserts have been applied
12. Provision where applicable of chamfer and channels have been fixed
13. The supervisor and surveyor shall check the lines and levels of the formwork when all bracing and strutting have been completed. Wherever required, the formwork shall be adjusted to conform to the required lines and levels.
14. The supervisor shall ensure that any damaged face of the formwork is repaired.
15. The foreman shall review the formwork when completed.
16. Where anchor bolts or embedded plates are to be suspended in the structure, the supervisor shall ensure that these arrangements are adequately supported as well as securely braced. All inserts and bolt groupings shall be checked for location and level prior to the placement of concrete as well as after the concrete is placed.
17. When the formwork activity is complete, the supervisor shall inspect the formwork and associated works, recording his observations on approved formats, formwork checklist and insert check list.
18. The QC inspector shall confirm the acceptance of this activity after review of the items.
19. Where large formwork elements are encountered, the QC inspector shall review the formwork bracings and supports with the engineer.
Concreting Typical sample
1. The supply order for estimated quantity may be placed in advance but real confirmation shall be done based on the pour approval.
2. After the inspections of the preparatory works pertaining to any element namely footings, stubs, columns, suspended slabs etc & the relevant approval, the order for the release of concrete from the batching plant shall be placed.
3. The required quantity shall be sequenced depending on the consumption frequency on site.
4. The concrete shall be poured either by the concrete pump or by the mobile crane depending on the necessity & convenience.
5. Necessary access to the location shall be prepared using proper supports or platforms duly inspected by the safety officer in charge.
6. Immediately, at the arrival of the truck mixer of concrete on site, slump, temperature, air contents etc all test samples to the specification requirement shall be taken by the ready mix supplier in the presence of the QA engineer.
7. In case the concrete does not meet the specification requirement, the truckload shall be rejected.
8. Arrangement shall also be made for the filling of the concrete cubes/cylinders on site & number of specimen to specification requirement.
9. After the truck is approved by the QA to be transported to the site location, the concrete pump, which should already be located in proper position, shall receive the load & pump out to the in situ delivery location.
10. The concrete laying gang already present on the site location shall receive & pour the concrete mix into the prepared elements from a height not more than 2 m from the edge of the boom chute pipe.
11. As soon as enough mix is available in the element to compact the mix conveniently, insertion vibrator shall be used by a trained operator to compact the mix till no more bubbles appear. Foreman shall direct the pump remote control operator about the boom movement & stop & hold points or stages during concreting.
12. Vibrator shall not be allowed to touch the forms side or re-bars. Over vibration shall not be permitted
13. Each Footing shall be poured in one go if not more than 500 mm in depth.
14. The widened portion of the stub in touch with soil shall also be poured in strips not more than 450 mm deep
15. Into columns the mix depth at one rotation shall be 450 mm & in different strips vertically, pouring shall be completed avoiding formation of cold joint
16. Top level of the concrete shall be levelled & the columns form top covered with plastic sheet
17. The portion of the pipe chute shall be inserted into column preparatory works to allow for a 2 m vertical fall maximum. Vertical forms of the columns shall be struck after 48 hours.
18. Inspection shall be made immediately post form striking & any defect in concrete shall be brought to QA Engineer notice for deciding remedial action.
19. Vertical surface shall be covered with saturated Hessian, further covered with polythene sheet cover or alternatively curing compound shall be sprayed over the water-wet surface to form a impermeable membrane not to permit evaporation.
20. The grade slab shall be poured in one go in depth bay wise between ground beams or walls.
21. For the suspended slabs, beams shall be poured first around the slab & prior to the formation of cold joint, the slab concrete shall be poured & the whole slab completed.
22. The joints if so required, shall be agreed in the beginning of the pour with the engineer. Water shall be sprayed over the form during hot weather prior to pouring to avoid flash setting of concrete with re-bars.
23. In case some plant break down is reported, immediately the last poured line shall be stopped by a formed surface & concrete terminated at that point & in no way shall recommence prior to 24 hours with further approval obtained. In such case previous formed joint shall be scabbled/hacked to expose all aggregate by removing laitance completely, washed with cement slurry & new concrete commenced making proper bond with old concrete.
24. Due care shall be taken that no spacers, electric conduits or any other insert is disturbed from its design or worked location. If so disturbed, it shall be immediately relocated according to the engineer site approval.
25. Immediately after the compaction of concrete is over & concrete starts setting in, arrangements for applying U1 finish to the top of slab surface shall be done by timber tamper.
26. Immediate curing shall be applied by spreading polythene sheet cover on slabs & footing.
27. Then after about 2 hours, polythene sheet shall be withdrawn temporarily & saturated hessian placed over concrete & recovered with polythene sheet & the concrete cured for specified period
28. If so, repair to hardened concrete is required, approved repair material shall be used according to manufacturer’s instructions.
Concrete Paving Typical
1. All the relevant underground services shall be laid in all respects prior to the commencement of the pavement work
2. The area to be paved shall be made ready by clearing all weak soil & by scarifying.
3. Approved sub base material 150mm thick or as specified, shall be filled up to the bottom of the concrete slab following the profile given on the drawing and compacted to 95 % dry proctor density.
4. Weed killer chemical shall be applied to the soil to prevent the organic growth if so specified.
5. The whole area shall be divided into parts to suit the services and the contraction joints formations & as shown on drawings
6. On the ’compacted filled area’ to be paved, polythene sheet 0.25mm shall be placed with end overlaps at least 150mm at all joints and intersections.
7. End forms shall be fixed on sides allowing a provision to place 20 dia MS dowel bars 650mm long & 300mm centres half painted with 2 coats bit mastic paint with 100mm long cardboard cap containing compressible material such as cotton waste at the
8. Expansion joint to the details shown on the drawing. The thickness of the expansion joint shall be 20mm
9. At contraction joints 25 x 25 mm plastic crack inducer shall be provided as shown in the detail & the joints cut for a depth of 20mm with a concrete cutting machine. Welded wire fabric mesh dia 6mm – 200# shall be placed in the bay centrally located with concrete spacers below.
10. Forms shall be set to correct levels so that the total thickness of the concrete is as indicated on the drawings.
11. QC inspection shall be conducted for the pour approval.
12. Concrete shall be poured in one layer and compacted using vibrators & given brush finish to correct levels.
13. Curing compound shall be spread on the surface for immediate curing covered with polythene sheet and later within 2 hours damp hessian added by removing polythene sheet temporarily and recovered thereafter.
14. The expansion joints between the two adjacent slabs shall be filled with elastic joint filler and sealed with a chemical resistant sealant complying with the details shown on the drawings.
15. QC inspection shall be conducted.
Concrete Lined Trapezoidal Ditches
1. Earth sectional depth dimension as included within specifications Depth 300 to 500 mm; 501 to 1000mm; 1000 to 1500mm.
2. Setting out dimension about the proposed ditches shall be marked.
3. Excavation shall be started & shaped to the design profile.
4. Compaction shall be done to the non-structural requirement.
5. Proper gradient as indicated on the design drawings shall be maintained.
6. Isolation layer shall be applied if so provided within the specification.
7. Blinding shall be applied on the compacted base to the design thickness.
8. Preparation for the lining concrete shall be carried out by placing in pre fabricated reinforcement to design details & sides formed at edges parallel to the ditch as well as at the construction joints.
9. After the inspection, concrete pour shall be carried out in alternate bays with unformed horizontal as well as sloping surfaces finished smooth. Remaining bays shall be carried out in the next day operation.
10. Curing shall be carried out accordingly to the approved procedures.
Expansion Joints between ditches
1. Size of the proposed joints to be filled/sealed is 15 mm wide x 15 mm deep.
2. The surface shall be cleaned of all dirt, dust and loosely adhering materials.
3. All grease and oil contamination shall be removed using hard small brushes, compressed air etc.
4. The fibreboard shall be removed to the required depth.
5. Under normal circumstances priming is not required.
6. Masking tape shall be used to confine the joint borders keeping the adjoining concrete surfaces clean.
7. The contents of the Can shall be removed by a Trowel or a Spatula.
8. The Bit mastic shall be applied to the prepared and masked portions.
9. In case of the vertical joints, bottom to top application sequence using a spatula or a trowel, shall be followed ensuring that the entire volume of the joint is filled in to effect a total contact with joint surfaces.
10. After application, the sealant shall be smoothened and compressed into the joint using a spatula or a putty knife moistened with cleaning solvent.
11. Masking tape shall be removed immediately after the application is completed to keep the concrete surface clean.
12. A full cure (a stage when the solvent evaporation is completed) shall normally consume
13. 4 to 6 weeks post application of the sealant.
14. Painting over concrete surface if so required, shall be carried out only after full cure has taken place.
Concrete Lined Rectangular Ditches
1. Setting out dimension about the proposed ditches shall be marked.
2. Excavation shall be started & shaped to the rectangular design profile.
3. Compaction shall be done to the non-structural requirement.
4. Proper gradient as indicated on the design drawings shall be maintained.
5. Isolation layer shall be applied if so provided within the specification.
6. Blinding shall be applied on the compacted base to the design thickness.
7. Preparation for the lining concrete shall be carried out by placing in pre fabricated reinforcement to design details & sides formed at edges parallel to the ditch as well as at the construction joints.
8. After the inspection, concrete pour shall be carried out in alternate bays with unformed horizontal surface finished smooth. Remaining bays shall be carried out in the next day operation.
9. Curing shall be carried out accordingly to the approved procedures.
Expansion Joints between ditches
1. Size of the proposed joints to be filled/sealed is 15 mm wide x 15 mm deep.
2. The surface shall be cleaned of all dirt, dust and loosely adhering materials.
3. All grease and oil contamination shall be removed using hard small brushes, compressed air etc.
4. The fibreboard shall be removed to the required depth.
5. Under normal circumstances priming is not required.
6. Masking tape shall be used to confine the joint borders keeping the adjoining concrete surfaces clean.
7. The contents of the Can shall be removed by a Trowel or a Spatula.
8. The Bit mastic shall be applied to the prepared and masked portions.
9. In case of the vertical joints, bottom to top application sequence using a spatula or a trowel, shall be followed ensuring that the entire volume of the joint is filled in to effect a total contact with joint surfaces.
10. After application, the sealant shall be smoothened and compressed into the joint using a spatula or a putty knife moistened with cleaning solvent.
11. Masking tape shall be removed immediately after the application is completed to keep the concrete surface clean.
12. A full cure (a stage when the solvent evaporation is completed) shall normally consume
13. 4 to 6 weeks post application of the sealant.
14. Painting over concrete surface if so required, shall be carried out only after full cure has taken place.
15. Galvanized grating shall be placed on the ditch later.
Termination Details to protective membrane
The following operational sequences shall be involved
Case 1
Concrete surface shall be cleaned of all dirt & dust using a brush.
1. Application of the waterproofing membrane according to the specifications to the defined levels keeping the top 200 mm or variable dimension according to the drawing above the finished ground level.
2. Lines shall be marked on all sides to correct level as per drawing.
3. Bead Lengths to exact site dimensions shall be cut to suit a close fit between the ends.
4. Every bead shall be provided with a minimum 3 # screws to be drilled and fastened into the concrete penetrating the membrane using an electrical operated Drill.
5. After the screws have been fastened and the beads are in proper alignment, approved sealant shall be applied to top of the bead keeping about 5 mm above the bead with a down ward lap as follows.
6. Sealant shall be applied using a gun fitted with conical nozzles adjustable to suit the width into the corner using an even trigger pressure & cleaning the nozzle occasionally to avoid contamination. A smaller timber spatula soaked in soapy water shall be used to compact the sealant into the joint/junction for a smooth polish finish formation. The mixing and application equipment shall be cleaned immediately after use.
7. QC inspection shall be conducted & the relevant ITP signed off
Case 2
1. Where grooves have already been chased, the waterproofing membrane shall be tacked in & sealant applied to the space left in the groove according to specifications and the manufacturer’s instructions. No Aluminium bead shall be used in this case.
2. Sealant shall be applied around bead continuously. AJESCONTRACTOR QC inspection shall be conducted & the relevant ITP signed off
Case 3
In gravel or soil area, membrane shall be terminated at a level ‘150mm plus’ below the footing top level keeping Aluminium bead details typical. All other details shall remain as in ‘case 1’ if no rebate has been chased. QC inspection shall be conducted & the relevant ITP signed off
Case 4
In the paved area, membrane shall continue up to the termination level but the protection board cease at 20 mm below the paving level filled with mastic on top keeping all other details as in case 1 if not chased for rebate. QC inspection shall be conducted & the relevant ITP signed off
Ignore if not applicable
Grouting to pipe rack bases typical
1. The surface to be grouted shall be chipped / scabbled without using mechanical bush hammer, to expose the aggregate and remove the laitance. The finished surface shall be free from oil, dust, dirt, paint, curing compounds etc and be soaked in with water for 24 hours prior to grouting to minimize the localized absorption as well as to assist the free flow of the grout.
2. The bolt holes/pockets shall be made water free prior to placement of grout.
3. The base plates/ bolts shall be clean and free of oil, grease and paint and correctly aligned according to the approved drawings.
4. The stainless steel shims 50x50x10 mm thick shall be in correct locations covered with mortar so as to allow at least 50 mm grout cover on shim sides.
5. The forms on the essential sides shall be erected at locations with chamfers.
6. An electric drill fitted with a paddle shall be used for the grout mixing purpose using water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928 or any other approved grouting material depending on to requirement.
7. The mixer shall be clean with no standing water.
8. 90 % of the measured quantity of water required to achieve the desired consistency according to the batch volume be added to the mixer before adding the grout and the Masterflow 928 or any other approved grouting material be added gradually, simultaneously pouring in the remaining 10 % water quantity during mixing, which has to be kept on for at least 3 to 5 minutes until a uniform lump free consistency is achieved.
9. Then the grout shall be poured continuously using the grout pour cone with a constant hydrostatic head of at least 15 cm.
10. Having poured the grout Masterflow 928 in place, all exposed grout shall be covered with clean dampen Hessian and be kept moist until grout is firm enough to accept a curing membrane.
11. The temperature range 4 to 32 degree C shall be maintained for the 3 post pour continuous days.
12. The grout thickness varies between 25 to 50 mm.
Ignore if not applicable
Water Tightness Test of RCC Structure typical Sump
1. The structure to be tested shall be completed of all RCC constructions according to the specified and agreed procedures.
2. Complete filling of the tie rod holes with MBT Master Flow 544 or Conbextra GB or an equal approved shall be carried out according to the manufacturer’s instructions.
3. Inlet shall be laid in place to the levels shown on the drawings as reflected on the water quantity schedule i.e. the Invert levels at maximum supply elevations.
4. The external surfaces of the structure shall be prepared & applied with the specified protective system.
5. QC Inspection shall be conducted for the approval of the membrane.
6. Structural backfilling shall be carried out externally to the project specifications & necessary field density tests conducted to the requirement.
Application of the floor screed as specified shall be carried out
1. The entire surfaces of structure to be tested shall be sweep blasted removing all loose spalls, dust dirt etc. The prepared internal surfaces shall be inspected by QC for approval.
2. The following operations shall be involved to conduct the water tightness test according to the BS 8007: 1987 Section 9.1 applicable to liquid retaining structures.
3. A graduated stick shall be provided on wall top to show the water levels to a ’mm’ count.
4. Potable water shall be filled into the respective pit structure at a rate 2 m per 24 hours for which the attached ‘filling scheduled quantities ‘shall apply. Attached schedule shall depend on the structure volume.
5. After water is filled in to the required level, it shall be allowed to stay for a period of 7 days for stabilisation, absorption and autogeneous healing. If so required, water shall be added to maintain the maximum test level in case it is lost during this period.
6. Test shall commence from 8th day and continue for 7 days for a design crack width of 0.1 mm according to specification requirement.
7. Observations regarding water level drops shall be recorded every 24 hours by visual measurements on mm scale.
8. The test records shall be documented on the approved form.
9. ‘ Structure Leak Test ‘and the judgement on the test made accordingly.
10. During this 7 days period, the total permissible loss in level shall not exceed 1/500 of the average water depth of the full tank or 10 mm.
11. After the test is successfully completed, water shall be pumped out either to the other structure for testing should that be ready to receive it or if not, to the other construction areas for curing or any other purpose as agreed leaving the pit empty.
12. Remedial Work if required.
13. In case of unsatisfactory performance of the water tightness test and upon the agreement with Technip, injection-grouting method may be adopted to seal the seepage routes.
14. Should the structure not satisfy the 7 days test, then after the completion of the remedial work, it should be refilled and if necessary left for a further stabilising period; a further test of 7 days’ duration should then be undertaken in accordance with this clause.
Concrete Protection Coating Typical
1. The method involves the following sequences in general.
2. Surface preparation, Mixing, Application Details- All grease, oil, dust, residual curing compound, mould release agent or other contaminants, which could impair adhesion, shall be removed from the surface by degreasing and washing.
3. The whole surface to be coated shall be cleaned using water jetting and visually inspected to ensure that the roughness does not exceed grade 80 sandpaper. All the holes, voids, depressions, spalls etc. shall be filled with Masterseal 550 or an equal approved mixed to a trowel consistency, scraped lightly into the surface, allowed to dry and later roughened by hand wire brush on the small areas and gently water jetted on the larger areas.
4. The filled areas shall be visually inspected to ensure that the correct mechanical key is achieved.
5. Mixing Master seal is supplied in the pre-measured units and shall be mixed on site using clean containers. The powder shall be slowly added to the liquid component and agitated /mixed for 2 minutes by using a slow speed hand power drill fitted with a suitable paddle attachment, until a homogeneous lump free consistency is obtained. The mix quantity shall be such that it could be consumed in one hour during application without allowing any retempering with water.
6. Application Coverage 1.8 Kg / sqm at 1 mm thickness.
7. The coating shall be 1 mm thick applied in one coat. In hot weather the surface to be coated shall be shaded from direct sunlight. The areas to be coated shall be saturated with fresh and clean water.
8. The prepared and the saturated surface shall be inspected by QC.
9. The mixed material shall be applied while the surface is visibly damp without standing water using short stiff brush or roller. (Roller shall be used in major /large areas). The evenness and the thickness of the applied coating shall be regularly checked during application while the material is still wet.
10. The materials shall be allowed to dry and visually inspected.
11. QC inspection shall be conducted.
12. Any missed areas shall be saturated and then touched up.
Ignore if not applicable
Lighting Poles Foundations Typical
Pre casting Area-The existing yard being used for the pre casting of manholes, catch basins etc. shall be employed for this purpose also.
The following operations are involved to carry out the production of the light poles foundation bases Pre installation operations
1. Fabricate and erect the side forms 4 #s to the specified dimensions.
2. Fabricate the rebars according to the specified details.
3. Provide the non-critical cathodic protection.
4. Provide the PVC cable duct.
5. Provide the bolt assembly to the requirement and location.
6. Provide the lifting lugs to carry a gravity load of at least 3 tonnes + handling stresses.
7. Pour the concrete. Cure the concrete immediately after pouring Post casting operations. To cure for the specified period.
8. Excavate the location to the required formation level. To blind the area to be founded with concrete.
9. Waterproof the blinding as specified. Keep the area ready in all respects well oriented & aligned to receive the foundation directly to be offloaded. Apply the water proofing membrane around as specified.
10. Provide the protection board as specified
11. Back fill the surrounding space to the relevant grade level Details.
12. The typical size of the foundation may be 1000x1000mm in plan and 1100mm deep.
13. A possible of 10 units may be produced by pre casting every day on an average.
14. The forms to the exact size with the preformed chamfers shall be prepared and erected.
15. The steel rebars shall be cut, bent to the required shape, placed and the cage prepared holding 75mm concrete spacers, be positioned into the forms.
16. 1 # 350 mm internal radius 100 mm dia PVC cable duct formed to the dimensions shall be anchored by binding wires to the exact locations shown on the drawing keeping the upper end flush with the concrete top.
17. The Lifting lugs as shown on the sketch shall be fixed in to the correct locations.
18. The forms for the block outs for the lifting lugs shall be fixed in to the correct locations as shown without clashing with the duct or the rebars allowing a protrusion of the hook.
19. The bolt assembly shall be fixed in exact position according to the design details.
20. The non-critical cathodic protection shall be arranged using a metallic continuous binding wire connecting all horizontal rebars terminating into a boss fixed at one location near the top in the middle of the side opposite the duct-carrying portion. All the supports and the dimensions shall be checked and the plumb monitored.
21. QC inspection shall be conducted.
22. The concrete shall be poured to all the prepared units in 3 layers in vertical sequence.
23. The appropriate vibrator shall be used for the compaction of the concrete. During concreting, care shall be taken to keep the anchor bolts’ position undisturbed and the intermittent checks be continuously made to monitor the spacing /centres between the bolts. After the concrete is poured in full & well compacted, the surface shall be levelled using a wooden float followed by light steel trowel. Immediately after the concrete starts setting, approved curing compound shall be sprayed on the surface forming a continuous membrane which be covered over with a polythene sheet according to the specifications.
24. After 2 hours, the polythene sheet shall be temporarily removed to spread over the concrete surface the saturated burlap cloth or hessian, and recovered immediately.
25. The side forms shall be removed within the specified period. The vertical concrete surfaces shall be spread with the curing compound immediately after striking the forms and covered with the polythene sheet according to requirement. The curing shall be continued for the specified period.
26. The relevant locations shall be made ready to receive the pre-cast units by completing the excavation, blinding, the horizontal waterproofing and forming the correct alignment.
27. QC inspection shall be conducted.
28. The unit shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the location for offloading on to the prepared ‘location to receive’ the unit. The unit shall be installed on the marked location according to the correct orientation to the lighting layout drawing.
29. QC inspection shall be conducted.
30. The protruding lifting lug eyes shall be cut to 60 mm inside the block out, the void filled with concrete by first scabbling the internal surface followed by cement slurry grouting and pouring concrete.
31. The external surfaces of the foundation shall be applied with the concrete protective membrane according to the specifications.
32. QC inspection shall be conducted
33. The membrane protection board shall be provided covering the surface to the specified details.
34. The back filling shall be carried out according to the specification up to the required levels in layers and up to the required ground grade or the pavement. The points to locate the cathodic protection shall be provided with a marker to trace the boss. The sequence shall be repeated for all the lighting poles foundations.
Pull Pits Typical
Operations in Pre casting Yard Pre casting Area.
1. The existing yard being used for the pre casting of manholes, catch basins and lighting poles foundations etc. shall be employed for this purpose also Form work.
2. The typical size of the Pit type shall be taken from the drawings.
3. On an average, 20 units shall be produced by pre casting every day The wooden forms to the exact dimensions with pre -formed chamfers shall be prepared and erected.
Rebars placement
1. The steel rebars shall be cut, bent to the required shape, placed with 75mm concrete spacers and positioned into the forms according to the details provided.
2. The Lifting lugs shall be fixed in to the correct locations.
3. All supports and dimensions shall be checked and corrected if required.
4. QC inspection shall be conducted before pouring concrete and signatures appended to ITPs
Pouring concrete & finishing
1. The concrete shall be poured into all the approved preparatory works in 1 layer by directly delivering from the concrete truck / transit mixer through the chute 1 # ¾” needle vibrator shall be used to compact the concrete and 1 # reserved standby.
2. After the concrete is poured in full & well compacted, the surface shall be levelled using a wooden float followed by light steel trowel.
Curing
1. Immediately after the concrete is finished, the surface shall be covered with polythene sheet with the edge lapped or tied down to exclude air circulation without permitting the membrane to be in touch with concrete surface according to the specifications.
2. After the concrete has stiffened but no longer than 2 hours, the polythene sheet shall be removed followed by immediate covering the surface with saturated (soaked with mix quality water) hessian and recovered with polythene sheet to prevent evaporation from the hessian. Throughout the curing period the hessian shall be maintained in a permanent wet condition using mix quality water.
3. The side forms shall be removed after the specified period of 24 to 36 hours as agreed.
4. The vertical concrete surfaces shall be draped with the saturated hessian immediately after striking the forms and covered with the polythene sheet held firmly in place along all edges & kept continuously wet for duration of curing.
5. The curing shall be continued for the agreed number of days.
6. QC inspection shall be conducted from time to time throughout the operations.
Lifting, loading & transportation
The covers shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the area concerned to offload on to the prepared ‘location to receive’.
On site operations- post laying of Cable ducts.
1. The area around the excavation coverage shall be barricaded to the site requirement.
2. Setting out
3. The setting out shall be carried out by the surveyor to the required co-ordinates.
4. QC inspection shall be conducted throughout the operation and ITP for the survey check signed off
Excavation
1. Excavation shall be carried out (manually if the ducts are not encased in concrete) to the specified formation levels i.e. 1300 mm (varying from area to area) from the finished grade monitored by surveyor
2. Compaction and the tests if so required, shall be carried out accordingly.
Mass concrete base
1. The formwork for the mass concrete that may 500mm wide and 150mm deep shall be prepared and erected to the settings.
2. AJE QC inspection shall be conducted from time to time throughout the operations and concrete pour ITPs signed off
3. Concrete shall be poured to the exact levels, finished properly and cured to the specified procedures
4. Concrete protection
5. Concrete protection shall be applied to the mass concrete to the details & specifications.
Block work in walls
1. 200mm Block work shall be constructed according to details to the required levels so that the cover top level is 100mm from the finished grade/ground level. In case the ducts are not laid in, opening shall be provided in the wall
2. QC inspection shall be conducted from time to time throughout the operations
Compacted sand fill
Uncompacted sand shall be filled as indicated on the drawing & in accordance with the specifications.
Compacted backfill
1. The remaining portion shall be backfilled and compacted to the specification requirement.
2. The top surface shall be well prepared, compacted and levelled to receive pre cast covers.
3. Placing the pre cast covers
4. The covers shall be offloaded by a crane from a trailer as transported from the pre casting yard to the relevant locations ready with one layer 0.25mm thick polythene sheet with laps 300mm, spread over.
5. The covers shall be properly spaced and levelled to the details shown on the drawing.
Sand fill
300mm deep sand backfill shall be carried out over the laid ducts not encased in concrete.
Backfill
1. As dug compacted backfill shall be carried out above the sand fill to the specifications.
2. AJE QC inspection shall be conducted from time to time throughout the operations with the relevant ITPs signed off
Lugs Fill
1. The sand shall be filled in the lifting lugs recess.
2. Concrete Protection
3. The exposed concrete surface is a part of pavement and therefore no protection shall be applied.
Massive Block Foundation- Thick Element – Typical
1. Wherever specified any reinforced concrete structure more than 800 mm in thickness & more than 8 cum of RCC quantity, the following procedure shall be followed.
2. Excavation shall be carried out to approved procedures. Blinding shall be carried out to approved procedures. Reinforcement & formwork fixing shall be carried out to approved procedures. Cathodic protection if so specified shall be fixed to design details & continuity checked. Specific attention shall be given to the concrete pour sequence. Since the quantity of the pour element & depth shall be considerably greater, concrete should be poured in continuous stepping fashion forming an acute angle with the vertical so that the formation of cold joints is completely avoided. The portion poured previously after vibration must receive over pour within the concrete setting time. A sketch shall be issued to site giving complete sequence of pouring. Concrete foreman must adhere to that & complete the pour successfully. Massive pour requires thermal curing as explained somewhere else in this document that shall be applicable here as well.
Foundations connected to paving concrete
1. These considerably small foundations shall be placed on the pavement concrete to transfer minor equipment stresses. Construction shall include erection of forms & reinforcement placement duly connected to paving.
2. Setting out shall be done & forms erected. Set out location area shall be roughened by scabbling.
3. Rebars shall be fixed to the details. Concrete spacers installed to sides & bottom. Any electrical insert placed in. Top-level line fixed with plastic chamfers. After inspection, concrete poured & curing effected to approved procedures.
Duct banks
Excavation shall be carried out to the defined sectional size. Proposed formation area shall be compacted to receive the concrete. Blinding concrete shall be placed to the required thickness. Forms for the sides of the duct bank concrete shall be erected. Nominal rebars shall be placed to the details. Design ducts shall be placed & fixed in defined positions using proper supporting arrangements so that during concreting operation these ducts remain in the set positions. Ends shall be closed properly allowing the ducts protrusion from the end forms. Ducts ends shall be closed preventing the ingress of dust or any foreign material. Inspections shall be conducted & concrete poured & cured accordingly to the specified colour. After the concreting is completed, marker shall be placed over the duct concrete & over backfill done.
Cable Trenches
Dummy / walled trench section Typical
1. The following operational sequences in brief are involved. Setting out to the exact alignment the route of the trench to the specified co-ordinates. Barricading the involved area to the safety department direction and requirement. Excavating the trench to the specified levels and sectional details. Preparing the formation to achieve the required levels and dimensions. Form work for the sides of the mass concrete strip beams. Pouring the mass concrete to the strip beam forms. Setting out the alignment for the trench block walls.
2. Block work 150mm thick in walls to the specified levels up to the pavement down stand beam soffit level.
3. Preparation and concreting the pavement portion monolithic with the down stand beam extended up to the top of the block wall. Backfilling the trench with the excavated earth to the specifications. Placing the pre cast coloured concrete covers in 1m or 3m standard lengths on the relevant compacted area. Sealing the joint between the pavement and the trench cover. Cable marker shall be provided.
Details about the above operations in general
1. The surveyor shall set out the alignment of the trench concerned according to the relevant details given on the paving and underground services location plans to the reference Co-ordinates.
2. QC shall conduct the inspection
3. The safety arrangement shall be discussed with the safety department and implemented accordingly to control the trench excavation, to provide barricades, night-lights, to divert the traffic if so required, and to adopt any other necessary measure. The excavation shall be carried out by an excavator to the lines and the levels. The surveyor shall monitor all stages of excavation to achieve the required profile. The excavated material shall be transported immediately by a dump truck to the earth stockpiles temporarily. After the excavation is over, the formation levels shall be well dressed and compacted to the specification requirement
4. The forms shall be fabricated for the mass concrete section. The fabricated forms of width 350mm and depth 100 mm shall be erected/ fixed on the prepared compacted formation duly aligned and levelled.
5. QC shall conduct the inspection throughout the stages of construction
6. The mass concrete shall be poured to the marked levels and tamped by wooden float. The forms shall be struck after the specified period. The curing of the mass concrete shall be carried out according to approved procedures and for the specified period. The alignment of the block walls 150 mm thick shall be set out and the block work carried out in courses in a straight line and plumb.
7. The whole number of courses shall be laid. The fractional block course if so remained to make up the required wall height, shall be constructed as a part of the pavement down beam concrete by extending the bottom to the top of the block walls. The pavement /down beam monolithic pouring shall be carried out to the specified details according to the procedures.
8. QC shall conduct the inspection throughout the stages of construction
9. The backfilling shall commence and the trench filled according to the specifications.
10. The pre cast covers of 1m or 3 m standard length shall be placed on the filled trench internal surface to the specified levels. The concrete shall be coloured to the specification requirement.
11. QC shall conduct the inspection throughout the stages of construction
Where the dummy trench runs over the duct bank Typical
1. All the operations described in general shall be applicable herein as well with the following amendments/additions to certain activities. Excavation shall be carried out to the top of the duct concrete only. The walls shall be started from the duct top level. Additionally, where the underground pipe runs crossing the Trench, the specified pipe shall be laid prior to the block work is commenced or openings shall be formed in the walls (Pipe laying operation by others). Flat width of the crossing shall be in size equal to the value given by the equation “Duct Bank length + 300x2 “.
2. Where the dummy trench and the direct buried trench run parallel
Typical
All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities. While constructing the buried trench, the profile of the dummy trench shall dictate the profile of the buried trench. Sloping profile to a grade 1 in 2 shall be formed as shown on the drawing.
Where the cable trench crossing with the closed drain pipe trench
Typical
All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities to be supplemented. The profile of the cable duct trench shall dictate the profile of the direct buried trench. The transition of the formations between the trenches and the crossing shall be in grade 1 in 2 as shown on the drawing. The length of the duct bank shall be equal to the value given by the equation. Width of the closed drain trench in mm + 2x100. The crossing flat width shall be the duct bank length + 2x300. A gap of 100mm shall be kept between the duct bank top and the closed drain bottom surfaces. The duct bank shall be constructed according to the details. Cable tiles under the closed drain trench shall be provided in the direct buried trench only. A joint shall be provided between the pavement and the closed drain trench wall.
Where direct buried trench crossing under dummy trench
Typical
All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities to be supplemented. A level difference of 350mm shall be kept between the elevations of the crossing formation and the dummy trench. The level transition shall be established by grading 1 in 2. The cables passing under the dummy trench shall be protected by cable tiles (By others) . The trench corner wall shall be constructed to the details showing the corner length on the trench internal face.
Where trench with dummy Trench crossing under direct buried cable trench
Typical
1. All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities to be supplemented. The profile of the cable duct trench shall dictate the profile of the direct buried trench. The transition of the formations between the trenches and the crossing shall be in grade 1 in 2 as shown on the drawing. The length of the duct bank shall be equal to the value given by the equation. Width of the direct buried cable trench in mm + 2x100. The crossing flat width shall be the duct bank length + 2x300. A gap of 100mm shall be kept between the duct bank top and the closed drain bottom surfaces. The duct bank shall be constructed according to the details.
2. Cable tiles under the closed drain trench shall be provided in the direct buried trench only.
Where direct buried trench crossing under direct buried cable trench
Typical
1. All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities to be supplemented. A level difference 700 mm shall be kept between direct buried trench and the crossing formation level. The crossing formation width shall be equal to the value from the equation in mm. (direct buried cable trench width + 400x2). The transition of the formations between the trenches and the crossing shall be to grade 1 in 2 as shown on the drawing.
2. Cable tiles shall be provided in unpaved areas and at trench crossing.
Electric Trench Layout at Pumps Typical
All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities. The pump base shall be constructed to the details. The trench walls shall be continued to the shape as shown.
Option
If so required and felt convenient for certain uniform section reaches, pre cast concrete units 100 mm thick may be utilised to substitute 150 mm thick walls directly resting on the prepared formation.
Underground Piping
In the scope, the following types of pipes are indicated to be included.
1. Carbon steel pipes gravity network 4” dia to 14” dia, coating material & welding, flange, gasket, bolting, testing, valve & flanges, sand filling, back filling/ pressure network etc.
2. Non reinforced concrete pipes, cutting, jointing, sand bedding, anchor blocks 200 to 500mm etc.
3. Reinforced concrete pipes, cutting, jointing, sand bedding, anchor blocks 200 to 2000 mm etc.
4. Ceramic gres pipes & fittings, sand bed, Y, T, cuts, leak test, 100 to 500 mm dia etc.
5. Bonna type pipes & fittings, sand bed, T, Y, anchor blocks 250mm to 2500mm dia etc.
6. Plastic pipes PVC gravity network 110 mm to 410 mm dia etc.
7. Polythene pipes gravity Y, T reduction piece, cuts, sleeves, leak test etc.
8. Plastic pipes pressure network 110 mm to 410 mm sand bed etc.
9. PVC pipes heavy-duty 110 mm to 410 mm send bed etc.
10. Polythene pipes pressure Y, T reduction piece, cuts, sleeves, leak test etc.
11. Cast iron cement lined pipes gravity etc.
12. RTRP pipes pressure+ gravity 100 to 800 mm etc.
13. The following activities are typically involved to carry out underground piping system etc.
14. Ensure no underground existing services exist in the area concerned.
15. Setting out the alignment of the proposed route according to survey details.
16. Providing safety control barriers on both sides of the excavation allowing enough clearance for the excavator & truck to work without hindrance.
17. After approval of the setting out, excavate the set out portion as trenching & continue up to the design depth according to the formation level of the pipe bedding following the approved excavation procedures.
18. The pipes & fittings shall be stacked properly on both sides of the trench according to the manufacturer’s instruction.
19. Prepare the bedding formation to the design levels & longitudinal profile specifically for gravity system.
20. Surveyor shall monitor the levels throughout
21. QC inspection shall be conducted to check the bedding
22. Bed shall be filled with sand up to the pipe external surface level.
23. Proper arrangement shall be made to down take the pipes. After down taking the pipes & fittings to the trench bed & placing roughly into set out alignment, surveyor shall give the exact alignment of the route.
24. After the route has been aligned truly & fittings included, counter weight using sand on the pipe surround shall be applied temporarily to avoid pipe uplift during pressure testing or mechanical anchors employed depending upon dia of the pipe & the quantum of water pressure. All joints shall be connected or filled according to specifications.
25. Wherever specified, for the steel flanges, bolting shall be carried out
26. Wherever specified, for the plastic or p v c pipes, push fit system of jointing shall be applied
27. Wherever specified, for the plastic pipes, joints shall be glued using tangit
28. Wherever indicated, to anchor the bend etc at turning using thrust block, block shall be constructed of concrete to resist the, resultant pressure during pressurizing.
29. Wherever specified, for the concrete or r c c pipes, special jointing material shall be applied to meet the requirement.
30. Wherever required, to use cut pipes to complete the length, pipes either Bonna or carbon steel or concrete or any other make, pipe shall be cut to the actual length of the piece required.
31. After all jointing has been completed, pressure testing shall be conducted for the ready portion with application of required bar pressure. Risers of the pipes shall be installed on both ends of the pipe line, filled with water under pressure which shall continue for the specified period of 24 to 72 hours during which period, observations of the water levels falling & the leak detection be conducted & recorded. Any leak detected in any part, that pipe part shall be removed & re installed & test repeated all according to approved ITPs
32. After the test has been successful, pipe service marker shall be placed for identification purpose & granular material filled on the pipe & its surround so that at least 200 mm layer is established on the crown of the pipe. This fill shall be compacted lightly. Later from this level to the ground, granular fill material shall be used to backfill the remaining section duly compacted in layers all according to approved procedures.
Ignore if not applicable
Epoxy grouting to vibrating machine bases Typical
➢ Thin section - A gap between a base plate and substrate below 25 mm
➢ Thick section- A gap between a base plate and substrate above 80mm
➢ Normal thickness- In between the thin and the thick sections
➢ The following activities are involved for normal thickness
➢ Surface preparation
➢ Metal parts that should not be bonded to the grout like jack screws of the reciprocating machinery and part of the foundation bolts shall be sealed with tape prior to grouting.
1. Base plates and equipment bases shall be uniformly supported in order to eliminate sag, distortion and levelled using both anchor bolts and jackscrews. Stainless steel shims 50x50x10 mm thick shall be placed in correct locations covered with mortar so as to allow at least 50 mm grout cover on shim sides.
2. Full extent of the foundation surface under the base plate or equipment to be grouted shall be chipped / scabbled & brushed to remove the weak upper layer of concrete and any oil soaked concrete areas prior to the installation of the base plate. Base plate surfaces in contact with epoxy grout shall be grit blasted so as to expose white metal. All surfaces and bolt pockets to receive grout must be clean & free of rust, oil, dirt, paint and residual curing compound. All base plate holding down bolts etc must be free of rust, oil, dirt or contaminants that could impair bond Formwork Unless otherwise shown on design drawing, the entire area under the base plate shall be grouted and the forms fixed around the plate keeping a minimum of 25 mm clearance from the plate edge and at least 50 mm from the edge of the pouring side so that total grout able area is equal to underside of the plate and the clearance around the plate.
3. Before the form work is fixed, it shall be ensured that the foundation area to be grouted and the bolts holes are clean A liquid tight formwork as practicable, shall be fixed around the base plate to prevent the leakage of the resin keeping the top of the forms 25mm above the underside of the base plate A chamfer 25mm x 25mm shall be provided on the sides so that top of the chamfer and the top of grout are in one level in case the whole of the foundation area around the plate is to be grouted, A 45 degree sloping surface above the form on the pouring side shall be constructed to create a pressure head to enable the grout material flow to cover full width of the pour. A coating of an approved release agent shall be applied to the formwork.
4. QC inspection shall be conducted to ascertain the form profile and general preparatory works
Grouting application
1. All dirt and debris shall be removed from the form work using compressed air Sufficient Grout material to completely fill the prepared area in a continuous process shall be made available Mixing equipment shall be demonstrated to be in a suitable as well as in good working condition.
2. A stand by equipment shall also be made available
3. Concrete surfaces to be grouted shall be completely dry before grouting Mixing Base and reactor components shall be poured into a suitable mixing vessel and mixing carried out for 1 minute or until successfully blended. All required quantity of aggregate shall be added to the mixing vessel which is to be kept turning and mixing continued until a uniform lump free consistency is achieved. Over mixing shall be avoided to prevent air entrainment Placing. All bolt pockets shall be filled with grout prior to pouring the rest of the under plate space as a separate operation to prevent voids formation Pouring of the grout shall start from one end of the base plate and continued until the material reaches the far side. Mixed grout shall be steadily poured down the formwork slope to avoid air entrapment.
4. Pouring shall be carried out only from one side of the base plate to avoid creation of voids and any reduction of the effective bearing area When the grout reaches the far side of the formwork which shall be ensured by poured material rising above the bottom of base plate, the pouring location has to move along the length of the base plate keeping the process continued until the whole area is completed.
5. QC inspection shall be conducted throughout the above operations to ascertain the proper implementation of the procedures according to the manufacturer’s instructions.
6. Shoulders-
7. Exposed surfaces shall be brushed with Solvent # 2 just before or as the grout gels
8. Curing No curing is required
Ignore if not applicable
As-built Drawings
1. As built drawings serve the purpose of telling the user about the building records that should be used for the purpose of maintenance/or for whatever purpose possible. It is therefore, an important & significant part of documentation as well as also a contractual obligation on the part of AJESCONTRACTOR & Technip which should be affected smoothly & regularly throughout the duration of project. Should there be no change on the Released for construction drawings i.e. the construction has been carried out all in accordance with the approved documents provisions, there shall be no purpose of As - built drawings. But in practice, to produce physical structures, some changes are imminent due to arising of new requirement, changes, effects of disciplinary interfaces to bring the work to proper use functions etc. During the whole currency of the contract, it should be an endeavour of the AJESCONTRACTOR that all changes are recorded on contract documents as Red Lines mark up & issued to Technip for approval. These Red Lines mark up shall form the basis of producing all As Built documents on the project. It is not the drawings only that are to be recorded but also all changes whatsoever for any document on record. All these As Built shall form part of hand over dossiers. Should as built records be maintained regularly, this part of the dossiers shall be comfortably produced. The site design engineers shall keep an eye on this activity & record changes regularly as red line mark up & process the documentation to fulfil the contractual obligation to this extent possible. It is expected of the site engineers, the design engineers as well as land surveyors to coordinate on site to comply with this obligation efficiently. All survey changes or variations shall also be recorded on the drawings based on the pre pour & post pour records taken from survey section. Surveyor shall present all such changes on the corresponding documents to be recorded as Red Line Mark ups.
2. The following paragraphs management procedures have been included just for the purpose of information as already covered within the New Buildings package Inspection & Test Plans All necessary Inspection & Test Plans shall be originated by the Quality Engineer in collaboration with Engineering in head office & Engineering in site team. These ITPs formats shall be issued for Technip & Company approval according to the procedures laid down on Project Quality plan. Production of all these documents shall be the responsibility of AJESCONTRACTOR Quality Manager/Engineer. Complete details about the quality management system have been included on the respective Quality Procedures document. Generally, ITPs for all disciplinary activities shall be produced for Technip & Company approval from site office in due course. All defined tests shall be conducted by Technip/Company approved laboratory located on site. For those items the tests shall be conducted by any Technip/Company nominated laboratory, for which facilities are not available on site. The details of these plans shall be submitted separately. Every ITP shall be allotted a document number along with a numbered checklist. Check list shall form the basis of inspection requirements.
Project Controls
1. Project Control management requires the formation of strategies those can be utilized optimally to achieve the target in minimum cost with best quality product
2. To achieve as aforesaid, it is extremely important that complete project should be analyzed from whole to one & all necessary resources to be used or deployed should be known in advance prior to commencement of physical works.
3. Based on the project design, construction, commissioning and maintenance durations, Analysis, planning & charting out at various levels shall be carried out by the Planning Engineer. Further based on these periods, all necessary resources shall be arranged & mobilized by human resources, materials, and technical managers in collaboration with Project Manager.
4. The plans shall be monitored regularly, as the project construction progresses, on a weekly basis, monthly bases & no delay allowed & if any, immediate recovery shall be planed. The relevant reporting shall project the real quantum of planned & actual physical works, resources available, deficiency of resources, material procurement status, materials delivered & expected time of arrival etc & all necessary measures required to keep the construction on line & valuation worked accordingly. Every effort should be made to keep the progress in line with plan.
Procurement
Note-The term Material herein includes equipment also
1. According to the site requirement & provisions made on the plan, for temporary materials & consumables, requisitions shall be raised from site by the relevant engineer, checked, numbered & coded by the material controller & approved by the construction manager for transmission to head office procurement manager for further action. Cost controller shall further check the budgetary provision applicable & give clearance to the purchase manager for procurement. Purchase manager shall then invite the inquiries from various sources of material, negotiate & prepare a comparative statement & based on the merits of responses / quotations, record his comments based on the comparative statement as well as recommendations for the considerations by the Management. After reviewing the proposal, the management shall approve or reject the proposal. Purchase order shall be made on the approved proposal. An alternative source shall be located for the rejected proposal. A copy of the approval shall be provided to the project manager for follow up the delivery.
2. For permanent works, proposed material shall be submitted for Technip / Company approval on requisite Material Approval request form along with brochures, samples if applicable, processed through the document centre after Project manager approval. After obtaining Technip / Company approval on the request, procurement manager shall process the requisitioned approved item based on the budget quantities following in line the procedures applicable for temporary materials.
3. After the material is delivered to site, material controller & relevant engineer shall check the quality & quantity of the delivery. Any deficiency in quantity, quality or any damage observed, shall immediately be notified to the procurement manager through construction manager. Delivery information shall be circulated to the concerned personnel & quality manager himself shall or delegate an inspector or the relevant inspector shall check the adequacy of quality & if necessary according to ITP provision, shall invite the Technip / Company engineer to inspect / examine the delivery. The selected samples of delivered materials shall be sent to an approved laboratory for technical tests for the purpose of certification of compliance. After inspections & approvals, delivered materials shall be recorded in stores receipt documents, an issue to site may be undertaken thereafter.
4. Post placement of purchase order, Procurement Manager shall track various stages of material production & transportation or shipment to the site/delivery & if so noticed that an expectation exists for the delay in delivery, shall apply all efforts to expedite the delivery on appointed date.
5. Materials shall be stored in proper designated areas complying with the manufacturer’s instructions. Separate area shall be located for the materials requiring certain temperature of storage. Stores shall be well constructed & shaded. Generally, all consumables shall be stored in shade provided with proper lock & key arrangement. Materials which remain unaffected by exposition to weather may be stored open duly protected under proper watch & ward.
6. Proper protection shall be made for all stored materials inside covered area or out side. Necessary protection by removable membranes such as polythene or tarpaulins shall be used to protect material from the ingress of moistures or from effect of dust.
7. Storage of all materials delivered shall be done complying to the set & approved procedures making sure that all inventories can be verified any time & that any material can be traced any time easily.
8. All entries of the incoming deliveries shall be recorded into the register & verified by the store keeper & material controller that it complies with the details on deliveries documents. Any deficiency noticed shall be immediately reported to the procurement manager.
9. After the acceptance of the material by the concerned authority only, a store issue shall be affected & recorded on the required issue documentation. Regularly the status of all receipts, issues & balance in stores shall be reported to the construction & project manager who shall act further depending on the project requirement.
10. Elaborate details have been given on the AJESCONTRACTOR procurement procedures document
PRE MOBILIZATION PLANNING
1. An elaborated, detailed and logical mobilization plan is essential for a successful start-up of construction activities. This plan must exhibit complete schedule, preparation and pre-construction activities necessary to ensure the timely availability of drawings, personnel, construction equipment, temporary facilities and materials at the job site to properly support the construction efforts.
2. This plan is already under preparation at tender stage & the schedule about all three packages have been included with the bid.
3. This outline plan shall be further developed after contract award and concluded within a week of the contract award. The mobilization plan shall be closely coordinated with the construction plan to ensure mobilization activities properly lead into and provide a smooth transition into initial construction activities.
4. A detailed bar chart schedule shall be prepared with early and late activity bars involving the main activities to achieve full mobilization of staff, labour, construction equipment and camp/site facilities, shall be prepared at the commencement of the contract.
5. Mobilization plans for staff & labour, accommodation and temporary facilities established during the bid stage would be reviewed, re-evaluated to ensue its fitness to meet the project requirement & updated to include any other activity necessary to meet the final requirement, which might have occurred then, since the day of original preparation. All necessary adjustment measures required shall be incorporated with the update & resolutions reached.
6. Additional site visits shall be undertaken immediately after the project kick off to confirm validity of the data collected during bidding stage, reconfirm assumptions and establish additional information required to permit smooth and timely mobilization & adhering to further activities durations strictly. The following descriptions shall be reviewed and confirmed.
➢ Access to the job site whether or not available without any obstacle.
➢ Location areas of temporary facilities whether or not available & if not resort to appropriate procedures.
➢ Company requirements for properly validated licenses and certificates to be held by construction personnel for the equipment, machines, vehicles, trades.
➢ Transport plans including the movement of equipment & vehicles.
➢ Loss prevention and safety requirements for the camp as well as for the site offices & site
➢ Arrangements for first-aid facilities
➢ Arrangements for drinking water and construction water, availability of sources
➢ Arrangements for electricity supply, requirement of generators & also study of direct supply
➢ Arrangements for storage fuels and lubricants
➢ Arrangements for sanitary & its disposal facilities
➢ Final arrangements for security interface with Technip & Company
➢ And all other essential activities needed for successful mobilization
Aforesaid review shall provide an impetus to promptly chart out all the processes involved with the mobilization with all solutions handed to the construction team for an efficient implementation.
About AJESCONTRACTOR Management Procedures in brief
Work Centres - AJESCONTRACTOR Head Office
Upon notification of contract award, the key personnel to the site Management Team shall be assigned. Construction personnel shall be mobilized to the project site office to provide input and direction to the project team. Successful project execution requires construction experts to be active from the onset of the project. The only activity to continue from Head Office after mobilization period is procurement. All procurement for the project shall be done from the corporate procurement section located in AJESCONTRACTOR Head Office at Musaffah, Abu Dhabi.
The following specific activities must be addressed early to be fully effective:
1. Finalize construction schedule requirements and subsequent approval from Contractor
2. Review manpower requirements for both non-manual and manual personnel; update these requirements by means of staffing schedules, histograms and craft mixes; and ensure subcontractors manning levels are compatible.
3. Review construction equipment needs and ensure that timely subcontractors mobilization plans are in place.
4. Review field procedures and method statements defining standards, policies and procedures required for the execution of the works and ensure they constitute “Project Specific” status.
5. Review environmental, safety and Health (ES&H) and site security plans to ensure compliance with the client’s specifications and guidelines.
6. Review Construction Quality plan in line with the guidelines of ISO 9000 and check Established QC parameters by discipline.
7. Overview temporary facility requirements, including indirects such as tools, consumables, gases and the like and check subcontractors compliance.
8. Actively pursue preliminary site activities such as approvals, permits, establishing contracts.
9. Ensure Lessons Learned & Practices from previous projects are well understood & should be applied effectively from the onset of the works itself to achieve professional products.
AJESCONTRACTOR Site Office
Actual ‘on site management’ would be from offices based on the site next to Contractor and Company’s office. AJESCONTRACTOR Site Office is fully supported by AJESCONTRACTOR Head Office at Musaffah.
The following major activities shall be carried out at site offices.
➢ Safety Regulation Enforcement
➢ Quality Assurance Enforcement and Procedures
➢ Construction Method Statements
➢ Construction Planning
➢ Site Documents Control
➢ Field Engineering & Design Controls
➢ Material Requisitions
➢ Materials Control and Tracking
➢ Materials Storage
➢ Work Procedures
➢ Physical Construction
➢ Site Administration
Mobilization
Mobilization shall be coordinated from the AJESCONTRACTOR Head Office at Abu Dhabi with input from AJESCONTRACTOR personnel already mobilized for the execution of Site Preparation Package and Temporary Facilities for Contractor and Company. Existing teams responsible for the execution of the those two mentioned packages already have substantial cadre of experienced professional well versed in mobilization of temporary facilities, project execution, QA / QC planning, Safety and security operations etc.
➢ Mobilization shall commence with the following activities:
➢ Kick off meeting to commence the sub contract
➢ Commencement of the required land surveys to establish various horizontal & vertical controls bench marks
➢ Incept of the engineering designs at the Firm office
➢ Soil Investigation by an approved laboratory
➢ Construction of temporary facilities
➢ Obtaining various permits from Authorities and conclusion of arrangements with local committees where necessary.
➢ Third party independent concrete testing laboratory credentials submission for approval.
Shortly after contract award, site surveying shall begin utilizing the Total Station System to establish accurate control points for the performance of the work.
1. As soon as practicable, the plans and specification for the site temporary construction facilities shall be finalized and released for installation.
2. During the installation of the temporary facilities existing AJESCONTRACTOR site offices shall be utilized to supervise the site activities required for the temporary facilities installation.
3. On completion of the site offices at ASAB, balance of the AJESCONTRACTOR construction staff shall be mobilized to the site along with construction equipment, tools, consumables, warehousing, storage and other items necessary to commence the work in accordance with the construction schedule. Temporary facilities at the job site shall include Generator Yard and Construction water storage tank, carpentry yard, re-bar fabrication, lay-down area, warehouse and workshop facilities at location A4.
4. At the start of the construction, an emphasis shall be given on the critical requirements of the construction schedule. Work shall be carried out under continual supervision and inspection over performance. Progress shall be monitored on the basis of actual installed quantities compared to scheduled quantities.
5. For construction areas, dedicated work crews shall be allocated for each discipline supervised by foremen and general foremen who in turn shall report to the discipline supervisors / site engineers. Based on the construction schedule requirements, necessary operational crews shall be formed and controlled over to meet the planned progress target to be physically achieved satisfactorily.
6. It is the responsibility of the supervisor/site engineer to ensure the efficient utilization of his material, workforce, tools and equipment.
7. For ‘construction operation water’ requirement, unless an alternative arrangement is made available, water shall be trucked from nearby Desalination plant.
8. Site ‘construction and temporary facilities electricity requirements’ shall be met by installing suitable size and suitable numbers of generators.
Subcontract Strategy
1. AJESCONTRACTOR shall carry out broadly all civil engineering works employing its own resources of manpower, machines, equipment etc.
2. Lower tier sub contracts shall be allowed for the execution of single operations such as supply of ready mix concrete, etc
3. Ready Mixed Concrete is envisaged supplied from an established RMC (Ready Mix Concrete) supplier, an establishment with proven track record duly approved for supplying concrete by GASCO, within 10 kms of the site. However, in the mean time, without reservations, we are also seriously considering installing our own concrete batching plant.
4. In case any minor or specialized work is necessary to be sub contracted on lower tier, Company procedures shall be apply for prequalification and award of the subcontracts.
Testing And Inspection
1. A field inspection and testing program shall be organized to be in line with AJESCONTRACTOR Quality manual & Approved Project plan under overall responsibility of the QA / QC Manager.
2. Prior to conduct any testing, Contractor and Company (as required by QC Plan and ITP) shall be advised of the tests for witness.
3. Wherever required vendor specialist shall be made available for conduct of testing and inspections.
Material Management
1. Once material has arrived at site, material management shall come under the purview and custody of the site store staff. The storekeeper, supported by his store assistant shall be responsible for the custody of the material prior to issue.
2. Material tracking from source to the place of installation shall be conducted by the computerized system. The construction manager shall be responsible to provide the technical oversight and direction for the control of materials at the construction site area. More information has already been elaborated in the foregoing.
Procurement
1. The Central procurement department located at the Al Jaber Energy Services, Musaffah, Abu Dhabi, UAE office shall be responsible for all purchases adhering to the following procedure.
2. Preparation of Purchase Requisition shall be made based on take-offs quantities calculated from the approved drawings documents. Purchase requisition shall completely, identify all applicable drawings, data sheets, specifications, vendor documentation requirements etc. with the inclusion of following information.
➢ Quantity of each item required with comprehensive breakdown
➢ Adequate information concerning nomenclature description, Material approvals, Quality required, applicable specifications, design & other drawings, etc/ or detailed outline of the material required.
➢ Required delivery dates for all major items.
➢ Delivery points of major items
➢ Inspection of the goods at the point of origin issue
➢ Certification of test data and/or compliance/ warranty
➢ Method of shipment (if goods imported), conditions/packing
➢ Instruction of holding, kitting consolidation, marking
➢ Drawings, manuals etc
➢ Spare parts requirements
➢ Special Instructions to vendors
A technical evaluation shall be done in house to verify the conformity with specifications.
1. Samples and technical information shall be submitted to Contractor. Once the final approval from the client is obtained, purchase order shall be raised.
2. Upon receipt of Purchase Requisition, a purchase order shall be raised and entered in the computer register system, indicating cost and budget allocation.
3. The procurement department shall maintain a follow-up system so that contact suppliers and/or manufactures may be made on continuous basis.
4. All questionable delivery commitments shall be expedited on a daily, weekly and monthly basis as required to ensure prompt delivery in accordance with the requirements.
Organization - Corporate Organization
1. Al Jaber Establishment formally known as Al Jaber transport & General Contracting Establishment The Contractor is an umbrella organization which has got numerous divisions within in itself and which is also the parent company for various subsidiaries. The Contractor Al Jaber Energy Services (AJES) is a separately registered company specifically set-up to target the energy sectors and its clients. AJESCONTRACTOR has been operating under the The Contractor Al Jaber Establishment umbrella since 1995.
2. Broadly all the activities of the above divisions and companies can be divided into:
➢ General Construction
➢ Heavy Lifting and Transport Services.
➢ Trading
➢ Industrial
➢ Plant Construction.
Site Organization
Proposed site organisation and responsibilities of the key personnel are enclosed. All supervisory staff shall be highly experienced and qualified drawn from on-going projects wherever possible.
Manpower Resourcing and Mobilization
1. All the personnel on site shall be employees of The ContractorAl Jaber Energy Services. All of the required personnel to execute the work are already in UAE and working on other sites. These sites are due for demobilisation in the coming months.
2. The planning department shall produce a histogram schedule of the resources by category. These schedules shall define the monthly manpower levels. The scheduled shall also be indicative of manpower mobilization.
3. The standard The Contractor Al Jaber Energy Services site supervision is based upon the principle of training. A charge hand shall be trained and supervised by a foreman. In normal cases a foreman shall supervise four charge hands. The charge hand shall then supervise approximately ten labours. Where a special process is conducted, this ratio may be revised accordingly.
4. Training is a requirement of the The Contractor Al Jaber Energy Services quality management system and foreman and charge hands shall conduct training of the manpower in their respective roles and functions. The recruitment of manpower shall ensure that background in the relevant job skill has been achieved. The training in quality awareness shall be an ongoing process through the quality department and the foreman.
5. Sufficient numbers of site supporting staffs which consists of Mechanics, Electricians, Auto Electricians, Guards, Water boys etc and other ancillary staff shall be deployed for the unhindered progress of the work.
6. The The Contractor Al Jaber Group contains at all times a vast pool of manpower in all Disciplines. These workforces are at all times working on various projects in multi discipline fields.
Equipment Resourcing and Mobilization
1. Based on the project schedule, the planning department shall generate the construction equipment schedules.
2. The Contractor The Al Jaber Group is one of the largest equipment rental companies in the GCC with over 5000 fleet where modern repair and machine facilities enable them to maintain a first class fleet of equipment.
3. It has been our company policy to weed out the old equipment on a periodical basis and keep the equipment fleet very young. We have one of the youngest fleets of equipment in the GCC based on size.
Execution Plan- Method statement
(project implementation strategy)
New Buildings Package
Sample Only
Engineering Design
a) Building Engineering Design Management necessitates an integrated approach to formulate an overall philosophy, able to achieve an intellectual product covering & incorporating a wide range of performance & serviceability requirements that shall completely meet intended functions of the proposed building adequately satisfying architectural, structural & allied services requirements. The target achievement of this fast track EPC project shall be kept in consideration by all discipline designers to release the necessary documents on planned line.
To accomplish this part of the package to the best possible standards, AJESCONTRACTOR shall invite certain (possibly 3) reputed & leading architectural engineering Firms as Engineering Services sub contractor. Based on the merits of each offer as well as applying the competency criteria, a preliminary selection shall be made. After obtaining Technip approval respecting this Firm, a formal appointment shall be made by executing an engineering services agreement.
Engineering Services Sub Contractor hereinafter called ‘Firm’
b) The scope of the Firm shall include but not be limited to carrying out the following engineering services’ operations for all buildings included within New Buildings Package
1. Undertaking additional surveys, intrusive surveys and investigations as may be necessary for the engineering designs. Soil Investigations as required accomplishing the design
2. (Topographic survey shall be performed by AJESCONTRACTOR)
3. Production of all architectural, structural & allied services schematic designs
4. Perform all studies, design calculations etc.
5. Secure all governmental and local Authority permits and approvals if so necessary. Compilation of any outstanding data deemed necessary for the completion of the detailed engineering design
6. Production of all architectural & structural detailed designs for Technip approval according to contract & sub contract requirement.
7. Act as AJESCONTRACTOR Design & Engineering representative for the relevant Buildings contract scope
8. Civil & Architectural scope from its inception to completion as & when required
c) Building services : conceptual drawings only for plumbing & sanitary, small power & lighting, HVAC, Fire Fighting & Fire & Gas Detection / Loss prevention, Structured Cabling System
1. Liaison, co-ordinate & lead AJESCONTRACTOR services subcontractors’ design & engineering efforts
2. (AJESCONTRACTOR services subcontractors shall be responsible for the detailed designs and engineering for their relevant scope based on the conceptual drawings and other basic documents issued by Firm) to obtain necessary approvals from Technip
3. Firm shall issue its whole drawings / documents production schedule immediately after the award & commence its design work keeping in line to the programme
4. Represent AJESCONTRACTOR at Technip offices / officials at FRANCE, Abu Dhabi and / or ASAB as AJESCONTRACTOR’s Design & Engineering representative during the course of the contract from its inception to completion as & when required
5. Engineering coordination with the Firm shall be conducted from AJESCONTRACTOR head office. All field interfaces shall be conducted from site offices in collaboration with AJESCONTRACTOR field engineers
6. All other remaining functional descriptions shall be conducted by AJESCONTRACTOR personnel both in the head office as well as on site office depending on function wise technical nature
7. All engineering design products shall be managed conforming international standards included on the contract documents for the technicalities as well as document controls.
8. Firm shall comply with the agreed documentation system & conduct its operation in all respects accordingly. All the design documents shall be given appropriate numbering reference to meet traceability requirement. AJESCONTRACTOR operates its own system of centralized document control, which shall be used fully complying in accordance to Technip & Client Company Procedures by reformation, if so required
9. Firm shall produce & issue the scheduled documents at various stages of works for reviewing, approval & AFC etc efficiently keeping in line with the project construction plan on various phases. Any delay on this account shall not be acceptable to AJESCONTRACTOR management
10. Immediately, after the issue of the control documents to the site team, field/design engineers shall conduct over review of design & construction ability & consequently relevant design engineer raise technical queries to remedy any discrepancies among these documents if so discovered, which should immediately be resolved by the Firm & duly informed to Technip. All such documents shall be processed through the documentation system facilitating most convenient trace ability for consultancy & reference
11. Consequent upon the resolution of discrepancies, the effected design drawings shall be revised & reissued for construction duly incorporated with the solutions & circulated through documents control regularly to all concerned personnel.
12. Buildings services schematic drawings shall be issued to sub contractors for further development of shop & working drawings for Technip approval & issued to the concerned parties after getting duly approved for construction
13. Necessary structural shop drawings shall be produced by AJESCONTRACTOR own engineering personnel in head as well as on site offices, which shall also be processed into document control system for Technip & issued to the concerned parties after getting duly approved for construction
14. Preparation of requisitions for enquiry and award, technically evaluate bids and review of vendor/lower tier subcontractor documentation shall be done by purchase manager in collaboration with project manager. All these procedures have been incorporated on the company procurement procedures document.
d) Detailed Engineering Design:
Preparation, issue and control of calculations, specifications, drawings, material requisitions and bills of material. Extent of computer application for these activities. At the very first stage of the commencement of the detailed designs, Firm shall formulate positioning of all framing members vertically & horizontally befitting coordinates as well as level controls, meeting the architectural requirement maintaining the basic design principles that the whole structural skeleton behaves as an integral unit with its centre of gravity passing through or within the permissible vicinity of the resultant of all the applied forces considered avoiding any eccentricity and that settlement of the soil is within permissible limits. After considering all direct & indirect imposed loadings according to the relevant codes, design model shall be generated using Firm software.
Loadings shall include, direct loads such as dead load, live load, seismic shear (though not applicable in Abu Dhabi geographical location) / wind load, blast load/effect, test load/application & also considering various analysis, a most critical case of resulting stresses shall be considered to be adopted for the dimensioning & further details of various vertical & horizontal members forming the framing skeleton. Generated model in 3D may be made available for the presentation to Technip & Company to explain & justify the adopted philosophy if so required. Calculations shall be done trying various options of loadings in 2D & 3 D & included with the design proposal for approval. These calculations shall be done & certified by a Chartered Engineer of Firm for structural adequacy & structural intended performance.
e) Services Designs
1. Designs of the services shall be carried out discipline wise.
2. Electrical - In accordance to the provision of electrical loadings design criteria as indicated on the Technip / Company documents, loadings, distribution of loading & all other parameters shall be adopted & calculated adhering to the international standards, IEE as well as UAE authorities regulations & schematic drawings produced meeting the architectural schematic drawings requirement
3. Similarly all loads from the HVAC disciplines as well as from the other remaining disciplines shall be included. This shall be done in close interface with all disciplines coordinated by the Services design coordinator/Design Project Engineer or Manager. All these details shall be included on the drawings documents for approval
4. All designs shall be generated using appropriate computer software package
f) Specialised discipline- Loss Prevention & others
1. On the similar pattern as described in the foregoing, detailed designs shall be calculated meeting all requirements of the contract specification, disciplinary performance as well as meeting international & conventional standards, complying local bodies statutory provisions.
2. From the foregoing approved documents, Bill of Quantities shall be generated discipline wise & building wise which document should be utilised for the purpose of Material Approval Proposal, Issue of requisitions of the approved materials to the procurement manager. The bill of quantities shall not constitute part of contract documents but serve guidance. All bills shall be generated using appropriate computer software package.
g) Specifications/Supplement Specifications
It is intended to adhere to Company specifications provided by Technip within the documents to every extent possible, however, to meet some particular requirement, supplement specifications shall be drawn & proposed for approval wherever necessary for producing better product or the materials for which no specification is defined. These shall be drawn in collaboration with Firm & AJESCONTRACTOR design team keeping in view an overall approach to documented specification criteria as well as conventional engineering & construction practice in similar circumstances.
h) Co-ordination Procedure
The following entitled co-ordinations shall be conducted during various stages of the design & execution that have been outlined below
Coordination between AJESCONTRACTOR & Technip head office
This part shall be conducted by regular interaction among AJESCONTRACTOR representatives Head Office based in Musaffah & Technip FRANCE office to help resolve all pre & post award issue of Engineering services & monitoring project controls
Coordination between AJESCONTRACTOR & Technip site office
This part shall be conducted by regular interaction among AJESCONTRACTOR & Technip site representatives to help resolve all pre & post award issue of Engineering services & monitoring project controls
Coordination between AJESCONTRACTOR & Firm
This part shall be conducted by frequent interaction between AJESCONTRACTOR & Firm representatives of all disciplines for the resolution of all designs issues, issue of all documents, approval of all documents & resolution of all engineering issues on site
Coordination between AJESCONTRACTOR / Firm & Technip
This shall resolve all issues respecting engineering designs particularly during design stage as well as generally during construction phases for efficient decisions making to help smooth execution of all activities
Coordination between AJESCONTRACTOR / Firm & Technip on site
This shall resolve all issues respecting engineering designs during construction phases on site for efficient decisions making to help smooth execution of involved activities
Coordination between AJESCONTRACTOR Site & Firm
This is essential to keep on fast track the availability of complete design information for all ongoing as well as planned activities & should the information be pending, it shall be identified, coordinated & made available on site prior to its requirement to avoid any problem of execution
AJESCONTRACTOR internal Coordination among various sections
AJESCONTRACTOR in Head office organized with all corporate sections necessary to meet the requirement of this project shall operate as an integral functional team keeping on resolving regularly & as required all issues of project designs & follow up in all respects. This coordination is ongoing on daily basis & frequent interaction among all corporate managers as well as supporting professionals help the resolutions of all current & forthcoming issues. Management meetings are conducted regularly for making decisions to avoid any pending identified problems
AJESCONTRACTOR internal Coordination among various sections on site
Similarly on site all project sections managers & supporting professionals shall coordinate to resolve all types of problems to avoid any pending identified problems & notify to corporate management for immediate resolutions should the solution not be possible from site.
i) Review and Approval of Documents
This requires effecting an instant action on the part of AJESCONTRACTOR that, whenever any document is received, it must be reviewed by its design team located at Head Office/Site office as the case may be prior to formally submitting to Technip. After its submission to Technip, Technip shall process it through its system & after obtaining company approval, return approved or commented original to AJESCONTRACTOR for further necessary AJESCONTRACTOR action. All documentation shall be carried out adhering to the AJESCONTRACTOR documentation system after tuning that in line to Technip & Company requirement
j) CAD Procedure
It is intended to use standard CAD software for the production of design & drawings. All standard system of designing shall be adopted at every workstation available in Firm offices. The details of all available software & hardware have been given in attachment. Also included the hardware & software details which are functional in proposed Engineering sub contractor/Firm office
k) Engineering Reporting and Change Control
The status of design progress shall be submitted to Technip on a weekly basis during progress meeting. Should any change be required, that shall be affirmatively considered subject to cost impact resolution & then the change incorporation request issued by AJESCONTRACTOR to Firm. The Firm shall then work on the revision, its calculations & advise to AJESCONTRACTOR & Technip of any adverse effect on the structural adequacy/performance or if any amendment to be applied to already worked element / member. Should there be no such adverse consideration, the design shall be revised & revised document issued following the documentation & approval procedures.
l) Document Control Procedure
AJESCONTRACTOR operates its centralized DCC (Document Control Centre) in head office that shall be tuned to Technip / Company documentation system & extended to site office to meet the project requirement. AJESCONTRACTOR document control system is enclosed for reference.
m) Vendor Print Numbering, Review and Distribution Procedure
All vendors shall be issued schedule of document numbers to be printed on the documents adequately in advance of documents preparation. All approved procedures of documents shall also apply to vendors' designs.
n) As-built Drawings
As built drawings serve the purpose of telling the user about the building records that should be used for the purpose of maintenance / or for whatever purpose possible. It is therefore, an important & significant part of documentation as well as also a contractual obligation on the part of AJESCONTRACTOR & Technip which should be affected smoothly & regularly throughout the duration of project. Should there be no change on the Released for construction drawings i.e. the construction has been carried out all in accordance with the approved documents provisions, there shall be no purpose of As - built drawings. But in practice, to produce physical structures, some changes are imminent due to arising of new requirement, changes, effects of disciplinary interfaces to bring the work to proper use functions etc. During the whole currency of the contract, it should be an endeavour of the AJESCONTRACTOR that all changes are recorded on contract documents as Red Lines mark up & issued to Technip for approval. These Red Lines mark up shall form the basis of producing all As Built documents on the project. It is not the drawings only that are to be recorded but also all changes whatsoever for any document on record. All these As Built shall form part of hand over dossiers. Should as built records be maintained regularly, this part of the dossiers shall be comfortably produced. The site design engineers shall keep an eye on this activity & record changes regularly as red line mark up & process the documentation to fulfil the contractual obligation to this extent possible. It is expected of the site engineers, the design engineers as well as land surveyors to coordinate on site to comply with this obligation efficiently. All survey changes or variations shall also be recorded on the drawings based on the pre pour & post pour records taken from survey section. Surveyor shall present all such changes on the corresponding documents to be recorded as Red Line Mark ups.
Inspection & Test Plans
All necessary Inspection & Test Plans shall be originated by the Quality Engineer in collaboration with Engineering in head office & Engineering in site team. These ITPs formats shall be issued for Technip & Company approval according to the procedures laid down on Project Quality plan. Production of all these documents shall be the responsibility of AJESCONTRACTOR Quality Manager / Engineer. Complete details about the quality management system have been included on the respective Quality Procedures document. Generally, ITPs for all disciplinary activities shall be produced for Technip & Company approval from site office in due course. All defined tests shall be conducted by Technip / Company approved laboratory located on site. For those items the tests shall be conducted by any Technip / Company nominated laboratory, for which facilities are not available on site. The details of these plans shall be submitted separately. Every ITP shall be allotted a document number along with a numbered checklist. Check list shall form the basis of inspection requirements.
Project Controls
1. Project Control management requires the formation of strategies those can be utilized optimally to achieve the target in minimum cost with best quality product
2. To achieve as aforesaid, it is extremely important that complete project should be analyzed from whole to one & all necessary resources to be used should be known prior to commencement of physical works.
3. Based on the project design, construction, commissioning and maintenance durations, Analysis, planning & charting out at various levels shall be carried out by the Planning Engineer. Further based on these periods, all necessary resources shall be arranged & mobilized by human resources, materials, and technical managers in collaboration with Project Manager.
4. The plans shall be monitored regularly, as the project construction progresses, on a weekly basis, monthly bases & no delay allowed & if any, immediate recovery shall be planed. The relevant reporting shall project the real quantum of planned & actual physical works, resources available, deficiency of resources, material procurement status, materials delivered & expected time of arrival etc & all necessary measures required to keep the construction on line & valuation worked accordingly. Every effort should be made to keep the progress in line with plan.
Procurement
Note-The term Material herein includes equipment also
According to the site requirement & provisions made on the plan, for temporary materials & consumables, requisitions shall be raised from site by the relevant engineer, checked, numbered & coded by the material controller & approved by the construction manager for transmission to head office procurement manager for further action. Cost controller shall further check the budgetary provision applicable & give clearance to the purchase manager for procurement. Purchase manager shall then invite the inquiries from various sources of material, negotiate & prepare a comparative statement & based on the merits of responses/quotations, record his comments based on the comparative statement as well as recommendations for the considerations by the Management. After reviewing the proposal, the management shall approve or reject the proposal. Purchase order shall be made on the approved proposal. An alternative source shall be located for the rejected proposal. A copy of the approval shall be provided to the project manager for follow up the delivery.
1. For permanent works, proposed material shall be submitted for Technip / Company approval on requisite Material Approval request form along with brochures, samples if applicable, processed through the document centre after Project manager approval. After obtaining Technip / Company approval on the request, procurement manager shall process the requisitioned approved item based on the budget quantities following in line the procedures applicable for temporary materials.
2. After the material is delivered to site, material controller & relevant engineer shall check the quality & quantity of the delivery. Any deficiency in quantity, quality or any damage observed, shall immediately be notified to the procurement manager through construction manager. Delivery information shall be circulated to the concerned personnel & quality manager himself shall or delegate an inspector or the relevant inspector shall check the adequacy of quality & if necessary according to ITP provision, shall invite the Technip / Company engineer to inspect/examine the delivery. The selected samples of delivered materials shall be sent to an approved laboratory for technical tests for the purpose of certification of compliance. After inspections & approvals, delivered materials shall be recorded in stores receipt documents, an issue to site may be undertaken thereafter.
3. Post placement of purchase order, Procurement Manager shall track various stages of material production & transportation or shipment to the site / delivery & if so noticed that an expectation exists for the delay in delivery, shall apply all efforts to expedite the delivery on appointed date.
4. Materials shall be stored in proper designated areas complying with the manufacturer’s instructions. Separate area shall be located for the materials requiring certain temperature of storage. Stores shall be well constructed & shaded. Generally, all consumables shall be stored in shade provided with proper lock & key arrangement. Materials which remain unaffected by exposition to weather may be stored open duly protected under proper watch & ward.
5. Proper protection shall be made for all stored materials inside covered area or out side. Necessary protection by removable membranes such as polythene or tarpaulins shall be used to protect material from the ingress of moistures or from effect of dust.
6. Storage of all materials delivered shall be done complying to the set & approved procedures making sure that all inventories can be verified any time & that any material can be traced any time easily.
7. All entries of the incoming deliveries shall be recorded into the register & verified by the store keeper & material controller that it complies with the details on deliveries documents. Any deficiency noticed shall be immediately reported to the procurement manager.
8. After the acceptance of the material by the concerned authority only, a store issue shall be affected & recorded on the required issue documentation. Regularly the status of all receipts, issues & balance in stores shall be reported to the construction & project manager who shall act further depending on the project requirement.
9. Elaborate details have been given on the AJESCONTRACTOR procurement procedures document
International and local transportation and customs clearance
10. Materials & equipment that have to be imported from overseas, shall also follow the foregoing procedures with the addition that necessary Letter of credits shall be opened by AJESCONTRACTOR adequately in advance of the required date of delivery adhering to schedule date, so that the delivery is shipped in time from original source. AJESCONTRACTOR procurement manager shall arrange all port clearances immediately of shipment arrival & material shipped to work site. Tests & Examinations shall be conducted similarly as aforesaid. Any claims of insurances for the damaged material shall be made immediately after inspections. Process to replace the damaged material shall be carried out at once to avoid any delay. If so required, AJESCONTRACTOR shall apply in time for any statutory road permit for the efficient transportation of the material by suitable vehicles. Elaborate details have been given on the AJESCONTRACTOR procurement procedures document.
Procurement and provision of construction spares, commissioning spares, insurance spares and special tools
11. These shall be processed applying the same methods of procurement & delivery received by AJESCONTRACTOR / its services or specialist sub contractors. Most probably, the spares shall form part of the order package. Elaborate details have been given on the AJESCONTRACTOR procurement procedures document
Recommendation for two-year operating spares for approval by Company in accordance with the G-SPIR format requirements
12. This provision shall be followed & spares delivered according to contract & Company requirement by AJESCONTRACTOR / its services sub contractors. Elaborate details have been given on the AJESCONTRACTOR procurement procedures document
Procurement and provision of two-years operating spares, (at cost and extra over Lump Sum Subcontract Price)
13. Similarly this provision shall be effected & spares delivered according to Technip / Company instruction to AJESCONTRACTOR subject to the approval of the procurement cost prior to the purchase order placement by AJESCONTRACTOR
Source inspection
14. If so required by Technip / Company, arrangement shall be made by AJESCONTRACTOR after meeting with the vendor or manufacturer, a date & time appointed for the inspection to the convenience of all parties concerned & required inspection at source conducted to the satisfaction of Technip or Company. Representatives from Technip and / or Company, AJESCONTRACTOR, services sub contractor & vendor shall constitute an inspection at source team. Proper record of inspection shall be made.
Compliance with Company’s criteria and procedures for selection of vendors including but not limited to compliance with local registration requirements and approval of purchase requisitions, bidders lists, technical bid summaries and award recommendations
15. We shall adhere to Company requirements.
Involvement by the UAE in particular and GCC in general with respect to the provision of local materials and services shall be encouraged
16. AJESCONTRACTOR honor & respect with due regards to the provisions of UAE & GCC policies for the materials & professional services which need be availed out of the local & GCC sources subject to the compliance with the quality requirement. Every effort shall be attempted by Procurement Manager to chart out the available ‘local & GCC sources’ & prepare a database to be used whenever any applicable procurement arises. This procedure is already followed by AJESCONTRACTOR. AJESCONTRACTOR vendors shall also comply with this requirement.
Pre Mobilization Planning
A thorough and logical mobilization plan is essential for the successful start-up of construction activities. This plan must detail all planning, preparation and pre-construction activities necessary to ensure the timely availability of drawings, personnel, construction equipment, temporary facilities and materials at the job site to properly support the construction efforts.
1. This plan is already under preparation at this stage.
2. This preliminary mobilization plan shall be further developed after contract award and concluded within a week of the contract award. The mobilization plan shall be closely coordinated with the construction plan to ensure mobilization activities properly lead into and provide a smooth transition into initial construction activities.
3. A time scale bar chart diagram shall be prepared with early and late activity bars detailing the main activities to achieve full mobilization of staff, labour, construction equipment and camp/site facilities shall be prepared at the commencement of the contract.
4. Mobilization plans for staff & labour, accommodation and temporary facilities established during the bid stage (as conceived in pre-mobilization planning) would be studied and re-evaluated in the light of any changes, which may have occurred since the day of preparation. All necessary adjustment measures shall be implemented.
5. Additional site visits shall be conducted immediately after the project kick off to confirm data collected during bidding stage, reconfirm assumptions and establish additional information required to permit smooth and timely mobilization. The following items shall be reviewed and confirmed.
➢ Access to the job site
➢ Locations of temporary facilities
➢ Company requirements for properly validated licenses and certificates to be held by construction personnel
➢ Transport plans
➢ Loss prevention and safety requirements
➢ Arrangements for first-aid facilities
➢ Arrangements for drinking water and construction water
➢ Arrangements for electricity supply
➢ Arrangements for storage fuels and lubricants
➢ Arrangements for sanitary & its disposal facilities
➢ Final arrangements for security interface with Technip & Company
Work Centres
AjesContractor Head Office
Upon notification of contract award, the key personnel to the site Management Team shall be assigned. Construction personnel shall be mobilized to the project site office to provide input and direction to the project team. Successful project execution requires construction experts to be active from the onset of the project. The only activity to continue from Head Office after mobilization period is procurement. All procurement for the project shall be done from the corporate procurement section located in AJESCONTRACTOR Head Office at Musaffah, Abu Dhabi.
The following specific activities must be addressed early to be fully effective:
➢ Finalize construction schedule requirements and subsequent approval from Contractor
➢ Review manpower requirements for both non-manual and manual personnel; update these requirements by means of staffing schedules, histograms and craft mixes; and ensure subcontractors manning levels are compatible.
➢ Review construction equipment needs and ensure that timely subcontractors mobilization plans are in place.
➢ Review field procedures and method statements defining standards, policies and procedures required for the execution of the works and ensure they constitute “Project Specific” status.
➢ Review environmental, safety and Health (ES&H) and site security plans to ensure compliance with the client’s specifications and guidelines.
➢ Review Construction Quality plan in line with the guidelines of ISO 9000 and check Established QC parameters by discipline.
➢ Overview temporary facility requirements, including indirects such as tools, consumables, gases and the like and check subcontractors compliance.
➢ Actively pursue preliminary site activities such as approvals, permits, establishing contracts.
➢ Ensure Lessons Learned & Practices from previous projects are well understood & should be applied effectively from the onset of the works itself to achieve professional products.
AJESCONTRACTOR Site Office
Actual ‘on site management’ would be from offices based on the site next to Contractor and Company’s office. AJESCONTRACTOR Site Office is fully supported by AJESCONTRACTOR Head Office at Musaffah.
The following major activities shall be carried out at site offices.
➢ Safety Regulation Enforcement
➢ Quality Assurance Enforcement and Procedures
➢ Construction Method Statements
➢ Construction Planning
➢ Site Documents Control
➢ Field Engineering & Design Controls
➢ Material Requisitions
➢ Materials Control and Tracking
➢ Materials Storage
➢ Work Procedures
➢ Physical Construction
➢ Site Administration
Mobilization
Mobilization shall be coordinated from the AJESCONTRACTOR Head Office at Abu Dhabi with input from AJESCONTRACTOR personnel already mobilized for the execution of Site Preparation Package and Temporary Facilities for Contractor and Company. Existing teams responsible for the execution of the those two mentioned packages already have substantial cadre of experienced professional well versed in mobilization of temporary facilities, project execution, QA / QC planning, Safety and security operations etc.
➢ Mobilization shall commence with the following activities:
➢ Kick off meeting to commence the sub contract
➢ Commencement of the required land surveys to establish various horizontal & vertical controls bench marks
➢ Incept of the engineering designs at the Firm office
➢ Soil Investigation by an approved laboratory
➢ Construction of temporary facilities
➢ Obtaining various permits from Authorities and conclusion of arrangements with local committees where necessary.
➢ Third party independent concrete testing laboratory credentials submission for approval.
Shortly after contract award, site surveying shall begin utilizing the Total Station System to establish accurate control points for the performance of the work.
As soon as practicable, the plans and specification for the site temporary construction facilities shall be finalized and released for installation.
During the installation of the temporary facilities existing AJESCONTRACTOR site offices shall be utilized to supervise the site activities required for the temporary facilities installation.
On completion of the site offices at ASAB, balance of the AJESCONTRACTOR construction staff shall be mobilized to the site along with construction equipment, tools, consumables, warehousing, storage and other items necessary to commence the work in accordance with the construction schedule. Temporary facilities at the job site shall include Generator Yard and Construction water storage tank, carpentry yard, re-bar fabrication, lay-down area, warehouse and workshop facilities at location A4.
At the start of the construction, an emphasis shall be given on the critical requirements of the construction schedule. Work shall be carried out under continual supervision and inspection over performance. Progress shall be monitored on the basis of actual installed quantities compared to scheduled quantities.
For construction areas, dedicated work crews shall be allocated for each discipline supervised by foremen and general foremen who in turn shall report to the discipline supervisors/site engineers. Based on the construction schedule requirements, necessary operational crews shall be formed and controlled over to meet the planned progress target to be physically achieved satisfactorily.
It is the responsibility of the supervisor/site engineer to ensure the efficient utilization of his material, workforce, tools and equipment.
For ‘construction operation water’ requirement, unless an alternative arrangement is made available, water shall be trucked from nearby Desalination plant.
Site ‘construction and temporary facilities electricity requirements’ shall be met by installing suitable size and suitable numbers of generators.
Subcontract Strategy
1. Building Engineering services shall be utilized by appointing a consulting firm, to be responsible for the complete architectural, structural design drawings & documents productions as well as for the services schematic designs drawings production. Firm shall also represent AJESCONTRACTOR regularly during the project currency
2. Detailed services designs shall be prepared by AJESCONTRACTOR services sub contractors
3. AJESCONTRACTOR shall carry out broadly all civil engineering works employing its own resources of manpower, machines, equipment etc.
4. Lower tier sub contracts shall be allowed for the execution of single operations such as supply of ready mix concrete, roofing finishes etc
5. Ready Mixed Concrete is envisaged supplied from an established RMC supplier, an establishment with proven track record duly approved for supplying concrete by GASCO, within 10 kms of the site. However, in the mean time, without reservations, we are also seriously considering installing our own concrete batching plant.
6. In case any minor or specialized work is necessary to be sub contracted on lower tier, Company procedures shall be apply for prequalification and award of the subcontracts.
Testing And Inspection
1. A field inspection and testing program shall be organized to be in line with AJESCONTRACTOR Quality manual & Approved Project plan under overall responsibility of the QA / QC Manager.
2. Prior to conduct any testing, Contractor and Company (as required by QC Plan and ITP) shall be advised of the tests for witness.
3. Wherever required vendor specialist shall be made available for conduct of testing and inspections.
Material Management
Once material has arrived at site, material management shall come under the purview and custody of the site store staff. The storekeeper, supported by his store assistant shall be responsible for the custody of the material prior to issue. Material tracking from source to the place of installation shall be conducted by the computerized system. The construction manager shall be responsible to provide the technical oversight and direction for the control of materials at the construction site area. More information has already been elaborated in the foregoing.
Procurement
The Central procurement department located at the Al Jaber Energy ServicesContractor, Musaffah, Abu Dhabi, UAE office shall be responsible for all purchases adhering to the following procedure.
Preparation of Purchase Requisition shall be made based on take-offs quantities calculated from the approved drawings documents. Purchase requisition shall completely, identify all applicable drawings, data sheets, specifications, vendor documentation requirements etc. with the inclusion of following information.
Quantity of each item required with comprehensive breakdown
Adequate information concerning nomenclature description, Material approvals, Quality required, applicable specifications, design & other drawings, etc/ or detailed outline of the material required.
➢ Required delivery dates for all major items.
➢ Delivery points of major items
➢ Inspection of the goods at the point of origin issue
➢ Certification of test data and/or compliance/ warranty
➢ Method of shipment (if goods imported), conditions/packing
➢ Instruction of holding, kitting consolidation, marking
➢ Drawings, manuals etc
➢ Spare parts requirements
➢ Special Instructions to vendors
A technical evaluation shall be done in house to verify the conformity with specifications.
Samples and technical information shall be submitted to Contractor. Once the final approval from the client is obtained, purchase order shall be raised.
Upon receipt of Purchase Requisition, a purchase order shall be raised and entered in the computer register system, indicating cost and budget allocation.
The procurement department shall maintain a follow-up system so that contact suppliers and/or manufactures may be made on continuous basis.
All questionable delivery commitments shall be expedited on a daily, weekly and monthly basis as required to ensure prompt delivery in accordance with the requirements.
Organization
Corporate Organization
The Contractor
Al Jaber Establishment formally known as Al Jaber transport & General Contracting Establishment is an umbrella organization which has got numerous divisions within in itself and which is also the parent company for various subsidiaries. Al Jaber Energy Services (AJESCONTRACTOR) is a separately registered company specifically set-up to target the energy sectors and its clients. AJESCONTRACTOR has been operating under the CONTRACTOR Al Jaber Establishment umbrella since 1995.
Broadly all the activities of the above divisions and companies can be divided into:
➢ General Construction
➢ Heavy Lifting and Transport Services.
➢ Trading
➢ Industrial
➢ Plant Construction.
Site Organization
Proposed site organisation and responsibilities of the key personnel are enclosed. All supervisory staff shall be highly experienced and qualified drawn from on-going projects wherever possible.
Manpower Resourcing And Mobilization
1. All the personnel on site shall be employees of The ContractorAl Jaber Energy Services. All of the required personnel to execute the work are already in UAE and working on other sites. These sites are due for demobilisation in the coming months.
2. The planning department shall produce a histogram schedule of the resources by category. These schedules shall define the monthly manpower levels. The schedule shall also be indicative of manpower mobilization.
3. The standard The Contractor Al Jaber Energy Services site supervision is based upon the principle of training. A charge hand shall be trained and supervised by a foreman. In normal cases a foreman shall supervise four charge hands. The charge hand shall then supervise approximately ten labours. Where a special process is conducted, this ratio may be revised accordingly.
4. Training is a requirement of the The Contractor Al Jaber Energy Services quality management system and foreman and charge hands shall conduct training of the manpower in their respective roles and functions. The recruitment of manpower shall ensure that background in the relevant job skill has been achieved. The training in quality awareness shall be an ongoing process through the quality department and the foreman.
5. Sufficient numbers of site supporting staffs which consists of Mechanics, Electricians, Auto Electricians, Guards, Water boys etc and other ancillary staff shall be deployed for the unhindered progress of the work.
6. The The Contractor Al Jaber Group contains at all times a vast pool of manpower in all Disciplines. These workforces are at all times working on various projects in multi discipline fields.
Equipment Resourcing And Mobilization
7. Based on the project schedule, the planning department shall generate the construction equipment schedules.
8. The Contractor The Al Jaber Group is one of the largest equipment rental companies in the GCC with over 5000 fleet where modern repair and machine facilities enable them to maintain a first class fleet of equipment.
9. It has been our company policy to weed out the old equipment on a periodical basis and keep the equipment fleet very young. We have one of the youngest fleets of equipment in the GCC based on size.
Construction Method Statement– New Buildings
1. Following the award of the project, a detailed contract scope works programme for the whole project shall be developed including all disciplines separately based on already approved outline preliminary programme appended under the coordination of our Construction Manager and Planning Engineer
2. The Method Statements related to various project activities shall be submitted for contractor’s approval prior to commencement of any activity during the execution stage.
Subcontracting
3. Develop and manage a lower tier subcontracting plan and subcontractor list AJESCONTRACTOR plans to carry out most of the civil activities itself but selected items shall be sub contracted on the lower tier such as ready mix concrete, roofing application, doors & windows manufacturing, painting application, raised flooring application, suspended ceiling installation etc.
4. Perform all lower tier subcontracting activities including specification of packages of Work to be subcontracted, pre-qualification of bidders, issue of ITBs, bid evaluation, recommendation and award. All relevant information shall be provided by the Project Manager to the purchase manager who should act immediately to conduct the required functions & the lower tier deal finalized after obtaining Company recommendation by the Project manager
5. a) Management of lower tier subcontractors and their activities
6. These operations shall be managed & controlled by the Construction Manager on site & reported to the Project manager
7. Monitoring and reporting of all lower tier-subcontracting activities This activity shall be affected by the project manager based on the construction manager report. The report shall be regularly provided to the planning engineer, head office & Company.
8. Involvement by the UAE in particular and GCC in general with respect to the provision of local services shall be encouraged. As included earlier somewhere else that UAE national policy shall fully be honored subject to making no compromise to the quality requirement
9. Construction including providing labour, supervision, safety and quality management, inspection, vendor support, temporary facilities and services, and construction equipment, tools, utilities and consumables. All these issues have been elaborated earlier somewhere else
10. b) Provision of Construction Camp, messing, transport to Jobsite, sanitation, utilities etc. for SUBCONTRACTOR’s personnel.
11. All these shall be fully undertaken by AJESCONTRACTOR based on the site requirement. A life camp shall be constructed on site to meet the workforce accommodation requirement. Messing shall be resolved by employing catering sub contractors so that all personnel & workers take good food. All utilities shall be provided to maintain good house keeping of the camp. All safety & emergency precautionary measures shall be undertaken to the contract requirement. AJESCONTRACTOR operates its own system of transport, which shall be extended for the use of workers transportation. Similarly, the arrangements shall be made for the employed high tier & low tier sub contractors on this package
All activities necessary for Mechanical Completion, Pre commissioning, commissioning, and Provisional Acceptance.
12. All activities for the buildings part have been described on the method statement appended as well as this document also integrates to Civil Works & Site Preparation Execution & Construction Method Statement.
All testing facilities required at Jobsite
13. AJESCONTRACTOR shall supply an independent testing laboratory equipped with all equipment necessary for involved tests for this package properly managed by qualified personnel meeting all QA testing & certification requirement.
Full responsibility for co-ordination with any Third Party Inspectorate
14. AJESCONTRACTOR aggress to extend its full cooperation to meet any Third Party Inspections. Project manager & Construction manager shall be responsible to affect this part of the contract.
Supply and coordination of lower tier subcontractor and vendor representatives as necessary
1. AJESCONTRACTOR shall supply & coordinate with all lower tier sub contractors & vendors or their respective representatives to the requirement. Supply of these shall be managed by the Purchase Manager while the Project manager shall manage on site. Coordination shall be conducted by the Construction Manager
2. Provision of waste management at all Jobsite locations, including disinvestments of all temporary works, upon completion of Work
3. Waste management shall be fully operational on a day to day basis both for garbage & sewage according to the planned arrangements. Safety manager shall be responsible for the operations of all such activities & report to the Construction/Project Manager regularly
4. Provision of medical and fire-fighting services at Jobsite and for temporary works
5. Medical male nurse shall be employed on job site First Aid centre. Male nurse shall take care of providing First Aid treatment to injured workmen immediately & then the worker if so necessary in the opinion of the male nurse, shall be sent to Contractor site clinic for further treatment. Safety manager shall be responsible for the operations of all such activities & report to the Construction/Project Manager regularly
SPECIFIC
SPECIFIC CONSTRUCTION METHOD STATEMENT– NEW BUILDINGS PACKAGE
1. It is known from the contract documents that 9 buildings for various intending use as Sub station +Bottle Store, Instrument Equipment Shelter+Bottle Store and Operator Shelter have been defined to be constructed
2. Keeping in view the nature of contract being EPC, AJESCONTRACTOR have decided to apply RCC in situ construction for all intended buildings accepting the Company direction on drawings. RCC framings shall meet the design criteria of blast resistant & resilient structure productions meaningfully. Sub Structures shall also be constructed of RCC in situ.
3. Soil on site is medium to very dense recommended to give 30 t / m^2 working bearing capacity at 4 m depth & about 10 t / m*2 at 1 m depth according to the soil investigation Geotechnical report issued by Arab Centre for Engineering Studies for ASAB area. Soil has been described as sand with some silt traces & classified as very good for the founding purpose for no water is available within explored strata. No dewatering is necessary for the foundation zones. Utilizing the good composition of the soil, the foundations shall be designed to the best of critical imposed stresses with most economical& optimum use of the construction materials.
4. Soil report bore holes log direct to employing spread footings in isolation, which shall be integrated by grade beams/walls to form an unit for compaction settlement & long-term consolidation controls. However, to verify the validity of the soil report, AJESCONTRACTOR may without reservations further conduct investigations based on the Engineering Services sub contracting firm recommendations, utilizing the services of an approved laboratory. Foundations shall be designed based on the soil report & further laboratory recommendations combined if so required.
5. The phases of the construction shall be adhered to meeting the set out milestones, which are very tight for the purpose of physically executing the buildings package. The construction teams shall be constituted to meet the requirement as exhibited on the organization chart. One common project site manager shall be an overall responsible for all on site execution operations & conduct interface with the head office duly supported by safety, construction, quality, technical & administration sections all to be well established on site. Project & Construction manager shall in collaboration constitute four independent dedicated teams for four working divisions/areas lead by each site engineer directly reporting to construction manager as shown on the organization chart. Each team shall comprise of one site engineer, required number of site foreman & further supported by charge hand from each trade. For each team one quality assurance/control engineer shall be deployed to conduct QA / QC procedures for the relevant area. One General foreman shall be deployed for the labour engagement responsibilities on various day-to-day activities. For all other organization details please refer to Project organization plan.
6. A surveying team shall be constituted lead by a chief / senior surveyor to carry out all site setting works from the stage of preliminary site survey to the point of recording red lines for the purpose of ‘as built’. Survey team shall coordinate with each site engineer to meet site requirement. It shall be the responsibility of each team to set out, inspect & record all layouts, pre & post concrete data for the purpose of approval & handover dossiers. All horizontal & vertical controls shall be established & monitored by the leader.
7. All approved controlled drawings shall be issued to surveying team to commence the setting out operations. After ensuring proper safety arrangements are in, survey barricading shall be established & necessary grids control fixed & inspected by QA / QC. Excavation shall commence after the clearance is obtained & continue according to the plan. Proper safety shoring shall be arranged during this activity when it crosses 1.5 m depth & arrangement for suitable access into pit made to the satisfaction of the safety inspector & company. All unsuitable excavated material shall continuously be removed from site & suitable material tip off to designated area. All environment controls shall be taken care off during this operation. A surveyor shall continuously ensure the depth of excavation does not exceed the design requirement. When the excavation reaches the formation level, dressing shall be started followed by compaction of the soil so that area is ready for inspections.
8. AJESCONTRACTOR QA / QC shall inspect the formation. After required clearance, arrangement shall be made for blinding all released area according to the approved method statements. Area shall be blinded to the design thickness minimum 75 mm properly levelled & trowel applied to make it suitable for the purpose to receive heavy duty concrete protection layer membrane. Then curing shall be carried out for 3 days. Application of the protection membrane shall commence thereafter over whole area of the blinding.
9. Foundations shall be set out to design details to permit formwork erection & rebar placement. All starter rebar shall also be fixed supported by plastic spacer. On sides also, plastic spacers shall be fixed to keep all rebar in proper position. Foundation top levels shall be fixed using 25 mm plastic triangular chamfers horizontally. Chamfer shall also be fixed on the vertical edges of the forms. Inspection shall be conducted followed by concrete pouring supplied by an approved ready mix plant. All ready mix record shall be maintained according to QA approved procedures. After concreting is finished, proper curing arrangements shall be made for the required number of specified days. Setting outs for further stub columns shall be done & preparatory works continued.
10. In parallel, all works regarding grade beams / walls shall continue complying with all the approved procedures. Fabrication of rebars shall be done in a designated area while fabrication of forms too in another designated area all according to approved procedures. After completing the preparatory works for the stub columns, inspections & pouring shall be carried out following all procedures. Operations of grade beams / walls shall be taken up on similar principle as other activities.
11. For sub stations where cable cellar suspended floor slab is to be built, shall be prepared together with surrounding sub structures. After curing is done for the specified period, protection membrane shall be applied on both horizontal & vertical surfaces followed by inspection & backfill in compacted layers to specified requirement. Field density tests shall be conducted to monitor the requirement of density & water content etc. Backfill shall continue up to the formation level below the grade slabs blinding in buildings & where cellar suspended floor slab is to be built, backfill shall be done around the grade structures.
12. Preparations shall be carried out for the cellar suspended slabs by erecting required supporting system, forms fixed, rebars placed, all services inserts provided & inspections conducted from all disciplines followed by the concrete pouring observing all QA procedures.
13. Similarly, on the areas where grade slab is to be built, after the completion of the backfill up to the bottom of blinding concrete i.e. formation level, plastic sheet shall be laid after compaction & levelling & all necessary under ground services completion, blinding concrete shall be poured, levelled & wood floated well to make it sufficient enough to receive the grade slab. After three days of curing on blinding, preparation for the grade slab works shall commence & rebars placed either by site fabrication or using pre fabricated mesh to design requirement. All necessary services shall be inserted, inspections conducted & concrete poured. At this stage of the building, major sub structural elements have been completed giving a way to commence the super structural works.
14. All preparatory works of superstructure elements shall come into full swing by the fabrication of the forms & steel rebar fabrication to the BBS details. Scaffolding shall be erected for the fixing & placing vertical rebars of columns & walls in all required areas. Steel rebars shall be fixed placed with spaces & inspections conducted. Any inserts necessary for the electrical conduit or earthing, shall be installed immediately & inspection conducted. Work of vertical forms shall commence for sides of columns as well as walls fixed using removable tie bolts with cones / boss at tie rod ends. Forms shall be made of fair face ply to produce specified texture to the elevation requirement. All exposed vertical edges shall be chamfered using plastic chamfer 25 x 25 mm triangular section nailed to the forms. Inspections shall be conducted for the elements ready for pouring. Pouring shall commence keeping the height of pour not more than 2 m using vertical pipe chute of the pump reaching up to necessary level. Curing shall follow adhering to the agreed or approved procedures. Similarly walls of transformer areas shall be built adhering to all QA procedures.
15. Next operation of erection of the propriety scaffolding to support the superstructure roof slab shall commence strictly complying with the scaffolding drawings. On parallel, operations of fabrication of forms & rebar shall be taken up. All vertical & grid controls shall be established by surveyor to keep in line & level all forms of beams alignment & soffits. Level of slab shall be established & then work of form fixing shall commence followed by placing of beams reinforcement. Services inserts such as electrical conduits, HVAC inserts or block outs if necessary & other inserts shall be marked for establishment. Works of steel rebar placement shall continue in parallel to speed up the preparatory works. An inspection of the preparatory works shall be conducted by all involved disciplines. After obtaining approval for the pour, pouring shall be carried out adhering to pouring method statement compliance. Curing shall be started immediately after finishing the surface as required by the curing compound manufacturer’s instruction for the application of compound & also by using water in combination all to agreed procedures.
16. Intermediate slabs on the Battery rooms shall be constructed following the foregoing procedure.
17. Erection of the scaffolding around shall extend to cover the parapet portion followed by formwork & rebar fixing. On the similar pattern as defined earlier, all inserts shall be fixed followed by all relevant inspections & pour. All aforesaid concreting operations shall be supported by necessary number of transit mixers, concrete pumps, nozzle vibrators conforming to perform 10000 oscillation per minute & all other necessary arrangements essential to perform the best task. Well-trained teams shall be engaged for such operations. All necessary safety measures shall be installed. If necessary during hot weather, rest pauses shall be allowed to workers with the provision of liquid or salt water. Forms shall be struck form the elements carefully ensuring full safety intact. Concrete surface shall be inspected immediately after removing form, cleaned & surface treatment to the project specification applied to produce specified class of surface texture i.e. smooth finish or sandy or rough or grouted.
18. Any defective concrete shall be applied remedial measures as agreed with the Company or Client. Wherever special openings have been provided in designs within the structural framing, those shall be provided within the formwork itself. Now the structural framing works have been completed giving way to attack on internal walls & other items such as dry wall lining & preparation for the roofing item. All preparations shall commence for the remaining works.
19. Block work shall be carried out wherever required for walls followed by services fix 1 items & then plastered over as specified.
20. Roofing shall commence by scabbling the slab surface, laying of light weight foam concrete in grade minimum % to receive water proofing membrane, membrane application followed by water leak test for 72 hours & then polystyrene boards laid over to be protected by concrete pavers. Seperation geotextile shall be provided according to applicator direction. Over concrete protection paint on parapet, Aluminum flashing shall be fixed to design details.
21. Services site team shall be inducted in full swing for carrying out all disciplinary operations.
22. Suspended ceiling fixers shall also enter in to commence the work. Where there is no ceiling, work on the slab finishes shall continue.
23. Wall lining work shall be carried out in accordance to design details after ensuring complete inspections of services conduits etc. are over.
24. Fixing of cable terminations framing steel as well as framing steel for the floor openings shall be carried out according to details.
25. Flooring shall be carried out in according to design details. Tiling shall be followed on required areas schedules to receive floor or wall tiles.
26. Concrete surfaces requiring protection shall be applied accordingly with 3 coat system or any other approved.
27. Operations of constructing transformer foundations shall be carried out & protection applied to that. Sumps shall be constructed to details in floor. Gravel filling shall be done around the transformer oil containments / enclosures.
28. All finishing items shall be carried out in wet areas & concealed piping works prior to that. Services operations shall be completed in all areas followed by finishing works. Services inspections shall be conducted prior to commence the finishing works.
29. When the works are ready involving the scope of telecommunication routes, an entry shall be allowed to the related other sub contractor from other scopes provided with full cooperation in all respects.
30. Works of external services within 5 m of building shall be completed & tested. All surrounding or backfills shall be completed to the specification provisions. Walkways works shall commence by filling & leveling around the building excluding the instrumentation room on the plant side portions. Walkway Kerb shall be fixed to the profile over the blinding concrete with haunch concrete over. Sand shall be filled over the compacted & profiled area of the walkways whereon the interlocking concrete blocks are to be fixed in to design pattern.
31. Necessary directional signs to be installed in buildings shall be fixed to approvals.
Pre commissioning, Commissioning, Provisional Acceptance and Final Acceptance All services individual items integrity & tests shall be conducted by related sub contractors & record maintained. After ensuring that each installation is efficient in performance, release for commissioning shall be given. Details are included within the technical literature / datasheet. All units of every discipline shall be tested on site to confirm adequate performance. All underground services invert level & crown level shall be checked ensuring proper setting to alignment. Manholes shall be cleared of all debris, dust or any foreign material. Water shall be applied with pressure to clear the dirt. Functions of all electrical as well as HVAC appliances & equipment shall be checked for adequacy of functioning. Similarly, all other services shall be checked to ensure that testing for the commissioning can be successfully conducted. According to the direction given by the integrated datasheet & brochures, discipline wise testing & commissioning shall be carried out & continues for one month.
Supply and coordination of lower tier subcontractor and vendor representatives as necessary All necessary lowers tier sub contractor & vendor representatives shall be provided to the scope requirement. Specialist vendors shall be employed for the specialist operations. These representatives shall manage all activities required to be carried out on site for the purpose of construction execution, pre commissioning & commissioning to the contract requirement. These personnel shall interact with Technip & company if so required for all technical & engineering involvement.
All activities necessary to achieve Pre commissioning, commissioning and Provisional Acceptance. Services disciplines such as electrical, fire alarm, & gas detection system, fire suppression system, internal sanitary & drainage, infrastructure of all other included services require pre commissioning, commissioning & provisional acceptance. All fix 1 & fix 2 procedures shall be conducted according to ITPs & approved procedures. Brief description has already been elaborated in the foregoing.
All utilities, fuels, lubricants, chemicals and catalysts required up to issuance of the Provisional Acceptance Certificate. Within Contractor scope
All required operating and maintenance documentation. All operating & maintenance manuals shall be submitted covering work scope items. These shall be prepared, compiled, documented & transmitted according to the provision of the sub contract requirement.
Warranty Obligations through to Final Acceptance shall be submitted for the work scope items
Further detailed method statements based on each significant activities shall be proposed while physically working on site prepared & approved by the site management. Yet some more details have been included for the purpose of indication only within the presentation of Civil Works package that can be opened from this document itself on soft copy. Click here
Both statements should be referred to as an integral document.
For further details on the services method statements for the package, please refer to the CCTC documentation to be attached within this proposal.
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Sample Only
Taweelah Unit III Um Al Nar
Water Transmission Scheme
Water Reservoir
Construction Method Statement
Scope
The purpose of this document is to define the construction procedures to be adopted for the construction of typical reservoirs. Four number reservoirs are to be built at one location. This statement is meant only for general description of the procedures for various operations involved. Other detailed typical statements shall be produced during the real execution of the works for each activity as standard procedures applicable to the project. The project duration is 20 months
Period for the tanks construction considered 14 months (60 weeks). Two tanks to be constructed simultaneously.
Ref. Documents
Drawings A1/71341/00/1142203 to 5, 1143201 to 16 all schematic
Reference Attached from Doka Formwork
G A Walls & Columns Top 50 systems
Formwork D 2 Tables
Specification For Concrete W-C-SS-005
Specification For Concrete Reservoirs W-C-SS-007
Design
Prior to the construction of the reservoir, all proposed forms shall be designed to the final requirement & calculations with drawings submitted for approval. The construction execution of the reservoir RCC structures shall be carried out based on the AFC drawings.
Existing services
Records shall be checked for the possibilities of any running service. Any existing services so located shall be informed to the relevant authorities as well as company for necessary actions. Trial pits shall also be excavated to scan whether or not any service exists.
Supervision & Control
Construction manager, Site engineer, construction foreman & charge hands shall control all activities on site according to the relevant job descriptions.
Survey
According to the AFC drawings, the surveying team shall locate the setting out lines, coordinates as well as the surrounding circulation area for the construction purpose. Since the dimension of the built up reservoir are given around 130 M x 90 M, proper arrangement shall be made to carry out the mass excavation works.
Topographical levels shall be recorded. The site shall be graded to the required ground level. All survey documents shall be prepared for the purpose of verification. Around the area, guide barricades shall be erected for the purpose of locating the grids & reference site levels. Benchmarks shall be established on all corners for the purpose of flying and reestablishing any of working locations. The establishment of the base corners points as well as the base level benchmark shall be conducted by licensed land surveyor & documents submitted to the engineer for approvals & records references.
Safety
All safety measures shall be taken according to the excavation requirement. Warning tapes Safety cones shall be provided around the defined working area. All safety signboards meant for the excavation safety shall be provided. Warning night-lights reflectors shall be provided around. Ladders shall be provided for the access into the working area located not more than 8 m spacing. Pouring platform for the people to work safely shall be constructed. For convenient access of heavy equipment into the formation area, ramps shall be provided from the existing or graded level from 2 opposite ends. If so required, dewatering arrangements shall be carried out continuously until the foundation slab is constructed. Toolbox talks shall be imparted daily for all the important operations involved. A safety officer shall inspect the works every day, during all concreting activities, form erection activities etc.
Materials
Concrete source-
Ready mix concrete from an approved supplier shall be used.
Rebar fabrication-
Rebar shall be fabricated on the steel yard located elsewhere on the site.
All fabricated bars shall be tagged according to the BBS (Bar Bending Schedule) references
Form fabrication-
Fabrication of the plywood forms shall be carried out on site based on
the specialist formwork vendor details. The supporting system shall be provided by the form vendor based on the detailed design approved by the engineer.
On site, the form works shall be erected according to the vendor
drawings.
The scope of the vendor formwork system shall be confined to retaining
walls, baffle walls, columns, flat slab.
Procedures / Method for one reservoir construction
Summary of the activities
General activities prior to structural construction
300 mm compacted granular sub base
75 mm concrete blinding
2 layers bituminous membrane
50 mm screed
Structural construction activities
RCC Elements involved-
Periphery retaining walls, Base slab, baffle walls, columns with heads, suspended slab, all components of the inlet & outlet chambers, components of the overflow chambers. Intermediate suspended slabs & walls, sump elements. Box outs, construction joints, expansion joints, stair structure, Roof up stands
General activities post structural construction
Filling the PVC pipes inserts within the walls with approved propriety material.
Fixing of Manholes covers & frames on roof.
Roofing & waterproofing
Roof handrails
External Walls pattern formation.
1200 mm wide interlocking paving around reservoir construction.
Detailed activities prior to structural construction
Excavation & Sub Grade
After the clearance from the engineer, excavation shall be started using heavy equipments removing the excavated material directly into the truck & transporting to the tip off stock piles or in case the material not to be used for the filling purpose, to a designated dumping area. During excavation, dust control shall be carried out by conventional means. Excavation shall be carried out approximately to the formation sub grade level only all according to the profile shown on the approved drawings. The surveyor shall control the levels to avoid over excavation. The excavated formation shall be dressed manually as well as using light rollers & after the formation profile is established, heavy rolling shall be carried out over the entire are to reach field compaction to 95 % of dry density. Field compaction test shall be conducted according to the standards & specification requirements. Quality Engineer shall inspect the profile
300 mm compacted granular sub base
Approved granular sub base is spread over the entire area in 2 layers. 1st layer shall be laid in a thickness so that after the rolling, the compacted thickness in both the courses is 300 mm. Thereafter, 2nd course construction shall be carried out. The top profile of the sub base shall be given according to the details which indicates a fall 1 in 500. Site sample testing shall be conducted according to the specification requirement for both courses.
75 mm concrete blinding & mass concrete to requirement
Blinding shall be done in stages parallel to the width of the reservoir. The whole blinding shall be divided into 6 bays each 20m wide & 90 m long. The one stage quantifies to about 135 cum which is feasible for a convenient casting. If so required, further formation of baying compartments could be established within each bay for alternative laying. Low profile strip formwork for the controlling sides shall be prepared. A concrete laying team shall be grouped for the purpose such that concrete received from the transit mixer is immediately pumped into the location & spread using teeth shovel / garden racks, to the strip profile level. Proper leveling shall be carried out using wooden float edge by the masons. The whole area shall be laid, profiled to true levels & given wooden float after the concrete is ready to receive the float. Polythene sheet shall be spread over the entire area. Curing shall be carried out for 3 days only. Before laying new concrete at the set edge of the previous blinding at the edge, cement slurry shall be applied to the edge so that new & old concrete is properly bonded. Mass concrete shall be carried out as shown on the approved contract drawings
2 layers bituminous membrane
At the end of the curing, the surface shall be cleaned of all dust particles, debris, water etc & inspected. Any cracks appearing or any damaged portion located shall be repaired. According to the manufacturer’s instruction, bituminous membrane shall be applied over the blinded surface.
50 mm screed
The membrane shall be protected by an application of 50 mm screed layer as soon as possible & cured accordingly by the repetition of the foregoing activities in sequence but in alternate bays.
Construction of peripheral retaining walls- major elements
Preparatory works for one corner L shape – 1 set, 4 stages in repetition
(Ref to attached drg GA walls from DOKA)
Preparatory works for straight walls – 1 set 40 m long, 6 repetitions
(Ref to attached drg GA walls from DOKA)
These elements comprise of the base slab, shear key & upright RCC
structures
Preparatory works for the base slab- non propriety formwork
384 repetitions of each bay
Each bay comprises of 4 sides
Preparatory works for the columns- propriety formwork
40 sets, 10 repetitions
Each column comprises of 4 sides
(Ref to attached drg Column top 50 from DOKA)
Preparatory works for baffle walls- propriety formwork
10 sets, 4 repetitions
Each wall comprises
Preparatory works for the inlet / outlet chamber as well as overflow
1 set, 2 repetitions
These comprise of base slab, walls, suspended slabs
Preparatory works for the suspended slab - propriety formwork
1 set, 2 repetitions
Flat slab construction
(Ref to attached drg D2 Tables from DOKA)
L shape wall
Setting out for each L shape wall at the corner shall be carried out on the screed for the base slab (Toe + Heel) portion. Re-bars shall be placed according to the details provided with due spacers. Chairs shall be provided between the top & bottom rebar layers. At the end of the every day work, polythene membrane shall be spread over the placed & fixed rebars for protection from humidity. Vertical forms shall be prepared at site using plywood & wooden battens all to approved methods. Arrangement for the construction joint shall be made for the insertion of approved water bar so that lower half of the bar is in the retaining wall base slab concrete. The retaining wall base slab shall be continuous without any joint. It shall be ensured that the set lines of the forms are in true alignment & plumb. All vertical sides shall be well supported so that 1 m high concrete pressure is sustained by the supporting system adequately without bulging.
After the clearance by the site engineer, QC inspection shall be conducted & engineers approval obtained for pouring concrete. About 500 cum of pour is in this programme that may take about 16 hours. The pouring shall be done in 3 layers so that cold joint is avoided. Two pumps shall be used for this pour. Concrete delivery shall be continuous. The portion of the green concrete at the wall junction shall be roughened before the concrete is hardened, The exposed portion of the concrete shall be properly finished to the defined levels & immediate / instant as well as specified duration curing shall be continuously carried out. Following preparatory works for the upper wall portion shall be continued.
Upright wall
Scaffolding shall be erected on both sides for accessing the workers to fix the rebars & erect the formworks for the upright wall. Rebars shall be placed properly in compliance with the design details & engineers approval obtained prior to the closure of the forms. At the end of the every day work, polythene membrane shall be spread over the placed & fixed rebars for protection from humidity. According to the formwork vendor’s design, the sides of the forms shall be erected & fixed.
It shall be ensured that the erected forms are in true alignment & plumb as well as outer wall forms in designed profile. The anchoring arrangements sleeved in shall be fastened properly. All supports as shown on the details shall be provided. A platform shall be built on top for the workers safe access & working. Water bar shall be inserted in all vertical positions duly welded using cross as well as Tees wherever required. Permanent bars shall also be inserted as shown on the vendor’s design. Outer forms shall be checked for the correctness of its compliance with design profile while vertical forms for verticality as we as alignment. QC inspection shall be conducted & engineer’s approval obtained
Programme shall be charted out for pouring about 250 cum in one go. The concrete pouring chute pipe shall be inserted vertically into the prepared works so that the net drop of concrete is not more than 2 m. Pour shall be carried out in layers not exceeding 450 mm so that vibrator nozzles penetrates internally. This pour shall consume about 10 hours. At the end of the pour, the top surface shall be properly floated & either curing compound instantly sprayed or covered with polythene sheet. Side supports shall be struck only after 48 hours.
Base Slab bay / Floor slabs
Size of the bay is 5 m x 5 m, 500 mm thick i.e 12.5 cum. Total number 384 bays.
Preparation for 40 bays shall be done in one go i.e 500 cum pour. Construction joints to be prepared around to detail requirement. Preparation of forms to be carried out around in general keeping in view that it allows for the continuation of rebars and also the insertion of water bar. At the end of the every day work, polythene membrane shall be spread over the placed & fixed rebars for protection from humidity. Rebar placement to be done continuously to the details
Rebars for the starter bars shall be placed for the baffle walls in the correct positions wherever defined
Rebars for the starter bars shall be placed for the columns in the correct positions wherever defined
Provision of surface water strip shall be made according to details. Provision of rebar chairs for the top & bottom rebars supports shall be made. Proper placement of concrete spacers shall be made. All the bars shall be properly bound to avoid any kind of slip or dislocation even though steel fixers shall be available to attend the pour to control the bars positions. Form carpenters shall also be available to control the alignment & levels. Two pumps shall be used for the pour for 16 hours programme.
Immediately after the finishing of the top surface to the defined profile, instant curing shall be carried out. After the concrete is set, curing shall be carried out as approved. Repetition of the bays shall be done accordingly to complete all 384 bays. Side supports shall be struck only after 24 hours.
Straight walls
Base Slab preparatory works shall be carried out similarly as given in the foregoing L shape pattern excepting that the forms are straight.
Upright wall
Each pour about 100 cum. In this case also, Scaffolding shall be erected for accessing the workers to fix the rebars & erect the formworks for the upright wall.
Rebars shall be placed properly in compliance with the design details & engineers approval obtained prior to the closure of the forms. At the end of the every day work, polythene membrane shall be spread over the placed & fixed rebars for protection from humidity. According to the formwork vendor’s design, the sides of the forms shall be fixed. It shall be ensured that the erected forms are in true alignment, profile & plumb.
The tie rods sleeved in shall be fastened properly. All supports as shown on the details shall be provided. A platform shall be built on top for the workers safe access & working. Water bar shall be inserted in all vertical positions duly welded using cross as well as Tees wherever required. Permanent bars shall also be inserted as shown on the vendor’s design. QC inspection shall be conducted & engineer’s approval obtained.
Programme shall be charted out for pouring about 250 cum in one go. The concrete pouring chute pipe shall be inserted into the form so that the net drop of concrete is not more than 2 m. Pour shall be carried out in layers not exceeding 450 mm so that vibrator nozzles penetrates internally. This pour shall consume about 5 hours. At the end of the pour, the top surface shall be properly floated & either curing compound instantly sprayed or covered with polythene sheet. Side supports shall be struck only after 48 hours.
Columns
About 75 cum in one go for 40 columns. In this case also, Scaffolding shall be erected for accessing the workers to fix the rebars & erect the formworks. Rebars shall be placed properly in compliance with the design details & engineers approval obtained prior to the closure of the forms. At the end of the every day work, polythene membrane shall be spread over the placed & fixed rebars for protection from humidity. According to the formwork vendor’s design, the sides of the forms shall be fixed. It shall ensured that the erected forms are in true alignment & plumb. The fixing arrangements shall be fastened properly. All supports as shown on the details shall be provided. A platform shall be built on top for the workers safe access & working to allow for comfortable & safe circulatory movement for the crew.
design.
QC inspection shall be conducted & engineer’s approval obtained. Programme shall be charted out for pouring about 75 cum in one go. The concrete pouring chute pipe shall be inserted into the form so that the net drop of concrete is not more than 2 m. Pour shall be carried out in layers not exceeding 450 mm so that vibrator nozzles penetrates internally. This pour shall consume about 8 hours. At the end of the pour, the top surface shall be properly finish rough & covered with saturated Hessian & polythene sheet. Continuous curing shall be conducted thereafter. Side supports shall be struck only after 48 hours.
Baffle walls
Each pour about 75 cum. In this case also, Scaffolding shall be erected for accessing the workers to fix the rebars & erect the formworks for the upright wall.
Rebars shall be placed properly in compliance with the design details & engineers approval obtained prior to the closure of the forms. At the end of the every day work, polythene membrane shall be spread over the placed & fixed rebars for protection from humidity. According to the formwork vendor’s design, the sides of the forms shall be fixed. It shall ensured that the erected forms are in true alignment & plumb. The fixing arrangements shall be fastened properly. All supports as shown on the details shall be provided. A platform shall be built on top for the workers safe access & working to allow for comfortable & safe circulatory movement for the crew.
QC inspection shall be conducted & engineer’s approval obtained. Programme shall be charted out for pouring about 75 cum in one go. The concrete pouring chute pipe shall be inserted into the form so that the net drop of concrete is not more than 2 m. Pour shall be carried out in layers not exceeding 450 mm so that vibrator nozzles penetrates internally. This pour shall consume about 5 hours. At the end of the pour, the top surface shall be properly floated & either curing compound instantly sprayed or covered with polythene sheet. Side supports shall be struck only after 48 hours.
Inlet chamber
Base slab of this chamber is at a lower level & 1 m thick. It also has walls & intermediate cantilever structure to be connected to the roof suspended slab. This shall be separately carried out in two stages.
Outlet chamber
This has a basement sump in stepped profile. Base slab of this chamber is at a lower level & 1.2 m thick. It also has grade level suspended slab. This shall be separately carried out in three stages.
Access stairs to roof 2 numbers
These stair structures are to be constructed on 3 columns on isolated footings.
The columns have to carry cantilevered steps & one landing
Stages
Construction of footings shall be carried out comprehensively according to conventional trade practices. Construction of columns shall be carried out comprehensively according to conventional trade practices. Construction of waist slab & steps shall be carried out comprehensively according to conventional trade practices. Preparatory works shall be similar to as defined in the foregoing excavation, blinding, formwork, steel fixing, pouring etc. (all shall be carried out comprehensively according to conventional trade practices)
Suspended Slab
Half portion in one go about 1400 cum. This is a flat structure transferring loads on the column heads. In one go half portion of the slab is intended to be poured as shown on drawing. The arrangement of the supporting system shall be strictly adhered to vendor’s instructions as shown on the attached drawing. Preparation & erection of forms shall be done following all approved details. Rebar placement shall be done to the details & the spacers provided accordingly. At the end of the every day work, polythene membrane shall be spread over the placed & fixed rebars for protection from humidity.
The location of the movement joints shall prepared so that 50 mm thick joint filler is fixed in position correctly as well as supported to remain so during concrete pouring. The forms for the up stands shall also be erected for monolithic pour with slab concrete for which the fixing arrangements be made accordingly. All block outs for the openings shall be prepared to the defined locations & properly anchored to remain in position.
The following quality checks shall be conducted prior to pouring is commenced
Slab alignment
➢ Levels
➢ Profile of the column head / drop heads
➢ Alignment of the up stands & verticality
➢ Re-bars placement as well as locations & centering
➢ Proper fixing of concrete spacers
➢ All inserts or services fixes if so required, shall be placed in & approved.
➢ It shall be ensured that no rebar is susceptible to any possible displacement any time or a possibility to correction must exist during pour.
➢ Certification of the supporting system by the form vendor engineer
➢ All access routes shall be properly tagged & certified by safety officer.
➢ During concrete delivery slump, temperature, air voids tests etc shall be recorded.
For pour, minimum 2 pumps shall be required for continuous placement of concrete & 1 pump to remain standby. Keeping a speed of 10 minutes for each truck, 60 cum each hour, 2 pumps shall pour the prepared portion in 10 hours followed by another overlapping 10 hours required for the wooden finishing of the unformed surface. Instant curing shall be carried out by spraying curing compound aver the area to control shrinkage cracks. Later, after final profile & finishing the surface, polythene layer shall be spread over the saturated Hessian to keep wet for at least 10 days continuously.
Striking of the forms shall be carried out only after 8 days. Whole exercise shall be repeated for the second half of the slab.
Reservoir testing
The structure when completed according to BS 8007 provisions water test shall be conducted to check any leakage. After closing all openings, water shall be filled gradually to the required level. The fall in the water level shall be monitored regularly at defined intervals according to the code provisions. The loss of the water should be within prescribed limits
Though not necessary in this case since the water is in cover, for the comparison of the loss by evaporation, a separate small container shall be kept which indicate the loss in level due to weather & the fall of the reservoir level corrected accordingly to reach net loss in level. After successful completion of the water test, water used for the test shall be pumped out to the other reservoir for testing of that reservoir in sequence.
Roofing
After the curing is completed, the whole surface shall be scabbled properly to expose the aggregate to meet the bonding requirement of foam concreting. The surface shall be prepared & any services plinth required shall be constructed to the details. True profile required for the drainage shall be prepared for foam concrete over the entire area. Foam concrete shall be produced on site & laid by specialist roofing sub contractor All other roofing operations shall be carried out accordingly to the approved method statement Roof waterproofing shall be tested by flooding with water for 48 hours Any leak detected shall be made good according to the agreed procedures.
Other General activities
Roof handrails shall be fixed to the required locations. Adequate arrangements shall be made to keep the internal space of the reservoir well ventilated during performing the application of concrete protections. All other activities about the concrete protection shall be carried out for the above ground concrete on the inner as well as on the external surfaces. All operations of the backfilling of the walls up to the formation levels shall be carried out according to the standard approved methods & field samples tested accordingly. Preparation of the walkways around shall be carried out for receiving the interlocking blocks.
Compaction shall be done for the formation of the walkway area. Works for the kerbstone shall be carried out. Laying of the interlocking blocks shall be carried out to the given profile & levels.
Equipment
Shovel. Excavator, tipper trucks, Roller, Compactor, Concrete pumps, Truck mixers as & whenever required, concrete vibrators, centrifugal pumps to boost out water from the reservoir etc
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Chapter 13
Environmental clauses for plant Industrial city in
Construction Contracts
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The Environmental Guidelines & Environmental Protection Criteria (EG&EPC) for Plant Industrial City, National Environmental Protection Law, and Environment and Natural Reserves standards, shall be complied with by Contractor and its Sub-Contractors operating within the boundaries of PLANT.
Contractor shall comply with all applicable rules and regulations of all relevant agencies having jurisdiction, which now exist or which may come into effect during the course of the Work, relating to environmental protection and management. Contractor warrants that it shall use its best endeavours to protect and to take care of all environmental and natural resources in order to prevent environmental pollution of any kind resulting directly or indirectly from the Work performed under the Contract.
Notwithstanding any provisions contained within the Contract, the Contractor shall assume all liabilities for environmental and human health damage of any kind arising directly or indirectly from the Work, and shall indemnify Company / Client and hold them harmless from and against any and all losses, claims, demands, costs, proceedings, damages, charges and expenses howsoever arising therefrom, whether or not caused by negligence, in whole or in part.
Without relieving the Contractor of any of its obligations detailed herein or as imposed by any relevant agency, authority, or any other body having jurisdiction, Company/Client may take part to any degree it deems necessary, in the control, removal and remediation of any pollution or contamination which is the responsibility of the Contractor, under the foregoing provisions or which is due to any act or omission, directly or indirectly, of the Contractor.
The Contractor shall reimburse Company/Client for the cost thereof provided always that the amount of any such cost may be deducted by Company / Client from any money due or becoming due to the Contractor.
Contractor shall furnish the following documents for the approval of Company/Client at least four (4) weeks prior to the commencement of the Work at the construction site.
Waste Management Plan
Environnemental Management Plan
Spill Contingency Plan
Contractor shall provide Company / Client with Material Safety Data Sheets (MSDS) for all chemicals / materials (where applicable) it shall use or supply prior to shipment.
Contractor shall dispose of all waste including but not limited to packaging, discarded material, unspent and serviced material in an environmentally acceptable and approved manner.
Contractor shall take immediate corrective action(s) to remedy any and all occurrence(s) of environmental pollution and report such incident(s) as per the environmental incident reporting requirement for PLANT. Company / Client is entitled to impose such penalty as specified in the Environmental Guidelines & Environmental Protection Criteria for Plant Industrial City (PLANT) should the Contractor fail to take the appropriate corrective action (s) or to report such incident. In case of an environmental incident Company / Client may take action to investigate the incident, assess its impact and/or take necessary corrective action and recover the cost involved by such action from the Contractor.
Contractor shall complete and submit an Environmental Discharge Form (in accordance with relevant EXHIBIT) to Company / Client prior to the commencement of any demobilisation. Demobilisation may only commence upon authorization / approval of this form by Company / Client.
Preventive Measures
HSE&S
Health, Safety, Environmental & Security
Standard Procedures / Hazard Control
This procedure is applicable to all projects construction site activities.
Purpose
To establish a procedure for systematically identifying all the hazards / risks associated with a task or job and to implement appropriate control measures.
Preventive Maintenance is of utmost significance for such an industrial project that must be kept in full considerations while conceptualizing any scheme. There should be a session of brain storming to find out the causes & solutions for meeting any hazard that may crop in during the operational life of the project. Every risk must be analysed as any miscalculation may lead to intensive fire breakout resulting in losses of billions of dollars as well as severe human loss.
There are nowadays several methods given in industrial safety as well as loss prevention methods for the disaster management to prevent such mishaps. The present scope of this book does not allow that to elaborate but informatively included. Let us divide the whole plant industrial area into various zones depending on defined & expected risks. Process area, non-process areas, explosive zone, secured zone, administrative zone, environment unsafe zone etc
Process area can be confined to the real trains zone which is a pure chemical product engineering portion comprising of all vessels involving oil & its storage. This is the only major potential source leading the plant to major fire as well as explosion hazards. All equipments must be made fireproof to the extent possible. The building contained in such zone must be made blast resistant. All arrangements of fire suppression must be made. Proper arrangements must be made for all personnel to use safety devices of all kinds depending of the nature of the hazard so that all users wear preventive dressing / equipment.
Hot as well as cold works areas are defined explicitly for the purpose of preventive adaptation as well as for issuing permits to work within & without plant for the engineering construction works in future. Safe procedure must be defined for such activities. No work should be allowed without granting of such permits. The lost gases or other products or bye products have the potential to spread into the environment air consequently transferring fire possibility a detailed study of that should be made to find a resolution to adopt for suppression measures.
Non process areas should be located distant enough say anything far up to 700 m from the real trains so as the effects are not relocated to this zone that requires only blast resilience structures. Accordingly fire suppression & blast control provisions be applied to the constructions as well as precautionary measures be defined for the personnel. Circulatory areas should be defined in between the process & non-process areas that cannot be definitely delineated but shall carry piping, traffic, roads & many other components of the plant. Accordingly the provisions be given for the disaster management. The most important aspect is the control from fire everywhere for which regular mockups should be conducted. Assembly points be clearly defined at various location that allow following fire alarm to assemble & await further directions from the wardens. Immediate medical attendants & ambulance should be installed. The piping routes must be defined corridors with proper fire protection & guards. No unauthorized person be allowed within the corridors.
Storage area particularly of oil raw material must be provided full protection from firing & explosion viewpoint. This is actually a very high potential source of fire & can cause heavy losses to industry as well as to humans. In case of fire disaster, adequately effective arrangements must be available fully all times to vacate the personnel as soon as possible from the assembly points & further off the plant to safer locations. All classes of fire suppression arrangement must be kept fully functional at the relevant hazard locations clearly defined to the personnel involved & competent fire fighting team made available. Regular training & mock-ups drills must be conducted to keep the involved humans alert to meet any unforeseen.
As far as adverse effects during an occurrence of earthquake are concerned,
Fire Protection
Introduction
The Contractor shall design the fire protection system based on this specification. The fire protection installations shall include all required systems and equipment for the adequate protection of the process and utilities areas. The design and engineering of the fire-fighting systems shall consider the plant layout, the isolation philosophy, the inventories & the critical equipment.
Fire Hazard Analysis study
The design of the fire-fighting systems shall consider the effectiveness of the individual agents. Water Fire extinguishing, exposure protection and cooling, fire intensity control, ignition prevention and prevention of vapor cloud formation. Foam Securing and extinguishing of spill fires in the plant. CO2 gas Fire extinguishing by means of oxygen reduction inside enclosures. Dry Chemical Powder Control and extinguishing of small flammable liquid spill fires and gas-flash fires. Inert gases ‘Inergen’ is one product recognised as environmentally safe to be used for Halon. It is composed of naturally occurring gases Nitrogen, Argon and CO2. Inergen may be used where an electrically non-conductive medium is required. Inergen systems are designed and installed complying NFPA-2001. IG-541 is the name of Inergen in NFPA 2001. The use of Inergen is subject to ‘room integrity overpressure testing’. In manned areas, a qualified pre-alarm status must be in place. Fire proofing, layout, isolation with bunding and catchment shall also considered.
Codes And Standards
It shall be the Contractor's responsibility to be, knowledgeable of the requirements of the relevant International Codes and Standards.
The following latest edition codes and standards to the extent specified herein, form shall be used as a minimum.
➢ National Fire Protection Association (NFPA)
➢ NFPA 10 Portable fire extinguishers
➢ NFPA 11 Low-Expansion Foam
➢ NFPA 11C Mobile foam apparatus
➢ NFPA 12 Carbon Dioxide Extinguishing System
➢ NFPA 13 Installation of Sprinkler System
➢ NFPA 15 Water Spray Fixed Systems
➢ NFPA 20 Installation of Centrifugal Fire Pumps
➢ NFPA 24 Private Fire Mains
➢ NFPA 30 Flammable and Combustible Liquids Code
➢ NFPA 70 National Electric Code
➢ NFPA 72 National Fire Alarm Code
➢ NFPA 850 Electric Generating Plants
➢ NFPA 2001 Clean Agent Fire Extinguishing System
Reference Documents
Project Specifications: Architectural Design Basis, Fireproofing, Electrical Design Guidelines, Power, Control and Earthling Cables, Technical Specifications for Piping Systems, General Piping Process and Utility Design, Layout and Drawing, Design and Installation of Glass-Fibre Reinforced Epoxy and Polyester Piping, Combustion Gas Turbines, Painting, Galvanising, Fire and Gas Detection System, System Cables, CCTV Philosophy, Building Management Systems, Preservation and Export Packing, Safety Equipment Specification , Criticality Rating Calculation Method , Shop Inspection and Test Requirements , Health, Safety and Environmental Philosophy , Project Drawings:
Fire Protection General Plant, Fire Water Diesel Pump
Document Precedence
The Contractor shall notify the Company of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. Resolution and / or interpretation precedence shall be obtained from the Company in writing before proceeding with the design / manufacture.
In case of conflict, the order of precedence shall be:
Data Sheet(s), Narrative Specification, Project Specifications and Standards, Industry Codes and Standards, Specification Deviation / Concession Control
The Contractor only through Concession Request format shall seek any technical deviations to this specification and its attachments. Concession requests require Company's review / approval prior to the proposed technical changes being implemented. Technical changes implemented prior to Company approval shall be subject to rejection.
Quality Assurance and Quality Control
Quality Management System shall comply with the applicable requirement of ISO 9001. The purpose of the description herein is to determine factory inspection and testing requirements for fire protection equipment, fire detection equipment, gas detection equipment and alarm system equipment including control panels that shall be listed in project specification. The level of shop inspection and test requirements is defined.
Description
The fire protection and extinguishing system shall include (but not be limited to):
Water supply and distribution system including pumps, mains, hydrants, monitors, hose boxes, hose reel stations and fire point shelters. Water spray systems for process equipment. An automatic CO2 fire suppression system inside gas turbine enclosures. Fire, smoke and gas detection and alarm systems in process areas. Automatic fire suppression systems protecting vital equipment inside buildings. Portable extinguishers (dry chemical powder, carbon dioxide and water) and other movables. General building protection (manual call points, hose reels, and portable fire-extinguishers) Fire Training Facility
The Basis Of Fire Protection
The basic objectives for fire protection is to limit or prevent the escalation of a fire, to avoid risk to life and to minimize material damage until the source of hazard has been isolated or consumed. Fire protection shall mainly be provided by automatically and manually operated fixed-installed systems in conjunction with portable and mobile fire-fighting equipment.
Requirements
Fire prevention and protection measures shall be considered during all stages of plant design.
Process and equipment design shall be assumed as following good engineering practices such as sufficient spacing of equipment, incorporation of emergency shutdown system, relieving system, drainage systems and other special safety considerations for the individual process requirements.
Equipment arrangement and distances between fire-hazardous equipment shall be set so that in the event of a fire, the possibilities for escalation are minimized; however, within an operational complex, it is not always feasible to achieve complete separation of equipment. Consequently, additional precautionary measures for fire protection shall be evaluated and submitted for Company approval.
This applies particularly to those areas where a chimney effect may occur. For example, a minor fire at a pump may affect overhead equipment causing the fire to rapidly develop. Also, the updraft associated with air-cooled heat exchangers may cause the fire to spread. Design of the fire-fighting system shall be based on the assumption that no fire-fighting equipment and no manpower for fighting fires from outside the plant shall be available in case of a fire.
A fire within the plant shall be controlled or extinguished by the plant fire brigade using plant fire engines and plant fire-fighting equipment and devices. The philosophy for designing the fire protection facilities is to utilize the automatic systems and the mobile equipment, which require a minimum number of fire fighters.
Access shall be provided for fire fighting particularly for equipment handling flammable liquefied gases or flammable products at or above auto-ignition temperature and the seal / luboil units of rotating equipment. Some equipment shall be protected with water spray systems to remain in operation until the fire brigade arrives to determine the appropriate method of extinguishing attack. The quantity of water required for fire protection shall be based on that is required to control and possibly extinguish one major fire situation at a time under the following conditions: Operation of deluge systems in the zone on fire (or at least 1 monitor), Operation of deluge systems of 2 adjacent zones if (or at least 2 monitors) and 2 hydrants (or 2 monitors).
Note: For large complex units the quantity of water required for fire protection shall be based on the Fire Hazard Analysis study and the QRA, which shall determine the “worst case scenario”.
Detection systems shall be installed in all the relevant areas (process units and buildings) to detect fire, smoke and gas. These shall where required, activate fire protection systems or raise an alarm for action to be taken.
Manual call point systems of the 'break glass' type shall also be installed throughout the plant in selected positions to raise an alarm. Indication panels shall be provided in the control room and fire station to enable operators to take appropriate action and to indicate if a fire protection system has been activated. Audible alarms and beacons shall be installed in process units which shall automatically actuate on leakage of gas, or on the outbreak of a fire. Cables for ESD solenoid valves shall be fireproofed and preferably laid in separate trays.
Passive fire protection shall be installed wherever needed on steel supports, towers, vessels, heaters and other process equipment when subjected to severe temperature generated by a liquid hydrocarbon or gas fire.
Positive pressure shall be maintained in the substations and a fire protection clean agent system installed to protect the equipment against damage due to fire. Television cameras with monitoring systems shall be installed to overlook general plant areas enabling operators to take appropriate action when fire, smoke or gas is detected. Around hydrocarbon production facilities, zones or spaces shall be defined in which a gas cloud with gas concentration likely to be above the lower flammability limit (LFL) be present when a major gas or vapor leakage occurs. These zones are called Restricted Zones.
The restricted zones concept shall be used to define preventive ignition measures to be taken into account for the items of equipment located inside a restricted zone, e.g. shutting down specified electrical equipment in explosive atmospheres. Hose boxes and fire points containing portable fire-fighting equipment to be located at strategic points adjacent to hazardous areas.
Portable fire extinguishers shall be available in those locations where rapid intervention with a relatively small fire extinguisher may prevent a small fire from escalating. The required portable equipment and its location shall be indicated in Fire hazard analysis which must be performed as part of detailed design to address each potential fire hazard
This analysis should consider the following aspects:
The type of combustibles, Fire load of the hazard, Flash points, Ignition sources, Temperature of combustibles, Combustible liquids, Flammable liquids, Exposure to adjacent combustion, Chemicals involved, Detection, alarm, automatic control and monitoring systems process area
The early detection of a developing fire and an early warning to operational and fire-fighting personnel form an important aspect in the basic concept of fire protection.
Fire and gas detection system
The fire and gas detection systems shall be designed complying with Design Specification. The systems shall be used to provide monitoring and control of the plant. Fire and gas detectors are part of fire and gas system. The system shall incorporate data acquisition and printer facilities. The system shall consist of but not be limited to: Fully intelligent system cabinets and their associated field interface cabinets located within the IES (instrument equipment shelters) and various buildings. Each system cabinet shall incorporate a display matrix for the areas it covers. A maintenance console shall provide diagnostic facilities for the system.
Alarm and maintenance printers
There shall be a separate Fire & Gas network connecting the fire and gas alarm system of all buildings and the plant. Necessary fire alarm signals shall be repeated on DCS through serial interface and displayed on control room DCS consoles. All fire alarm systems shall have local panels with display matrix in respective buildings. Alarm lights and audible alarms shall be provided in the plant for the various systems.
Lights shall have different colors for different types of alarms. These lights shall be located in the same general areas as the detectors. Alarm colors (lights) provided in the plant area shall be the same on the matrix panel and CRT graphics and should be as follows:
Blue for flammable gas detectors
Red for fire detectors and manual call points
Orange for toxic gas detectors
Maintenance shall be considered for the detector location. Detectors for areas such as compressor shelters should be accessible from crane platforms. Ladders may be used.
Flammable gas detection
Flammable gas detection in open areas
A flammable gas detection system shall be furnished. The signal from the flammable gas detectors shall be sent to Instrument Equipment Shelters (IES) and then to the Control Room (CR).
The CR shall send a signal to a panel in the fire station.
Flammable gas detectors shall alarm at multiple points. The first alarm shall sound at about 10 % of the lower flammability limit (LFL). The sensor system shall be designed to alarm again at 25% of LFL.
When 10 % LFL is reached, each detector shall give:
An individual visual alarm (blue flashing light) on the concerned matrix panel showing the location of gas detection and the system buzzer shall actuate.
The signal shall be sent via the data highway to the fire and gas detection system in the fire station and control room it shall initiate:
An audible and visual alarm in the Control Room, fire station, maintenance workstation
When 25 % LFL is reached, it shall be added:
A common audible alarm and a common visual alarm (blue flashing light) in the concerned process plant area.
An audible and visual alarm in the Control Room, fire station, maintenance workstation & concerned area operator shelter
Flammable gas detectors for hydrocarbon gases shall be located on two criteria
General area coverage detectors shall be as follows:
Between process units handling flammable gases and liquids and process units having open flames.
Around process units handling high-pressure flammable gases (greater than 20 barg). Specific locations based on past industry experience. Detectors shall be provided in the following locations:
on gas compressor seals and
on seals for pumps which handle flammable liquids, inside the entrance to ventilation intakes and on manifolds and hydrocarbon valves to be defined by Company
The type of flammable gas detectors shall be such that concentrate of flammable gas be measured and displayed in the range of 0 to 100 % lower flammability limit (LFL).
Flammable gas detection in the buildings
The buildings are divided in 2 categories as follows:
The process buildings:
➢ Instrument Equipment Shelter (IES))
➢ Electrical Substation (SS)
➢ Operator Maintenance Shelter (ZM)
➢ Sulphur Weigh station Building (WS)
➢ Sulphur Weigh station Truck Driver Building (J2)
➢ Process Chemical Shed (PCS)
➢ Compressor Shelter (CPS)
➢ Smoke room (SM)
➢ Fire Point Shelter (FPS)
➢ Analyser shelter
The non-process buildings:
➢ Laboratory
➢ Storage building
➢ Chemical store
➢ Cooled chemical store
➢ Maintenance building
➢ Fire station
➢ Gate Houses
Process buildings (except analyser shelter)
Three flammable gas detectors shall be provided at the air intake of HVAC system (if any).
A hydrogen (H2) gas detector shall be provided in battery rooms of substations and IES where seal batteries are used. When 10 % of LFL for flammable gas detector or H2 detector is reached, each detector shall give:
An individual visual alarm (bleu flashing light) on the concerned matrix panel showing the location of gas detection.
An audible and visual alarm (blue flashing light) at the entrance and in the concerned building.
An audible and visual alarm in the control room.
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
When 2 out of 3 HC detectors or 1 out of 1 H2 detector reach 25% LFL, the following actions shall be added:
An audible and visual alarm in the Control Room,
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
An audible and visual alarm in the concerned area operator shelter
The ventilation system shall be stopped and dampers closed except for H2 detection in battery room.
Cut-off power supply of Operator maintenance shelter (for flammable gas detection at the air intake of Operator maintenance shelter)
Each H2 detector located inside a battery room shall cut off the battery feeder.
Analyser shelter
Two flammable gas detectors shall be provided at each air intake of HVAC system. One flammable gas detector shall be installed inside the analyser.
When one detector reaches 10% LFL, it shall give: A general audible alarm in the IES associated with the concerned plant area. An individual visual alarm (blue flashing light) on the concerned matrix panel showing the location of gas detection.
A visual alarm in the analyser shelter.
An audible and visual alarm in the control room.
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
Shutdown of sockets located inside Analyzer shelter.
When 25 % of LFL is reached by one detector, the following actions shall be added:
A general audible alarm in the IES associated with the concerned plant area.
An individual visual alarm (blue flashing light) on the concerned matrix panel showing the location of gas detection.
A visual alarm in the analyser shelter.
An audible and visual alarm in the control room.
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
Shutdown of sockets located inside Analyzer shelter.
If 2 out of 2 detectors reach 25% LFL, the following action shall be added:
The ventilation system shall be stopped and dampers closed.
An audible and visual alarm (blue flashing light) in the concerned process area
An audible and visual alarm (blue flashing light) in the concerned process area operator shelter
Non process building
Two flammable gas detectors shall be provided at the air intake of new HVAC system (if any) depending on detection philosophy.
When one detector reaches 10 % of LFL, it shall give:
An individual visual alarm on the concerned control or matrix panel showing the location of gas detection and the system buzzer shall be activated.
An audible and visual (blue flashing light) alarm (if any) at the entrance and in the concerned building.
An audible and visual alarm in the control room.
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
When 2 out of 2 detectors reach 25% LFL, the following actions shall be added:
An indication in the control room.
An indication in the fire station.
An audible and visual alarm in the maintenance workstation
The ventilation system shall be stopped and dampers closed
Flammable gas detection for packages
Three flammable gas detectors shall be located at each air duct inlet of the package.
For the flammable gas detection (distribution and installation) for packages refer to “Instruments furnished with packages” When 10% LFL is reached, each detector shall give:
A general audible alarm in the IES and substations associated with the concerned plant area.
An individual visual alarm (blue flashing light) on the concerned matrix panel.
The signal shall be sent via the data highway to the fire and gas detection system in the fire station and control room to initiate:
An audible and visual alarm in the Control Room,
An audible and visual alarm in the Fire Station.
An audible and visual alarm in the maintenance workstation
When 25% LFL is reached, it shall be added:
An audible and visual alarm in the Control Room,
An audible and visual alarm in the Fire Station.
An audible and visual alarm in the maintenance workstation
When two out of two detectors reach 25% LFL, the following actions shall be added:
A common audible alarm and a common visual alarm (blue flashing light) in the concerned process plant area.
Shutdown of the machine.
Close ventilation dampers and shutdown ventilation fans
Isolate power supply to all equipment not suitable for zone 1
Toxic gas detection
A toxic gas detection system shall be furnished. The signal from the detectors shall be sent to IES and then to the CR. The CR shall send a signal to a panel in the fire station.
H2S gas detection in open areas
H2S detectors shall be located on two criteria:
General coverage detectors shall be as follows:
Between the flares
Inside area handling substantial quantities of H2S and containing operating personnel
Specific location detectors shall be as follows:
On seals of gas compressors handling H2S
On seals of pumps handling fluids containing H2S.
On areas of control valves handling gases that have a significant percentage of H2S.
On sulphur Sumps
Concentrations of H2S gas shall be measured and displayed over the selectable range of 0-50 ppm.
The first alarm point shall be set at 10 parts per million (ppm volume) H2S.
The second alarm shall be set at 20 ppm.
Fire Protection Design Basis
When 10 ppm is reached, each detector shall give:
A general audible alarm in the IES associated with the plant area concerned and operator shelter
An individual visual alarm (orange flashing light) on the concerned matrix panel showing the location of gas detection.
The signal shall be sent via the data highway to the fire and gas detection system in the fire station, control room and maintenance workstation. It shall initiate:
A common audible alarm and a common visual alarm (orange flashing light) in the concerned process plant area.
An audible and visual alarm in the Control Room,
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
When 20 ppm is reached, the following alarms shall be added:
A common audible alarm and a common visual alarm (orange flashing light) in the concerned process plant area.
An audible and visual alarm in the Control Room,
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
H2S Gas Detection In buildings
Process buildings (except analyser shelter)
Two H2S detectors shall be provided at the air intake of HVAC system (if any).
When 10 ppm of H2S is reached, each detector shall give:
A general audible alarm in the IES associated with the concerned building.
An individual visual alarm (orange flashing light) on the concerned matrix panel showing the location of gas detection.
An audible and visual alarm (orange flashing light) at the entrance to and in the concerned building.
An audible and visual alarm in the control room.
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
When 1 out of 2 detectors reach 20 ppm, the following actions shall be added:
An audible and visual alarm in the control room.
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
The ventilation system shall be stopped and dampers closed.
Analyser shelter
One H2S detector shall be provided at each air intake of HVAC system.
In units containing H2S, one H2S detector shall be provided inside analyser shelter.
When one detector reaches 10 ppm, it shall give:
A general audible alarm in the IES associated with the concerned plant area.
An individual visual alarm (orange flashing light) on the concerned matrix panel showing the location of gas detection.
A visual alarm (orange flashing light) in the analyser shelter.
An audible and visual alarm (orange flashing light) in the concerned process area.
An audible and visual alarm in the control room.
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
When one detector reaches 20 ppm, the following actions shall be added:
An audible and visual alarm in the control room.
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
An audible and visual alarm (orange flashing light) in the concerned process area. If the concerned detector is located at HVAC air intake, the ventilation system shall be stopped and dampers closed.
Non process buildings
Two H2S detectors shall be provided at the air intake of new HVAC system (if any) depending on detection philosophy.
When one detector reaches 10 ppm, it shall give:
An individual visual alarm on the concerned control or matrix panel showing the location of gas detection.
An audible and visual (orange flashing light) alarm (if any) at the entrance to and in the concerned building
An audible and visual alarm in the control room.
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
When 1 out of 2 detectors reach 20 ppm, the following actions shall be added
An individual visual alarm on the concerned control or matrix panel showing the location of gas detection.
An audible and visual (orange flashing light) alarm (if any) at the entrance to and in the concerned building
An audible and visual alarm in the control room.
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
The ventilation system shall be stopped and dampers closed.
SO2 detection
SO2 detectors shall be used in sulphur handling units as fire detectors:
SO2 is a product of sulphur combustion. When 3 ppm is reached, each detector shall give:
A general audible alarm in the IES associated with the concerned plant area.
An individual visual alarm (red flashing light) on the concerned matrix panel showing the location of gas detection.
An audible and visual alarm in the control room
An audible and visual alarm in the maintenance workstation
An audible and visual alarm in the fire station.
A common audible alarm and a common visual alarm (red flashing light) in sulphur handling units.
Concentration of SO2 gas shall be measured and displayed over the selectable range of 0-20 ppm.
SO2 detectors shall be provided in sulphur handling units for liquid sulphur pumps, sulphur sump, sulphur plant incinerators, reaction furnaces.
Cl2 Detection
Cl2 Detectors shall be provided to chlorine packages and connected to the Fire & Gas system.
Closed circuit television monitoring systems
A closed circuit television system shall be supplied.
Closed circuit television and monitoring system shall be in accordance with
Manual call / egress gate points
A system of manual call points and egress gate points for initiating a fire alarm shall be provided as part of the plant fire protection system.
Manual call points connected to Fire and Gas system shall be clearly recognized, provided with signs and located as follows:
Along roads in the plant area at intervals not exceeding 50 m, preferable at or near lampposts. Inside the plant and positioned:
At the exit doors of IES
Along logical escape routes
At each exit door of electrical substation
At each exit door of operator shelter
Near sulphur loading bay.
Also manual call points shall be located at the emergency exit point from process areas (usually the normal entrance and exit).
Egress gate points (box containing key for plant fence door) shall be located as follows:
At each egress gate inside plant
When there is a double fence for plant and for sulphur truck road, at each egress gate outside plant and at each egress gate for sulphur truck road.
When operated, manual call points and egress gate points shall give:
A general audible alarm in the building or IES associated with the concerned plant area.
A general audible and visible (red flashing light) alarm in the concerned process plant area.
An individual visible alarm (red flashing light) on the matrix panel.
The operation of the manual call points and egress gate points shall be sent via the data highway to the Fire and Gas Detection System in the fire station and control room, it shall initiate:
An audible and visual alarm in the Control Room,
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
Fire detection
Fire detection in open area
Fusible plug detectors shall be installed on equipment protected by a fixed deluge system. These shall activate the concerned deluge system. The pressure drop in the fusible loop shall be detected by one low-pressure switch (PSL) and the firewater flow rate in the deluge pipe shall be detected by one high-pressure switch (PSH). The PSL shall give:
A visual alarm (red flashing light) on the matrix panel
An Air low-pressure alarm in the control room
An audible and visual alarm in the fire station
An audible and visual alarm in the maintenance workstation
An audible and visual alarm in the concerned process area
The PSH shall give:
A general audible alarm in the concerned IES.
A visual alarm (red flashing light) on the matrix panel.
A High water pressure alarm in the control room
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
A common audible alarm and a common visual alarm (red flashing light) in the concerned process plant area.
A pressure transmitter shall be added on deluge system fusible loops. In case of Low air pressure in the fusible loop, this transmitter shall send a signal to the plant DCS.
Fire detection in the buildings
Optical smoke detectors and heat detectors rate of rise type shall be used.
When executive action is expected, voting is required based on two separated loops with a maximum of 6 detectors per loop in case the system is not addressable. If executive action is not required, only one loop shall be installed with a maximum of 6 detectors per loop in case the system is not addressable.
Heat detectors shall be installed in offices, smoking areas, HVAC rooms of IES and substations, battery rooms of IES and operator shelters.
Smoke detectors ionization type shall be installed in building corridors, WCs, UPS rooms of IES, control room of IES, battery rooms, switchgear room of electrical substation, power generation enclosures and diesel driven engines enclosures. The fire detection by one detector on one loop shall give:
A visual alarm (red flashing light) on the matrix panel in IES associated with the concerned building with the system buzzer.
A general audible alarm in the IES associated
An audible and visual alarm (red flashing light) at the entrance to and in the concerned building
An audible and visual alarm in the control room
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
The fire detection by two detectors on two separate loops shall give the following additional actions:
A general audible alarm in the IES associated
An audible and visual alarm (red flashing light) at the entrance to and in the concerned building
An audible and visual alarm in the control room
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
Stop ventilation system and close fire dampers of the concerned building
Release after an adjustable ‘time delay’ the automatic extinguishing system allocated to the concerned loops (when applicable).
Where there is an executive action, 2 detectors shall be installed per 50 m² (as per BS 7273). Which on separate loops. When installed for alarm only, one detector per 50 m² with a maximum of 6 detectors per loop shall be provided.
The smoke and heat detectors in the enclosed rooms shall be looped separately i.e. to include all the smoke detectors in the ceiling void to be in separate loops, and all the smoke detectors in the floor void to be in another separate loops i.e. not to club detectors at ceiling void and detectors from floor void in the same loop. A remote indicator shall be provided for each detector installed in the ceiling and the floor.
Fire detection for packages
For the flammable gas detection (distribution and installation) for packages refer to “Instruments furnished with packages”
At least two rates of rise heat detectors shall be optimally located in each enclosure compartment of the packages.
When any detector is activated, the following alarm shall be initiated:
A general audible alarm in the IES associated with the concerned plant area.
The signal shall be sent via the data high way to the Fire and Gas Detection system in the fire station and control room; it shall initiate:
An audible and visual alarm in the fire station.
An audible and visual alarm in the maintenance workstation
When two detectors are activated, the following alarms and actions shall in addition be activated:
A common audible alarm and a common visual alarm (red flashing light) in the concerned plant area,
An audible and visual alarm in the Control Room
An audible and visual alarm in the Fire Station
An audible and visual alarm in the maintenance workstation
Shutdown and electrical isolation of the machine,
Stop fuel supply (when applicable) Shut-down of the ventilation system and closure of the fire dampers (when applicable)
Release after an adjustable time delay of the CO2 extinguishing system (30 sec).
Fire detection in Non process buildings
Fire detection philosophy is fitted to installation. For each building, the fire control panel shall be provided.
If necessary, fire detectors shall be relocated or recovered.
One detector obtains executive action or one loop (no voting by two separated loops). The fire detection by one detector or one loop shall give:
An individual visual alarm on the concerned control or matrix panel associated with the concerned building
An audible and visual (red flashing light) alarm (if any) at the entrance and in the
concerned building.
An audible and visual alarm in the main control room
An audible and visual alarm in the in fire station
An audible and visual alarm in the maintenance workstation
The ventilation HVAC system shall be stopped and dampers closed.
Basis For A Fire Protection Water System
Firewater shall be readily available at all the appropriate locations, at the required pressure and flow. Firewater should not be used for any other purpose.
Fire water rate
Fire water rate design criteria
The quantity of water required for fire protection shall be calculated based upon the criteria of section
Firewater ring main system
Firewater ring mains of the required capacity shall be installed to surround all processing units, loading facilities, warehouses, workshops, and utilities. Normally, these units shall also be bounded by service roads. Large areas shall be sub-divided into smaller sections, each enclosed by firewater mains equipped with hydrants and block valves.
The minimum size of fire water main shall be 8”(200 mm)
The firewater mains shall be provided with full bore valve-flushing connections so that all sections and dead ends can be properly flushed out. The flushing connections shall be sized for a fluid velocity in the relevant piping of not less than 80% of the velocity under normal design conditions, but not less than 2 m/s.
Firewater mains shall be installed underground in order to provide a safe and secure system. Depth of cover shall not be less than 1.1 m. A pressure transmitter shall be installed on the main header every 500m and connected to the Plant fire Alarm System.
The firewater mains network pipe sizes shall be calculated using an approved computer program. The complete calculation shall be based on design rates at a minimum pressure of 7 bar g at the take-off points of each appropriate section, and calculations made to prove that pressure drop is acceptable with a blocked section of piping in the network. The firewater ring main pressure shall be such that under fire conditions a pressure of 7 barg exists at the most remote location under the corresponding design flow conditions. The maximum allowable velocity in the system is 3.5 m/s.
Firewater mains - installation and material selection
Piping materials shall conform to Design Specification.
At each main tee, the number of isolation valves shall be the number of branches minus one. Block valves shall be incorporated in the ring main system so that sections can be isolated for maintenance, etc. These sections shall be selected so that the number of consumers is not more than 6. The valves shall be butterfly / gate valves with position indicators. The firewater ring main systems shall be equipped with hydrants, monitors, hose reel stations and deluge valves.
Hydrants
Firewater mains shall be provided with permanent hydrants, located in strategic positions around utilities units / areas. In the process areas, hydrants shall be provided with a top mounted water monitor. Each hydrant shall have an isolation valve in addition to the hydrant valve.
Hydrants shall be as per ones with 4 x 2 1/2 outlets.
Take-off points shall be on the side of the header.
Hydrants connected to buried lines do not require bottom drains.
The spacing between hydrants shall not exceed the following:
Around utility areas 70 m (3 length of hose)
Around process unit, 50 m (2 length of hose)
Hydrants shall be readily accessible from roads and located in such a way that possible damage by road traffic be minimized, provided with a guard post and concrete drainage area. The location shall not be less than 1.5 m from the edge of the road shoulder and at least 12 m from road crossings, sharp road curves, and buildings or other structures.
Monitors
Firewater mains shall be provided with permanent monitors spaced note more than 50 m around processing units. Monitors to be installed on firewater hydrants shall be located at least 15m away from protected equipment to ensure accessibility in case of a fire. Rotation, elevation and nozzle adjustment shall be done manually without gears. When monitors are in use, it shall be possible to leave the monitor unattended operating safely. The monitors shall comply with the following requirements:
Upstream of the mounting flange, each monitor shall be provided with a butterfly valve accessible from grade.
The monitor shall have a capacity of at least 120 m3 / hr at 7 barg. Larger capacity monitors require the Company approval.
Min /max operating pressure to be respectively 6 /16 barg.
The water monitor shall have a 2-½ inch threaded end allowing easy connection of an adjustable nozzle of the constant flow fog to jet stream type.
Monitors shall be of such design that the hydraulic forces (jet reaction), considering pressure surges when opening the upstream block (butterfly) valve, are balanced.
The monitor shall be able to rotate 360 degrees by means of a turret, lockable in any position. Elevation setting shall be from 15 degrees below to 85 degrees above the horizontal i.e. a total 100 degrees.
Rotation and elevation movement lever operable, setting and locking shall be easy. The moving parts shall be fully protected / enclosed against sand and salt spray. Monitors and nozzles shall be of materials and coatings suitable for use with seawater in outdoor weather conditions.
Monitor shall be tested and certified by an independent authority to be approved by the Contractor. The manufacturer shall provide a copy of the certified test report. As a minimum the test report shall include the following data:
Foot print (width x depth), i.e. area where 80% of the total water flow hits the horizontal plane through the raised face of the mounting flange for jet and 30 degrees fog (both at 30 degrees elevation), Throwing distance (trajectory) measured from nozzle exit to center of foot print, Pressure at monitor inlet flange, Flow rate, Diameter of used hose connection, Wind speed and direction,
Angle between wind direction and water trajectory.
Firewater supply
Firewater supply storage shall be a volume equal to 12 hours consumption at maximum main pump flow rate.
The well water being saline shall serve an emergency source only. The complete fire water main system must be flushed with fresh water after being used for emergency purpose.
Firewater pumping facilities
Firewater shall be provided by pumps of the horizontal split case centrifugal type (the number of pumps shall be according the worst case scenario).
Firewater pumps are installed in a location considered to be safe from the effects of fire, clouds of combustible vapour and from collision or crash damage by vehicles.
Firewater pumps shall be electric driven with one diesel driven (backup). Pumps as well as drives shall comply with the requirements of NFPA20 and applicable Design Specifications.
The power of the drives for both main and stand-by units shall be so rated, that it is possible to start the pumps against an open discharge with pressure in the fire-water ring main system under non-fire conditions, normally at 2 to 3 barg.
When the pressure in the firewater ring main system drops below the minimum required static normally approximately 2.7 barg, the first firewater pump shall attempt to start.
Thereafter, at 30 seconds intervals, the next designated available pump shall also attempt to start if the system pressure is less than 10 barg.
Contractor shall define the start-up logic. The automatic starting facilities shall be configured to allow system testing including simulation of alarm activation while the standby system remains operational.
Manual starting of each pump unit shall be possible at the pump, at the control room and at the fire station. Manual stopping of each pump unit shall only be possible at the pump station.
The operation of the main firewater pumps shall actuate an alarm in the control room and fire station panels indicating system pressure.
The system shall be protected from surge and hammering. Hydraulic studies of the system shall be performed to ensure that water hammer does not occur at all expected operating conditions.
Hydraulic calculations shall be performed using approved software to verify that the firewater pumps capacity (flow rate and pressure) is satisfactory to achieve the required flow rate in each area at 7 bars g minimum. (This shall apply for both electrical and diesel driven pumps)
The response time for starting the firewater pumps and for feeding the plant area shall be measured on site for adjustment if necessary.
A ring main surge analysis shall be performed.
The diesel engines of the firewater pump shall meet the requirements of NFPA 20 and the applicable Design Specifications. The following additional requirements shall also apply: The capacity of the diesel storage tank shall be such that the engine can operate on full power for at least 12 hours.
The tank shall be installed at a safe distance from the engine with the bottom at least 0.2 m above the suction valve of the diesel injection pump or as specified by the pump vendor. The tank shall be provided with a sump, an expansion dome, a level gauge and a low level alarm which shall sound when the level of the diesel has reached the ‘2-hour diesel’ remaining level. The tank shall be provided with one connection for refilling directly from diesel distribution network. A clutch shall not be installed between diesel engine and pump. The discharge line from the pump shall be fitted with a check valve, a test valve, a pressure gauge and a block valve with a locking device.
The test line arrangement shall allow testing of either pump while the spare pump remains available for service. The test valves shall have a common return line with a flow-metering unit. Each pump shall be connected separately to a common manifold. The pump discharge manifold shall be connected to the firewater ring main system by a separate pipeline with a block valve of the same size as the ring main. The firewater ring main pressure shall be such that under fire conditions a pressure of 7 barg exists at the most remote location under the corresponding design flow conditions the maximum allowable velocity in the system being 3.5 m / s. Batteries for the diesel pump and the fire pump controllers shall be located in normally air-conditioned areas.
Deluge systems
Hose reels
The hose reel stations for process units shall be designed
The hose reels for buildings shall be designed as the hose reel stations but without the associated foam station as for process units.
Foam Compound Storage
Foam compound Storage is necessary. The Contractor has to determine the suitable quantities and the mode of storage.
Portable and Mobile Fire Fighting Equipment
Portable and mobile equipment, in accordance with the requirements shall be
available at the first line of attack and for the backing-up of fixed fire protection systems.
Hose boxes
Hose boxes shall be installed at every other hydrant or monitor. Each box shall contain 4 fire hoses and 2 water branch pipes.
Fire / Safety point shelters
A weatherproof fire point shelter shall be located near each process and utility unit at non-hazardous area duly equipped with the following:
8 fire hoses in weatherproof cabinet.
2 x 75 kg ABC wheeled dry chemical powder fire extinguishers.
3 spray / jet nozzles.
1 Foam making branch pipe complete with pick-up tubes and probes.
5 Jerry cans each contains 25 liters foam (Fluoro-protein foam FP 70 - AFFF type may be considered as an alternative).
2 Breathing Apparatus sets 30 min in weatherproof boxes.
1 Stretcher.
1 First Aid Box
At chemical handling areas, the fire point shelters shall also be equipped with chemical resistance gears (boots, gloves, face shields and cover-alls)
Fire extinguishers
The extinguishers shall be positioned within process units and along walkways such that the travel
distance between the extinguisher and the possible fire hazard is limited to 15 meters for process units and 30 meters for other areas. For compressor handling flammable gas one extinguisher to be provided within 5 meters of the equipment at each floor level. In buildings fire extinguishers shall be installed in concealed type cabinet combined with hose reel.
Dry chemical powder cartridge type suitable for types A, B and C fires shall be provided in process unit, utilities unit and near transformers. These shall be provided at pumps, compressor handling flammable products and at vessels with a liquid hold up more than 1 m3. These shall be also provided on high-level walkways. Units shall also be provided in buildings.
Wheeled ABC dry chemical powder extinguisher shall be located in fire point shelters only.
CO2 extinguishers shall be used for electric and / or electronic equipment fires such as switchgear houses, substations, instrument equipment shelters, analyzer buildings and laboratory. CO2 extinguishers shall be installed close to electrical and / or electronic equipment with travel distance 6 m maximum. Wheeled Carbon Dioxide extinguishers shall be supplied for substations and boiler areas.
For offices, no water extinguishers shall be provided but only 9 kg dry powder and 5 kg CO2 extinguishers. Water hose reels each containing 11/2”diameter fire hose of maximum length 31 m shall also be installed, connected to the fire water system.
Fire fighting steam
If necessary, utility connections from the low-pressure steam system shall be provided for steam lances with 15 m long electrically earthen hoses. Steam lances should be used to smother small fires caused by leakage from equipment handling flammable products on or above auto-ignition temperature
First aid boxes
One first aid box each shall be installed in each operator shelter, fire point shelter, electrical substation and IES building.
Substations shall be provided with Suitable first aid boxes.
Breathing apparatus
30 min Breathing Apparatus sets shall be located in fluids containing H2S Process, Utility areas, operator shelters, IES, analyzer rooms and SCADA shelter, fire point shelters. Breathing apparatus sets shall be kept inside weatherproof boxes (as per the one). Additional BA (10%) shall be provided in fire station as back up. A breathing air supply for maintenance shall be also provided
Fire blankets
Wall mounted Fire Blankets shall be provided and installed within Process and Utility units at strategic locations.
Fire-fighting vehicles
Fire Fighting vehicles and ambulance shall be provided for new plants as per requirements.
Safety Showers And Eye Washes
Safety Showers and / or Eye Washes shall be provided in chemical handling areas
Fire Training Facility
The fire training facility shall be located with a safety distance of 100 meters from all units.
A branch from the firewater network shall run to the fire training facility. This branch shall be fitted with 2 hydrants and 2 hydrants with top mounted monitors.
Fireproofing
The main objective of fireproofing of steel structures is to prevent the escalation of fires to an unacceptable level providing a temporary protection until full fire-fighting capabilities can be deployed. Judicious application of fireproofing shall delay an eventual collapse of steel structures and allow it to occur gradually depicting visible signs that provide time for isolation of the affected equipment as well as for operating and fire-fighting personnel to evacuate safely. For specific information as to the requirements for fireproofing
Fire Station
Fire station shall be designed as per requirements.
Note: For large processing complexes the addition of satellite or new fire stations shall be considered (based on the minimum response time to the farthest point from the main fire station).
Fire Protection Requirements Per Area
Gas turbines, Emergency generators and compressors enclosures
An automatic CO2 fire suppression system shall be installed to protect the inside of gas turbine,
Emergency generators and flammable gas compressor enclosures for protection against hazardous gas mixtures and fires. Inerting the enclosure by the reduction of oxygen shall suppress and extinguish the fire. The automatic CO2 shall meet the requirements of NFPA 850 and NFPA 12. All equipment shall be UL and / or FM approved or Vendor National approval. CO2 bottles shall be equipped with pressure indicators and with weighing indicator connected to Fire and Gas System. Each system shall comprise a dedicated fire and gas detection and protection system with extensive requirements with respect to detection, visible / audible alarms, logic, delay of agent release, area ventilation etc. The dedicated fire and gas system shall meet the requirements of NFPA 850, 70 and 72.
Gas turbines and compressor sets installed in the open air shall be protected by a fixed-water spray system.
General process areas
Fixed-installed fire-protection and fire-fighting systems Monitors
Fixed-installed, manually adjustable and operated water monitors shall be positioned at strategic points around hazardous areas. For the specification of monitors. Water spray systems or deluge systems, Open automatic water spray systems shall be installed for the protection of the following equipment:
All pumps handling products close to or above their auto-ignition temperature.
Pumps handling C4 and lighter products.
Note:
The pump and a width of 1.5 m around the pump shall be covered by water spray. The water rate directly over the pump shall be approximately 40 dm3 / min / m2 and on the area around the pump 20 dm3 / min / m2.
All compressors handling C4 and lighter products which are not installed in enclosures and cannot be covered by fixed-installed, manually adjustable and operated water monitors. Water rate shall be 40 dm3 / min / m2 of ground surface.
All vessels, columns and exchangers normally holding a liquid volume of C4 and lighter products of more than 5 m3.
Water rate shall be 10.2 dm3 / min / m2 of equipment surface.
Vertical vessels and columns shall be fully sprayed up to a height of approximately 15 m above the potential source of fire, excluding the skirt.
For equipment installed in congested areas where escalation could occur, a spray system shall be provided at the potential source of fire generally pumps with additional protection to cover a resultant spill fire and the facing surface areas of adjacent equipment applying water rates as given above.
Items of equipment containing flammable products which are installed in locations where a chimney effect occurs in the event of a fire or pumps handling flammable products located underneath air-cooled heat exchangers or critical flanged connections. Water rate shall be 20 dm3 /min / m2 of ground surface for pumps and of equipment surface for other items.
Each deluge system shall be fed from two different separated headers and provided with drainage facilities. Deluge valves shall be located at least 15 m away from the protected equipment, protected against radiant heat by a suitable protection wall and against collision by crash barriers painted in fluorescent red and white paint. Each automatic deluge valve system shall be provided with an air reservoir as a back up in case of instrument air failure. It shall be mounted on a skid. Deluge systems spray nozzles shall have blow-off plastic caps.
Flushing facility for deluge valve systems shall be provided to prevent salt deposits accumulation and to prevent system piping corrosion. Deluge system shall initiate the local fire alarm. Deluge system activation shall also give alarms as well as indication at both main control room, fire station and automatically start the main pump. Each deluge valve shall be provided with strainer and bypass connections.
Hose reel station
Hose reel stations shall be provided in process units. Two stations shall be positioned within 23 meters (walking distance) from any point within the production facilities area. Hose reel stations shall be equipped with 31 meter of 1-1/2”, 19 mm internal bore, 500 # non-collapsible rubber hose and adjustable flow, combination straight-stream fog type (all brass) nozzles. Reels shall allow hose to be put into service without unwinding the reel. Manifolding including an eductor shall be provided at each station to permit the use of water only or to allow the introduction of foam from a 115 liters stainless steel foam tank. Hose reel stations shall be protected inside weatherproof closed cabinets.
Portable fire fighting equipment
Steam lances
Low-pressure steam lances with associated utility connections shall be located proximate to pumps, compressors handling flammable products at / above auto-ignition temperatures and in sulphur recovery units.
Buildings
Fire protection systems shall be installed in buildings. The protection of a building is based on fighting the fire from both the inside and from the outside of the building. Firewater shall be available close to and inside some buildings. The type of fire protection systems applied depends on location, equipment to be protected and the particular fire hazard. Equipment replacement and its replacement value shall also be considered when making an assessment for the design of the fire protection systems. The protection and detection shall be normally provided in areas as defined below. Protection for specific buildings shall also be given.
Where relevant, all doors to enclosed spaces shall be provided with an instruction plate which clearly indicates what type of extinguishing agents are installed in the particular space.
Fire protection for building areas
Instrument Equipment Shelter (IES) and Electrical Substations (SS)
CO2 fire extinguishers shall be provided.
IES except HVAC. SS except HVAC.
An automatic Inergen fire suppression system shall be installed for protection against fires.
Inerting the enclosures shall suppress and extinguish the fire. The automatic system shall meet the requirements of NFPA 2001. All equipment shall be UL and / or FM approved or Vendor National approval. Inergen bottles shall be equipped with pressure indicators. All the Inergen system shall be activated directly from the approved control panel PLC and shall not be interfaced with any separate control box.
Where the chances of failures are more important, Inergen activation signal from PLC shall be wired in duplex to reduce the malfunction (i.e. one pair from each PLC). Inergen release to different rooms in IESs shall be distinguished i.e. the Inergen gas shall be released only in the room where fire is detected and not to the whole IESs. Manual mechanical activation of Inergen cylinders shall be provided in case of automatic activation fails. At Inergen release, the pressure calculations shall not exceed the limits to avoid door damage and floor tiles flying. Calculations shall be integrated with HVAC ventilation system design i.e. integrity test shall be carried out and provided to Company for review.
Door switches shall be designed to inhibit overriding each others i.e. action from one switch (manual or auto) shall not be changed from any other switch.
Systems and procedures shall be established to de-energize system when area is occupied.
Lockout system shall be provided to all suppressant systems.
HVAC control panels shall be protected by automatic release CO2 system.
Manual call points shall be provided at each exit door.
Operator shelter
No hose reels shall be installed.
Only 9 kg dry powder portable extinguishers shall be installed.
Chemical shed
Fire protection shall consist of 9 kg dry chemical powder fire extinguishers and hose reel with 31 m hose connected to the fire water supply.
Hydrocarbon-type fire
This specification describes the minimum fireproofing requirements for protection against a hydrocarbon-type fire. The hydrocarbon fire is defined in U.L. 1709. The protection is necessary for vessel skirts and other steel support structures where their sudden collapse due to fire would seriously endanger personnel, lead to the release of large quantities of flammable products and / or toxic materials, lead to consequences beyond the property limit (including environmental damage) or endanger major equipment. In special cases Fireproofing is required for critical control and electric cables.
The fire exposure resistance time shall be of 2 hours when exposed to a hydrocarbon fire as defined in the UL 1709 or in the BS 476 Part 20, Appendix D.
The extent of fireproofing shall be shown on the construction drawings. Fireproofing details shall be in accordance with standard drawings.
The standard fireproofing material is lightweight vermiculite concrete for steel structures and intumscent mastic for critical control and electric cables.
Definitions
Fireproofing Zones
Only specific structures and equipment located within a Fire Proofing Zone (FPZ) shall be fireproofed. A FPZ shall only be applied to a plant or system with a maximum operating inventory of more than 5 metric tons of flammable product. In this context, a “system” is the smallest volume of piping and equipment (including vessels) that can be “blocked in” in the event of a fire. These zones shall be identified early in the detailed engineering phase of the Project
For liquid pool fires, the FPZ is a volume which a cylinder shall have a radius of 9 m from the Potential Source of Leakage (PSL) and a height of 9 m above the Hazard Level (HL).
For liquid or vapour torch fires, the FPZ is a volume with a special shape. The radius of the sphere shall be 9 m.
Sphere / bullet storage shell (up to their connecting flanges and nozzles) containing liquefied gases shall be considered as Fire Potential Equipment.
Structures Supporting Equipment
Steel structures located within a FPZ shall be fireproofed when the supported equipment contains a total of more than 2 metric tons of flammable product or has a total mass (including contents) of more than 10 metric tons or contains toxic material or sudden failure is likely to cause danger to personnel.
Steel structures within a FPZ supporting air coolers shall be fireproofed if the air cooler contains a total of more than 1 metric ton of flammable product or the total mass of the air cooler(s) supported by the structure exceeds 2.5 metric tons (including contents).
Steel columns, beams and any members within the FPZ designed for the purpose of reducing the effective buckling length of the columns shall be fireproofed.
When resistance to mechanical damage is required towards the bottom of a column, the fireproofing shall be made of reinforced concrete erected from grade level up to a minimum 1.8 m height.
Stairways, walkways, and platforms designed mainly for live loads and top surfaces of beams supporting floor plates, gratings or equipment are normally not fireproofed.
In the early stages of design features which shall be considered include:
Comparison of cost and construction time for prefabricated concrete structures versus steel structures and fireproofing.
Fire protection policy and plant availability.
Minimizing the need for bracing in a framework where fireproofing is required.
The weight of fireproofing.
The increased overall dimensions of fireproofed members.
Prefabrication
Measures to protect supporting steel structures from torch fires generating thermal radiation level of 350 KW / m² are in descending order of preference:
A judicious location and orientation of PSL’s relative to supporting steel structures in order to avoid impact of accidentally released product jets and in case of ignition of the resultant jet flame on the structure.
Application of fire shielding either near the PSL or near the surfaces to be protected to deflect the jet or jet flame and thus avoid impact.
If neither of the above is possible or practical, application of the fireproofing as specified.
Steel Pipe Supports
Individual pipe supports and steel structures supporting overhead piping located in an FPZ shall be fireproofed if one or more of the following apply:
The pipe is a flare line or an emergency depressurizing vent line.
The pipe contains toxic material.
The pipe is connected to equipment which would be severely damaged by additional nozzle loading in the event of loss of pipe support.
The pipe runs beneath an air cooler whose steel support structure is fireproofed (including horizontal members).
The pipe carries fire-fighting water and / or other utilities which would reduce the fire-fighting capability in the event of loss of support.
The pipe is an instrument airline or hydraulic control line whose loss would interfere with the ability to shut down the plant.
Spring hangers shall be fireproofed with suitable easy removable covers such as PYTEC fire protection system or equivalent.
Columns of pipe racks and pipe supports shall be fireproofed from HL up to 0.3 m below the lowest horizontal member of the structure.
Diagonal bracing for resisting only lateral forces shall not be fireproofed.
Vessels and Exchangers
The outside of skirts of vertical vessels located within an FPZ shall be fireproofed if the vessel contains a total of more than 2 metric tons of flammable product, the total mass (including contents) being more than 10 metric tons or it contains toxic material. The inside of skirts shall be fireproofed if the diameter is 1.2 meter and above.
Inside and outside fireproofing of vessel skirts shall be in accordance with the reference Standard Drawing
Supports for Insulation and Fireproofing.
Saddles supporting horizontal vessels and exchangers shall not be fireproofed.
If there are flanged pipe connections within the circumference of the skirt of vertical vessels, Fireproofing shall be applied to the inside of the skirt as well.
ESD Valves
Actuators of ESD valves when match “Emergency Shut Down Philosophy”, Protection flow chart shall be fireproofed using flexible covers. Flexible covers shall be installed directly on actuator casing with uniform thickness. The fire protection shall protect the actuators at least 30 minutes assuming a continuous total exposure to fire with a flame temperature of 1100 °C.
Critical Control and Power cabling serving safeguarding systems shall be installed and fire protected against direct radiation and flame impingement.
Codes and Standards
The following latest codes and standards to the extent specified herein shall apply. Alternate standards and codes meeting the requirements of the referenced standards and codes may be used with approval of the Company.
American Welding Society Publication (AWS)
AWS D1.1 Structural Welding Code
Underwriter’s Laboratories, Inc. (UL)
UL 1709 Fire Resistance Rapid Temperature Rise
Occupational Safety And Health Administration (OSHA)
Code of Federal Regulations, Title 29
British Standards
BS 476 Part 20 : 1987 New Appendix D : Hydrocarbon Curve Torch Fire
Decision Flow Chart for Fireproofing of Structures Supporting Equipment
General
The standard fireproofing material is lightweight vermiculite concrete. Alternative proprietary system with proven track record may be used. The extent of fireproofing shall be as indicated on the design drawings. The required thickness of fireproofing material shall be calculated according to the criteria Hp/A and from data derived from fireproofing Manufacturer’s data sheets.
Materials
Light weight vermiculite Concrete shall be used as the fireproofing material. Any proprietary cementitious fireproofing system should incorporate a water repellent and / or seal coat layer to protect the material from staining and / or ingress of detrimental substances. Minimum curing period shall be 7 days.
Material Performances
a. Two hour protection based on testing according to UL 1709, hydrocarbon curve or according to BS 476 (Part20) Appendix D.
b. Shore hardness shall be at least 40.
Installation
All application procedures and materials used shall be in strict accordance to the manufacturer’s published manuals. Any deviations from these established methods shall be submitted to Contractor for approval and Company for review before application on Site.
General Considerations for Application of Materials
a. Surface preparation
Steel work surfaces which are to be fireproofed with lightweight vermiculite concrete shall be prepared and painted in accordance with Specification for Painting.
Where alternative fire proofing materials are proposed, the specification for the surface preparation and painting shall be considered as integral part of this fire protection and details be submitted for approval to Contractor.
b. Fireproofing supports and mesh reinforcement
The Applicator in accordance with the manufacturer’s recommendations, shall submit for approval the detailed procedure for the fireproofing installation to the Contractor prior to commencing work.
Mesh reinforcement shall be plastified & galvanized or be stainless steel type to ensure the durability of the fire protection against environmental corrosion.
c. Top coat
Any seal coat or paint system for application to the external surfaces of the fireproofing materials must be recommended by the manufacturers shall approved by Contractor.
d. Accidental damage
Columns (steel members) which have fire proofing of light weight vermiculite concrete and which are located within 1.5 m of an access way for vehicles and maintenance equipment shall be protected from damage. The type of protection proposed shall be submitted for approval to Contractor.
e. Sealing
At all locations where steelwork emerges from fireproofing, the interface shall be sealed.
Application methods on steel profile
Depending on the sizes of steel profile:
For steel profile up to 200 mm between wings / flanges the “Solid Fill” method shall be used. For Steel Profile above 200 mm between flanges the “Following The Profile” method shall be used.
The boxed configuration is not allowed.
Inspection and testing
Inspection and testing shall be carried out in accordance with the site QA / QC procedures provided by the fireproofing material manufacturer.
The applicator shall ensure that all work is inspected at all stages for quality control in respect of reinforcement strength, coverage, thickness, finish uniformity and application.
The applicator shall ensure that all materials meet the service conditions and design requirements.
Acceptance of applied thickness shall be based upon random measurements, but in no case shall be less than the minimum stated within the fireproofing manufacturer’s application specification and this document.
Repair
Repair of damaged or defective areas shall be accomplished in the same manner as the original coating as specified in this document and the manufacturer’s instructions.
Repair materials and procedures shall be approved by Contractor prior to commencing repair work.
Surface finishing of repaired material shall be identical to the finish of the adjacent original approved application.
Definitions
Employer – Project owner
Safety Task Analysis Risk Reduction Talk (STARRT) - a process that utilises employees to identify and resolve environmental, safety and health related hazards associated with a task prior to its being performed.
Job Hazard Analysis (JHA) - identifies key job steps, tools, equipment, potential environmental, safety and health hazards, hazard control practices, essential personal protection equipment (PPE) for larger, more complex and usually repetitive jobs. It is prepared by a team normally consisting of a representative from the environmental, safety and health department, employee supervisors, and field-engineering representative
Task - a specific activity or subpart of a job (i.e., installing a pipe hanger, building a concrete form or installing electrical power to a fabrication area).
Hazard Control Sheets – A series of risk assessment sheets used for assisting line supervision in developing the STARRT / JHA process.
Responsibilities
Site Manager
Ensure that this procedure is being applied for the control of all activities through Contractor Supervision and Subcontractor Management
Health, Safety and Environment Supervisor / Manager
Is responsible for the development of this procedure and monitoring compliance
Site Manager – (Subcontractor)
Shall ensure that sufficient resources are provided to implement this procedure and that the procedure is understood and applied correctly.
Site Superintendents / Supervision & Subcontractor
Shall be thoroughly familiar with this procedure with their individual responsibilities regarding its implementation and enforcement.
Shall carry out regular inspections (daily) of their work areas to ensure that the requirements under this procedure are being followed.
Instructions
Guidelines for STARRT
Subcontractor Supervision shall ensure employee involvement in the STARRT process by:
Ensuring that all employees under their charge are trained in the STARRT process.
Establishing a system to follow-up with all of their crews to verify the STARRT process is being correctly implemented.
Requiring employees to participate in an individual STARRT review prior to the start of each shift for each new task.
Supervisors shall discuss the hazards relating to the project / facility with the employees to compile information necessary to complete the STARRT card
Upon completion of the STARRT card supervisors shall review the requirements of the card with the employees performing the work and the supervisor should sign the card.
The Card shall be translated into the common spoken language and displayed for review in the immediate work area.
STARRT cards are to be returned to the supervisor and forwarded to the Subcontractor Safety Supervisor’s office as appropriate at the end of each shift or completion of the work task. The supervisor is responsible for ensuring that cards are properly completed, signed and returned.
STARRT cards should be reviewed for proper usage / completion by the Health, Safety and Environmental Supervisor and maintained on file in the subcontractor HS&E Office.
Guidelines for Job Hazard Analysis (JHA)
The JHA may be included as part of a work plan or work package and the requirements of the JHA be incorporated into hazardous work permits (HWP) as well as project / facility specific HSE plans as appropriate.
A JHA of specific jobs or operations is required for but not limited to the following:
High risk jobs
New jobs or tasks that present unspecified or unknown hazards.
Jobs or tasks involving new equipment, machinery or procedures.
Major job categories that shall be repeated frequently.
Jobs or tasks that have historically experienced a repeated or significant rate of accidents, injuries, exposures or near misses.
Jobs involving environmental remediation of hazardous waste.
Jobs or tasks that in the professional judgment of the responsible HSE Representative require a formal JHA.
Jobs or tasks are broken down into a series of successive steps or activities. Required or anticipated tools and equipment for each step or activity are to be included. All potential hazards within each step or activity are identified.
Include the following hazard categories in the JHA:
Chemical exposures / Oxygen deficiency / Exposures to ionizing and non-ionizing / radiation / Electrical hazards / Physical hazards / Fire and explosion / Temperature extremes / Excessive noise / Biological hazards
Input should be solicited from multi-disciplinary professional staff for hazard evaluation. This input should include safety, industrial hygiene, health physics, and engineering personnel.
After all known suspected or potential hazards have been identified and accident experience reviewed, a plan must be developed with solutions to eliminate or control hazards.
The elimination or control of the hazard should be implemented first by engineering methods, then by administrative methods and as a last resort, by the proper use of Personal Protection Equipment (PPE).
Guidelines For Using the Hazard Control Sheets
The Hazard Control Sheet applicable to a work activity shall be used as a reference on developing a STARRT card or a specific Job Hazard Analysis.
In circumstances where a STARRT card or JHA are not deemed necessary then the Hazard Control sheet may be used as a guideline for conducting a task team talk by supervision to their employees.
References
BS HSE Procedures / Attachments / STARRT Card
Job Hazard Analysis and Control Program Sheets
Safety Task Analysis Risk Reduction Talk (STARRT) Card
Notation:- Y-Yes, N-No, Na-Not Applicable
|Supervisor: | |
| | |
|Date: | |
| | |
|Job Description: | |
| | |
|Primary Hazards Risks: | |
| | |
|Location: | |
| | |
|Electrical |Y |N |Na |
|Locked & Tagged | | | |
|Try & Test | | | |
|Disconnected | | | |
|Excavation | | | |
|Shored / Battered | | | |
|Ladder Provided | | | |
|Daily Inspection | | | |
|Entry Permit | | | |
|Hazards (Body) | | | |
|Fall Potential | | | |
|Pinch Points | | | |
|Electrical Shock | | | |
|Housekeeping | | | |
|Slip -Trip | | | |
|Flying Particles | | | |
|Thermal Burns | | | |
|Manual Lifting | | | |
|Sharp Object | | | |
|Permits | | | |
|Hot Work | | | |
|Confined Space | | | |
|Breaking Process | | | |
|Excavation | | | |
|Critical Lift Plan | | | |
|Personnel Basket | | | |
|Emergency Equipment | | | |
|Fire Extinguisher | | | |
|Safety Shower | | | |
|Eyewash | | | |
|Permit Displayed | | | |
|All Conditions Met | | | |
|Evacuation | | | |
|Assembly Area | | | |
|Hazards (Environmental) | | | |
|Airborne Particles | | | |
|Vapours | | | |
|Hot / Cold Surfaces | | | |
|Hot / Cold Materials | | | |
|Noise | | | |
|Heat Stress | | | |
|Proper Equipment | | | |
|Man Lift | | | |
|Personal Basket | | | |
|Forklift | | | |
|Jlg Lift | | | |
|Crane | | | |
|Chainfall | | | |
|Hand Tools | | | |
|Poared Tools | | | |
|Good Conditions | | | |
|Operator Certificate | | | |
|Proper Rigging | | | |
|Current Inspection | | | |
|Trucks, Tractors, Etc | | | |
|Overhead Work Or | | | |
|Floor Opening | | | |
|Fixed Barricades | | | |
|(Tape) Danger | | | |
|(Tape) Caution | | | |
|Barriers | | | |
|Signs | | | |
|Hole Cover / Cleat | | | |
|Handrails / Toe board | | | |
|Process Equipment | | | |
|Valves Locked | | | |
|Tags Hung | | | |
|Blinds Installed And Tagged | | | |
|Proofed | | | |
|Standby Person | | | |
|Confined Space | | | |
|Fire Watch | | | |
|Sandblast Person | | | |
|Traffic Watch | | | |
|Welding | | | |
|Shields | | | |
|Fire Blanket | | | |
|Fire Extinguisher | | | |
|Cylinders Secured | | | |
|Combustibles | | | |
|Moved Sparks | | | |
|Sparks Contained | | | |
|Hazards (Chemical) | | | |
|Msds’s Reviewed | | | |
|Chemical Burn | | | |
|Skin / Eye Irritant | | | |
|Inhalation | | | |
|Personal Protective Equipment | | | |
|Work Gloves | | | |
|Chemical Gloves | | | |
|Anti vibration Gloves | | | |
|Wet Suits | | | |
|Foot Guards | | | |
|Rubber Boots | | | |
|Mono Goggles | | | |
|Face Shield | | | |
|Fresh Air | | | |
|Ear Protection | | | |
|Safety Harness | | | |
|Burning Goggles | | | |
|Hard Hat | | | |
|Safety Glasses | | | |
|Respirator | | | |
|Other | | | |
| | | | |
| |Print Employee Name | |Employee Signature |
Supervisor Name (print) Supervisors signature
Job Hazard Analysis (Jha) And Control Program Sheets.
Job Hazard Analysis
|Description: |Location: | |Page of |
| | | | | | |
|Key Job Steps |Potential Injury |Tools Or Equipment Used |Engineering Safe Practices, Equipment, Ppe, Etc. |
| |Or Health Effect | | |
| | | | |
| | | | |
|Responsible Supervisor: | |Safety & Health Representative: | |
|Date: | |Date: | |
ATTACHMENT 7.2
Hazard Analysis and Control Programme Sheets
|001 |Civil Works |Evacuation |
|002 |Civil Works |Concreting and Shuttering |
|003 |General |Transportation of Gas Cylinders |
|004 |General |Gas Cutting |
|005 |General |Grinding |
|006 |General |Welding |
|007 |General |Diesel Engines |
|008 |Mechanical Installation |Radiography |
|009 |Mechanical / Commissioning |Pressure Testing |
|010 |Electrical Installation |Cable Drum Handling |
|011 |Electrical Installation |Cable Pulling |
|012 |Electrical Installation |Cable Laying / Cable Termination |
|013 |General |Material Handling |
|014 |General |Handling of Steel |
|015 |General |Handling of Timber |
|016 |Civil |Concrete Pours |
|017 |Civil |Steel Fixing |
|018 |Civil |Backfilling of Excavations |
|019 |Mechanical Installation |Transportation / Lifting of Heavy Equipment |
|020 |Temporary Works |Erection of Scaffolding |
|021 |Temporary Works |Provision & Maintenance of Safe Scaffolding |
|022 |Temporary Works |Dismantling of Scaffolding |
|023 |General |Use of Hazardous Substances |
|024 |Civil Works |Erection of Fencing |
|025 |Civil Works |Fabrication of Gates |
|026 |Civil Works |Erection of Gates |
|027 |General |Removal of Waste Material |
|028 |Mechanical |Erection of Steel Work |
|029 |Mechanical |Installation of pipeline and Valve Fittings |
|030 |Electrical |Electrical Work |
|031 |Civil Works |Rock Drilling |
|032 |Civil Works |Rock Blasting |
|033 |Site Preparation |Earthworks |
|034 |General |Site Transport |
Hazard Analysis and Control Programme
Civil Works
REF No:- ...A - 001.......................................
|Activity |
|Excavation |
|Hazards |
|Cables / pipelines buried underground. |
|Existing Structures / Buildings. |
|Existing pipes being struck or cracking at joints. |
|Vehicles / Plant driving into excavation. |
|Personnel falling into excavation. |
|Collapse of excavation. |
|Accumulation of Gas / Water. |
|Control Measures |
|Cable avoidance tool to be used prior to excavating in order to determine cable routes. |
|Services drawings to be used to determine cable / pipeline route. |
|Trial hand digging to be undertaken in order to verify cable / pipeline route. |
|Detailed study to be undertaken if excavation work is to be carried out adjacent to existing and / or temporary foundations / buildings. |
|Temporary shoring or supporting of structures in order to prevent collapse to be approved and completed prior to commencement of |
|excavation. |
|Pipe-work / Cables exposed by excavation to be supported. |
|Stops / Barriers to be provided where necessary at excavation edges in order to prevent vehicles driving into them. |
|Banks-men to be provided whenever vehicles are working adjacent to excavations. |
|Guardrails to be erected around excavations where risk of falling 2 meters or more. |
|Excavations deeper than 1.1 meter to be adequately opened, benched or supported. |
|Adequate means of access / egress into excavations to be provided. |
Hazard Analysis and Control Programme
Civil Works
REF No:- ...A - 002.......................................
|Activity |
|Concreting And Shuttering |
|Hazards |
|Unsafe means of access onto shuttering. |
|Manual and mechanical handling. |
|Handling and use of cement / concrete. |
|Use of hand tools / power tools. |
|Control Measures |
|Access for personnel to carry out work on shuttering to be planned. Safe means of access to be provided at all times in order to prevent|
|risk of falls from height. |
| |
|Suitable and sufficient craneage to be provided in order to alleviate manual handling of shuttering and associated components. Manual |
|handling procedure to be developed and implemented. |
| |
|Handling to be controlled by experienced slingers where necessary. |
|Banks-men consideration of high wind conditions and associated risks to be recognized. |
| |
|Personnel to be provided with appropriate P.P.E during work with cement / concrete - gloves, rubber safety footwear, R.P.E, hearing |
|protection etc. Training to be given on hazards associated with work with cement / concrete. |
| |
|Hand and power tools to be properly maintained. Defective tools shall not be used. |
| |
|Dangerous moving parts of machinery to be guarded. |
| |
|NOTE: Wash out area for concrete trucks to be identified to prevent build up of waste concrete. |
Hazard Analysis and Control Programme
General
REF No:- ...A - 003.......................................
|Activity |
|Transportation Of Gas Cylinders |
|Hazards |
|Fire / Explosion during transportation. |
|Manual handling and health risk. |
| Control Measures |
|1) Cylinders to be supported during transportation in order to prevent them falling over. |
| |
|2) Cylinders to be segregated by type in order to prevent fire / explosion risk. |
| |
|3) Valve caps to be fitted to all gas cylinders during transportation. |
| |
|4) Loading / Off-Loading of cylinders to be carried out by competent person utilizing correct slinging techniques. |
| |
|5) Cylinders being off-loaded from a vehicle should not be dropped to the ground and shall not be rolled. |
Hazard Analysis And Control Programme
General
REF No:- ...A - 004.......................................
|Activity |
|Gas Cutting |
|Hazards |
|Cylinder explosion. |
|Damage to eyes. |
|Fire. |
|Explosion risk - Live plant. |
|Control Measures |
|Oxygen cylinders valves / fittings to be kept free from grease / oil. |
| |
|Flashback arrestors to be fitted to gas cylinders. |
| |
|Gas hoses and gauges to be maintained in a safe condition and inspected daily. Defective hoses and gauges are to be replaced |
|immediately. |
| |
|Cylinders to be used in the vertical position and secured against falling. |
| |
|Personnel carrying out gas cutting operations shall wear suitable eye protection. |
| |
|Suitable measures e.g. Provision of fire blankets / fire watchers shall be taken to prevent the risk of fire during cutting operations. |
| |
|Prior to gas cutting operations in Life plant areas, gas checking shall be carried out and work shall proceed in accordance with permit |
|to work requirements. |
Hazard Analysis And Control Programme
General
REF No:- ...A - 005......................................
| |
|Activity |
|Grinding |
| |
|Hazards |
|Damage to eyes / hearing / other body parts. |
|Fire / Explosion. |
|Wheel burst. |
| |
| |
|Control Measures |
|1) Grinders to be maintained in good condition and inspected prior to use. |
| |
|2) Guards to be fitted to grinders. |
| |
|3) Changing of abrasive wheels to be carried out by trained and authorized personnel using proper disc spanners. |
| |
|4) Personnel carrying out grinding work shall wear suitable eye protection and hearing protection. |
| |
|5) Grinding operations in Live plant areas shall be carried out in accordance with the permit to work requirements. |
| |
|6) Grinding operations shall be controlled in order to prevent the risk of injury to other personnel from sparks / metal splinters. |
| |
|Housekeeping in the areas at grinding operations to be maintained to a high level. |
Hazard Analysis And Control Programme
General
REF No:- ...A - 006......................................
| |
|Activity |
|Welding |
| |
|Hazards |
|Damage to body parts. |
|Fire / Explosion. |
|Electrocution. |
|Health impairment. |
| |
|Control Measures |
|Welders shall be provided with and wear the following personal protective equipment:- |
|Welding gloves |
|Overalls |
|Welding goggles with correct filter |
|R.P.E (where identified) |
|Flammable materials shall be removed from areas where welding is to be undertaken. |
|If (2) is not practicable, other suitable precautions shall be taken to alleviate fire and explosion risk e.g. Provision of fire blankets|
|/ fire watcher. |
|Fire extinguisher to be immediately available in the area of any welding operation. |
|Before welding operations are carried out, the materials involved and their by-products shall be identified, the risks assessed and |
|necessary control measures identified in order to prevent possible respiratory disease / systemic poisoning (e.g. cadmium, stainless, |
|galvanized, lead coated materials). |
|Welding cables and cable joints shall be maintained in a good condition. |
|Welding returns should be firmly connected to the metal on which welding is taking place. This to be carried out by means of well |
|constructed earthing clamps only. |
|In order to prevent risk of Arc Eye injury to other personnel, suitable screens to be placed around the welders working area. |
|Damp, humid and wet conditions shall be a consideration for the voltage and type of transformer used. |
Hazard Analysis And Control Programme
General
REF No:- ...A - 007.......................................
|Activity |
|Diesel Engines (Process Areas) |
|Hazards |
|Engine exhaust fires. |
|Over-speeding of the engine in live plant areas. |
|Control Measures |
|Spark arrestors to be fitted to diesel engine exhausts. |
|Chelwyn valves shall also be fitted where needed |
Hazard Analysis And Control Programme
Mechanical Installation
REF No:- ...A - 008.......................................
|Activity |
|Radiography |
|Hazards |
|Exposure to radiation. |
|Control Measures |
|Site radiography shall only be carried out by competent and experienced radiographers |
|Site radiography to be carried out in accordance with the procedure for site radiography set out in Employer HSE Manual. |
|Local working rules shall be submitted by the N.D.T. contractor prior to work |
|Emergency equipment e.g. local shielding, sand bags, tongs to be provided on site. |
|Warning signs / barriers / flashing lights / alarms to be provided. |
|Radiation meters to be calibrated and certification |
|Contractors, adjacent working and security to be notified in advance. |
Hazard Analysis And Control Programme
Mechanical / Commissioning
REF No:- ...A - 009.......................................
|Activity |
|Pressure Testing |
|Hazards |
|Bursting of blinds / pipes / fittings under pressure testing. |
|Control Measures |
|Pressure testing of piping shall only be carried out by competent and experienced personnel |
|The pipe-work under test and the surrounding area to be barricaded / cordoned off and suitable warning signs to be displayed. |
|Personnel shall be instructed not to enter areas where pressure testing is being undertaken. |
|A written procedure for gradual pressurization to be developed. |
|All fittings e.g. sight glasses, gauges, bursting discs likely to fail under test pressure to be removed. |
Hazard Analysis And Control Programme
Electrical Installation
REF No:- ...A - 010.......................................
|Activity |
|Cable Drum |
|Handling |
|Hazards |
|Cable drum falling. |
|Trapping injuries. |
|Control Measures |
|Damaged cable drums not to be used. |
|Vehicles to be sited with regard to site traffic and area for offloading to be barricaded off. |
|Cable drums to be loaded / off-loaded using slings of an adequate safe working load. This operation is to be carried out by |
|experienced and competent personnel. |
|Cable jacks to be placed on even surfaces. |
|Cable drums shall be located on cable jacks designed for purpose and of a suitable capacity and base. |
|Protruding nails on cable drums to be removed / bent over. |
|Cable drums to be checked when stored. |
Hazard Analysis And Control Programme
Electrical Installation
REF No:- ...A - 011......................................
|Activity |
|Cable Pulling |
|Hazards |
|Cable drum falling. |
|Trapping injuries. |
|Manual handling - back injuries. |
|Control Measures |
|Personnel to wear suitable gloves / footwear when cable pulling. |
|Cable jacks to be of a sufficient capacity and placed on an even surface. |
|Personnel shall be instructed in cable pulling techniques, including the requirement for ensuring good manual handling techniques are |
|adopted. |
|Assessment of the weight of cable to be pulled and numbers of persons required to be defined. |
Hazard Analysis And Control Programme
Electrical Installation
REF No:- ...A - 012.......................................
|Activity |
|Cable Laying / Cable Termination |
|Hazards |
|Cable drum falling. |
|Trapping injuries. |
|Manual handling - back injuries. |
|Control Measures |
|Personnel to wear suitable gloves / footwear when cable laying / terminating cables. |
|Cable jacks to be of a sufficient capacity and placed on an even surface. |
|Warning signs to be positioned adjacent to cable laying / cable termination areas. |
|Personnel shall be trained in cable laying / cable termination techniques including the requirements for ensuring good manual handling |
|techniques are adopted. |
|Cable terminations shall be carried out by trained and competent personnel using suitable tools |
|Permit to work system to be followed to ensure that glanding and termination of cables are on electrically isolated panels. |
Hazard Analysis And Control Programme
General
REF No:- ...A - 013.......................................
|Activity |
|Material Handling |
|Hazards |
|Manual handling - back injuries |
|Control Measures |
|Whenever practicable, mechanical lifting aids e.g. cranes, forklift trucks etc., shall be used to alleviate the requirement for manual |
|handling. |
|Supervision shall assess weight, center of gravity etc. and determine the number of persons required to carry out the work safely. |
|Personnel should be trained in manual handling techniques. |
|Gloves, Safety footwear and goggles to be worn by personnel engaged in material handling. |
|Good housekeeping measures shall be enforced in order to prevent slips, trips and falls during material handling. |
|Material shall be stored in designated areas. |
Hazard Analysis And Control Programme
General
REF No:- ...A - 014.......................................
|Activity |
|Handling Of Steel |
|Hazards |
|Trapping injuries. |
|Falling material. |
|Manual handling. |
|Slips, trips and falls. |
|Control Measures |
|Personnel to wear suitable gloves / footwear and goggles when handling steel. |
|Personnel to be trained in slinging and banks-man techniques in order to ensure the materials are lifted in a safe manner. |
|Suitable equipment is to be used to lift the steelwork. |
|Steel shall be stored in a designated area on wooden skids / sleepers. |
|Good housekeeping standards shall be maintained in steel lay-down areas in order to prevent slips, trips and falls. |
|Tug lines should be used when lifting / traveling materials by cranes. |
|Personnel not involved in any steel handling operation to be kept clean of the area of work. |
Hazard Analysis And Control Programme
General
REF No:- ...A - 015.......................................
|Activity |
|Handling Of Timber |
|Hazards |
|Trapping injury |
|Slip, Trip and Fall |
|Hand injury |
|Control Measures |
|Personnel to wear suitable gloves / footwear when handling timber products. |
|Timber to be de-nailed in order to prevent puncture wounds. |
|Timber shall be stored in designated areas away from offices and other buildings. |
|Good standards of housekeeping shall be maintained in order to prevent slips, trips and falls. |
|Swarm wood chips and sawdust must be removed in a timely manner to prevent accumulation of a fire hazard. |
|Circular saws to be fitted with riving knives and guards. |
|Push sticks to be used for the cutting of timber by circular saws. |
|Personnel shall be instructed on the safe operation of mechanical equipment. |
Hazard Analysis And Control Programme
Civils
REF No:- ...A - 016......................................
|Activity |
|Concrete Pours |
|Hazards |
|Manual handling. |
|Defective plant / equipment. |
|Falling materials. |
|Control Measures |
|Personnel placing concrete shall wear suitable gloves / footwear and eye protection. |
|Plant and equipment used during concrete placing to be operated by trained and authorized personnel under close supervision |
|All plant and equipment shall carry current certification and be maintained in a safe condition. Defective plant / equipment to be |
|removed from service and effective remedial actions taken. |
|Slinging and lifting operations to be carried out by trained personnel |
|Unauthorized personnel must be prohibited from entering areas where concrete placing activities are being undertaken. |
|Access across re-bar fixing shall be maintained with timber boarding to provide a safe access and place of work. |
Hazard Analysis And Control Programme
Civil Works
REF No:- ...A - 017.......................................
| |
|Activity |
|Steel Fixing |
|Hazards |
|Falling material |
|Slip, Trip and Fall |
|Manual Handling. |
|Cut injuries. |
| |
|Control Measures |
|Experienced and trained steel fixers shall be used with adequate supervision provided. |
|Steel fixers should wear suitable gloves / footwear and eye protection. |
|Re-Bar shall be lifted into the work area using certificated lifting equipment and tackle. |
|Re-Bar off-cuts / wire to be removed in order to prevent slips, trips and falls. |
|Steel fixers to use proper tools in order to assist in bar bending (type activities). |
|Tool box talks shall be conducted emphasizing the hazards of bar bending (pinch points) and handling steel re-bar (sharp edges) |
|Exposed vertical bars e.g. pile CAPs that are sited in a manner that expose personnel to risk shall be bent, covered or protected by some|
|other means. |
Hazard Analysis And Control Programme
Civil Work
REF No:- ...A - 018......................................
| |
|Activity |
|Backfilling Of Excavations |
|Hazards |
|Collapse of excavation. |
|Physical injury due to proximity of plant. |
|Control Measures |
|Only approved mechanical shovels / JCB are to be used to carry out this work. |
|Plant used to backfill excavations should carry current certification and maintained in a safe condition. |
|The plant shall be operated by trained and authorized personnel |
|Banks-men shall be used to control the backfilling operation in order to prevent plant working too close to the excavation edge. |
|Unauthorized personnel should be excluded from areas where the backfilling of excavations is taking place. |
|A survey of the area to be carried out, to assess risks to any adjacent structures and/or utilities that may exist. Operators to be |
|briefed on any identified potential hazards. |
Hazard Analysis And Control Programme
Mechanical Installation
REF No:- ...A - 019.......................................
| |
|Activity |
|Transportation / Lifting Of Heavy Equipment |
| |
|Hazards |
| |
|Defective equipment. |
|Overloading of vehicles. |
| |
|Control Measures |
|Plant / Equipment used shall be maintained in a good condition. |
|Licensed and experienced operators shall be used to carry out this activity. |
|The loading of equipment to be carried out in accordance with company approval. |
|Loading shall be closely supervised in attendance of trained banks-men. |
|Rigging/Crane studies shall be undertaken (if required) to ensure the lifting operation is carried out in a controlled and effective |
|manner utilizing any existing lifting points provided. |
|The weight of any such load shall be determined to ensure that overloading is prevented. |
|Banks-men shall wear reflecting vests or jackets or other means of personal identification |
Hazard Analysis And Control Programme
Temporary Works
REF No:- ...A - 020......................................
| |
|Activity |
|Erection Of Scaffolding |
|Hazards |
|Scaffolders fall from height. |
|Scaffolders / Other personnel injured by falling materials. |
|Control Measures |
|Scaffold erection to be undertaken by trained scaffolders working under competent supervision. |
|Safe means of access/egress to be provided and maintained for the scaffolders carrying out the erection work. |
|Suitable and sufficient material shall be available in order for the scaffold to be erected properly. |
|Scaffolders to wear gloves, safety footwear, safety helmets and safety harnesses during scaffold erection activities. |
|Scaffold components to be lifted using safe techniques. (Components should neither be thrown up to the scaffolder nor to the ground). |
|Unauthorized personnel to be excluded from the area where scaffold erection is being carried out. |
|Scaffolds and access ladders to be tagged as ‘Safe to use’ by a competent person on completion, prior to use |
Hazard Analysis And Control Programme
Temporary Works
REF No:- ...A - 021......................................
| |
|Activity |
|Provision And Maintenance Of Safe Scaffolding |
| |
|Hazards |
|Collapse of scaffold |
|Personnel falling from scaffolding. |
|Control Measures |
|Detailed consideration shall be given to all scaffolding to ensure that it is properly planned and erected to meet the working |
|requirements, designed to carry the necessary loading and maintained in a sound condition (B.S. 5973 shall be followed as guidance). |
|Scaffolding shall be provided with adequate ties / supports in order to prevent collapse. |
|Scaffolding shall be inspected and tagged prior to use |
|Regular inspections of scaffolding shall be undertaken and recorded in order to ensure that the structure is maintained in a safe |
|condition. |
|Personnel working from scaffolds shall be instructed not to interfere or alter an existing scaffold. |
|Effective actions to be taken by supervision in order to ensure that scaffolding defects are rectified immediately e.g. guard-rails |
|replaced, toe-boards replaced etc. |
|Only authorized scaffolders shall be allowed to alter the scaffolding in any way. Supervision shall liaise with scaffolders in order to |
|ensure that the co-ordination of scaffolding maintenance. |
|Incomplete scaffolding to be clearly identified and personnel should be prohibited from using such structures. |
Hazard Analysis And Control Programme
Temporary Works
REF No:- ...A - 022.......................................
| |
|Activity |
|Dismantling Of Scaffolding |
|Hazards |
|Fall off scaffold material, during dismantling. |
|Fall off scaffolders / other personnel during dismantling. |
|Control Measures |
|Dismantling of scaffolding to be carried out by trained and competent scaffolders under supervision. |
|An assessment (by the supervisor in charge) of the best method of dismantling the scaffold shall take place that reduces overall risks, |
|risk at falling material and maintenance of the stability of the structure. |
|No ties or bracing shall be removed in advance of general dismantling. |
|Working platforms shall be dusted and cleared of all materials and debris before dismantling commences. |
|All possible access to the dismantled sections of scaffolding should be barred and a warning sign displayed. |
|Scaffold materials shall be loared carefully. The ‘bombing’ of scaffold materials shall be strictly prohibited. |
|Surplus boards and fittings shall be removed from the platforms as the work progresses and at the end of each day. |
|Tubes and fittings shall be stacked at ground level unless the first lift has been designed to support the extra loading. |
| |
|Unauthorized personnel shall be excluded from areas where the dismantling of scaffolding is taking place. |
Hazard Analysis And Control Programme
General
REF No:- ...A - 023.......................................
|Activity |
|Use Of Hazardous Substances |
|Hazards |
|Health impairment. |
|Fire/explosion. |
|Environmental impact. |
|Control Measures |
|Assessments on the hazards and risks to health by potentially harmful substances shall be carried out. These assessments shall detail |
|the control measures that should be taken to reduce risks to health. |
|Material safety data sheets (MSDS) and assessments of the risk and necessary control measures to be put in place prior to the work being |
|carried out. |
|Personnel shall be instructed to take appropriate precautions to protect their health from the hazards. Training to be given in the |
|correct use and maintenance of personal protective equipment. |
|Hazardous substances shall be stored in a safe manner. Materials shall be segregated in accordance with good practice e.g. keeping |
|oxidizing and reducing agents apart. |
|Contingency arrangements should be in place to prevent the spillage of any hazardous substance to the ground. |
Hazard Analysis And Control Programme
Civil Works
REF No:- ....A - 024....................................
|Activity |
|Erection Of Fencing |
|Hazards |
|Fall of material. |
|Manual handling. |
|Slip, trip and fall. |
|Control Measures |
|Erection of fencing to be carried out by personnel who have been briefed in the correct method of work. |
|Good housekeeping standards shall be maintained during the work. |
|The correct tools shall be used during the stretching of mesh. |
|Posts shall be lifted with mechanical assistance in order to alleviate manual handling. |
|Personnel to wear gloves, safety footwear and safety helmets during the work. |
|Training shall be given on the hazards associated with work with cement/concrete. |
|Permit(s) to work shall be required when working adjacent to overhead lines, underground utilities etc. |
Hazard Analysis And Control Programme
Civil Works
REF No:- ......A - 025.......
|Activity |
|Fabrication Of Gates |
|Hazards |
|Falling materials. |
|Fire and explosion. |
|Damage to body parts. |
|Electric shock. |
|Control Measures |
|Gate fabrication to be carried out by personnel who have been familiarized with the requirement for safe working practices. |
|Personnel to wear gloves, safety footwear and welding goggles with the correct filter during this work. |
|Welding shall be carried out in dry conditions and in accordance with the requirements of the Hazard Analysis and Control Procedure 006. |
|Gas cutting to be carried out in accordance with the requirements of the Hazard Analysis and Control Sheet 004. |
|Good standards of housekeeping shall be maintained in the fabrication area. |
|Fire extinguishers shall be provided. |
|Oxy/Acetylene sets to be sited in an adjacent location with valve keys fitted and secured upright and flash back arrestors fitted. |
Hazard Analysis And Control Programme
Civil Works
REF No:- .........A - 026................................
|Activity |
|Erection Of Gates |
|Hazards |
|Fall of gate. |
|Damage to body parts. |
|Manual handling. |
|Control Measures |
|Gate erection to be carried out by trained personnel under supervision. |
|Personnel to wear gloves, safety footwear and safety helmets. |
|Sharp edges on the gates to be removed by grinding prior to erection. |
|The lifting of gates into position shall be undertaken using suitable lifting tackle and equipment. |
Hazard Analysis And Control Programme
General
REF No:- .........A - 027.......
|Activity |
|Removal Of Waste Material |
|Hazards |
|Manual handling |
|Damage to body parts |
|Occupational health problems |
|Control Measures |
|Personnel engaged in the removal of waste material shall wear gloves, safety footwear and safety helmets. |
| |
|Light waste to be swept up and removed in a wheelbarrow. |
|Heavier waste e.g. steel off-cuts, drums etc. should be removed using mechanical plant e.g. fork lift truck, excavator etc. |
|Waste material shall be stored in designated areas in skips. |
|Waste material classified as hazardous shall be removed by a contractor classed as competent for the task |
|Hazard sheet shall be followed for the handling of any hazardous waste. |
Hazard Analysis And Control Programme
Mechanical
REF No:- ......A - 028..................................
|Activity |
|Erection Of Steelwork |
|Hazards |
|Falls from height. |
|Structural stability. |
|Manual handling. |
|Falling materials. |
|Trapping injuries. |
|Slips, trips and falls. |
|Control Measures |
|Steel erection shall be carried out by trained and competent personnel working under supervision |
|Method statements detailing the proposed erection schemes shall be produced. These method statements shall identify hazardous site |
|features and other aspects likely to impair safe erection. The proposed methods for ensuring the stability of the framework and its |
|components during erection and until completion shall also be addressed. |
|Steelwork shall be lifted into position using suitable certified lifting tackle/equipment. |
|Trained banks-men/slingers shall be used to control the lifting operations. |
|Personnel should wear gloves, safety footwear and safety helmets. Safety harnesses to be worn and attached to a secure anchor point when|
|erection work is being undertaken. |
|Safe means of access onto steelwork to be provided and maintained. |
|Good housekeeping standards shall be maintained in areas where equipment erection is being undertaken. |
|The area of the site affected by erection operations shall be designated as a restricted area:- barriers and notices to be erected to |
|prohibit entry to non-erection personnel. |
Hazard Analysis And Control Programme
Mechanical
REF No:- .....A - 029..........
|Activity |
|Installation Of Pipeline And Valve Fittings |
|Hazards |
|Manual handling. |
|Trapping. |
|Slip, trip and fall. |
|CONTROL MEASURES |
|Installation shall be carried out by trained and competent personnel working under supervision |
|Heavy fittings shall be lifted using suitable certificated lifting tackle / equipment and tug lines. |
|Personnel should wear gloves, safety footwear and safety helmets. |
|Suitable tools should be used to assist in the installation of fittings. |
|Good housekeeping standards shall be maintained in areas where installation work is being undertaken. |
|Pipelines shall only be installed on structures, which have been mechanically complete or are safe to work from. |
|Rigging studies shall be prepared for spool pieces/valves etc. Being placed inside structures of limited access. |
Hazard Analysis And Control Programme
Electrical
REF No:- ................A - 030..........................
|Activity |
|Electrical Work |
|Hazards |
|Fall from height. |
|Electric shock. |
|Fire and explosion. |
|Control Measures |
|Electrical work shall be carried out by trained and competent electrician, these persons should have the technical knowledge and |
|experience to understand the hazards, which may arise during the work and the precautions which need to be taken. |
|Work on live conductors, or on electrical equipment, which has been made dead shall be carried out only under an appropriate permit to |
|work procedure. |
|Safe means of access to be provided for electricians required to work at height (e.g.) ladders, scaffold towers … etc. |
|Insulated tools should be used in order to carry out electrical work. |
Hazard Analysis And Control Programme
Civil Works
REF No:- .............A - 031.............................
|Activity |
|Rock Drilling |
|Hazards |
|Cables / pipelines buried underground. |
|Existing structures/buildings. |
|Noise. |
|Control Measures |
|Cable avoidance tools to be used prior to rock drilling in order to determine presence of live cables. |
|Services drawings to be used to determine cable/pipeline routes. |
| |
|Trial hand digging to be undertaken in order to verify cable/pipeline routes. |
|Temporary sharing or supporting of existing foundations / buildings to be carried out prior to commencement of rock drilling. |
|Personnel carrying out drilling work shall wear safety helmets, gloves, safety footwear and hearing protection. |
|Unauthorized personnel should not be allowed in areas where rock drilling is being undertaken. |
Hazard Analysis And Control Programme
Civil Works
REF No:- ........A - 032......
|Activity |
|Rock Blasting |
|Hazards |
|Use of explosives. |
|Noise. |
|Control Measures |
|Only trained and experienced shot-firers to be permitted to use explosives. |
|Before explosives are used a written system of work shall be prepared. Personnel involved in the blasting operation must be made aware |
|of the safe systems of work prior to be followed. Consideration shall include: blast mats, audible alarms, site inspection and |
|communications. |
|Sentinels and visual warning signs shall be posted around the area likely to be affected by the blast. |
|Effective actions shall be taken to ensure that the danger area is clear of all personnel / animals immediately before firing occurs. |
|An audible means of giving warning that a shot is about to be fired and to sound the all clear to be provided. |
|The police site personnel and other relevant parties shall be notified of shot firing times. |
|Existing foundations/pipes in the vicinities of the rock blasting shall be protected by shoring |
Hazard Analysis And Control Programme
Site Preparation
REF No:- ................A - 033.....................
|Activity |
|Earth Works |
|Hazards |
|Movement Of Heavy Mobile Plant |
|Dust |
|Noise |
|Control Measures |
|Drivers, operators and banks-men of mechanical plant and equipment shall be trained, competent and at least 18 years of age. Only |
|authorized drivers and operators shall be allowed to use plant and equipment. |
|Drivers and operators to be trained not only in the correct operation of the plant and equipment but also in the limitations of its use |
|and the hazards, which exist if it is not used properly. |
|Preventive maintenance program shall be established to ensure that all plant and equipment is systematically inspected, serviced, |
|repaired and maintained as necessary. |
| |
|Prior to earthworks commencing overhead and buried electrical cables and other pipelines shall be identified and precautions taken to |
|prevent damage to these services. |
|Non-essential personnel shall be kept well away from the area of operation and trained banks-men should be provided where necessary. |
|Measures shall be taken to prevent dust from impairing visibility by use of water spray on roads and if practicable a one-way system for |
|traffic. |
|Site speed limits to be set and strictly enforced. |
|Plant items should not be parked so as to cause an obstruction to other plant or site activities, or so close together as to cause danger|
|to personnel in the vicinity. A stacking system to be operated away from the area of activity if required. |
|Plant shall be fitted with reversing alarms where appropriate. |
|Employees working in the vicinity of earth moving operations should wear safety helmets, safety footwear and high-visibility vests. |
|Drivers should not remain on a vehicle being loaded unless a suitable overhead protective canopy is provided. Personnel should stand |
|well clear of loading operations. |
|Personnel shall be instructed to establish contact with the driver prior to walking in path of a vehicle. |
|Sleeping under or against vehicles is strictly prohibited. |
Hazard Analysis And Control Programme
General
REF No:- ..........A - 034........................
|Activity |
|Site Transport |
|Hazards |
|Vehicle / Pedestrian Interface |
|Site Conditions |
|Contact with structures / overhead lines |
|Vehicle Defects |
|Falls into excavations |
|Control Measures |
|Site conditions shall be taken into account in the selection of plant. Drivers to be fully trained in the election of plant and be aware|
|of the limitations of their machines and in safe operating procedures. |
|Vehicles shall be maintained in an efficient state, in efficient working order and in good repair. Basic maintenance to be carried out |
|by the driver/operator on a daily/weekly basis. Defects found shall be repaired before the vehicle is put into service. Periodic |
|servicing of vehicles to be carried out in accordance with the manufacturers instruction. |
|Speed limits shall be established and clearly displayed for traveling on site haul roads. |
|Personnel working adjacent to haul roads should wear high visibility jackets and suitable warnings to be displayed where people can see |
|them in good time. |
|The possibility of vehicles coming into contact with overhead structures or power-lines shall be reduced by erecting height gauges of the|
|goad post type, constructed from non-conducting material, distinctively marked with red and white stripes or bunting. |
|Drivers to be instructed not to leave vehicles with their engine running. |
|Drivers to be instructed not to carry unauthorized passengers. |
|Safe working procedures shall be planned in order to reduce the possibility of personnel being struck by reversing vehicles. These may |
|include (i) avoiding the need to reverse by providing a one-way system of (ii) the exclusion of pedestrians from areas where vehicles |
|have to reverse. (iii) The provision of banks-men. (iv) The fitting of reversing alarms to vehicles. |
|Vehicles shall be prevented from falling into excavations by (a) clearly marking haul roads and securely fencing off the immediate |
|excavation area, (b) providing a banks-man to guide the vehicle and warn personnel in the excavation to keep clear, and (c) by providing |
|a fixed stop e.g. timber baulk securely anchored, well back from the edge. |
|Vehicles should not be overloaded, and the loads to be evenly distributed, secured, and not projecting beyond |
|The sides or back of the vehicle. If some projection is unavoidable then the load to be properly marked in order to ensure that the |
|projection is clearly visible. |
|Drivers should not remain in their vehicles whilst they are being loaded with loose materials. |
|The loading and unloading of tipper lorries shall be attended by a competent banks-man. Tipper lorries should not be allowed to move off |
|until the body has been loared. |
|Dumpers should not be allowed to travel with the body in a raised position unless inching forward to discharge the load. |
|Connections between trailers and towing units shall be securely fixed using the correct towing pin, and the trailer parking brakes |
|applied before disconnection from the towing vehicle. |
Scaffold Procedure
The purpose of this procedure is to provide guidelines for the erection, modification, dismantling and storage of scaffolding that shall be constructed / used on project. Implementation of these guidelines shall be essential to allow a means of safe access to work fronts using scaffolding that is assembled, inspected and maintained in a safe and accident free environment.
The procedure shall Provide guidance on how to manage "scaffold services" to ensure that only well designed, erected and maintained scaffolds can provide safe means of access and a safe working area for end users.
Specify the minimum acceptable safety codes and specifications.
Define the parties involved in the scaffolding works
Identify the responsibilities of parties
Describe the types of scaffold approved (including modular) and any limitations on its use
Outline minimum safe work practices to be applied during the erection of scaffolds including the use of fall arrest equipment and tools, training requirements and competencies / skills (certified / experience) of scaffolding supervisors / workers.
Establish a procedure to control how scaffolds can be erected, modified and dismantled
safely including any safety checks.
Highlight the need for the proper use of this scaffold system to other workers by incorporating ‘how to use scaffold safely’ into the ‘safety inductions’ required before permission to enter site is granted
Require quality audits to be undertaken to ensure compliance with this procedure.
Scope
The following procedure shall cover all scaffolding erected, dismantled, modified and stored on the project including any off-site or subcontracted elements of the project that require scaffolding to execute the works. Compliance With Statutory Regulations
The following international standards shall be applied for the project:
BS EN 39:2001 - Loose steel tube for tube and coupler scaffolds prEN 74-1 - Couplers, spigots and base plates for use in falsework and scaffolds - Part I: Couplers for tubes – Requirements and test methods.
BS EN 12811-1:2003 - Scaffolds – Performance requirements and general design or equivalent approved Codes of Practice.
BS 2482:1981 - Specification for timber scaffold boards
EN 354:2002 - Personal protective equipment against falls from a height - Lanyards
EN 355:2002 - Personal protective equipment against falls from a height - Energy Absorbers
EN 361:2002 - Personal protective equipment against falls from a height - Full Body Harness
EN 362:2004 - Personal protective equipment against falls from a height - Connectors
EN 364:1992 - Personal protective equipment against falls from a height - Test Methods
EN 365:2004 - Personal protective equipment against falls from a height - General
requirements for instructions for use and for marking
EN 795:1996 - Personal protective equipment against falls from height - Anchor devices
requirements for testing prEN 12402-4 - Personal flotation devices Part 4, Class D (inland / close to shore. 100 N), safety requirements prEN 1263-1 – Safety Nets
Contractor shall obtain prior written approval in the event alternative standards are proposed. The request for a substitution shall include a comparison of proposed alternative standard(s) with British Standard / Euro Norm listed above, highlighting any differences.
Definitions
Scaffolding Representative
Employee of the Contractor certified and approved to supervise and inspect scaffolding works.
Subcontractor
A party having a contract with the Contractor to carry out work required for the realisation of the project
Subcontractor Scaffolding Worker
Employee of a subcontractor such as qualified scaffolders, scaffolding foremen and
supervisors who are certified and approved to carry out scaffolding work
Subcontractor Scaffolding Inspector
Employee of a subcontractor certified and approved to carry out inspection of scaffolding work
End User -Any party authorised to be on site that has cause to utilise scaffolding.
Responsibility
Contractor shall ensure that the scaffolding provided by any subcontractor complies with
the safety and erection regulations for scaffolding.
Contractor shall be responsible for ensuring that scaffolding is only erected, modified or
dismantled by or under the direct supervision of a competent and experienced person.
NO scaffolding should be modified by any person other than approved subcontractor
scaffolding workers.
Contractor shall require that subcontractors engaged in scaffold works:
Provide all scaffolding workers with overalls, hard hats, leather gloves, safety glasses and safety boots as well as ‘fall arrest’ safety equipment. In addition, ear defenders, dust masks and life vests shall also be provided where necessary.
Train all scaffolders in the use of ‘fall arrest’ equipment so that scaffolders are tied off at all times.
Provide scaffold workers, supervisors and inspectors who are qualified and whose qualification has been verified with trade tests. Records of tests, qualification certificates, training and performance shall also be maintained
Provide qualified scaffold workers, supervisors and inspectors who are trained in the proper use of fall arrest equipment and maintain records of qualification certificates, training and performance.
Provide training for scaffold inspectors, supervision and labour from a competent electrical specialist on when scaffolds must be earthed.
Contractor shall implement a scaffold inspection and control system to be common across the project.
Contractor shall appoint sufficient number of suitably qualified and experienced scaffolding representatives to manage, supervise and audit the inspection system used
by scaffold subcontractor staff and labour.
It is the responsibility of the Subcontractor to provide sufficient suitably qualified scaffolding inspectors to provide an inspection signature prior to access to the scaffold
being given to the relevant workforce.
Subcontractor shall also be responsible for Carrying out inspections including scaffold tube, boards, ladders and other materials within the contractors approved storage area to ensure no damaged tubes or boards reach the site from the storage area prior to erection. Defective materials shall be destroyed and disposed off from site.
Ensure that inspectors, foremen and scaffolding supervisors immediately report any breaches of safety or discipline regarding the integrity of the scaffold by other discipline contractors to the Contractor’s scaffolding representative or their own safety representative.
Contractor’s scaffolding representative shall be responsible for:
Coordination and communication across all scaffolding subcontractors 100% audit of special scaffolds
Auditing of the scaffold inspection and control system for standard scaffolds
Auditing the inspection of materials in storage areas
Providing safety training to end users on safe use of scaffolding onsite including checking that the inspection date be current and not beyond the 1 week validity
Contractor shall include instructions on the safe use of scaffolding in the site induction given to all labour, staff and visitors before site entry is permitted. This shall specifically include the prohibition of scaffold modification by any party other than qualified scaffolder labour, the obligation to immediately report any scaffolding defects observed, and authorisation to stop any work being carried out from it and immediately remove a green scaffold tag when such defects are noticed.
Types Of Scaffold
Special Scaffolds
A scaffold that falls within the following categories shall be designated as non-standard, special construction and as such requires the additional safety checks specified below. This includes the requirement for Contractor’s representative to carry out 100% audit of all special scaffolds and countersign the tag and logbook.
Load Bearing Scaffold
Load bearing scaffold is one that is required to carry any load other than an evenly distributed load of 2.5kN/m2 or is subject to point loading. Examples may include scaffolds used as falsework in supporting civil type structures such as concrete floors, or that used as means of support for lifting equipment such as chain blocks and winches. This type of scaffold shall always be approved in advance by Contractor’s representative and supported with drawings the relevant load calculations. Erection of this type of scaffold cannot commence until full approval has been granted and it may not be utilised until a full inspection by Contractor’s representative is carried out and the installation assembly approved.
Engineered Scaffold
Any scaffold structure in excess of 38m height shall be designed by a competent engineer and approved by the Contractor’s HSE Manager
Suspended Scaffolds
Bosun’s chairs and gondola type scaffolds are not covered by this specification. Permission for their use shall only be given by the Contractor’s HSE Manager following submission of detailed method statements specific to the particular proposed application. Use of Bosun’s Chair shall be permitted only in exceptional circumstances and then only with the approval of Company’s HSE Manager.
Cantilever Scaffold
Cantilever scaffold shall be erected from beams which protrude beyond the face of the building or structure. Contractor shall implement the same approval and inspection requirements as for load bearing scaffolds detailed above.
NOTE: Supporting data provided for approval shall include details of the proposed fixing method.
Hanging Scaffolds
Hanging scaffold shall be one that is suspended from a point of support above the intended final working platform. Contractor shall implement the same approval and inspection requirements as for cantilever scaffolds including details of the proposed fixing method.
Mobile Scaffolds
Mounted on castor wheels consisting of four or more standards. The wheels must be locked when users are on the scaffold. When moving the scaffold no personnel should be on it for any reason. The maximum height / base ratio for a mobile scaffold shall be:
a) Indoors: 3.5:1 b) Outdoors: 3:1 up to a maximum of 3 lifts or 6m.
Standard Scaffolds
Subcontractor may elect to use scaffold types rated as suitable for differing loads for routine construction activities in accordance with the categories listed below. Where this approach is adopted, subcontractor shall specify how the different load capacities shall be readily and visually identified to ensure workers do not create safety hazards by wrongly loading up scaffolds as a minimum this shall require identification on the scaffold safety tag.
Heavy Duty
Scaffold erected for the use of multiple disciplines, civil, mechanical, piping, electrical, with a maximum allowable weight of 2.5kN/m2
Light Duty
The main purpose of this type of scaffold is for painting, plastering, glazing and light electrical work and in some cases inspection requirements with a maximum allowable weight of 1.5kN/m2.
Safety During Erection, Modification and Dismantling of Scaffold
Below are the basic principles that should be adopted as a minimum requirement:
Use and Care of Fall Arrest equipment
Fall arrest equipment shall consist of a full body harness with 1.75m double lanyards
incorporating integral shock absorbers one of which to be tied off to a secure anchorage at all times. Each lanyard shall terminate with a 55mm opening scaffold hook for one handed operation Inspection of which equipment shall be carried out by a competent person at intervals recommended by the manufacturer or at an absolute minimum of one (1) month. Records of these inspections shall be kept and be made available for safety audits.
An approved person, specifically trained to carry out inspection of fall arrest equipment shall train all project scaffolding personnel in the’ use, inspection and maintenance of fall arrest equipment’. Records of this training shall be kept. Fall arrest equipment shall be worn at all times and 100% tie-off be required for all persons when the following situations occur:
Work is taking place 2m or greater above a working platform / grade.
Work takes place at any height above a significant hazard (eg uneven or rocky surface,
water, etc). Work is outside the confines of a complete platform. Work is taking place from mobile working platforms. When raising or lowering materials (with a double guarded handrail provided). Anchor Points shall wherever possible be above shoulder height. Always clip on to Ledgers supported with load bearing couplers, Guardrails supported with load bearing couplers, Transoms supported by the ledgers in the lift above fixed at both ends by single couplers
Never clip on to Standards, Ledgers supported with putlog or half couplers, Ledgers or guardrails within a bay where it has a joint, Guardrails supported with a putlog or half couplers, Transoms below foot level, Transoms when underslung below ledgers.
Tools
Tool belts to be provided and worn at all times. No adjustable, open ended or home made wrenches to be used. Only the correct socket type wrench shall be used when tightening couplers which shall assist in the reduction of hand and wrist injuries. Apply the correct torque on the coupler and reduce the risk of slippage and tools falling to ground level.
Barricade
During any scaffolding works (erection, modification, dismantling), warning tape and signs shall be erected to prevent others entering the work area.
Working in a Marine Environment .
When working close to or over water, PPE requirements shall be reviewed. A full Job Safety analysis shall be conducted and where appropriate, fall prevention equipment would be replaced by life vests for works over water. In addition, a suitable boat shall be readily accessible, equipped with at least one boat hook, one ring buoy and 20m of 10mm polyester rope.
Confined Space Working
Work in any confined space shall be carried out in accordance with the Confined Space Entry Procedure required to be developed for the project which typically require the use of a permit system for entry, low voltage power supply for lighting and provision of a trained watchman.
Requirements Specific To Scaffolding Works
To prevent hazards from falling objects, protection by means of a physical barrier (eg. scaffold boards) shall be provided inside and out, above entry points to confined space areas such as tanks and other equipment items.
Scaffolding erected inside equipment shall generally be built up from the floor.
Where it is proposed to construct a cantilever scaffold attached to a support ring or similar, the attachment method shall be provided by a purpose made clamp.
Attachment by adapting the use of jacking devices such as adjustable base plates shall not be permitted.
Contractor’s HSE Manager shall review and approve any proposed method.
Protection From Falling Objects During Demolition
Contractor shall ensure that all horizontally stored or erected tubes are closed with a purpose made plastic end cap to prevent objects being inserted into the tubes (eg small tools, rubbish etc) that subsequently falls out during demolition.
Regulations For Scaffolding
Only metal scaffolding systems shall be used.
Scaffolding built with tubes and couplers shall be in accordance with BS EN 39 and use
galvanised steel tubes with a minimum 48.3mm outside diameter, wall thickness of 3.2mm and yield strength of 235N/mm2. Couplers shall comply with prEN 74-1.Where proprietary quick assembly / modular scaffold systems are used, the contractor shall provide full technical data and seek written prior approval before use. Modular scaffolds shall be subject to approval and installed in accordance with manufacturers written instructions.
Ladders
The use of rope, cable or home made ladders shall not be permitted on the project unless specifically permitted by the HSE Manager.
Wooden ladders shall not be permitted
Metal / Aluminum ladders shall not be used near or in the vicinity of electrical installations
Extendable ladders shall be permitted for access only and shall be no longer than 10.5m (extended). Minimum overlap shall be in accordance with manufacturer’s
recommendations or 1m, whichever is the greater.
No ladders are to be utilized as supports for working platforms.
One person only shall be allowed on a ladder always facing the rungs when ascending or descending. No tools or objects are to be carried by the user.
Inspection of ladders shall be carried out as required . Any defective ladders discovered in the inspection shall be removed from site.
Ladders shall be installed on a firm base, erected with a 1:4 slope (1 horizontal to 4
vertical ) with 1 meter or 5 rungs protruding above the landing platform and a sideways
exit or entry provided to the landing platform. Safety bars or gates at the landings shall
be installed. Ladders providing access to high working platforms shall have a landing platform every 5m. Landings shall be 2000 x 1200mm as a minimum and not be utilised as storage places. As minimum, ladders shall be secured at both the top and bottom using clamps. Where they are required to ensure stability, additional intermediate support points shall also be secured with clamps. Ladders should be installed at the earliest possible phase of the erection and removed as late as possible to minimise the need for scaffolders to climb around the structure A minimum of 200mm clearance is the required vertical and horizontal area behind ladder rung.
Scaffold Planks
Scaffold planks providing the working platform shall be slip resistant. If timber boards are used they should be 38mm thick and comply with BS 2482.
It is recommended that cleats should be used to fix down boards with the underside of the boards clamping to the top of the scaffold wherever possible. If this is not feasible ensure fixing from the top causes no tripping hazards.
Timber boards shall be adequately supported by transoms and bearers spaced at a distance of 1.2m to 1.5m as required by the loading of the scaffold. Every board shall have three supports unless its thickness or span is sufficient to prevent sagging under load.
Timber scaffold boards shall extend a minimum 50mm beyond the putlog or transom with a maximum permissible overhang of 4 times the board thickness. Prefabricated metal planks shall be installed in accordance with manufacturer’s instructions.
Boards should be butted together (on all scaffolds except circular structures) but, when
lapped boards are used, bevelled pieces to minimize the risk of tripping should be fitted at the laps.
Minimum width for platform shall be 600mm (3 boards)
Guard Rails and Toe Boards
A guard rail shall be provided at the outer edge and ends of all scaffolds. It shall be 1m or more above the working platform level.
A mid-rail shall also be provided located half way between the top pf the toe board and the guard rail.
Toe boards should also be fitted on the outer edges of the scaffold structure. The toe boards shall be minimum 150mm high with a maximum gap of 12mm between the board and the scaffold.
Guard rails, mid-rails and toe boards in accordance with 7.2.5 shall also be provide the distance between the ledge of a working platform and an adjacent wall exceeds 225mm.
Foundations
All scaffolds must be constructed on an area that has been compacted
The regular scaffold inspections shall include a check for undermining of foundations by other subcontractors. If any undermining is apparent, the inspector shall remove any personnel working on the relevant scaffold, then close down the scaffold (by means of the scafftag system) and inform the HSE representative.
No scaffold bases are to be constructed by means of temporary supports i.e. laying scaffold board over voids or trenches to support the sole plates is not permitted.
The load at the base of a standard of a high scaffold may exceed two (2) tonnes. A load of this magnitude may cause subsidence if not properly distributed over a sufficient area.
When required, supporting earthwork shall be compacted to ensure a sound foundation.
Soleplates
Generally, a continuous timber soleplate of 200mm x 200mm x 38mm shall be satisfactory to
distribute the load from a base plate to the ground. However, in some cases, in addition to ground compaction, it may be necessary to increase the thickness and the area of the soleplate.
Earthing of Scaffold
Scaffolding that carries lighting or small power circuits greater than 50V shall be bonded to the protective carrier of the circuit that it carries. Below this voltage no bonding is required, and for circuits above it earthing shall be designed and installed by a competent person (qualified electrician).
Scaffold Inspection And Control System
Contractor shall establish a system of control for scaffolds. The proposed system shall be illustrated it by producing typical flow schemes showing how the process is controlled from request stage through to demolition. The responsibilities of each party and methods of
communication between them shall clearly be defined on the flow schemes.
The system shall include the registration and inspection of new build scaffolds, subsequent recorded periodic inspections and the use of a tagging system with the following features:
A register / logbook of scaffolds shall be established recording a scaffold request from an enduser and a unique identification number for the scaffold to be built.
Upon completion, before the scaffold is allowed to be used, the scaffold shall be inspected by a qualified inspector, and the date and name of the inspector shall be recorded.
The inspection is only valid for seven calendar days. Any scaffold erected for longer than 1 week must be reinspected to revalidate the inspection tag.
Scaffolds must also be inspected after bad weather which may affect the scaffolds strength and stability.
Subsequent daily checks and inspections following modifications shall be recorded in the Register / logbook concluding with a record of the dismantling date.
A standard checklist shall be developed by Contractor and used for all inspections across the site. The checklist shall include a check of whether earthing of the scaffold is required. Status of a scaffold shall be indicated on site by using a tag attached to the structure itself. The tag consists of two elements, a holder and an insert. The holder shall be placed on the scaffold structure as soon as possible after the initial erection, and as close as possible to the point of access or ladder access. Where a scaffold has more than one access, a tag shall be attached at all of the entry points.
The scaffold tag has a hole in the top, which must be placed over a tube in order to secure it.
Holders must not be affixed by any other means.
Scaffolds must not be used if they have a red “DO NOT USE SCAFFOLD” symbol on the holder.
The scaffold tag insert is green in colour and when it is present it signifies to potential users that it is safe to use. When a scaffold has been inspected and passed, tags are to be signed by the responsible inspector using a permanent ink pen.
The green insert contains more significant information than the holder and is used to record details of statutory inspections, the maximum allowable loading.
While the RED holder is in place, access to the scaffold structure is prohibited to non
scaffold personnel.
When a scaffold is to be structurally modified, the scaffold crew assigned the work shall
remove the green scaffold tag and barrier off the area. The tag shall therefore only comprise the red holder with the “DO NOT USE SCAFFOLD” symbol, and only scaffold personnel allowed on the scaffold. Once the modification is complete, the scaffold should be reinspected by the inspector prior to use and when accepted, the GREEN tag would be inserted into the holder signifying it being safe to use.
If a scaffold requires a minor modification for a short period due to construction reasons, e.g. removal of handrail or board to allow pipe installation, only scaffold personnel shall be permitted to make the modification. Contractor shall develop a detail procedure to control these type of modifications that cover the following non-exhaustive list of concerns:
Provision of ‘stand-by’ scaffold crew(s) to ensure minimal waiting time for
workers requiring the modifications.
Safe use of scaffold during the work that created the need for modification (ie use of fall arrest equipment by all scaffold users) Reinspection and recertification of scaffold
Chapter 14
HSE&S
Health, Safety, Environmental & Security
Standard Procedures
Enviornmental Control
Scope
Adherence to the requirements within the Environmental Control Procedures shall minimise the impact of construction activities to land, air, water, flora and fauna. These requirements apply to all construction activities and applicable locations throughout the camps, Preparation of Access Ways and work areas associated with the installations under the control of Contractor.
The Environmental Control Procedure describes the requirements during construction for Spill Prevention and Response / Waste Management / Dust Control / Traffic / Noise and Vibration Control. The responsibilities, management, co-ordination and review of these environmental activities are to be implemented by Site Manager in coordination with QA / QC and HSE departments.
Purpose
The Environmental Control Procedure (ECP) describes the environmental compliance activities for Contractor Construction personnel and their contracted entities.
The objectives of the ECP are to define the specific environmental activities required to: Comply with the provisions of the Contract, HSE standard specification and other applicable environmental legal documents, mitigate the environmental impact of construction activities & fully comply with the Environmental Protection Practices.
Contractor Construction team shall comply with this Procedure during construction, start-up and initial operation of the system. Each subcontractor involved in construction activities shall be provided with a copy of this Procedure and required to comply with its contents. Periodic reviews of the Procedure shall be performed to confirm its adequacy & effectiveness so that the Procedure be updated to meet the practical requirement.
Definitions
Employer means-Project owner
Employer Representative- Any person authorised by Employer to act on their behalf
Contractor Representative- A person authorised by Contractor to act on their behalf.
Waste Material or effluent or other unwanted surplus substance that requires disposal because it cannot be re-used or recycled or there is no economic demand for it.
Responsibilities
Contractor Site Manager has overall responsibility for ensuring that the environmental controls described in this ECP are effectively implemented on Site in coordination with QA / QC Manager as well as the site HSE Manager.
Instructions
Health, Safety & Environmental Impact Assessment
The Health, Safety and Environmental Assessment preparation includes an assessment of the impact of Construction activities and the Construction Camp on the environment and suggests measures to mitigate the impact.
The suggestions made are summarised in the table 1 along with the control measures that Contractor shall be undertaking.
Table 1: Environmental Issues and AJESCONTRACTOR Control Measures.
Construction
|Environmental Issue |Suggestions |AJESCONTRACTOR Control Measures |
|Contaminated Land. |The soil from areas of contamination shall be removed and disposed of to any |AJESCONTRACTOR shall contact the local authorities for disposing the |
|Contamination of Land by any accidental oil spills or any effluent |approved landfill. |contaminated soil in approved land fill |
|during the construction activities. | | |
|Protection of ground Waters and Wadis. |Any wash water run-off requires a system of temporary impoundment and settling to |A silt retention trap shall be constructed at all wash water facilities. This |
|The ground waters and others water sources like Wadis are utilised |remove silt before returning to the ground. This shall be carried out during site |retention shall allow settling of sand, silt, and grease etc. and only clear |
|for agriculture and cattle feeding by local population and weeds and|preparation. |water surface shall run-off to ground. |
|plants growing in the area. This water source has to be protected |Sewage must be treated and only treated water allowed to run out to ground. Sewage |Sewage Treatment plant shall be installed at each camp to control the sewage |
|from any pollution from construction activities. |treatment plants shall be installed and operational along with construction camp |water out-lets. |
| |In isolated locations local methods shall be followed. | |
| | | |
|Site Preparation. |AJESCONTRACTOR to have a traffic management system in place with temporary haul road|Temporary haul roads shall be constructed and kept as clear as is practicable |
| |and traffic segregation, where practicable. |from sand. |
| |Dust control measures to be implemented. Roads shall be maintained to reduce dust as|Dust suppression measures shall be used to control dust such as water sprays. |
| |practical. | |
|Dust. |Temporary roads shall be constructed for site traffic. |Top layer of fine dust shall be graded away from traffic route as practical |
|Dust shall be exacerbated by site activities such as stripping and |Water spray bowsers shall be used. |Water shall be sprayed to suppress the flying of dust. |
|vehicle movements. | | |
|The area experiences sand storms. | | |
|Noise. |Regular inspection of all equipment working in the project shall be done so as to |All equipments shall be maintained to acceptable noise level as recommended by |
|Excessive Noise level created by the constant operation of plants |maintain minimised noise levels in accordance with manufactures recommendations. |manufacturer |
|and equipment. | |Noise protection equipments shall be used by personal if require to work in |
| | |high noise level areas |
|Construction Camp. |Sewage treatment plant to be installed in both camps. |Sewage Treatment Plant shall be installed and maintained to meet the |
|Camps shall provide accommodation, catering and sanitation for |Traffic segregation must be implemented. |requirements arising from the sewage at camps. |
|approx. all workforce personnel. Waste arising from these camps |Dust suppression methods must be implemented. |Heavy traffic shall be separated from light vehicles and separated access roads|
|shall be significant, as shall traffic to and from the camps. | |maintained. |
| | |Grading the road and water spraying regularly shall control dust. |
|Oil Spillage. |Use of Bunded storage for any oil or fuel products for containing accidental leak |Oil and fuel products shall be stored in bunded area for containing any |
|The possible chances of oil leaks and spills from the fuel refilling|Availability of recovery facilities for any leaked pollutant |accidental leak. |
|tankers, storage tanks and from brake down of equipment shall |Use of drip trays while refuelling or handling fuel or oil products. |Recovery materials like absorbents, sand and sand bags shall be available in |
|contaminate the ground and pollute the adjacent ground water. | |the vicinity to the immediate use |
| | |Drip trays shall be used to contain leaks while handling oil or refuelling. |
| | |The recovered contaminated soil and associated materials shall be collected and|
| | |disposed in safe method. |
Spill Prevention and Response
Contractor should believe in prevention first and foremost by applying commitment with best practices throughout construction. However, in the event of an unforeseen natural disaster or man-made incident that results in a threat to the environment, Contractor shall be prepared to respond in a timely and effective manner that should limit environmental damage to a minimum. In many cases major pollution incidents can be prevented if appropriate pollution prevention measures are applied at an early stage. Planning of applicable methods is the key to any success, therefore both preventative measures as well as incident response strategy should be addressed as given below.
Spill Prevention
The following procedures shall be carried out to reduce the possibility of a spill that may be harmful to the environment or to the health and safety of the staff:
Appropriate precautions shall be taken so far as is reasonably practicable to protect storage areas and equipment from vandalism.
Stores of potentially polluting material shall be situated on an impervious base and surrounded by an impervious bund capable of containing a volume 10% greater than the store. Valves shall be checked periodically on routine HSE inspections to ascertain that they are closed.
Special consideration shall be given to any leakages arising from the surface run-off around temporary stockpiles of materials. All stationary diesel and petrol operated construction equipment shall have impervious drip trays placed beneath them during operation. Any spillages into the drip trays shall be collected for safe disposal.
Vehicles and mobile equipment shall be regularly inspected and maintained to confirm they are not leaking or dripping. Operators shall be instructed in their HSE training to notify their supervisors if there occur any problems with their vehicles whereby appropriate maintenance be given. Maintenance of construction plant maintenance shall be closely supervised and measures shall be implemented to prevent hydrocarbon contamination. These measures shall include use of drip trays, absorbent materials close at hand and careful disposal of any used materials.
Major equipment and vehicles shall be re-fuelled on an impervious base. Care shall be taken not to spill any fuel and absorbent materials be close at hand. Stationary equipment with impervious drip trays shall be re-fuelled in-situ; fuel containers shall be sealed after use and stored on an impervious base away from water bodies.
Higher levels of dust containment shall be used for contaminated excavated material than used for other material. Appropriate measures may include: use of fine water sprays to thoroughly moisten all surfaces and maintain surface moisture; use of protective fences or screens to provide shelter from winds; minimising unnecessary handling of material and enclosure of excavated material in wind proof containers prior to removal from site.
Spill Response
The magnitude of the discharge / spill shall determine the extent of the actions that have to be made necessary
The key actions in responding to a spill to minimise its environmental impact are:
An Early Detection.
Regular inspections and training shall be carried out to enable an early detection. It is everyone’s responsibility to be aware of potential pollution risks.
Notify Supervisor / Emergency Team
Notify supervisor who shall notify the Site Manager or HSE Manager. Emergency services shall be notified as necessary.
Assess Safety Risk To Humans
Only attempt containment and cleanup operations of spilled substances when it can be performed safely.
If spilled material is flammable, eliminate sources of ignition near spill area.
Personnel and neighbours are to be evacuated if they are at risk
Secure the area and establish perimeter control at a safe distance from the spill.
Stop Source of Spill.
When it can be performed safely, stop source of spill. Pollution control equipment shall be available from site administration offices, storage and re-fuelling areas.
Contain Spill (If Liquid).
Liquid spills - If the spill is liquid, its path shall be blocked or diverted and then soaked up using an absorbent material.
Gaseous spills / leaks – A gaseous leak must be stopped at source as soon as possible and shall then disperse in the air. It is not practicably possible to contain a gaseous leak but weather conditions should be checked to assess the most likely direction the pollutant shall take if it poses a risk to human health followed by the area evacuation.
No spills shall be rinsed away. Contaminated soils and clean-up materials from spills must be handled properly using personal protective equipment. These should be stored in a suitable container that is then labelled and taken away to be further stored in the appropriate location for subsequent safe disposal. Screen / cover stockpiles of polluted matter to prevent dispersion.
Dispose With Care.
Contaminated soils and used clean-up materials shall be treated as hazardous waste and be disposed of accordingly at a designated disposal site.
Document Incident.
The Site HSE Manager shall be responsible for ensuring a report is filed containing information on date, time, location, type and quantity of spilled material, description and cause of incident, action taken, name of person reporting the incident and recommended actions for ensuring the incident doesn’t reoccur.
Spill Response Materials
Spill response / pollution control materials shall be stored in a safe location on site in close proximity to the storage and waste areas. This material is to be used to contain and clean up pollution for that care shall be taken to dispose of any absorbent materials properly. They shall not be washed away. The Site HSE Manager shall keep stocks well maintained and replenished. Spill Response materials shall include the following:
Sand / Sand bags / Buckets and Shovels / Storage Containers
Sand is one of the most versatile containment materials which can be used to soak up spillages of oil, chemicals and used in sand bags to block off substances from sensitive areas or channel them to a predetermined collection point. Sand stocks must be dry and buckets with shovels readily available. Mechanical loading shovels, excavators and dump trucks may also be available for sand distribution and clean up. Storage containers for contaminated materials and earth shall be bund, located in the waste storage area, labelled and treated as hazardous waste.
Waste Management
It is Contractor’s policy to minimise and reuse / recycle waste materials whenever possible and to dispose of remaining wastes in accordance with this Procedure.
Before wastes can be disposed of appropriately, these first need be categorised and segregated. This in practice is often made difficult due to the wide range of solid, chemical and effluent waste that needs to be segregated stored and disposed of. The Site Manager is held responsible for the allocation of a trained official to guide and control the classification, storage, handling, transport and disposal of wastes.
Waste can generally be classified as either:
Domestic and municipal waste
Non-hazardous industrial waste
Hazardous waste.
In table 2, over, the storage and disposal methods for re-usable / recyclable materials, domestic waste, non-hazardous construction waste, hazardous waste and waste water and sanitary waste are described.
Table 2: Waste Storage and Disposal Controls
|Category |Storage |Disposal |
|All Wastes |A specific area to be designated for storage of waste before it is disposed off|Waste shall be transported to the designated area agreed with Local |
| |site. |Authorities which is the concerned Municipality. |
| |Selected sites should stand away from water bodies, drainage ditches and be |Disposal of waste should take place at the designated area as necessary |
| |located on hard-core to minimise the risk of soil contamination. |supervised by the Local Authorities. |
| |Containers be bunded where necessary. |Vehicles delivering waste to the disposal area should be covered where |
| |Fire prevention systems and pollution control equipment shall be provided for |necessary to prevent dropping, leaking, sifting or blowing of solid waste|
| |storage facilities where necessary to prevent fires or the releases of |from the vehicle. |
| |hazardous materials to the environment. |Any spillages or waste lost from disposal vehicle en route to the |
| |Storage areas should be made inaccessible to animals and visitors. |disposal site should be promptly cleaned up. |
| |Storage containers shall be of sufficient size and number to contain all solid |Before starting work, the HSE Manager shall confirm that drivers have |
| |wastes generated between collections. |specialised training related to the handling and disposal of their cargo.|
| | |The HSE Manager shall maintain a working file keeping a record of the |
| | |waste being disposed. This shall include date, time, type of waste, |
| | |approx. volume of waste, and disposal method. |
| | |The landfill and incineration site shall be periodically inspected. |
|Re-usable / Recyclable |Re-usable material shall be kept in an orderly manner and in an accessible |The Re-usable materials shall be sent to Yard for appropriate re-cycling |
|Timber |location. | |
|Metals | | |
|Paper | | |
|Domestic Waste |An adequate number of containers shall be strategically placed throughout the |Domestic waste shall be disposed off through the Municipality facilities.|
|Food Waste |construction areas and temporary facilities. These should be regularly | |
|Domestic Trash |collected and taken to the main waste storage area. | |
| |All food waste shall be properly stored in containers with sealed tops to | |
| |minimise the possibility of vermin infestation. | |
|Non-Hazardous Construction Waste |Construction debris and demolition material shall not be allowed to accumulate |Combustible waste shall be taken to the Municipality Incineration area |
|Combustible, e.g. non re-usable timber, card packaging wastes |such that it presents an environmental, health and / or safety hazard. |Non-combustible waste shall be taken to the Landfill area. |
|Non-combustible e.g. concrete etc. |Inert construction waste shall be segregated into combustible and | |
| |non-combustible. | |
| |Flammable substances must be kept away from sources of ignition. | |
|Hazardous Waste: |The Site Manager shall confirm that a trained official is allocated to guide |Hazardous waste shall be disposed of in the area designated by |
|According to UN classification hazardous wastes can be categorized as |and control the classification, storage, handling, transport and disposal of |municipality. It shall remain segregated and in the labeled storage |
|follows: |wastes. |containers. |
|Explosives |Hazardous waste shall be retained in a secure area with an impervious bunded |The HSE Manager shall maintain a register of all hazardous waste and |
|Gases (including toxic and flammable gases) |base. |disposal methods. Safety Data sheets shall be consulted the HSE Manager.|
|Flammable liquids including solvents |The area shall be away from sources of ignition. |The general points above in the ‘ALL WASTES’ section apply. |
|Flammable solids |This area shall be at least 17m away from water bodies and drainage ditches. |Incompatible hazardous wastes shall not be transported together. |
|Oxidizing agents and organic peroxides |Different types of hazardous waste shall be stored separately to avoid adverse | |
|Toxic and harmful substances including toxic metals |chemical reactions and facilitate eventual treatment. | |
|Radioactive |Hazardous waste shall be stored separately from non-hazardous waste. | |
|Corrosives, including acids and alkalis |Hazardous waste shall be stored in tightly closed leak-proof containers made of| |
|Other dangerous substances. |or lined with materials that are compatible with the hazardous waste to be | |
|Hazardous wastes generated on site may include: |stored. Containers shall be clearly marked with appropriate warning labels to | |
|Contaminated Land |accurately describe their contents and detailed safety precautions. Labels | |
|Chemical Wastes including cleaning fluids, lubricants, paints, dye, |shall be waterproof, securely attached and written in Local language and | |
|coating substances, solvents, corrosion inhibitors, biocides, emulsions |English. Where ever possible chemicals should be kept in their original | |
|etc. |container. | |
|Batteries/ Capacitors |Hazardous chemicals shall be stored and handled in accordance with the | |
|Hydrocarbon Waste |manufacturers Material Safety Data Sheet (MSDS). | |
|Fire extinguishants |Spill prevention measures shall be adhered to. | |
| |The Site HSE Manager shall maintain a register of all hazardous waste and | |
| |disposal methods. Safety Data sheets shall be consulted by the Site HSE | |
| |Manager. | |
| |Equipment, materials and skills shall be readily available to deal with | |
| |spillages. | |
| |Washing facilities shall be available. | |
|Sanitary Waste and Waste Water |Storage / Treatment |The treated effluent water shall be used for irrigation and dust control |
|Waste water and sewage arising from the camp. |Fresh water supplies shall be segregated from wastewater in accordance with |after it has been analysed to confirm that it is safe for these purposes |
| |Health Requirements of Contract Documents. |utilisation. |
| |No wastewater shall be injected into the groundwater. |The sewage treatment plant shall be erected and commissioned operational |
| |All wastewater shall be allowed for settling the silt before allowing to drain |during the first phase of camp occupancy. |
| |to the ground | |
| |All camp units shall be connected to a sewage main which run through a PVC | |
| |pressure line to a treatment system located adjacent to camp. | |
| |The treatment system shall be based upon the use of an extended | |
| |aeration-activated sludge process with an aeration system and solids separation| |
| |using settlement, shall consist of twin streams each with adequate capacity. | |
| |All treated effluent shall gravitate to a chlorine contact tank where | |
| |chlorination takes place to achieve a chlorine residual of 0.5 – 1.0 ppm prior | |
| |to passing to a designated collection basin located adjacent to the camp. | |
| |The facilities shall be maintained by contractor to minimise interruption. | |
Dust and Emissions
The most prevalent construction emission is fugitive dust, however, emissions of Carbon mono-oxide “CO” and related exhaust gases are likely to emerge from diesel generators as well as from activities such as on-site painting, re-fuelling of equipment, application of adhesives, waterproofing chemicals and the incomplete combustion of fuel in construction equipment. Note that none of the planned activities shall cause the release of H2S gas.
The Dust and Emissions occurrence must be controlled during construction to an acceptable level by the following controllable suggestions:
Avoid unnecessary idling of vehicles and machinery.
Fuel, paint and chemical containers be kept sealed when not directly in use.
All vehicles and Construction Plant be properly maintained to minimise excessive exhaust emission. Where possible, engines shall be located away from work areas. Should problems arise, for example defective equipment, which result in generation of fumes, gases or odours on-site, operators be instructed through their HSE Awareness Training to shut down and notify their supervisor to facilitate the appropriate mitigation response.
Dust be controlled as far as is practicable. Control measures can significantly help minimise dust in most cases, apart from in the case of sand storms. If a severe sand storm occurs, the Site Manager should decide if work needs to shut down. After the storm, the roads should be cleaned. Fugitive dust emissions should be minimised by implementing the following controls:
Water spraying. This shall be conducted at a frequency to keep the surfaces moist. Treated wastewater or ground water shall be used for this purpose.
All the concerned persons shall be required to fully cover with sheeting or spray water on open-bodied trucks hauling sand, gravel or soil between on-site and off-site areas. Any transgressions should be immediately brought to the attention of the hauler concerned by the Site HSE Manager. Failure to comply with this requirement shall result in the offender being prevented from accessing the site. If sandblasting operations are required, these operations should be located and scheduled so as to minimise noise and dusting effects on adjacent work areas.
Excavation faces not being worked should, if required, be moistened.
Deliveries of finely ground materials should be in bag form or stockpiled in specified locations where the material can be suitably covered. Minimum drop heights shall be used during material transfer. The roads around the site particularly at the site entrance shall be monitored on a regular basis. These shall be kept as clear from dust and dirt as is practicable. Should it found to be necessary, the road in the vicinity of the site entrance shall also be swept.
Construction personnel shall be required to enter the site over prepared surfaces and park in designated lots. Should problem areas arise which result in excessive dust generation on-site, workers should be instructed through their HSE Awareness Training to notify their supervisor to facilitate the appropriate response.
Traffic
The following traffic controls shall apply:
Construction area access shall be limited to only for construction vehicles.
Non-essential vehicles parking on site shall be restricted to designated areas.
Site access shall be limited to established roadways and traffic shall be routed to the site avoiding residential areas as far as is practicable.
The majority of construction vehicles shall be restricted to designated parking areas for that parking regulations be established and enforced.
All road surfaces be maintained in safe and passable conditions.
Vehicle washing facilities be on site.
Environmental Friendly Practices
Environmental Friendly Construction Practices
Follow all permit and environmental mitigation requirements.
Stay within project boundary. Watch for and avoid flagged exclusion zones onsite. Leave wildlife and vegetation alone. Conduct with care project activities that can affect wildlife and vegetation (e.g. clearing) to avoid unnecessary disturbance. Do not dump waste in streams, ponds, lakes, rivers, wetlands, natural drainages or other sensitive areas.
Implement and maintain erosion control and storm water measures as appropriate such as drainage ditches and trenches to divert flows away from active work areas, structures to prevent situation from reaching surface waters and sedimentation ponds to settle out storm water particulates.
Place drip pans under all standing mobile equipment.
Respond to spills by stopping the source of the spill and immediately notifying the supervisor. Contain any spill and clean it up using absorbent materials. Do not rinse spill away. Document, report type and quantity of spilled material, date, time, and cause of spill and cleanup as required.
Maintain equipment in proper operating condition. Stockpile overburden, spoil, and fill at least 50 feet from surface water and wetlands whenever possible.
Recycle treated wastewater as dust control if allowed and where practicable. Avoid using oil as a dust suppressant.
Store wastes in properly designated areas. Label all containers accurately. Store hazardous waste securely in closed containers. Ship hazardous wastes to appropriate treatment and disposal facilities per local requirements.
Do not burn anything except untreated wood.
Recycle / reuse welding rods, used batteries, used oil, solvents, paints, paper, glass, scrap wood or metal, where required and as much as possible.
Immediately stop work and notify the supervisor if human remains or archaeological artefacts are found.
Immediately stop work and notify your supervisor, if contaminated soil (unusual colouration or odour) or underground storage tanks are discovered.
Ask your Supervisor or Environment, Safety and Health representative if you have any questions.
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Chapter 15
Sample Only
Commercial
Sub Contracts
It is intended for the sake of information exchange as well as dissemination to the readers particularly those who are aspiring to appear for PE certification examinations. The data included herein is not claimed to be entirely original in essence. Based on the experience, a collection has been done & amended to my understanding of the practical aspects of contracts & engineering in the field as well as in designs. The main contract forms relating to the EPIC contracts have not been included for that constitutes a top serial level document & young engineers may not draw much benefit but nevertheless, a practical understanding of the subject may be drawn from the provided information for all examination as well as practical purposes.
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Contracting Co.
Plant Project
Seller technical services agreement
SubContract:
This subcontract is entered into as of the date day of month, 2025, between Contracting Co Ltd. (hereinafter called "Contractor") and ‘name a company’ organised and existing under the laws of country with its principal offices located in address (hereinafter called "Subcontractor").
Whereas, Contractor has been awarded the project for the building of Facility for Petrochemical Industry located at ‘unknown’;
And whereas, Subcontractor acknowledges that it has sufficient knowledge and understanding of the nature, the location and the infrastructure of the Jobsite:
And whereas, the Subcontractor is able to perform all specified Works in accordance with the terms and conditions of this subcontract;
Now therefore, it is agreed as follows:
Subcontractor's Work/s consist/s of provision of technical assistance and direction to Contractor during the installation and/or commissioning of Subcontractor furnished Products supplied under Purchase Order (Relevant Purchase Order Number), Equipment Description and all associated requirements which are more particularly described in relevant Exhibits. All Works specified below shall be performed by the Subcontractor in accordance with all the provisions of this subcontract, consisting of the following Subcontract Documents:
Subcontract Form of Agreement
EXHIBIT "A" General Conditions
EXHIBIT "B" Special Conditions
EXHIBIT "C" Statement of Work and Compensation/Consideration
Based on the satisfactory performance by Subcontractor of this subcontract, Contractor shall pay to Subcontractor as full consideration, agreed compensation in accordance with the prices set forth in Exhibit "C" and with the payment provisions of this subcontract.
This subcontract embodies the entire agreement between Contractor and Subcontractor and supersedes all other previous writings. The parties shall not be bound by or liable for any statement, representation, promise, inducement or understanding not set forth herein.
Contractor: Subcontractor:
Contracting Co. Ltd. ABC
Authorised Authorised
Signature: Signature:
Print Name: Print Name:
Print Title: Print Title:
Contracting Co. Ltd.
Plant Project
EXHIBIT "A"
Construction Subcontract General Conditions
Table Of Contents
GC Title
1 Independent Subcontractor
2 Authorized Representatives
3 Notices
4 Subcontract Implementation And Interpretation
5 Order Of Precedence
6 Standards And Codes
7 Laws And Regulations
8 Permits
9 Taxes
10 Labor, Personnel And Work Rules
11 Commercial Activities
12 Publicity And Advertising
13 Safety And Health
14 Environmental Requirements
15 Site Conditions And Natural Resources
16 Differing Site Conditions
17 Title To Materials Found
18 Survey Control Points And Layouts
19 Subcontractor's Work Area
20 Cleaning Up
21 Cooperation With Others
22 Responsibility For Work, Security And Property
23 Subcontractor's Plant, Equipment And Facilities
24 Illumination
25 Use Of Completed Portions Of Work
26 Use Of Contractor's Construction Equipment
Or Facilities
27 First Aid Facilities
28 Inspection, Quality Surveillance, Rejection
Of Materials And Workmanship
29 Testing
30 Expediting
31 Force Majeure
32 Changes
33 Disputes
34 Records And Audit
35 Warranty
36 Backcharges
37 Indemnity
38 Patent And Intellectual Property Indemnity
39 Assignments And Subcontracts
40 Suspension
41 Termination For Default
42 Optional Termination
43 Final Inspection And Acceptance
44 Non-Waiver
45 Severability
46 Survival
Appendices
A-1 – Contractors Project HSE Plan (including Owner’s Commitment to Health, Safety and the Environment & Owner’s Health, Safety and Environmental Policies
A-2 Selection Criteria for Lowertier Subcontractors
Exhibit "A"
Construction Subcontract General Conditions
GC-1 Independent Subcontractor
Subcontractor represents that it is fully experienced, properly qualified, registered, licensed, equipped, organized, and financed to perform the Work under this Subcontract. Subcontractor shall act as an independent and not as an agent of Contractor or Owner in performing this Subcontract, maintaining complete control over its employees, all of its suppliers and further subcontractors on any tier. Nothing contained in this Subcontract or on any lower-tier purchase order or subcontract awarded by independent Subcontractor shall create any contractual relationship between any supplier or subcontractor on any tier and either Contractor or Owner. Subcontractor shall perform the Work hereunder in accordance with its own methods subject to compliance with the Subcontract provisions.
GC-2 Authorized Representatives
Before starting work, Subcontractor shall designate in writing an authorized representative acceptable to Contractor to represent and act for Subcontractor specifying any / all limitations of such representative's authority. Such representative shall be present / dedicated or be represented at the Jobsite at all times when work is in progress duly empoared to receive communications in accordance with this Subcontract provisions on behalf of independent Subcontractor. During periods when the Work is suspended, arrangements shall be made for an authorized representative acceptable to Contractor for any emergency work that may be required. All communications given to the authorized representative by Contractor in accordance with this Subcontract shall be binding upon Subcontractor. Contractor shall designate in writing one or more representatives to represent and act for Contractor and to receive communications from Subcontractor. Notification of changes of authorized representatives for either Contractor or Subcontractor shall be provided in advance in writing to the other party. Subcontractor shall not change its Representative without the prior written approval of Contractor
GC-3 Notices
Any notices required hereunder shall be in writing and may be served either personally on the authorized representative of the receiving party at the Jobsite by facsimile, by courier or express delivery or by certified mail to the facsimile number or address of that party as shown on the face of the Subcontract Form of Agreement or at such facsimile number or address as may have been directed by written notice.
GC-4 Subcontract Implementation and Interpretation
Subcontractor shall follow and utilize Contractor’s “Implementation Documents” such as but not limited to Project procedures, plans, regulations, rules, report formats and forms established to meet the requirements of and transmit information necessary under this Subcontract including any revisions thereto. This shall include Contractor approved Subcontractor submitted plans, means and methods for the Work. Implementation Documents are neither intended to nor shall supersede the provisions / requirements of the Subcontract Documents.
All questions concerning interpretation/construction or clarification of this Subcontract or applicable standards and codes including the discovery of conflicts, discrepancies, errors or omissions or the acceptable performance thereof by Subcontractor, shall be immediately submitted in writing to Contractor for resolution. Subject to the provisions of the General Condition titled "Changes" all determinations, instructions and clarifications of Contractor shall be final and conclusive unless determined to have been fraudulent or capricious or arbitrary or so grossly erroneous as necessarily to imply bad faith or not supported by substantial evidence. At all times, Subcontractor shall proceed with the Work in accordance with the determinations, instructions and clarifications of Contractor. Subcontractor shall be solely responsible for requesting instructions or interpretations and solely liable for any costs and expenses arising from its failure to do so.
All dates and time periods referred to in this Agreement relate to the Gregorian calendar. Unless expressly stated otherwise, “days” shall mean consecutive calendar days.
GC-5 Order Of Precedence
All Subcontract Documents and subsequently issued Change Notices/Orders and Amendments are essential parts of this Subcontract with a requirement occurring in one is binding as though occurring in all. In resolving conflicts, discrepancies, errors or omissions, the following order of precedence shall be applicable to be used:
Subcontract Form of Agreement
Exhibit "C" – Quantities, Pricing and Data
Exhibit "B" - Special Conditions
Exhibit "A" - General Conditions
Exhibit "D" - Scope of Work
Exhibit "D" - Technical Specifications and
Exhibit "E" - Drawings
GC-6 Standards And Codes
Wherever references are made in this Subcontract to standards or codes in accordance with which the Work under this Subcontract is to be performed, the edition or revision of the standards or codes current on the effective date of this Subcontract shall apply unless otherwise expressly stated. In case of conflict discovery between any referred standards / codes and any Subcontract Documents, Contractor shall determine the governing document. Based on this resolution the subcontractor shall continue the job without any delay subject to the provision that the matter of not accepting the Contractor’s resolution may be communicated in writing for future claims if so any.
GC-7 Laws And Regulations
All applicable laws, ordinances, statutes, rules, regulations, orders or decrees in effect at the time the Work under this Subcontract is performed shall apply to Subcontractor, its employees as well as representatives.
Subcontractor shall obtain all licenses necessary to carry on business in the country or countries and any political subdivisions thereof wherein any part of the Work is performed, shall give all required notices, shall furnish any necessary bonds, securities or deposits required by the relevant authorities to permit performance of the Work in any or all jurisdictional areas.
Subcontractor shall obtain all necessary licenses, temporary permits, authorizations and give all notices required from it under the laws of the nation (state, national, municipal, local or other laws).
Subcontractor shall not, under any circumstances, enter into negotiations with any governmental authority or agency to develop acceptance of variations or revisions to the nation law.
Subcontractor shall hold harmless, defend and indemnify Contractor and Owner from and against any liability or penalty which may be imposed upon by the nation governmental authorities on Contractor and Owner by reason of any alleged violation of the laws of the nation arising out of Subcontractor’s acts or omissions or of those of its personnel while performing Work in the national jurisdiction.
Subcontractor shall be fully aware of the latest local statutory requirements and ordinances which shall be included within the Subcontract price for all technical, commercial and financial effects of conforming with the requirements of all local regulatory bodies having any effect whatsoever on the performance of this Subcontract which effects shall be Subcontractor’s entire and sole liability as well as responsibility.
Subcontractor acknowledges that it is fully aware of the latest statutory requirements of relevant bodies for which price has been included within the Subcontract for all technical, commercial and financial effects of conforming with the requirements of all local regulatory bodies having an impact whatsoever on the performance of this Subcontract which effects are Subcontractor’s entire and sole liability as well as responsibility.
Subcontractor shall ensure that it is and its subcontractors are officially registered in the nation to the extent required by applicable laws and that they and their employees shall comply with sponsorship, immigration, residence and employment laws while in the nation.
If Subcontractor discovers any discrepancy or inconsistency between this Subcontract and any law, ordinance, statute, rule, regulation, order or decree, Subcontractor shall immediately notify Contractor in writing.
If during the term of this Subcontract, there occurs statute changes or imposition of new laws, ordinances, statutes, rules, regulations, orders or decrees (but excluding changes to tax laws where such taxes are based upon Subcontractor's inventory, income, profits/losses or cost of finance, and any taxes that may be levied on Subcontractor’s staff, agents and employees) in nation not known or foreseeable at the time of signing this Subcontract, which become effective impacting adversely the cost or time of performance of this Subcontract, Subcontractor shall immediately notify Contractor with detailed documentation of such effect in terms of both time and cost of performing the Subcontract. If the Work is affected by such changes and Contractor concurs with their effect, an equitable adjustment shall be made pursuant to the General Condition titled "Changes." This provision of the subcontract is very delicate in essence to be dealt with properly so as to prevent the parties from harming each other.
GC-8 Permits
Except as otherwise specified, Subcontractor shall procure and pay for all permits, licenses, certifications and other applicable governing authority fee requirements and inspections other than inspections performed by Contractor or Owner and shall furnish any documentation, bonds, security or deposits required to permit performance of the Work as a whole or in parts.
GC-9 Taxes
Subcontractor shall be liable for and shall indemnify Contractor against all taxes, imposts, duties, withholding taxes, charges or other dues or assessments of whatsoever nature levied on or chargeable to Subcontractor or its other subcontractors in the nation or elsewhere and payable on or in respect of anything done under the Subcontract or in connection therewith.
All taxes, imposts, duties, withholding taxes, charges or other dues or assessments of whatsoever nature levied on or chargeable by the government of the nation on Subcontractor or its subcontractors which are introduced after the effective date in respect of anything done under the Subcontract or in connection therewith and of which Subcontractor could not have been aware, shall be paid by Subcontractor and its subcontractors without delay and reimbursed by Contractor at actual cost.
Under no circumstances whatsoever, shall Contractor be liable to reimburse Subcontractor or its subcontractors, their servants, agents, staff or employees assigned to perform Work or provide any services hereunder in respect of any tax to which such servants, agents, staff or employees are or may after the effective date be subject or which Subcontractor or its subcontractors may by law or contract be required to pay or reimburse and which is levied by the government of the nation or any other government or jurisdiction on any payments made to or income, receipts or revenues of such servants, agents, staff or employees.
All payments relating to registration charges or sponsorship to enable Subcontractor and / or its subcontractors to work in the nation shall be to the sole account of Subcontractor.
Provided that the imports into the nation are effected through ports in the nation and provided further that the procedural requirements of the concerned authorities are complied with, Subcontractor shall not be liable for the payment of any customs duty levied by the government of the nation on goods imported for the performance of the Work under this Subcontract as Owner is exempt from such duty.
Subcontractor shall therefore import all goods into the nation only through ports in the nation and secure the release of goods imported for the performance of the Work from the customs authorities without paying any customs duty thereon. Contractor shall give to Subcontractor within five (5) working days of receipt of Subcontractor’s request such reasonable documentary support as Subcontractor may require for the purpose to represent to the relevant authorities the case of custom exemption on the goods imported for the project under this subcontract.
For the avoidance of doubt, this exemption shall not apply to Subcontractor’s construction plant and equipment / material imported in connections with the temporary works. Furthermore, Subcontractor alone shall be liable for any customs duty levied in respect of imports through ports other than ports in the nation and / or on account of failure to comply with the procedural requirements of the concerned authorities.
All port dues, landing pilotage, lighterage and all other dues and charges whatsoever relating to the importation of goods shall be to the sole account of Subcontractor.
Subcontractor shall pay all taxes, levies, duties and assessments of every nature due in connection with the Work under this Subcontract and shall make any and all payroll deductions and withholdings required by law and hereby indemnifies and holds harmless Contractor and Owner from any liability on account of any and all such taxes, levies, duties, assessments and deductions.
The aforesaid provision has been introduced to meet the requirement of the governments which consider exemption of any customs duties on certain goods to be used for the permanent inclusions on certain significant project.
GC-10 Labour, Personnel And Work Rules
Subcontractor shall employ only competent and skilled personnel to perform the Work and remove from the Jobsite any Subcontractor personnel determined to be unfit or to be acting in violation of any provision of this Subcontract. Subcontractor is responsible for maintaining labor relations in such manner that there is harmony among workers by complying with as well as enforcing Project and Jobsite procedures, regulations, work rules and work hours established by Contractor and Owner.
Contractor may at its sole discretion deny access to the Jobsite to any individual by written notice to Subcontractor. In the event an employee is excluded from the Jobsite, Subcontractor shall promptly replace such individual with another fully competent and skilled to perform the Work.
Subcontractor shall, to the extent permissible under applicable law, comply with the provisions of all labour agreement(s) which apply to the Work performed under this Subcontract. If required by the terms of any such labour agreement(s), Subcontractor shall, immediately after Subcontract award, agree to comply with and be bound by the terms of such labor agreement(s).
GC-11 Commercial Activities
Neither Subcontractor nor its employees shall establish any commercial activity or issue concessions or permits of any kind to third parties for establishing commercial activities on the Jobsite or any other lands owned or controlled by Contractor or Owner.
GC-12 Publicity And Advertising
Subcontractor shall not make any announcement, take any photographs or release any information concerning this Subcontract or the Project or any part thereof to any member of the public, press, business entity or any official body unless prior written consent is obtained from Contractor.
The taking of photographs or video of Owner’s existing facilities is not permitted without the prior written consent of Owner and Contractor.
All photographs or videos taken by Subcontractor shall be treated as confidential information subject to the provisions of the General Condition titled ‘Nondisclosure’ shall apply
GC-13 Safety and Health
Subcontractor shall be solely responsible for conducting operations under this Subcontract to avoid risk of harm to the health and safety of persons and property, for inspecting and monitoring all its equipment, materials and work practices to ensure compliance with its obligations under this Subcontract.
Subcontractor shall be solely responsible for developing and implementing a Health, Safety and Environment Plan (HSE) pursuant to the terms of this Subcontract. Subcontractor’s HSE Plan shall as a minimum conform and comply with:
All applicable laws, ordinances, statutes, rules, regulations and codes governing safety and health in the workplace;
Subcontractor’s specific Scope of Work under this Subcontract; and
Contractor’s safety and health standards as set forth in the Special Condition titled “Safety, Health And Security Requirements as well as Contractor’s and Owner’s HSE Plans, including revisions thereto.
Owner’s Commitment to Health, Safety and the Environment and Owner’s Health, Safety and Environmental Policies included within Contractor’s HSE Plan as Appendix 1 hereto.
Contractor highlights the following as key requirements for any site work, requiring Contractor approval, in order to allow the above work to proceed. These must be submitted for Contractor approval 10 working days before the start of work on site.
A full and comprehensive risk assessment of the activities and instigating mitigating measures to reduce the risk of any major accident to ALARP
A Project specific HSE Plan including interface document between Project and the existing Operations in line with Operator Code of Practice, Management of Contractor HSE and details of the necessary resource to implement it.
A Project specific Emergency Plan
SubContractor shall ensure that any SIMOPS activities are identified and formally reported to Contractor. SIMOPS reports shall be submitted 10 working days before the start of any work on site.
SubContractor may propose the use of his own procedures to replace some or all of those listed in Contractors HSE Plan subject to participating in an Interfacing Process with Contractor to agree any substituted procedures. The results of any Interface Meeting shall be documented by SubContractor and submitted in an HSE Interface Plan 10 working days before the start of work on site.
Subcontractor shall provide written details of how it shall comply with all relevant recommendations specified in the Phase HSEIA and its component documents, i.e. QRA, COMAH, CEMP, EIS.
Subcontractor shall abide by all Contractor’s and Owner’s HSE requirements/ regulations and all relevant legislation / statutory requirements including all laws, rules and regulations (as amended from time to time) of the governments of the nation or any other agency or authority whether relating to the existing facilities, the Site, the systems, the plant, the installations or the Project and shall make available all such requirements and regulations applicable to Subcontractor’s employees and its other subcontractors / instruct them to observe and abide by the said regulations.
Subcontractor shall when preparing all subcontracts and purchase orders, attach an instruction that all applicable HSE requirements of this Subcontract shall be complied with and clearly state that the terms of all such requirements are available on request and shall notify Contractor of any violations of such requirements and recommend corrective actions thereof.
Subcontractor shall take all other precautions necessary to protect persons and property from damage or injury arising out of the Work and shall obligate its subcontractors or other persons under its direction and control to comply with statutory, Owner and Contractor’s own regulations as applicable to the security of the Site and accommodation areas.
Subcontractor shall take all necessary precautions to avoid causing damage to services, including service lines such as cables, pipelines, etc. buried or otherwise and shall be liable to the owners of such utility services for any damage thereto arising out of or in relation with the performance of Work by Subcontractor, its employees, agents or subcontractors without prejudice to the provisions of the General Condition “Indemnity.”
Within thirty (30) calendar days after Subcontract award and in any event prior to commencing work at the Jobsite, Subcontractor shall submit its HSE Plan to Contractor for review and approval.
To the extent allowed by law, Subcontractor shall assume all responsibility and liability with respect to all matters regarding the safety and health of its employees and the employees of Subcontractor’s suppliers and subcontractors of any tier with respect to the risks under this Subcontract.
Subcontractor’s failure to correct any unsafe condition or unsafe act by its employees, suppliers or subcontractors regardless of tier may, at the sole discretion of Contractor be grounds for an order by Contractor to stop the affected work or operations until the unsafe act or condition is corrected to Contractor’s satisfaction at Subcontractor’s expense.
If the unsafe act or condition continues, including items such as poor housekeeping, despite notice and reasonable opportunity to effect a resolution, Contractor may, at its sole discretion, correct the unsafe act or condition at Subcontractor’s expense pursuant to the General Condition titled “Backcharges” or terminate this Subcontract pursuant to the General Condition titled “Termination For Default.”
Subcontractor shall assign to the Jobsite, on a full time basis, one (or more as necessary for compliance with the terms of this clause) HSE representative(s) acceptable to Contractor. Such HSE representative(s) shall be physically located at the Jobsite, be responsible for carrying out Subcontractor’s HSE plan, have authority for correcting unsafe acts or conditions by Subcontractor, its employees and employees of Subcontractor’s suppliers or subcontractors of any tier and shall participate in periodic HSE meetings with Contractor. Subcontractor, instruct its personnel on the requirements of Subcontractor’s HSE Plan, coordinate with other Jobsite contractors and subcontractors on HSE matters required for the Work.
Unless otherwise specified by Contractor, Subcontractor shall furnish all safety equipment required for the Work, require the use of such safety equipment and provide safety instructions to its employees. All safety equipment must be manufactured to a standard acceptable to Contractor as set forth in the Special Condition titled “Safety, Health And Security Requirements.”
Subcontractor shall maintain accident and injury records as required by applicable laws and regulations. Such records shall be made available to Contractor upon request. Subcontractor shall furnish Contractor with a weekly and monthly summary of accidents, injuries and labor hours / man hours lost to work related injuries of its employees and employees of Subcontractor’s suppliers and subcontractors of any tier, in an approved format designated by Contractor. Subcontractor shall develop and submit for Contractor approval a set of HSE Key Performance Indicators and report monthly on the performance of these. Sub-Contractor’s reporting procedures shall be described in detail in the HSE Plan.
Subcontractor shall develop and fund an HSE Incentive scheme covering his entire scope of work and describe such scheme in his HSE Plan. The scheme shall recognise the need for working with other Sub-Contractors to integrate to some extent with an overall scheme for the site.
Subcontractor shall immediately report to Contractor any death, injury or damage to property incurred or caused by Subcontractor’s employees and employees of Subcontractor’s suppliers and subcontractors of any tier.
Subcontractor shall acknowledge that it has received and reviewed a copy of Owner’s and Contractor’s Health, Safety and Environmental (HSE) requirements and regulations.
GC-14 Environmental Requirements
Throughout performance of the Work, Subcontractor shall conduct all operations in such a way as to minimize impact upon the natural environment and prevent any spread or release of contaminated or hazardous substances.
Subcontractor shall:
Comply with all applicable laws, regulations, ordinances, statutes, rules, and codes governing environmental requirements and conduct the Work based on the requirements of this Subcontract, including compliance with permit requirements and Project plans and approvals.
Provide all documentation required by all levels of governing authority or Contractor concerning environmental requirements.
Provide and maintain effective planning and field control measures for the following activities:
Wastewater discharges to land, surface water or groundwater,
Extraction/supply of water,
Storm water management,
Spill prevention and response,
Erosion and sedimentation control,
Air emissions and dust control,
Noise control,
Waste and hazardous waste management and
Work area restoration, including revegetation.
Archeological and Palaeontological discoveries
This shall include obtaining certifications; conducting requisite analyses and monitoring of such activities as required by the Subcontract Documents, permit conditions or other applicable law utilizing appropriate equipment and proceeding in accordance with permit requirements.
Be responsible for developing and maintaining a written Environmental Compliance Plan in accordance with Subcontractor’s established practices, including but not limited to compliance with all applicable laws/regulations and the requirements of the Owner’s and Contractor’s Project HSE Plan as well as Project Construction Environmental Control Plan (CECP). Subcontractor shall have sole responsibility for implementing and enforcing its Environmental Compliance Plan.
SubContractor Environmental Compliance Plan shall be submitted for Contractor Approval 10 days before the start of work on site. Contractor’s review of Subcontractor’s plan shall not relieve Subcontractor of its obligations under this Subcontract or as imposed by law. Subcontractor shall be solely responsible for the adequacy of its Environmental Compliance Plan, Comply with all access restrictions including prohibitions on access to certain areas on or adjacent to the Jobsite, require its personnel and those of its suppliers and subcontractors of any tier comply with all signage and flagging related to such restricted areas. Restricted areas may include but are not limited to: designated wetlands; environmental mitigation study areas; cultural / historical / archaeological sites; designated fish, wildlife or vegetative habitat.
Require that its personnel do not hunt, fish, feed, capture, extract or otherwise disturb aquatic, animal or vegetative species within the Project boundary or while performing any tasks in performance of the Work.
Subcontractor shall not proceed with any renovation or demolition work until asbestos surveys and notifications have been completed to the appropriate regulatory agencies, in accordance with the division of responsibility outlined in the Project’s CECP and Contractor specifically authorizes that work to proceed. Should asbestos containing materials be uncovered during Subcontractor’s Work, the provisions of subclause 9 below shall apply.
Immediately stop work in any area where contaminated soil indicators (such as odour or appearance), unknown containers, piping, underground storage tanks, or similar structures are discovered; or any other materials which are reasonably suspected to be toxic or hazardous. Subcontractor shall then immediately notify Contractor and the stop work area shall be determined by Contractor duly confirmed in writing. Activity in the stop work area shall only resume upon Contractor’s written approval.
Immediately stop work in any area where cultural resources or artifacts with archaeological or historical value are discovered and immediately notify Contractor. The stopped work shall proceed in the manner set forth in subclause 9 above. No artifacts, items or materials shall be disturbed or taken from the area of discovery. Neither Subcontractor nor any of its suppliers and subcontractors of any tier shall have property rights to such artifacts, items or materials which shall be secured and guarded until turned over to Contractor or the appropriate authorities. Subcontractor shall also require that its personnel and those of its suppliers, subcontractors of any tier comply with this provision, respect all historic and archaeological sites in the area. Manage, store and dispose of all hazardous waste generated by Subcontractor during its Work in accordance with national, regional, local requirements and as outlined in the Project CECP. This includes, but is not limited to: waste minimization; hazardous waste generator registration; hazardous materials inventory with Material Safety Data Sheets (MSDS) for each hazardous material on site; employee training; hazardous waste spill management and reporting; proper storage of hazardous waste; equipment decontamination; onsite and offsite transport of hazardous waste; selection, use of offsite interim and final disposal facilities.
Subcontractor’s obligations under the General Condition titled “Indemnity” apply to any liability arising in connection with or incidental to Subcontractor’s performance or failure to perform as provided in this clause.
In the event any pre-existing contamination is found at the Work site, immediate notification shall be made by Sub-Contractor to Contractor. Contractor shall liaise with company who shall evaluate and assess remedies required after sampling and testing such contaminated material in and around the locality of such material discovery. Company shall provide Contractor with all results of any test and sampling program which is to be passed to Sub-Contractor to provide support to company in assisting company or third parties to have contaminated waste removed form the site and disposed of in accordance with all applicable rules, regulations and legislation. The Work in the affected area may only resume after specific written authorization is received from company
GC-15 Site Conditions And Natural Resources
Subcontractor shall have the sole responsibility for satisfying itself concerning the nature, location of the Work, the general and local conditions, including but not limited to the following:
Transportation, access, disposal, handling and storage of materials;
Availability and quality of labor, water, electric power and road conditions;
Climatic conditions, tides and seasons;
River hydrology and river stages;
Physical conditions at the Jobsite and the Project area as a whole;
Topography and ground surface conditions; and
Equipment and facilities needed preliminarily to and during the performance of the Work.
The failure of Subcontractor to acquaint itself with any applicable conditions shall not relieve Subcontractor of the responsibility for properly estimating the difficulties, time or cost of successfully performing Subcontractor's obligations under this Subcontract.
GC-16 Differing Site Conditions
Subcontractor acknowledges that it has satisfied itself as to the character, quality and quantity of surface and sub-surface materials or obstacles to be encountered insofar as this information is reasonably ascertainable from inspection of the Jobsite, including all exploratory work as well as from the drawings and Specifications provided under this Subcontract.
Where Contractor or Owner has made investigations of subsurface conditions in areas where work is to be performed under this Subcontract, such investigations are made by Contractor or Owner for the purpose of study and design. If the records of such investigation are included in the Subcontract Documents, the interpretation of such records shall be the sole responsibility of Subcontractor. Neither Contractor nor Owner assumes any responsibility whatsoever in respect to the sufficiency or accuracy of such investigations, the records thereof or of the interpretations set forth. There is no warranty or guarantee either express or implied that the conditions indicated by such investigations or records thereof, are representative of those existing throughout such areas or any part thereof or that unforeseen developments may not occur or that materials other than or in proportions different from those indicated may not be encountered.
Subcontractor shall immediately notify Contractor in writing before proceeding with any work which Subcontractor believes constitutes a differing site condition with respect to:
Subsurface or latent physical conditions at the Jobsite differing materially from those indicated in this Subcontract; or
Previously unknown physical conditions at the Jobsite of an unusual nature, differing materially from those ordinarily encountered and generally recognized as inherent in work of the character provided for in this Subcontract.
Contractor shall then investigate such conditions and make a written determination. If Contractor determines that such condition does constitute a differing site condition, Subcontractor may then pursuant to the General Condition titled "Changes," submit a written proposal for an equitable adjustment setting forth the impact of such differing site condition. Failure of Subcontractor to give the required immediate notice of the differing site condition, shall be made grounds for rejection of the claim to the extent Contractor or Owner is prejudiced by such delay.
GC-17 Title To Materials Found
The title to water, soil, rock, gravel, sand, minerals, timber and any other materials developed or obtained in the excavation or other operations of Subcontractor or any of its lower-tier subcontractors and the right to use said materials or dispose of same is hereby expressly reserved by Owner. Neither Subcontractor nor its subcontractors of any tier nor any of their representatives or employees shall have any right or interest in said materials nor shall they assert or make any claim thereof.
GC-18 Survey Control Points And Layouts
Survey control points as shown on the drawings shall be established by Contractor.
Subcontractor shall complete the layout of all work and be responsible for execution of the Work in accordance with the locations, lines and grades specified or shown on the drawings subject to such modifications as Contractor may require while work progresses.
If Subcontractor or any of its lower-tier subcontractors or any of their representatives or employees move or destroy or render inaccurate any survey control point, such control point shall be replaced by Contractor at Subcontractor's expense. No separate payment shall be made for survey work performed by Subcontractor.
GC-19 Subcontractor's Work Area
All Subcontractor work areas on the Jobsite shall be assigned by Contractor. Subcontractor shall confine its operations to the areas so assigned. Should Subcontractor find it necessary or advantageous to use any additional off-site area for any purpose whatsoever, Subcontractor shall at its expense provide and make its own arrangements for the use of such additional off-site areas.
GC-20 Cleaning Up
Subcontractor shall at all times keep its work areas in a neat, clean and safe condition. Upon completion of any portion of the Work, Subcontractor shall promptly remove from the work area all its equipment, construction plant, temporary structures and surplus materials not to be used at or near the same location during later stages of the Work.
Upon completion of the Work and prior to final payment, Subcontractor shall at its expense satisfactorily dispose of all rubbish, remove all plant, buildings, equipment and materials belonging to Subcontractor and return to Contractor's warehouse or Jobsite storage area all salvageable Contractor or Owner supplied materials. Subcontractor shall leave the premises in a neat, clean and safe condition.
In event of Subcontractor's failure to comply with the foregoing requirements, Contractor may accomplish cleaning up at Subcontractor's expense.
GC-21 Cooperation With Others
Contractor, Owner, other contractors and other subcontractors shall be working at the Jobsite during the performance of this Subcontract and Subcontractor's work or use of certain facilities may be interfered with as a result of such concurrent activities. Contractor reserves the right to require Subcontractor to schedule the order of performance of the Work in such a manner as shall minimize interference with work of any of the parties involved.
GC-22 Responsibility For Work, Security And Property
A. Work in Progress, Equipment and Material. Subcontractor shall be responsible for and bear any and all risk of loss or damage to work in progress pursuant to the Special Condition titled "Title And Risk Of Loss," to equipment and materials.
B. Delivery, Unloading and Storage. Subcontractor's responsibility for materials and plant equipment required for the performance of this Subcontract shall include:
Receiving and unloading;
Storing in a secure place and in a manner subject to Contractor's review. Outside storage of materials and equipment subject to degradation by the elements shall be in weathertight enclosures provided by Subcontractor;
Delivering from storage to construction site all materials and plant equipment as required; and
Maintaining complete and accurate records for Contractor's inspection of all materials and plant equipment received, stored and issued for use in the performance of the Subcontract.
C. Security. Subcontractor shall at all times conduct all operations under this Subcontract in a manner to avoid the risk of loss, theft or damage by vandalism, sabotage or any other means to any equipment, materials, work or other property at the Jobsite. Subcontractor shall continuously inspect all equipment, materials and work to discover and determine any conditions which might involve such risks and be solely responsible for discovery, determination & sequential correction of any such conditions.
Subcontractor shall comply with Contractor's and Owner's security requirements for the Jobsite. Subcontractor shall cooperate with Contractor and Owner on all security matters promptly complying with any Project security arrangements established by Contractor or Owner. Such compliance with these security requirements shall not relieve Subcontractor of its responsibility for maintaining proper security for the above noted items, nor it be construed as limiting in any manner Subcontractor's obligation with respect to all applicable laws and regulations and to undertake reasonable action to establish and maintain secure conditions at the Jobsite.
D. Property. Subcontractor shall plan and conduct its operations so as not to:
Enter upon lands in their natural state unless authorized by Contractor;
Damage, close or obstruct any utility installation, highway, road or other property until permits and Contractor's permission thereof have been obtained;
Disrupt or otherwise interfere with the operation of any pipeline, telephone, electric transmission line, ditch or structure unless otherwise specifically authorized by this Subcontract; or
Damage or destroy cultivated and planted areas and vegetation such as trees, plants, shrubs and grass on or adjacent to the premises which as determined by Contractor do not interfere with the performance of this Subcontract. This includes damage arising from performance of work through operation of equipment or stockpiling of materials.
Subcontractor shall not be entitled to any extension of time or compensation on account of Subcontractor's failure to protect all facilities, equipment, materials and other property as described herein. All costs in connection with any repairs or restoration necessary or required by reason of unauthorized obstruction, damage or use shall be borne by Subcontractor.
GC-23 Subcontractor's Plant, Equipment And Facilities
Subcontractor shall provide and use for the Work only such construction plant and equipment as are fit to producing the quality and quantity of work and materials required by this Subcontract within the time or times specified therein on Schedule.
Subcontractor shall mobilise to the site all necessary construction plant, equipment and tools of every kind required for the performance, execution and completion of the Work. If such construction plant, equipment and tools brought on Jobsite are not sufficient in the opinion of Contractor, Subcontractor shall provide at its expense such additional construction plant, equipment and tools as Contractor deems necessary.
Before proceeding with the Work, Subcontractor shall furnish Contractor with information and drawings relative to such equipment, plant and facilities as Contractor may request. Upon written order of Contractor, Subcontractor shall discontinue operation of unsatisfactory plant, equipment or facilities and either modify the unsatisfactory items or remove such items from the Jobsite.
Subcontractor shall, at the time any equipment is moved onto the Jobsite, present to Contractor an itemized list of all equipment and tools including but not limited to power tools, welding machines, pumps and compressors which list must include description, quantity and serial number where applicable. It is recommended that Subcontractor identify its equipment by color (other than yellow), decal and etching. Prior to removal of any or all equipment, Subcontractor shall clear such removal through Contractor. Subcontractor shall not remove construction plant, equipment or tools from the Jobsite before the Work is finally accepted without Contractor's written approval.
All Subcontractor’s construction plant, Goods and other things provided by Subcontractor shall, when brought on the Jobsite, be deemed to be exclusively intended for the purpose of the Work, which or any part thereof, Subcontractor shall not remove same while required at the Jobsite.
GC-24 Illumination
When any work is performed at night or where daylight is obscured, Subcontractor shall at its expense, provide artificial light sufficient to permit work to be carried on efficiently, satisfactorily and safely permitting thorough inspection. During such time periods, the access to the place of work shall also be clearly illuminated. All wiring for electric light and power shall be installed and maintained in a safe manner meeting all applicable codes and standards.
GC-25 Use Of Completed Portions Of Work
Whenever, as determined by Contractor, any portion of the Work performed by Subcontractor is suitable for use, Contractor or Owner may, upon written notice, occupy and use such portion. Use shall not constitute acceptance or relieve Subcontractor of its responsibilities or act as a waiver by Contractor or Owner of any terms of this Subcontract.
Subcontractor shall not be liable for normal wear and tear or for repair of damage caused by any misuse during such occupancy or use by Contractor or Owner. If such use increases the cost or time of performance of remaining portions of the Work, Subcontractor shall pursuant to the General Condition titled "Changes," be entitled to an equitable adjustment in its compensation or schedule under this Subcontract.
If, as a result of Subcontractor's failure to comply with the provisions of this Subcontract, such use proves to be unsatisfactory to Contractor or Owner, Contractor or Owner shall have the right to continue such use until such portion of the Work can, without injury to Contractor or Owner, be taken out of service for correction of defects, errors, omissions or replacement of unsatisfactory materials or equipment as necessary for such portion of the Work to comply with the Subcontract; provided that the period of such operation or use pending completion of appropriate remedial action shall not exceed twelve (12) months unless otherwise mutually agreed in writing between the parties.
Subcontractor shall not use any permanently installed equipment unless such use is approved in writing by Contractor. When such use is approved, Subcontractor shall at Subcontractor's expense properly use, maintain and upon completion of such use, recondition such equipment as required to meet specifications.
If Contractor or Owner furnishes an operator for such permanently installed equipment, all services performed shall be under the complete direction and control of Subcontractor while such operator be considered Subcontractor's employee for all purposes other than payment of such operator's wages, Workers' Compensation Insurance or other benefits.
GC-26 Use Of Contractor's Construction Equipment Or Facilities
Where Subcontractor requests Contractor and Contractor agrees to make available to Subcontractor certain equipment or facilities belonging to Contractor for the performance of Subcontractor work under the Subcontract, the following provisions shall apply:
Equipment or facilities shall be charged to Subcontractor at agreed rental rates;
Contractor shall furnish a copy of the equipment maintenance and inspection record which be maintained by Subcontractor during the rental period;
Subcontractor shall assure itself of the condition of such equipment assuming all risks and responsibilities during its use;
Subcontractor shall, as a part of its obligation under the General Condition titled "Indemnity," release, defend, indemnify and hold harmless Contractor and Owner from all claims, demands and liabilities arising from the use of such equipment.
Contractor and Subcontractor shall jointly inspect such equipment before its use and upon its return. The cost of all necessary repairs or replacement for any damage other than normal wear shall be at Subcontractor's expense; and
If such equipment is furnished with an operator, the services of such operator shall be performed under the complete direction and control of Subcontractor while such operator be considered Subcontractor's employee for all purposes other than for the payment of wages, Workers' Compensation Insurance or other benefits.
GC-27 First Aid and Medical Facilities
Sub-Contractor shall establish a Clinic to provide for the entire construction workforce. This shall be staffed on a 24 hour a day basis by qualified medical personnel, including Doctors. The Clinic provision is in addition to the provision of qualified first aiders and first aid facilities by each Major Sub-Contractor.
Subcontractor shall be responsible for providing first aid and first aid facilities for all Subcontractor’s and its lower tier subcontractor’s personnel employed in the performance of the Work in and around the Jobsite including Subcontractor’s camp location. Such facilities shall conform to the laws and regulations of the nation and company with all medical requirements.
The construction site is located in an area where international standard hospitals are available. There is also a hospital about … km from the construction site. Therefore, an infrastructure and organisation is already established with which Sub-Contractor shall establish agreements that allow extension for the use of these facilities by all personnel on the plant area.
Where Contractor or Owner have first-aid facilities at the Jobsite they may, at their option make available their first-aid facilities for the treatment of employees of Subcontractor who be injured or become ill while engaged in the performance of the Work under this Subcontract.
If First Aid facilities and/or services are made available to Subcontractor's employees then in consideration for the use of such facilities and the receipt of such services, Subcontractor hereby agrees:
To include as a part of its obligation under the General Condition titled "Indemnity" the obligation to release, defend, indemnify and hold harmless, Contractor and Owner from all claims, demands and liabilities arising from the use of such services or facilities; and
In the event any of Subcontractor's employees require off-site medical services including transportation thereto to promptly pay for such services directly to the providers thereof. It is also added that a full time ambulance facility shall be available on the plant location to meet any emergency.
GC-28 Inspection, Quality Surveillance, Rejection Of Materials And Workmanship
Any inspection or testing of any part of the Goods or Work at any location for its preparation, that check is required under the codes and standards specified in the Subcontract, shall be the responsibility of Subcontractor.
Subcontractor shall allow Contractor and/or Owner the freedom of access at all reasonable times to all places where Work is performed or relevant information is stored for the purpose of reviewing the conduct and progress of Work for the purpose of quality assurance.
Contractor shall have free access to all documents in Subcontractor’s possession prepared or in the course of preparation in performance of Work including those services performed by its subcontractors within three (3) working days of the written request.
All material and equipment furnished and work performed shall be properly inspected by Subcontractor at its expense and at all times be subject to quality surveillance / quality audit by Contractor, Owner or their authorized representatives who upon reasonable notice be afforded full and free access to the shops, factories or other places of business of Subcontractor, its suppliers and subcontractors of any tier for such procedures. Subcontractor shall provide all necessary equipment, fuel, power, tackle, labor, instruments, safe and adequate facilities, drawings, documents and samples as requested, provide assistance and cooperation including stoppage of work to perform such examination as may be necessary to determine compliance with the requirements of this Subcontract. No Work shall be covered up or put out of view without the consent of Contractor and Owner. Subcontractor shall afford full opportunity for Contractor and Owner to examine any Work which is about to be covered up or put out of view and/or to examine foundations before equipment or Systems are placed thereon. Failure of Contractor or Owner to make such quality surveillance or to discover defective design, equipment, materials or workmanship shall not relieve Subcontractor of its obligations under this Subcontract nor prejudice the rights of Contractor or Owner thereafter to reject or require the correction of defective work in accordance with the provisions of this Subcontract.
Subcontractor shall notify Contractor at least eighteen (18) days in advance of the date on and the place at which any part of the Goods or Work shall be ready for testing. Should any postponement become necessary, Subcontractor shall provide written notification at least nine (9) days prior to the originally scheduled date for inspections outside of the nation and seventy-two (72) hours prior to the originally scheduled date for inspections within nation. Contractor shall give Subcontractor twenty-four (24) hours notice in writing of its intention to attend the test or ask for a postponement of not more than forty-eight (48) hours, if required.
If any work is determined by Contractor or Owner to be defective or not in conformance with this Subcontract, the provisions of the General Condition titled "Warranty" shall apply.
GC-29 Testing
Unless otherwise provided in the Subcontract, testing of equipment, materials or work shall be performed by Subcontractor at its expense in accordance with Subcontract requirements. Should tests in addition to those required by this Subcontract be desired by Contractor, Subcontractor shall be given reasonable notice to permit such testing. Such additional tests shall be at Contractor's expense.
Subcontractor shall furnish samples as requested , provide reasonable assistance and cooperation necessary to permit tests to be performed on materials or work in place including reasonable stoppage of work during testing.
GC-30 Expediting
The equipment and materials furnished and work performed under this Subcontract shall be subject to expediting by Contractor or its representatives be afforded full and free access to the shops, factories and other places of business of Subcontractor, its suppliers and subcontractors of any tier for expediting purposes. As required by Contractor, Subcontractor shall provide detailed schedules and progress reports for use in expediting and cooperate with Contractor in expediting activities.
GC-31 Force Majeure
No delay or failure in performance by either party shall constitute default or give rise to any claim for damages to the extent such delay or failure is caused by Force Majeure. Unless such Force Majeure substantially frustrates performance of this Subcontract, Force Majeure shall not operate to excuse, but only to delay performance.
The term "Force Majeure" as employed herein shall be defined as strikes (excluding strikes occurring among the employees of Subcontractor or its subcontractors of any tier) or other industrial disturbances of a general nature, acts of the public enemy, wars, undeclared wars, acts of terrorism acts of governments including the governments of the nation or else, blockades, insurrections, riots, epidemics, landslides, earthquakes, lightning, civil disturbances, explosions and any other cause or event which is unavoidable, insurmountable and similar to the kind herein enumerated or equivalent forces not within control of the Party affected thereby, which that Party is unable to overcome by the exercise of due diligence.
Delays attributable to and within the control of Subcontractor's suppliers or subcontractors of any tier shall be deemed delays within the control of Subcontractor.
If Subcontractor's performance of this Subcontract is delayed by a Force Majeure occurrence, Subcontractor shall immediately provide Contractor written notification of the delay and its estimated duration. Immediately upon termination of the Force Majeure occurrence, Subcontractor shall:
Notify Contractor of resumption of work; and
Submit a plan to minimize and mitigate the effect of the Force Majeure occurrence upon completion of the Work.
Any claim on the part of Subcontractor for an extension of time by reason of a suspension under this clause shall be made within a reasonable time after the end of the suspension. Subcontractor shall promptly submit for review a revised schedule for performance of Work. Subject to the provisions of this General Condition as set forth below, such extension shall be the sole remedy for the delay.
If a suspension of any obligation by virtue of this clause lasts for a continuous period of Thirty (30) days, Contractor may terminate this Subcontract forthwith in whole or in part by so notifying Subcontractor in writing. Such termination by Contractor shall take effect on receipt by Subcontractor of the written notice. Upon such termination both Parties shall be released from any further obligations under the Subcontract but both Parties retain all rights and claims arising prior to the effective date of the termination. The provisions of this paragraph shall apply mutatis mutandis to Subcontractor save that Subcontractor shall have the right of termination only after the suspension under this clause lasts for a continuous period of ninety (90) days.
If Contractor elects not to terminate the Subcontract as stated above then the Work shall be deemed suspended with effect from the expiry of the said thirty (30) day period and thereafter, the provisions of the General Condition titled Suspension shall apply)
Force Majeure shall not include financial distress of either Party.
GC-32 Changes
Contractor may at any time without notice to the sureties if any, by written Change Notice unilaterally make any change in the Work within the general scope of this Subcontract, including but not limited to changes:
In the drawings, designs or specifications;
In the method, manner or sequence of Subcontractor work;
In Contractor or Owner-furnished facilities, equipment, materials, services or site(s);
Directing acceleration or deceleration in performance of the Work and
Modifying the Subcontract Schedule or the Subcontract Milestones.
In addition, in the event of an emergency which Contractor determines endangers life or property, Contractor may use oral orders to Subcontractor for any work required by reason of such emergency. Subcontractor shall commence and complete such emergency work as directed by Contractor. Such orders shall be confirmed by Change Notice.
All other modifications to this Subcontract shall be by written Amendment signed by both parties.
If at any time, Subcontractor believes that acts or omissions of Contractor or Owner constitute a change to the Work not covered by a Change Notice, Subcontractor shall within eight / ten (8 / 10) calendar days of discovery of such act or omission, submit a written Change Notice Request explaining in detail the basis for the request. Contractor shall either issue a Change Notice or deny the request in writing.
If any change under this clause directly or indirectly causes an increase or decrease in the cost of or the time required for, the performance of any part of the Work under this Subcontract whether or not changed by any order, an equitable adjustment shall be made and the Subcontract modified accordingly.
Contractor shall not accept any request for a Change Notice from Subcontractor where the scope of the Works and concept of the Project’s overall objectives are not affected, where the requested Change Notice is merely a closer definition, change in detail or alteration in the manner in which the Works are to be carried out or which is normal engineering development. Should any work or Goods be required which are not denoted in the Specifications or elsewhere in the Subcontract but which in the reasonable opinion of Contractor and by exercise of Subcontractor’s stated expertise and application of normal good engineering and construction standards can be considered necessary for the proper execution of the Works then Subcontractor shall perform this work or furnish said Goods as if so denoted without request for a Change Notice.
If Subcontractor intends to assert a claim for an equitable adjustment under this clause, it must within eight (8) calendar days after receipt of a Change Notice, provide written notification of such intent and within a further twenty (20) calendar days, pursuant to the Special Condition titled "Pricing Of Adjustments," submit to Contractor a written proposal setting forth the nature, schedule impact and monetary extent of such claim in sufficient detail to permit thorough analysis and negotiation.
Any delay by Subcontractor in giving notice or presenting a proposal for adjustment under this clause shall be grounds for rejection of the claim if and to the extent Contractor or Owner is prejudiced by such delay. In no case shall a claim by Subcontractor be considered if asserted after final payment under this Subcontract.
Subcontractor shall also demonstrate through the critical path programme and logic diagram the specific effect on the Schedule of each Change Notice which in Subcontractor’s opinion shall result in a revision to the completion date and/or to any specific Milestone date that has been established in the Subcontract.
Failure by Contractor and Subcontractor to agree on any adjustment shall be a dispute within the meaning of the General Condition titled "Disputes."
Subcontractor shall proceed diligently with performance of the Work pending final resolution of any request for relief, dispute, claim, appeal or action arising under the Subcontract and comply with any decision of Contractor.
Subcontractor shall maintain separate accounts for each Change Notice.
GC-33 Disputes
Subcontractor shall not be entitled to claim and neither Contractor nor Owner shall be liable to Subcontractor or its lower-tier suppliers or subcontractors in tort (including negligence), or Subcontract except as specifically provided in this Subcontract.
Any claim arising out of or attributable to the interpretation or performance of this Subcontract which cannot be resolved by negotiation shall be considered a dispute within the meaning of this clause.
If for any reason Contractor and Subcontractor are unable to resolve a claim for an adjustment, Contractor or Subcontractor shall notify the other party in writing that a dispute exists and request or provide a final determination by Contractor. Any such request by Subcontractor shall be clearly identified by reference to this clause and shall summarize the facts in dispute and Subcontractor's proposal for resolution.
Contractor shall, within thirty (30) calendar days of any request by Subcontractor, provide a written final determination setting forth the contractual basis for its decision and defining what Subcontract adjustments it considers equitable. Upon Subcontractor's written acceptance of Contractor's determination the Subcontract shall be modified and the determination implemented accordingly or, failing agreement, Contractor may in its sole discretion pay such amounts and/or revise the time for performance of the Work in accordance with Contractor's final determination.
If Contractor’s final determination is not accepted by Subcontractor the Parties agree to proceed in accordance with Special Condition SC-45 titled “Arbitration”.
Subcontractor shall not at any time suspend performance of the Work or any of its obligations under the Subcontract pending resolution or settlement of a dispute and shall proceed with all due diligence with the Work and all its other obligations in full compliance with the Subcontract.
GC-34 Records And Audit
Subcontractor shall maintain records and accounts in connection with the performance of this Subcontract which shall accurately document incurred costs, both direct and indirect of whatever nature for a period of five (5) years from the expiration of Subcontractor's warranty unless otherwise specified by applicable law.
Contractor and/or Owner or its duly authorised representative shall have access at all reasonable times to Subcontractor’s and its other subcontractors’ books, records, correspondence, instructions, invoices, plans, drawings, receipts, vouchers and memoranda of every description pertaining to Work for the purpose of auditing and verifying the cost of the Work or for any other reason associated with Work. Such right shall not extend to the audit of the makeup of any lump sum price, any fixed prices, unit rates or percentage mark-ups contained in Exhibit “C” and to the audit of changes agreed on lump sum basis. Subcontractor is under no obligation to provide priced copies of subcontract agreements and purchase orders relating to any lump sum price.
Contractor and/or Owner and its authorised representatives shall have the right to reproduce any of the aforesaid documents. Subcontractor shall include in its subcontracts a similar obligation on part of its subcontractors.
GC-35 Warranty
Engineering and Design Warranty
Subcontractor warrants that the design, basic and detailed engineering of the Project and any part thereof shall be performed by Subcontractor in accordance with accepted international standards of good engineering, management and industrial practices; conform to the specifications and descriptions set forth in the Subcontract documents; meet the performance guarantees stated in this Subcontract and function accordingly.
Construction Warranty
Subcontractor warrants that the construction and workmanship under this Subcontract shall be executed in a professional and workmanlike manner, be free from defects and conform to specifications and other requirements contained in the Subcontract documents or with other specifications mutually agreed upon.
Warranty Of Goods
Subcontractor guarantees title to all goods procured and/or supplied by it and warrants the merchantability and fitness of such goods for the use intended under this Subcontract. Subcontractor further warrants that all goods designed, specified and procured by it and used for or included in the Installations shall be new and conform to the specifications contained in the Subcontract or with other specifications mutually agreed upon and that such goods used for or installed, shall be procured only from good, reputable and responsible vendors. If any such items are found defective, Subcontractor shall at Contractor’s and/or Owner’s option, rectify or replace such defective item at its own cost.
Decennial Structure Warranty
Subcontractor warrants the safety, soundness and stability of the Installations and its liability therefrom, shall be subject to the mandatory provisions of the laws of the nation.
Painting & Coating Work Warranty
Subcontractor warrants that the paint and coatings used on the Installations shall be free from defects, fit for the purpose. its preparation and application shall be carried out in conformity with the specifications in a professional and workmanlike manner by certified personnel
Consequences
If at any time until the expiry of the warranty period, the Work, Installations or the design or basic and detailed engineering thereof, are shown to be defective, deficient or otherwise inadequate by reason of any act, breach, default or omission by Subcontractor whether negligent or not or should Subcontractor fail to comply with the representations and warranties set forth in this Subcontract then Subcontractor shall, at its own cost and expense, promptly re-perform all necessary work whereby such corrections and changes to the Work, Installations and the design, basic and detailed engineering thereof are carried out as are necessary to remedy or correct the said defects, deficiencies or inadequacies and to meet the said representations and warranties including without limitation:
a. procuring, testing, inspecting, insuring, freighting and shipping of repaired or replacement goods to the Jobsite;
b. dismantling the affected goods, Installations and reinstalling repaired or replacement goods, Installations; and
c. testing or re-testing the whole or any part of the Installations so affected.
If Subcontractor fails to meet its warranty obligations or to re-perform work or rectify or remedy any defects, deficiencies or inadequacies in the Work, Installations within a reasonable time after receipt of a written notice by Contractor so to do then Contractor may re-perform the work or rectify or remedy the defects or deficiencies or inadequacies or procure the services of others to do so at Subcontractor risk who shall bear all costs incurred as a result thereof and Contractor shall be entitled to deduct the whole or any costs or expenses incurred from any monies due to Subcontractor under this Subcontract or otherwise recover them from Subcontractor.
Saving Of Other Rights
The foregoing warranties shall not be interpreted as a limitation upon but are in addition to all other warranties and guarantees expressed in the Subcontract which shall apply in all respect of the Work.
Warranty Period
The Warranty Period is as defined in Special Condition SC-1 titled “Definitions”
Except as otherwise stated in below with respect to the Decennial Structure Warranty and Extensions to Warranty Period, the guarantees, representations and warranties given by Subcontractor, the liability of Subcontractor to correct and remedy defects, deficiencies or inadequacies, shall apply throughout the Warranty Period and provided that Subcontractor has fulfilled all its warranty and other obligations under this Subcontract and subject to Subcontractor having issued to Contractor a form of release in a format agreed by Contractor, Contractor shall issue the final acceptance certificate to Subcontractor at the end of Warranty Period.
Any Work re-performed, replaced, remedied or rectified hereunder shall itself be warranted by Subcontractor on the terms of this clause for a single period of twelve (12) months commencing from the date of acceptance by Contractor of such re-performed, replaced, remedied or rectified Work provided however that the Warranty Period shall not in aggregate exceed twenty-seven (27) months from the effective date of the issuance of Plant Test Run Certificate or twenty-four (24) months from the effective date of the last Provisional Acceptance Certificate but without prejudice to the provisions below in respect of any extended warranty.
If in the period following the commencement of Warranty Period, re-performance or rectification of any defective, deficient or inadequate Work causes the entire plant or systems to be shut down, the representations and warranties and the liability of Subcontractor to correct and remedy defects, deficiencies or inadequacies shall remain in force and issuance of the Final Acceptance Certificate be deferred by a period of time equal to the period from shutdown until the completion of the re-performance or rectification of the defective, deficient or inadequate Work and acceptance thereof by Contractor.
Extensions To Warranty Period
Subcontractor’s liability to re-perform, rectify and remedy defects, deficiencies or inadequacies in the Work, Installations shall extend beyond the Warranty Period in the following circumstances:
(a) Subcontractor’s decennial liability to OWNER stated above shall continue until it expires in accordance with the laws of the nation
(b) Subcontractor shall be considered to have discharged any painting warranty on the expiry of a period of five (5) years from the date of issuing the last Provisional Acceptance Certificate.
Any other warranty obligation expressly stated in the Subcontract to survive the Warranty Period.
Subcontractor's Primary Responsibility
Subcontractor shall be primarily liable with respect to all guarantees, representations and warranties set forth in the Subcontract including warranties with respect to its subcontractors or vendors whether or not, any event or defect, deficiency or inadequacy is covered by a subcontractor or vendor warranty and Contractor need only seek recourse from Subcontractor for re-performance, rectification or remedial action.
Subcontractor warrants to Contractor and Owner that equipment and materials furnished under this Subcontract shall be new, of clear title and of the most suitable grade of their respective kinds for their intended uses, unless otherwise specified. All workmanship shall be first class and performed in accordance with sound construction practices acceptable to Contractor. All equipment, materials and workmanship shall also conform to the requirements of this Subcontract.
Subcontractor warrants all equipment and material it furnishes and all work it performs against defects in design, equipment, materials or workmanship for a period from Work commencement to a date twelve (12) months after acceptance of the Project as a whole by Owner.
If at any time during the warranty period, Contractor, Owner or Subcontractor discovers any defect in the design, equipment, materials or workmanship, immediate written notice shall be given to the other parties. Subcontractor shall within a reasonable time propose corrective actions to cure such defects to meet the requirements of this Subcontract.
Contractor at its sole discretion, may direct Subcontractor in writing and Subcontractor agrees to:
Rework, repair or remove and replace defective equipment and materials or re-perform defective workmanship to acceptable quality at a time and in a manner acceptable to Contractor;
Cooperate with others assigned by Contractor to correct such defects and pay to Contractor all actual costs reasonably incurred by Contractor in performing corrective actions; or
Propose and negotiate in good faith an equitable reduction in the Subcontract price in lieu of corrective action.
All costs incidental to corrective actions including demolition for access, removal, disassembly, transportation, reinstallation, reconstruction, retesting and re-inspection as may be necessary to correct the defect and to demonstrate that the previously defective work conforms to the requirements of this Subcontract shall be borne by Subcontractor.
Subcontractor further warrants that any and all corrective actions it performs against defects in design, equipment, materials and workmanship for a period of twelve (12) months in addition to any existing warranty period following acceptance by Contractor of the corrected work.
Warranty Shutdown Inspection
At an appropriate time to be decided at Owner’s and/or Contractor’s sole discretion, but in any case prior to the end of the Warranty Period, a warranty shutdown of the Installations shall be conducted to inspect and record the condition of the Installations. The shutdown may, at the discretion of the Contractor be performed in modular fashion to suit Owner’s operational requirements
Contractor shall provide Subcontractor a notice of twenty one (21) days in respect of its plan for warranty shutdown of the Installations. Subcontractor shall attend the inspection of the Installations during the said warranty shutdown along with Owner and Contractor personnel and assist Owner and/or Contractor in recording all defects and deficiencies in the Installations. Any defects and deficiencies observed in the Installations shall be rectified by Subcontractor in accordance with its warranty obligations under the Agreement.
Should Subcontractor fail to attend the inspection of the Installations as notified, Owner And Contractor shall have the right to proceed with the inspections on its own. Any defects and deficiencies observed by Owner and / or Contractor and notified to Subcontractor following such inspection shall be rectified by the Subcontractor without recourse to another inspection.
Subcontractor shall prior to commencement of the remedial work demonstrate its readiness in terms of adequate resources and manpower and all such work shall be performed on a round the clock basis.
GC-36 Backcharges
Contractor may, in addition to any other amounts to be retained hereunder, retain from any sums otherwise owing to Subcontractor amounts sufficient to cover the full costs of any of the following:
Subcontractor’s failure to comply with any provision of this Subcontract or Subcontractor’s acts or omissions in the performance of any part of this Subcontract but not limited to violation of any applicable law, order, rule or regulation including those regarding safety, hazardous materials or environmental requirements;
Correction of defective or nonconforming work by redesign, repair, rework, replacement or other appropriate means when Subcontractor states or by its actions indicates that it is unable or unshalling to proceed with corrective action in a reasonable time; and/or
Contractor agrees to or is required to take action or perform work for Subcontractor such as cleanup, off-loading or completion of incomplete work.
Contractor may also backcharge against Subcontractor for work done or cost incurred to remedy these or any other Subcontractor defaults, errors, omissions or failures to perform or observe any part of this Subcontract. Contractor may, but shall not be required to give Subcontractor written notice before performing such actions or work or incurring such cost.
The cost of backcharge work shall include:
Incurred labour costs including all payroll additives;
Incurred net delivered material costs;
Incurred lower-tier supplier and subcontractor costs directly related to performing the corrective action;
Equipment and tool rentals at prevailing rates in the Jobsite area; and
A factor of sixty percent (60%) applied to the total of Items for Contractor's overhead, supervision and administrative costs.
The backcharge notice may request Subcontractor's concurrence for Contractor to proceed with the required action or work. Subcontractor’s failure to concur shall not impair Contractor's right to proceed with the action or work under this or any other provision of this Subcontract.
Contractor shall separately invoice or deduct from payments otherwise due to Subcontractor the backcharge costs. Contractor's right to backcharge is in addition to any / all other rights and remedies provided in this Subcontract or by law. The performance of backcharge work by Contractor shall not relieve Subcontractor of any of its responsibilities under this Subcontract including but not limited to express or implied warranties, specified standards for quality, contractual liabilities, indemnifications as well as meeting the Subcontract Milestones of the Special Condition titled "Commencement, Progress and Completion Of The Work."
GC-37 Indemnity
Subcontractor hereby releases and shall indemnify, defend, hold harmless Contractor, Owner, their subsidiaries, affiliates and the officers, agents, employees, successors, assignees and authorized representatives of all the foregoing from and against any and all suits, actions, legal or administrative proceedings, claims, demands, damages, liabilities, interest, attorney's fees, costs, expenses, and losses of whatsoever kind or nature in connection with or incidental to the performance of this Subcontract, whether arising before or after completion of the Work hereunder in any manner directly or indirectly caused, occasioned or contributed to in whole or in part or claimed to be caused, occasioned or contributed to in whole or in part by reason of any act, omission, fault or negligence whether active or passive of Subcontractor, its lower-tier suppliers, subcontractors or of anyone acting under its direction or control or on its behalf.
The foregoing shall include but is not limited to indemnity for:
Property damage and injury to or death of any person including employees of Contractor, Owner or Subcontractor.
The breach by Subcontractor of any representation, warranty, covenant or performance obligation of this Subcontract.
Subcontractor's aforesaid release, indemnity and hold harmless obligations, or portions or applications thereof, shall apply even in the event of the fault or negligence whether active or passive or strict liability of the parties released, indemnified or held harmless to the fullest extent permitted by law but in no event shall these apply to liability caused by the shallful misconduct or sole negligence of the party released, indemnified or held harmless.
GC-38 Patent And Intellectual Property Indemnity
Except in respect to items that have been specified by Contractor or are supplied to Subcontractor by Contractor or on Contractor’s behalf, Subcontractor shall at its expense, indemnify, defend and hold harmless Contractor and Owner from and against any claims, actions, suits costs (including legal and experts’ costs), expenses and liabilities of every kind and nature which may be brought against or incurred by Contractor or Owner at any time for infringement or alleged infringement of any intellectual property that may be specified or used by Subcontractor or its subcontractors relating to:
the use, design, composition, mode of fabrication or other particulars of the Installations or any one or more of the elements of apparatus, structures, systems, plant or any combination thereof or any part thereof furnished or specified for the Work.
the use of any raw, unfabricated or unassembled materials, composition of various materials, fabrication procedure, heat treatment or other things entering into the manufacture of said element of apparatus, structures or systems or plant or any part thereof or
the use of any construction methods, tools, machines or construction devices used in or specified for the execution of Work; and
the design, process and / or technology used in the installations, plant, systems or incorporated therein.
Contractor shall promptly notify Subcontractor in writing of such claims or the institution of such action or suit and permit Subcontractor to conduct Contractor’s defence. Subcontractor shall pay all costs and expenses of any such action or suit, including compensation and expenses of experts and counsel of its choice and selection. Subcontractor shall also pay and hold Contractor and Owner free and harmless from expenses incurred or any damages or other sums awarded or assessed in any such action or suit.
Contractor reserves the right to conduct its own defence and be represented by counsel of its own selection, but in either event agrees to co-operate in the defence of any such action or suit and to furnish all the evidence in its control.
In connection with any claims, actions, suits or liabilities referred to in above, Subcontractor reserves the right to acquire at its expense, immunity from suit or licence under intellectual property on which such claims, actions, suits or liabilities are related for the construction, operation or use and maintenance of Installations by Contractor in accordance with the design, specifications and procedures furnished and/or approved in writing by Subcontractor or its subcontractors.
Contractor also reserves the right, in connection with such claims, actions, suits or liabilities of making such alteration to Work or Installations at Subcontractor’s expense, as may be required to eliminate the alleged infringement, provided however, that such alteration does not impair the safe operation or use of the Installations or unreasonably interfere with their continuous operation or results in any cost or expenses on the part of Contractor.
GC-39 Assignments And Subcontracts
Any assignment of this Subcontract or rights hereunder in whole or part, without the prior written consent of Contractor shall be void except that upon ten (10) calendar days written notice to Contractor, Subcontractor may assign monies due or to become due under this Subcontract provided that any assignment of monies shall be subject to proper set-offs in favour of Contractor and any deductions provided for in this Subcontract.
Subcontractor shall not subcontract to any third party for the performance of all or any portion of the Work without the advance written approval of Contractor. Purchase orders and subcontracts of any tier must include provisions to secure all rights and remedies of Contractor and Owner provided under this Subcontract and must impose upon the lower-tier supplier and subcontractor all of the duties and obligations required to fulfill this Subcontract.
Subcontractor shall, in selection of any proposed lower tier subcontractor, ensure that such proposed subcontractor complies with the selection criteria as defined in Appendix A-2 to these General Conditions.
Copies of all purchase orders and subcontracts are to be provided to Contractor upon request. Pricing may be deleted unless the compensation to be paid thereunder is reimbursable under this Subcontract.
No assignment or subcontract shall be approved which in essence amount to relieve Subcontractor or its sureties if any, of their responsibilities under this Subcontract.
Subcontractor shall be fully responsible for any part of Work performed by its lower tier subcontractor(s), for their acts, omissions by persons either directly or indirectly employed to the same extent as it is for the acts and omissions of persons directly employed by Subcontractor)
Subcontractor shall ensure that lower tier subcontractor(s) are officially registered in the nation to the extent it is required by applicable laws and that they and their employees comply with sponsorship, immigration, residence and employment laws while in the nation.
GC-40 Suspension
Contractor may by written notice to Subcontractor, suspend at any time the performance of all or any portion of the Work to be performed under the Subcontract. Upon receipt of such notice, Subcontractor shall, unless the notice requires otherwise:
Immediately discontinue work on the date and to the extent specified in the notice;
Place no further orders or subcontracts for material, services or facilities with respect to suspended work other than to the extent required in the notice;
Promptly make every reasonable effort to obtain suspension upon terms satisfactory to Contractor of all orders, subcontracts and rental agreements to the extent these relate to performance of suspended work;
Continue to protect and maintain the Work including those portions on which work has been suspended; and
Take any other reasonable steps to minimize costs associated with such suspension.
Upon receipt of notice to resume suspended work, Subcontractor shall immediately resume performance under this Subcontract to the extent required in the notice.
The extra cost incurred by Subcontractor in giving effect to Contractor's instructions under this General Condition shall be borne and paid by Contractor unless such suspension is:
Otherwise provided for in the Subcontract or
Necessary by reason of default on the part of Subcontractor.
Provided that Subcontractor shall not be entitled to recover any such extra cost unless it gives written notice of its intention to claim to Contractor within ten (10) days of Contractor's order. Contractor shall settle and determine such extra payment and / or extension of time to be made to Subcontractor in respect of such claim as shall by mutual agreement be fair and reasonable.
If Subcontractor intends to assert a claim for equitable adjustment under this clause, it must pursuant to the General Condition titled "Changes" and within ten (10) calendar days after receipt of notice to resume work, submit the required written notification of claim and within twenty (20) calendar days thereafter its written proposal setting forth the impact of such claim.
If the progress of Work or any part thereof is suspended on the written order of Contractor and if permission to resume work is not given by Contractor within a period of ninety (90) days from the date of suspension then unless such suspension is otherwise provided for in the Subcontract or necessary by reason of default on the part of Subcontractor, Subcontractor may serve a written notice on Contractor requiring permission within twenty eight (28) days from the receipt thereof to proceed with Work or that part thereof in regard to which progress is suspended and if such permission is not granted within that time, Subcontractor by a further written notice so served may, but is not bound to, elect to treat the suspension where if affects part only of Work as a lawful termination by Contractor of such part under the General Condition titled Optional Termination hereof or where it affects the whole Work as termination of the Subcontract by Contractor.
GC-41 Termination For Default
Notwithstanding any other provisions of this Subcontract, Subcontractor shall be considered in default of its contractual obligations under this Subcontract if it:
Performs work which fails to conform to the requirements of this Subcontract;
Fails to make progress so as to endanger performance of this Subcontract;
Abandons or refuses to proceed with any of the Work including modifications directed pursuant to the General Condition titled "Changes;"
Fails to fulfill or comply with any of the terms of this Subcontract;
Engages in behavior that is dishonest, fraudulent or constitutes a conflict of interest with Subcontractor's obligations under this Subcontract or if
Subcontractor becomes insolvent or makes a general assignment for the benefit of creditors or reasonable grounds for insecurity arise with respect to Subcontractor's performance.
Upon the occurrence of any of the foregoing, Contractor shall notify Subcontractor in writing of the nature of the failure and of Contractor's intention to terminate the Subcontract for default. If Subcontractor does not cure such failure within forty-eight (48) hours from receipt of notification or sooner if safety is involved or fails to provide satisfactory evidence that such default shall be corrected within a reasonable time, Contractor may, by written notice to Subcontractor and without notice to Subcontractor's sureties if any, terminate in whole or in part Subcontractor's right to proceed with the Work following which Contractor may prosecute the Work to completion by another Subcontract or by any other method deemed expedient. Contractor may take possession of and utilize any data, designs, licenses, equipment, materials, plant, tools and property of any kind furnished by terminated Subcontractor considering these necessary to complete the Work.
Subcontractor and its sureties if any, shall be liable for all costs in excess of the Subcontract price for such terminated work reasonably and necessarily incurred in the completion of the Work including cost of administration of any purchase order or Subcontract awarded to others for completion.
Contractor shall not be required to obtain competitive tenders for completing such work but may make such arrangements as in Contractor’s judgement shall best accomplish timely completion.
Upon termination for default Subcontractor shall:
Immediately discontinue work on the date and to the extent specified in the notice and place no further purchase orders or subcontracts to the extent that they relate to the performance of the terminated work;
Inventory, maintain and turn over to Contractor all data, designs, licenses, equipment, materials, plant, tools, and property furnished by Subcontractor or provided by Contractor for performance of the terminated work;
Promptly obtain cancellation upon terms satisfactory to Contractor of all purchase orders, subcontracts, rentals or any other agreements existing for performance of the terminated work or assign those agreements as directed by Contractor;
Cooperate with Contractor in the transfer of data, designs, licenses, information and disposition of work in progress so as to mitigate damages;
Comply with other reasonable requests from Contractor regarding the terminated work and
Continue to perform in accordance with all of the terms and conditions of this Subcontract such portion of the Work that is not terminated.
If, after termination pursuant to this clause, it is determined for any reason that Subcontractor was not in default, the rights and obligations of the parties shall be the same as if the notice of termination had been issued pursuant to the General Condition titled “Optional Termination”.
GC-42 Optional Termination
Contractor may, at its option terminate for convenience any of the Work under this Subcontract in whole or from time to time in part at any time by written notice to Subcontractor. Such notice shall specify the extent to which the performance of the Work is terminated giving the effective date of such termination. Upon receipt of such notice, Subcontractor shall:
Immediately discontinue the Work on the date and to the extent specified in the notice and place no further purchase orders or subcontracts for materials, services or facilities other than as may be required for completion of such portion of the Work that is not terminated;
Promptly obtain assignment or cancellation upon terms satisfactory to Contractor of all purchase orders, subcontracts, rentals or any other agreements existing for the performance of the terminated work or assign those agreements as directed by Contractor;
Assist Contractor in the maintenance, protection and disposition of work in progress, plant, tools, equipment, property and materials acquired by Subcontractor or furnished by Contractor under this Subcontract and
Complete performance of such portion of the Work which is not terminated.
Upon any such termination, Subcontractor shall waive any claims for damages including loss of anticipated profits on account thereof but as the sole right and remedy of Subcontractor, Contractor shall pay in accordance with the following:
The Subcontract price corresponding to the work performed in accordance with this Subcontract prior to such notice of termination;
All reasonable costs for work thereafter performed as specified in such notice;
Reasonable administrative costs of settling and paying claims arising out of the termination of work under purchase orders or subcontracts;
Reasonable costs incurred in demobilization and the disposition of residual material, plant and equipment; and
A reasonable overhead and profit on these items of this paragraph.
Subcontractor shall submit within thirty (30) calendar days after receipt of notice of termination a written statement setting forth its proposal for an adjustment to the Subcontract price to include only the incurred costs described in this clause. Contractor shall review, analyze, verify such proposal and negotiate an equitable adjustment after which the Subcontract shall be modified accordingly.
GC-43 Final Inspection And Acceptance
When Subcontractor considers the Work or any Contractor identified independent portion of the Work under this Subcontract to be complete and ready for acceptance, Subcontractor shall notify Contractor in writing. Contractor with Subcontractor’s cooperation, shall conduct such reviews, inspections and tests as may be reasonably required to satisfy Contractor that the Work or identified portion of the Work conforms to all requirements of the Subcontract. If all or any part of the Work covered by Subcontractor’s notice does not conform to Subcontract requirements, Contractor shall notify Subcontractor of such nonconformance on which Subcontractor take corrective action followed by the corrected work re-inspected until all Subcontract requirements are satisfied.
Contractor shall issue a Notice of Provisional Acceptance for individual portions which have been satisfactorily inspected subject only to Contractor’s Final Acceptance of the Work as a whole.
Contractor’s written Certificate of Final Acceptance of the Work under this Subcontract shall be final and conclusive except with regard to latent defects, fraud or such gross mistakes as amount to fraud or with regard to Contractor’s and owner’s rights under the General Condition titled “Warranty”.
Mechanical Completion, Provisional Acceptance and Final Acceptance are as defined in Special condition SC-1 titled “Definitions”.
GC-44 Non-Waiver
Failure by Contractor to insist upon strict performance of any terms or conditions of this Subcontract or failure or delay to exercise any rights or remedies provided herein or by law or failure to properly notify Subcontractor in the event of breach or the acceptance of or payment for any goods or services hereunder or the review or failure to review designs shall not release Subcontractor from any of the warranties or obligations of this Subcontract and not be deemed a waiver of any right of Contractor or Owner to insist upon strict performance hereof or any of its rights or remedies as to any prior or subsequent default hereunder nor any termination of work under this Subcontract by Contractor operate as a waiver of any of the terms hereof.
GC-45 Severability
The provisions of this Subcontract are severable. If any provision shall be determined to be illegal or unenforceable, such determination shall have no effect on any other provision hereof and the remainder of the Subcontract shall continue in full force and effect so that the purpose and intent of this Subcontract shall still be met and satisfied.
GC-46 Survival
All terms, conditions and provisions of this Subcontract which by their nature are independent of the period of performance, shall survive the cancellation, termination, expiration, default or abandonment of this Subcontract.
EXHIBIT A
APPENDIX A-1
Owner’s Commitment to Health, Safety and the Environment & Owner’s Health, Safety and Environmental Policies is provided in :
Project Health, Safety & Environmental Plan
Early Works Emergency Preparedness Plan
Simultaneous Operations (SIMOPS)
Subcontractor shall provide the Works in accordance with the requirements of these plans which are provided somewhere else
EXHIBIT A
APPENDIX A-2
Selection Criteria for Lowertier Subcontractors
Subcontractor shall comply with the following Selection Criteria in the selection of its lowertier subcontractors:
Licenses and Certificates
Valid Trade License from nation authorities covering the services to be provided along with oil and gas classification (for those subcontracted services to be provided within the nation)
Valid Registration Certificate from nation Chamber of Commerce & Industry covering the services to be provided along with oil and gas classification (for those subcontracted services to be provided within the nation)
Experience and Capability Requirements
Structured organisation, manpower and equipment in a condition that allows safe operation and in quantities that would meet job requirements
Adequate direct experience in jobs of similar scope and order of magnitude in the last five years
Current workload and availability of resources to comply with schedule requirements
Documented QA Systems and Procedures (typically compliance with ISO 9001)
Documented Health, Safety and Environmental Systems and Procedures (typically compliance with ISO 14001)
Excellent Safety Record
Compliance Requirements
Compliance with the subcontract scope
Compliance with Specifications
Compliance with the schedule requirements
Commercial
Financial soundness and solvency
Contracting Co. Ltd.
Onshore Gas Development Project
EXHIBIT "B"
Construction Subcontract Special Conditions
TABLE OF CONTENTS
SC Title
1 Definitions
2 Insurance
3 Contractor - Furnished Drawings And Specifications
4 Contractor - Furnished Utilities And Facilities
5 Contractor - Furnished Materials And Equipment
6 Contractor - Furnished Permits
7 Subcontractor - Furnished Drawings, Data And Samples
8 Commencement, Progress And Completion Of The Work
9 Subcontract Schedule
10 Temporary Access And Haul Roads
11 Safety, Health And Security Requirements
12 Explosives
13 Performance And Payment Securities
14 Measurement For Payment
15 Invoicing And Payment
16 Pricing Of Adjustments
17 Quality Assurance Program
18 Title And Risk Of Loss
19 Component Warranties
20 Applicable Law
21 Modifications To Exhibit “A”
22 Release Of Consequential Damages
23 Nondisclosure
Sc Title Page
24 Measurement System
25 Liquidated Damages
26 Key Personnel
27 Language Requirements
28 Drugs, Alcohol And Weapons
29 Right To Work Tools And Work Product
30 Importation Of Equipment, Materials And Services
31 Provision Of Documents
32 Contractor Review Of Documents
33 Labour
34 Customs And Duties
35 Component Warranties
36 Conflict Of Interest
37 Arbitration
38 Hazardous Waste Handling
39 Deficient Works
40 Goods And Services
Appendices
B-1 Owner Furnished Insurance
EXHIBIT "B"
Construction Subcontract Special Conditions
SC-1 Definitions
Owner means Company, its authorized representatives and successors in interest.
Contractor means Contracting Co. Ltd., and all of its authorized representatives acting in their professional capacities.
Subcontractor means [To Be Designated] , its authorized representatives, successors and permitted assigns.
Project means the Onshore Gas Development Project for Owner located in nation for which the Work under this subcontract is being performed.
Project Document/s means the Subcontract , all hard copy and electronic versions of Project documents which shall include but not be limited to all FEED documents, drawings, P&IDs, PFDs, isometrics, plot plans, general arrangements, specifications, materials requisitions, data sheets and calculations, indices, manuals, reports, procedures, estimates, accounts, summaries, compilations, agreements including subcontractors agreements, related materials and any other document defined or described in any of the foregoing.
Provisional Acceptance means the stage when all work for the Project has been satisfactorily completed barring any minor exceptions as determined by Owner and Owner’s issuance of Provisional Acceptance Certificate(s) to Contractor for the Project under Owner/Contractor EPC Contract.
Final Acceptance means the expiry of the Warranty Period and when Subcontractor has fulfilled its obligations under the Owner/Contractor EPC Contract.
Warranty Period means the period commencing on the effective date of issuance of Plant Test Run Certificate for the Project under the Owner / Contractor Contract and ending after fifteen (15) months from the effective date of the issuance of Plant Test Run Certificate or twelve (12) months from the effective date of the last Provisional Acceptance Certificate whichever is earlier, as such period may be extended in accordance with the General Condition “Warranty” and without affecting or diminishing Subcontractor’s warranty obligations under this Subcontract which have arisen from the date or effective date of the first Provisional Acceptance Certificate if any.
Work means all the stated or implied activities to be performed by Subcontractor as required by the Subcontract Documents.
Jobsite means all locations in nation where Installations are to be permanently constructed, erected, tested, operated and maintained and all other locations where construction activity shall be performed under this Subcontract, including temporary installations required for execution of the Works.
Subcontract Milestone(s) means the established completion date(s) set forth in the Special Condition titled "Commencement, Progress and Completion of The Work."
Subcontract Schedule means the Work execution schedule developed and approved pursuant to the Special Condition titled "Subcontract Schedule."
Effective Date means the date when the Subcontract is deemed to have come into force which date is specified in the Form of Agreement.
EXHIBITS means EXHIBIT A, EXHIBIT B, EXHIBIT C, EXHIBIT D, and EXHIBIT E together with their appendices and attachments of this Subcontract.
Existing Facilities means the Existing Plant, equipment, installations and other facilities at, near or adjacent to the Jobsite owned or operated by Owner or its Affiliates.
Goods mean any and all things, including but not limited to materials and equipment (including spare parts) required for and to be incorporated in the Work.
Installation (s) means the permanent facilities including the System (s), Plant, buildings, structures, civil works, amenities and facilities or any of which constitute the Project as described in the EXHIBITS.
Plant means the unit (s) described in EXHIBITS ‘C’, ‘D’ and ‘E’ to be constructed, erected, installed and tested as part of the Work.
Specifications means specifications, drawings and procedures included or referenced in the Subcontract documents or implied therein and any modifications or additions thereto as may from time to time be approved by Owner or Contractor.
System (s) means a grouping of equipment and components, including foundations, structures, mechanical, electrical, control systems, piping and associated parts that perform a single service, function and operation as a licensed process, utility system and / or facility, which defines a specific Plant function
Nation means country where work is executed.
SC-2 Insurance
1.0 Insurance To Be Provided By Subcontractor
Without limitation to its obligations and responsibilities under this Subcontract, Subcontractor during the whole period of the Subcontract from commencement until the issue of Final Acceptance Certificate shall at its own expense obtain and thereafter maintain in full force and effect (or cause to be obtained and maintained) the insurance policies set forth below to be effected in the name of Subcontractor. Subcontractor shall cause the insurers or underwriters thereof to waive their rights of subrogation against Contractor and Owner indemnified parties and where feasible, to include the names of Contractor and Owner as additional assured parties.
Subcontractor shall require the same insurance from its subcontractors under the same conditions as required herein.
A. Worker’s Compensation (Owner's Liability)
Worker’s Compensation and Owner's Liability Insurance covering the employees of Subcontractor for all compensation and other benefits required of Subcontractor by Worker’s Compensation or similar statutory insurance laws of any nation or political subdivision thereof to which Subcontractor’s operations under this Subcontract are subject in respect of liability for bodily injury by accident or disease including death resulting therefrom sustained by any employee of Subcontractor arising out of and in the course of his/her employment. The limit of liability under Owners Liability Section shall be not less than United States Dollars one million (US$ 1,000,000/-) per occurrence.
B. Motor Vehicle Third Party and Passenger Liability
Motor vehicle Third Party and passenger liability insurance in respect of death of or injury to persons and/or loss or damage to property in respect of motor vehicles used by Subcontractor in connection with the execution of the Work and shall ensure that subcontractors maintain such insurance in respect of motor vehicles used by them.
Such insurance shall provide an unlimited indemnity for death of or injury to persons and the equivalent of not less than United States Dollars one million (US$ 1,000,000/-) per occurrence for loss of or damage to property which shall be extended as may be necessary to cover any additional cover required by statutory requirements in the country of location of the Work.
C. Construction Plant and Equipment
Temporary works and all construction plant and equipment brought on Site by Subcontractor or its subcontractors for use in connection with the Project and any other property under the care and custody of Subcontractor not covered by Contractor hereof, to their full value against all loss or damage from whatever cause arising.
D. Marine Insurance on Vessels, Craft or Floating Equipment
Insurance in respect to any vessels, craft and other floating equipment owned, chartered or hired by Subcontractor or its subcontractors used in connection with the execution of the Work shall cover all risks of physical loss or damage howsoever arising including war, civil war, strikes, and the like up to a limit equivalent to the value of such vessels, craft or floating equipment and including marine third party liability insurance in respect of legal liability to third parties of not less than United States Dollars two million (US$ 2,000,000/-) together with protection and indemnity risks with a member of the International Group of P&I Clubs including endorsements for charterers liabilities, pollution for maximum limits, cargo legal liabilities, removal of wreck, full collision liabilities and full coverage for all crew liabilities. Such insurances shall contain an express condition that the amount realisable under the Liability Section of the Policy is either up to the limit of Sum Insured or to the actual amount of claim whichever is lower and shall be free from the application of limitations of shipowners' liability under the nation. Maritime law or any other law in force relating to the shipowners' liability.
E. Aircraft Insurance on Aircraft or Helicopters
All aircraft or helicopters owned or hired by Subcontractor or its subcontractors used in connection with the execution of works/services against all risks of physical loss or damage howsoever arising, including war, civil war, strikes and the like up to a limit equivalent to the value of such aircraft or helicopters and including legal liability to third parties and passenger liability up to a limit of not less than United States Dollars two million (US$ 2,000,000/-) per accident.
F. General Third Party Risks Insurance
General third party liability insurance covering liabilities arising out of any activities of Subcontractor. Such insurance shall have a limit of liability not less than United States Dollars two million (US$ 2,000,000/-).
Evidence Of Insurance
Subcontractor shall furnish Contractor within thirty (30) days from the effective date with certificates of insurance issued by the relevant insurers or underwriters evidencing the risks insured against pursuant to the provisions of this clause also showing all parties assured and levels of indemnity. Notwithstanding the above, in respect of risks that the Subcontractor can demonstrate are not imminent immediately upon the effective date, Subcontractor shall provide the insurance certificates not later than thirty (30) days prior to the commencement of the relevant activity.
Deductibles
All deductibles provided under the insurances arranged by Subcontractor as required under this clause (the amounts of which Subcontractor acknowledges to have seen) shall be for the account of and paid by Subcontractor.
Insurers To Be Used
For Work performed in the nation, insurance policies arranged in accordance with this clause shall also comply with Law with one or more of the following national insurance companies:
Notice to contractor and remedy on subcontractor's failure to insure
Subcontractor shall provide Contractor with timely advance notice of any changes in the terms of the policies, which are to be carried by Subcontractor under this clause including any cancellation notices.
If Subcontractor fails to keep in force the insurance which may be required to effect under the terms of this clause, then Contractor may effect and keep in force any such insurance and pay the premium as may be necessary for that purpose and from time to time deduct the amount so paid by Contractor in respect of such premium from any money due or which may become due to Subcontractor or recover the same as a debt due from Subcontractor.
Protection Of Contractor’s Rights
Approval by Contractor of any insurer or terms of insurance proposed by Subcontractor shall not relieve Subcontractor from any obligation or liability under or arising from this Subcontract or under the mandatory provisions of law.
Costs And Incidental Expenses
All costs and incidental expenses incurred in relation to the preparation of claims under the policies arising out of matters for which Subcontractor is responsible under the Subcontract shall be borne by Subcontractor.
2.0 Owner Furnished Insurance:
Without limitation of Subcontractor’s obligations and responsibilities under the Subcontract, Owner shall at the appropriate time, insure (subject to the following provisions) at its own expense in the joint names of Owner and Contractor and its subcontractors performing works at the work Jobsite in respect of :-
Land, Sea and Air Transit Insurance
All materials, machinery and other property of whatsoever kind for incorporation in the Works during marine shipments, land and air transportation. Such insurance shall include an insurer’s waiver of subrogation in favour of Contractor Indemnified Parties and shall be subject to London Institute Cargo Clauses.
Insurance of Work in Progress during Construction
The Works, the Goods for incorporation or intended to be incorporated therein, Owner’s equipment if any, all in connection herewith and Existing Facilities, but excluding items which Subcontractor is required to insure under this Special Condition, subsection 1.0 titled “Insurance To Be Provided By Subcontractor” , shall be insured, against insurable physical loss of damage to the replacement value thereof from commencement of construction at the Jobsite until completion of the Work and also during the Warranty Period
General Legal Third Party Risks Insurance
Physical loss of or damage to any Third Party property or injury to or death of any Third Party which may arise out of or in connection with the execution of the Project, such insurance to be on a combined single limit of not less than US Dollars Twenty Million (US$20,000,000) in respect of any one accident or series of accidents arising out of one event.
Deductibles to Owner’s Furnished Insurance
The deductibles provided under the insurance to be arranged by Owner shall be for the account of and paid by Subcontractor as follows:
If following loss or damage to Work, or other loss or damage insured pursuant to this Special Condition, subsection 2.0, titled “Owner Furnished Insurance”, a claim is made under a policy of insurance effected by Owner, Subcontractor shall be paid the amounts (if any) recovered from such policy upon rectifying the loss or damage or settling the relevant liability as the case may be and after deducting the amounts due to Owner, if any, in respect of Owner’s expenses. Provided, however, that Subcontractor’s liability for rectification of any such loss or damage shall not exceed the deductible amounts per occurrence specified in Exhibit “B”,Appendix B-1. Owner undertakes to make on-account payments to Subcontractor to fund the cost of rectification of any such loss or damage in excess of United States Dollars Ten Million.
In the event of any failure by Subcontractor to make good in accordance with the terms of the Subcontract, such loss or damage to the Project, which falls within the deductibles and exceptions aforesaid, Owner may deduct the applicable amounts from the sums otherwise due to Subcontractor under the Subcontract or recover the same as a debt due from Subcontractor.
Claims Procedure
Subcontractor and/or its subcontractors shall notify insurers with one copy to Owner and one copy to Contractor of any occurrence likely to give rise to a claim under Owner’s insurances as soon as possible and in any event within three (3) days of such occurrence coming to the notice of Subcontractor.
Subcontractor shall also submit in co-ordination with Owner the entire claim documents to the Insurers directly and shall handle all claim negotiations directly with the Insurers. After approval and signature of the claim discharge receipt and letter of subrogation by Owner, the actual settlement of the claim amounts due to Subcontractor shall be effected by the Insurers directly to Subcontractor’s account, with the claim amounts due to Owner being effected by the Insurers directly to Owner’s account.
Notifications:
In accordance with the submittal requirements outlined above, Subcontractor shall deliver the original and two (2) copies of the Certificate(s) of Insurance required by this clause and all subsequent notices of cancellation, termination and alteration of such policies to:
Eastern Co. Ltd.
Attention: Project Subcontracts Manager
Reference: Subcontract No.
SC-3 Contractor-Furnished Drawings And Specifications
Contractor shall furnish specifications and prints of engineering design drawings for each part of the Work under this Subcontract. Such drawings shall give information required for the preparation of shop detail drawings by Subcontractor.
Subcontractor shall, immediately upon receipt thereof, check all specifications and drawings furnished and shall promptly notify Contractor of any omissions or discrepancies in such specifications or drawings.
All drawings listed in Exhibit "E" Drawings are a part of this Subcontract; however, Subcontractor shall perform work only in accordance with drawings marked "Issued for Construction" (IFC), which may be issued by Contractor after execution of this Subcontract. Such IFC drawings shall be issued by Subcontract Change Notice and upon issuance become a part of the Subcontract, superseding or supplementing the original Subcontract drawings. If Subcontractor considers such issue to be a change affecting cost or schedule the provisions of the General Condition titled "Changes" apply. Subcontractor shall perform work only in accordance with IFC drawings and any subsequent revisions thereto, and with Contractor reviewed drawings submitted by Subcontractor in accordance with the Special Condition titled "Subcontractor-Furnished Drawings, Data And Samples."
Two (2) copies of such specifications and one (1) full size reproducible copy and three (3) full size prints of such drawings shall be furnished to Subcontractor without charge. Any additional copies of such specifications and drawings shall, upon Subcontractor's request, be furnished to Subcontractor at actual cost.
SC-4 Contractor - Furnished Utilities And Facilities
Utilities. The utilities listed below shall be furnished by Contractor without cost to Subcontractor, provided that all such utilities shall be furnished at outlets existing on the Jobsite and Subcontractor shall, at its expense, extend such utilities from said outlets to points of use and at completion of all the Work remove all materials and equipment used for such extensions.
None
Facilities. The facilities listed below shall be furnished by Contractor. Such facilities may be used by Subcontractor without charge, provided that any such use shall be subject to written approval of Contractor.
None
SC-5 Contractor - Furnished Materials And Equipment
Contractor shall furnish to Subcontractor, at Contractor’s designated warehouse or Jobsite storage area, the items listed below to be incorporated into or used in performance of the Work under this Subcontract or a designated area agreed with Subcontractor. Such items shall be furnished, without cost to Subcontractor, provided that Subcontractor shall, at its expense, prepare a material request, load at Contractor’s warehouse or Jobsite storage location, transport to points of use, unload and care for such items until final disposition thereof. At time of acceptance of any such item from Contractor, Subcontractor shall sign a receipt therefore. Signing of such receipt without reservation therein shall preclude any subsequent claim by Subcontractor that any such items are received from Contractor in a damaged condition and with shortages. If at any time after acceptance of any such item from Contractor any such item is damaged, lost, stolen or destroyed, such item shall be repaired or replaced at the expense of Subcontractor. Items required to be replaced may, at its option, be furnished by Contractor. Upon completion of all the Work under this Subcontract, Subcontractor shall, at its expense, return all surplus and unused items to Contractor's designated warehouse or Jobsite storage area.
Contractor shall exert every reasonable effort to make delivery of such materials and equipment so as to avoid delay in the progress of the Work. However, should Contractor, for any reason, fail to make delivery of any such item and a delay result the provisions of the General Condition titled "Changes" apply. Subcontractor shall take all appropriate action to mitigate the consequences of such delay.
Materials to be furnished by Contractor:
None
SC-6 Contractor-Furnished Permits
The General Condition titled "Permits" notwithstanding, Contractor shall without cost to Subcontractor, furnish the permits listed below; however, Subcontractor shall, as necessary, provide Contractor and Owner with assistance in obtaining such permits. Subcontractor shall, in accordance with said General Condition titled "Permits," provide all other permits. All such Contractor-furnished permits are available for examination at the project office of Contractor during regular business hours.
Permits to be furnished by Contractor:
One
SC-7 Subcontractor-Furnished Drawings, Data And Samples
Contractor review and permission to proceed does not constitute acceptance or approval of submittals including, but not limited to, design details, calculations, analyses, test methods, construction methods, rigging plans, certificates or materials developed or selected by Subcontractor and does not relieve Subcontractor from full compliance with the Subcontract requirements.
Drawings
Where drawings are required for:
Fabrication of Subcontractor-furnished equipment or materials,
Installing Subcontractor-furnished equipment or materials, or
Planning and performance of the Work under this Subcontract;
such drawings shall be submitted by and at the expense of Subcontractor before fabrication, installation or performance is commenced, allowing at least thirty (30) calendar days for review by Contractor unless otherwise shown on the Subcontract Schedule. Such drawings shall include, but not be limited to, matchmarks, erection diagrams and other details, such as field connections for proper installation, erection of equipment or materials, and performance of the Work.
Drawings of a specific piece of equipment shall identify components with the manufacturer's part number or reference drawing number clearly indicated. If reference drawing numbers are used, the review data of such drawings shall be included.
Drawings shall indicate design dimensions, maximum and minimum allowable operating tolerances on all major wear fits, e.g., rotating, reciprocating or intermittent sliding fits between shafts or stems and seals, guides and pivot pins. The sequence of submission of all drawings shall be such that all information is available for reviewing each drawing when it is received.
All drawings submitted by Subcontractor shall be certified by Subcontractor to be correct, shall show the Subcontract number and shall be furnished in accordance with the Subcontract Drawings and Data Requirements Form(s). Contractor shall conduct a review of Subcontractor's drawings and a reproducible drawing marked with one of the following codes shall be returned to Subcontractor.
Code Notation
1. Work may proceed.
2. Revise and Resubmit. Work may proceed subject to resolution of indicated comments.
3. Revise and Resubmit. Work may not proceed.
4. Review not required. Work may proceed.
Although work may proceed on receipt of a drawing with a Code 2 notation, Subcontractor must resolve the comments indicated, resubmit and obtain a Code 1 notation before release for shipment or completion of the affected work.
Samples
Where samples are required, they shall be submitted by and at the expense of Subcontractor. Such submittals shall be made not less than thirty (30) calendar days prior to the time that the materials represented by such samples are needed for incorporation into the Work. Samples shall be subject to review and materials represented by such samples shall not be manufactured, delivered to the Jobsite or incorporated into the Work without such review.
Each sample shall bear a label showing Subcontractor's name, Project name, Subcontract number, name of the item, manufacturer's name, brand name, model number, supplier's name, and reference to the appropriate drawing number, technical specification section and paragraph number, all as applicable.
Samples which have been reviewed may, at Contractor's option, be returned to Subcontractor for incorporation into the Work.
Certificates and Data
Where certificates are required, four (4) copies of each such certificate shall be submitted by and at the expense of Subcontractor. Such submittal shall be made not less than thirty (30) calendar days prior to the time that the materials represented by such certificates are needed for incorporation into the Work. Certificates shall be subject to review and material represented by such certificates shall not be fabricated, delivered to the Jobsite or incorporated into the Work without such review.
Certificates shall clearly identify the material being certified and shall include but not be limited to providing the following information: Subcontractor's name, Project name, Subcontract number, name of the item, manufacturer's name, and reference to the appropriate drawing, technical specification section and paragraph number, all as applicable.
All other data shall be submitted as required by the Subcontract Documents.
As-Built Drawings and Specifications
Drawings:
Progress As-Builts. During construction, Subcontractor shall keep a marked-up-to-date set of as-built blueline drawings on the Jobsite as an accurate record of all deviations between work as shown and work as installed. These drawings shall be available to Contractor and Owner for inspection at any time during regular business hours.
Final As-Builts. Subcontractor shall at its expense and not later than thirty (30) calendar days after Final Acceptance and before Final Payment furnish to Contractor a complete set of marked-up as-built reproducible drawings with "As-Built" clearly printed on each sheet. Subcontractor shall accurately and neatly transfer all deviations from progress as-builts to final as-builts. As-built drawings shall be provided where specified and as required to reflect as-built conditions.
Specifications:
Progress As-Builts. During construction, Subcontractor shall keep a marked-up-to-date set of as-built specifications on the Jobsite annotated to clearly indicate all substitutions that are incorporated into the Work. Where selection of more than one product is specified, annotation shall show which product was installed. These specifications shall be available to Contractor and Owner for inspection at any time during regular business hours.
Final As-Builts. Subcontractor shall at its expense and not later than thirty (30) calendar days after Final Acceptance and before Final Payment furnish to Contractor a complete set of marked-up as-built specifications with "As-Built" clearly printed on the cover. Subcontractor shall accurately and neatly transfer all annotations from progress as-builts to final as-builts.
Endorsement:
Subcontractor shall sign each final as-built drawing and the cover of the as-built specifications and shall note thereon that the recording of deviations and annotations is complete and accurate.
SC-8 Commencement, Progress and Completion Of The Work
Subcontractor shall carry out the Work with due diligence in accordance with good practices and standards of workmanship in order to meet the key dates detailed in the Schedule.
Subcontractor shall complete the Work under the Subcontract to meet the following Subcontract Milestone dates. As provided in this SC-8, Handover means “Complete all Work, including all mechanical completion, testing and commissioning activities, provide all technical assistance and training, deliver all documentation (including O&M Manuals), bring into operational use and handover to Contractor“
Subcontractor shall give Contractor full information in advance as to its plans for performing each part of the Work. If at any time, Subcontractor's actual progress is inadequate to meet the requirements of this Subcontract, Contractor may notify Subcontractor to take such steps as may be necessary to improve its progress. If, within a reasonable period as determined by Contractor, Subcontractor does not improve performance to meet the Subcontract Milestones set forth above, Contractor may require an increase in Subcontractor's labor force, the number of shifts, overtime operations, additional days of work per week, expedited shipment(s) of equipment and materials, and an increase in the amount of construction plant and equipment, all without additional cost to Contractor. Neither such notice nor Contractor's failure to issue such notice shall relieve Subcontractor of its obligation to achieve the quality of work and rate of progress required by this Subcontract.
Noncompliance with Contractor's instructions shall be grounds for Contractor's determination that Subcontractor is not prosecuting the Work with such diligence as shall assure completion within the times specified. Upon such determination, Contractor may terminate this Subcontract pursuant to the General Condition titled "Termination For Default."
Subject to the warranties which survive the warranty period, the Work shall be considered complete upon issuance to Subcontractor by Contractor of the Final Acceptance Certificate.
SC-9 Subcontract Schedules
Subcontractor shall within ten (10) calendar days of subcontract award submit for Contractors written approval a 30/90 day kick off schedule.
The schedule shall clearly show all activities in detail, including start and completion of mobilisation and discreet work elements and work element interrelationships necessary to complete all services and separable parts for a period of ninety (90) calendar days following the subcontract award / notice to proceed. In addition the schedule shall show in summary, the proposed plan and approach for performance of all major subdivisions of work during the entire contract period. It shall contain sufficient detail to assure Contractor of the feasibility of the plan and approach proposed by Subcontrator.
Level of detail required;
Tasks in the 90 day schedule should be sufficiently detailed to describe activities that include but not limited to, the following:
Mobilisation
Construction and installation of any temporary works
Issue of any technical deliverables required by Contractor
Required permitting activities
Approvals required by Subcontractor from Contractor
Early activities required for material purchases
Provision of such financial instruments as may be required by the agreement
Provision of such insurance documents that may be required by the agreement
Issue of the Subcontract schedule
Issue of progress measurement / reporting procedure
Subcontractor shall, within thirty (30) calendar days of Subcontract award and before the first progress payment is made, submit to Contractor for its written approval a Subcontract Schedule. The schedule shall consist of a precedence network diagram using the critical path method (CPM) to show each individual essential activity in sequence to meet the Subcontract Milestones of the Special Condition titled "Commencement, Progress And Completion Of The Work." The diagram shall show durations and dependencies including contractual review periods, permitting activities and off-Jobsite activities such as design, fabrication of equipment, procurement, delivery of materials, and items to be furnished by Contractor. It shall show total float and free-float times. Float shall not be considered to be for the exclusive benefit of either Contractor or Subcontractor. Extensions of time for performance required under other Subcontract clauses shall be made only to the extent that equitable time adjustments for affected activities exceed the total float available along their paths.
The activity listing shall show the following information for each activity on the diagram:
Identification by node number;
Description of the task or event;
Duration;
Personnel by craft;
Equipment;
Earliest start and finish dates; and
Latest start and finish dates.
In addition Subcontractor shall submit a complementary and detailed narrative description of its plan for performing the Work. The narrative description shall summarize equipment and personnel requirements by craft to complete a resource loaded schedule, and provide other schedule assumptions such as planned work week, shift patterns, permitting, deliverable times required by Contractor, and any other salient points related to the methods to be employed in completing the work.
The planned progress that is envisaged from the plan shall be described by way of a series of “S” curves related to progress for Overall Subcontract, Procurement and Construction activities, calculated using the procedure and methodology described in SC -14.
Subcontractor shall promptly inform Contractor of any proposed change in the schedule and narrative and shall furnish Contractor with a revised schedule and narrative within ten (10) calendar days after approval by Contractor of such change. The schedule and narrative shall be kept up to date, taking into account the actual work progress and shall be revised, if necessary, every thirty (30) calendar days. The revised schedule and narrative shall, as determined by Contractor, be sufficient to meet the requirements for completion of any separable part and all of the Work as set forth in this Subcontract.
During the performance of the Work, Subcontractor shall submit to Contractor periodic reports on the actual progress. Such progress reports shall include the following:
Monthly A copy of the Subcontract Schedule showing actual progress to date overall and for the major parts of the Work, as compared to planned progress. To be provided on every last Thursday of the month
Monthly A jobhour comparison by craft of actual versus planned staffing;
Weekly A three-week look-ahead personnel forecast by craft. Variation from approved schedules and plans shall be noted and rationalized;
Weekly A rolling four-week schedule showing one week actual progress and a three-week look-ahead forecast. Variation from approved schedules and plans shall be noted and rationalized;
Weekly A weekly report of quantities installed versus total quantities on items of the Work selected by Contractor;
Weekly A weekly report of labor productivity comparing actual versus planned jobhours on items of the Work selected by Contractor. Variation from approved schedules and plans shall be noted and rationalized;
Daily A daily force report listing all personnel by craft and work assignment; and
Daily A daily plant and equipment report showing the construction facilities and plant and equipment utilized in the Work.
As required Other reports as may be required by Contractor from time to time to satisfy itself that work is progressing as planned in the appropriate manner.
Schedules and reports shall be furnished in hardcopy and/or electronic files as specified by Contractor. To permit electronic exchange of schedule data to the greatest extent possible Subcontractor shall use Primavera P3TM scheduling software version 3.1 Contractor may provide coding structure to Subcontractor for development of schedule. Where applicable the MS suite of software may be used.
SC-10 Temporary Access and Haul Roads
Subcontractor shall, at its expense, construct and maintain temporary access and haul roads as may be necessary, including any hard standings and provision of adequate temporary bridging of pipe and cable tracks for the proper performance of this Subcontract. Subcontractor shall submit a layout of all proposed roads prior to road construction. The layout shall show widths of roads, direction of traffic, curves, grades and related information in sufficient detail for review by Contractor. Roads constructed on Contractor’s or Owner's land or rights-of-way shall be subject to Contractor’s and/or Owner’s approval.
All Temporary Works shall be properly designed and substantially constructed to carry such loads as shall be imposed on them. Subcontractor shall submit for the approval of Owner and/or Contractor its drawings and calculations relating to the strength and stability of any Temporary Works as well as the methods proposed for the erection thereof. If the Owner and/or Contractor upon receipt of such drawings and calculations is not satisfied with any aspect of the Temporary Works, they may require the Subcontractor to take additional measures at the Subcontractor’s own cost.
All Temporary Works supplied by Subcontractor shall be removed on completion of the Work to Contractor’s satisfaction.
SC-11 Safety, Health and Security Requirements
In the development and implementation of its Health, Safety and Environment Plan (HSE Plan) and performance of the Work, Subcontractor shall conform and comply with Contractor’s “Health, Safety And Enviromental Standards” .
In performance of the Work under this Subcontract, Subcontractor shall establish and maintain a security program, implementing and supplementing Project security requirements. This shall include a written Security Plan which shall be submitted to Contractor for review and approval within thirty (30) calendar days after Subcontract award and in any event prior to commencing work at the Jobsite. Such program shall include:
Controlled access to office, warehouse, material and equipment sites.
Physical security of office, warehouse, material and equipment sites, to include periodic security checks of all work areas assigned to Subcontractor.
Control of material and equipment packaging, transportation, and delivery to the Jobsite.
Accountability procedures for storage, requisition and issue of material and equipment.
Personnel security to include, but not limited to, compliance with Project work rules (access, badging, prohibited activities and items, etc.)
Communications security to include, but not limited to, use of radios, radio finders, beacons, etc.
Compliance with the Project Emergency Response Plan to include, but not limited to, emergency notification lists, personnel accountability procedures, etc.
Compliance with all Project security programs and the coordination measures, with Contractor, Owner and others on the Jobsite, established for that purpose.
Prompt reporting of incidents of loss, theft or vandalism to CONTRACTOR, subsequently detailed and provided in writing.
Subcontractor’s Security Plan shall be added as an appendix to its Project HSE Plan.
Subcontractor shall ensure that all manual/non manual personnel on Jobsite, whether direct or indirect are issued with safety personal protection items to a minimum of hard hat, safety shoes, overalls, ear plugs and safety glasses to a quality as defined in the Project Safety Procedure and acceptable to Contractor. High Visibility vests shall also be provided, for any personnel working in the vicinity of moving or unloading vehicles, or near to lifting and handling of heavy loads, or working in low light conditions. Any personnel without the minimum foregoing shall not be allowed access to the Jobsite. In the event of Subcontractor’s failure to comply with the foregoing requirements, Contractor shall furnish the necessary personal protection items and backcharge Subcontractor under Exhibit ‘A’, General Conditions, GC-36, titled ’Backcharges’
Subcontractor shall strictly ensure the availability on the Jobsite, throughout the duration of the Subcontract, adequate supplies of good quality chilled potable water for all Subcontractor’s personnel. Contractor reserves the right, at Subcontractor’s expense, to have potable water samples analysed and certified fit for consumption. In the event of Subcontractor failure to comply with the foregoing requirements, Contractor shall furnish the necessary chilled potable water and means of distribution, and backcharge Subcontractor under Exhibit ‘A’, General Conditions, GC-36, titled ’backcharges’
Safety and Security of Owner’s Existing Facilities
The safety of the Existing Facities, their uninterrupted operation and safe and unhindered access thereto by Owner and its Affiliates, shall be of paramount importance in relation to Subcontractor’s performance of the Work.
With regard to any part of the Work requiring inter-ties or inter-faces with Existing Facilities, to the extent that it directly affects the Existing Facilities, or requires access to the Existing Facilities, determination of the sequence of performance of the Work, working practices, number of Subcontractor’s personnel admitted to the Existing Facilities and issuance of work permits therefore shall be subject to the prior examination and approval of Owner or the relevant authority.
Subcontractor’s safety personnel shall assist Owner And Contractor to determine safety levels/requirements for such any activities within the Existing Facilities but the final decision shall rest with Owner.
SC-12 Explosives
Explosives shall be transported to the Jobsite only when required to perform the Work under this Subcontract and with prior notice to and written approval of Contractor. Subcontractor shall be responsible for properly purchasing, transporting, storing, safeguarding, handling and using explosives required to perform the Work under this Subcontract. Subcontractor shall employ competent and qualified personnel for the use of explosives and, notwithstanding any other provision in the Subcontract to the contrary, shall assume full responsibilities for the cost of any incidental or consequential damages caused by the improper use of explosives. Residual surplus explosives shall be promptly removed from the Jobsite and properly disposed of by Subcontractor.
SC-13 Performance and Payment Securities
Unless expressly waived by Contractor, Subcontractor shall, within ten (10) calendar days after subcontract award and prior to commencing the Work or entering the Jobsite, furnish to Contractor the following securities:
1. Subcontractor hereby agrees to provide to Contractor, within Ten (10) days of the coming into force of this Subcontract, an unconditional and irrevocable first demand Performance Bank Guarantee in the form set out herein and in the amounts provided for below. Such Performance Bank Guarantee, the cost of which is deemed to be included in the subcontract price, shall be to secure Subcontractor’s obligations under this Subcontract notwithstanding any Changes, alterations or extensions of time that may be given or agreed upon.
The Performance Bank Guarantee shall remain valid until settlement of all issues between the Parties following termination of this Subcontract, pursuant to the provisions hereof or until issuance of the Notice of Final Acceptance (excluding painting works), by Contractor whichever is the earlier. The Performance Bank Guarantee shall be provided by a bank registered in national or a prime international bank, nominated by Subcontractor and approved by Contractor.
The Performance Bank Guarantee shall be in the currency of US Dollars and equivalent to ten percent (10%) of the subcontract price. The value of the Performance Bank Guarantee shall be increased or decreased in steps of ten percent (10%) each time the subcontract price is increased or decreased by an amount equal to ten percent (10%) of the original subcontract price.
The value of the Performance Bank Guarantee shall be reduced to fifty percent (50%) of its then current value upon issuance of the Notice of Provisional Acceptance last issued.
Prior to the issuance of the Notice of Final Acceptance (excluding painting works) and with specific reference to the extended painting warranty provisions as described in the General Condition entitled “Warranty”, Subcontractor shall automatically provide an unconditional and irrevocable first demand Performance Bank Guarantee modified with reference to the specified painting works, from a bank registered in national or a prime international bank and approved by Contractor. The value of the subject Bank Guarantee shall be a sum equal to five percent (5%) of the estimated value of painting works (such value to be agreed between both Parties prior to issuance of the last Notice of Provisional Acceptance) and shall remain valid for the duration of the warranty period for the painting works.
Contractor may make a claim on the Performance Bank Guarantee in respect of any breach of contract or liability of Subcontractor whatsoever arising under the Subcontract including without limitation and for the avoidance of doubt any breach of Warranty or failure to comply with the requirements of the General Condition entitled “Warranty”. Contractor in making any such claim shall not be obliged to notify Subcontractor specifying the default of Subcontractor upon which it bases its claim. Contractor shall on making any claim under the Performance Bank Guarantee comply with the requirements and procedures stated in the Performance Bank Guarantee.
In the event that the Performance Bank Guarantee has an expiry date that shall expire prior to the expiry of the relevant periods referred to in this Special Condition, Subcontractor shall procure that a prime international bank approved by Contractor shall, prior to the date falling thirty (30) days before the expiry of the Performance Bank Guarantee, have extended or provided a replacement Performance Bank Guarantee in an amount equal to the Performance Bank Guarantee to take effect at least twenty one (21) days prior to the expiry of the Performance Bank Guarantee being replaced.
In the event that Subcontractor fails to extend or replace the Performance Bank Guarantee or Subcontractor fails to renew or reinstate the Performance Bank Guarantee in the stated amount to be maintained, Contractor shall be entitled
to :-
make any immediate call on the Performance Bank Guarantee up to the full amount thereof ;
retain for its own account from the monies received pursuant to any call any amount which it would have been entitled to demand from time to time under the Performance Bank Guarantee had it been extended or replaced, and
retain the monies received pursuant to i) and ii) above until Subcontractor procures an extension or replacement of the Performance Bank Guarantee or the period for which the Performance Bank guarantee is required to be provided pursuant to the terms of the Subcontract expires.
In the event that the Subcontract allows for payment of an advance payment, then Subcontractor shall be required to provide to Contractor, prior to any advance payment, an advance payment bank guarantee equal to 100% of the advance payment value which shall be unconditional and irrevocable and effective until the full amount of the advance payment is recovered by Contractor.
Such securities shall be issued in a form and by a bank acceptable to Contractor. Subcontractor shall vary the value of such securities as necessary and called for by the issuing bank to equal all subcontract changes made pursuant to the General Condition titled "Changes" including, but not limited to, increase or decrease in scope, value, and schedule acceleration or deceleration.
SC-14 Measurement For Payment
To establish a basis for payment against lump sum items set forth in Exhibit C, Subcontractor shall, within ten (10) calendar days after Subcontract award, provide a lump sum breakdown (Schedule of Values) which proposes:
Contractor shall review Subcontractor's Schedule of Values, determine the appropriate tasks and values for progress payments and so advise Subcontractor in writing.
At level 1 A breakdown between Engineering, Procurement and Construction activities.
At level 2 A breakdown for each Level 1 activity a reasonable number of measurable interim tasks required to accomplish each element within an area.
Progress measurement shall be based upon the physical progress against each of the activities / sub-activities and deliverables according to a set of weighted values, allocated according to the effort required to complete calculated at Levels 3/ 4 For working out the weightage of various activities within each area and within each phase of the Project, the following basis shall be used:
|a) |Engineering |- |Man-hours |
|b) |Manufacturing & Delivery (Civil items and other SITE procured small |- |Cost |
| |items excluded) | | |
|c) |Construction and Pre-commissioning |- |Man-hours |
Relative weightings for developing the overall S-Curves against the above three phases and for each area shall be developed and agreed prior to implementation with Contractor. These weightings shall remain fixed for the duration of the works.
Weighted Value System;
Each activity or deliverable listed in Level-3 schedule shall be assigned weightings based on man-hours/ cost depending on the estimated work content.
Activity or deliverable weight factors shall be computed based on the estimated man-hours/cost as a fraction of the total man-hours/cost for each Area / Phase / Discipline etc. and for the whole subcontract.
The weight factors thus computed from Level-3/4 schedules shall be rolled up to Level-2 and Level-1 by Area / Phase / Discipline etc. in line with the agreed Work Breakdown Structure (WBS).
Progress Measurement
In case of Engineering Services and Manufacturing & Delivery activities, progress against each activity / sub-activity level shall be based on assigning certain pre-defined % progress representing the achievement of specific intermediate control points required to complete the activity / deliverable.
In case of Construction progress against each activity / sub-activity level shall be measured based on the quantity of work completed as a percentage of the total quantity of work to be completed, again based for each commodity on a series of interim control points.
Total progress of each subcontract Area / Phase / Discipline etc. shall be computed by multiplying the activity % progress by its weight factor and thereafter summing up the products.
Achievement of any deliverable at an intermediate Control Point stage does not automatically mean achievement of the said Control Point progress. Subcontractor’s Progress Measurement System shall make necessary allowance for deduction of weighted progress if deliverables are rejected by Contractor as not being of the required standard.
Overall progress of the Subcontract shall be calculated by integrating the progress against each Area / Phase / Discipline etc. as described above.
rogress Measurement / Weightage System Proposed for the Project
Details of weighted values for the various major activities are to be proposed by Subcontractor, for review/approval by Contractor prior to implementation. Subcontractor shall propose the detailed system for measuring the progress of the subcontract for Contractor review and approval prior to implementation.
General
Following activities shall not be assigned any weightage. This would mean that the man-hour requirements against the following activities shall not be considered for progress computation:
Project Management.
Project Control.
QA/QC
Subcontract Management
Mobilization / Demobilization.
Subcontractor shall then provide a schedule of the monthly progress payments (Estimated Payment Schedule) required to perform the Work in accordance with the Subcontract Schedule approved pursuant to the Special Condition titled "Subcontract Schedule." The Estimated Payment Schedule shall apply either the Schedule of Values, a reasonable estimate of progress on tasks represented by unit prices, or a combination thereof.
Written monthly estimates shall be prepared by Subcontractor for Contractor's approval covering the amount and value of work satisfactorily performed by Subcontractor up to the date of such estimate. Such estimate may be made by strict measurement, or by estimate, or partly by one method and partly by the other. Estimates shall not include materials or equipment not incorporated into the Work. The quantity of work to be paid for under any item for which a unit price is fixed shall be the number of Contractor approved units of work satisfactorily completed in accordance with the specified unit measurement for payment provisions of this Subcontract.
Subcontractor shall make all surveys necessary for determining all quantities of work to be paid under this Subcontract. Copies of field notes, computations and other records made by Subcontractor for the purpose of determining quantities shall be furnished to Contractor upon request. Subcontractor shall notify Contractor prior to the time such surveys are made. Contractor, at its sole discretion, may witness and verify such surveys. Measurements and computations shall be made by such methods as Contractor may consider appropriate for the class of work measured and the estimate of quantities of work completed shall be compatible with the reporting requirements of the Special Condition titled "Subcontract Schedule". The dividing limits, lines or planes between adjacent items or classes of excavation, concrete, or other types of work where not definitely indicated on the drawings or in the specifications shall be as determined by Contractor.
Contractor shall review Subcontractor's monthly estimate and return an approved copy to Subcontractor. Pursuant to the Special Condition titled "Invoicing And Payment," Subcontractor shall prepare and submit to contractor invoices in accordance with the approved monthly estimates.
SC-15 Invoicing And Payment
Subcontractor shall prepare and submit invoices as follows:
1. Subcontractor submits estimates by the 20th of the month, and
2. Contractor reviews the estimates with Subcontractor and upon approval returns them for submittal with Subcontractor's invoice on the 1st scheduled working day of the following month.
Subcontractor shall certify in each invoice that there are no known outstanding mechanic's or material-men's liens, and that all due and payable bills have been paid or are included in the application for payment.
Within sixty (60) calendar days after receipt of a correct invoice in New Delhi, Contractor shall pay Subcontractor ninety percent (90%) of the approved invoice amount retaining the balance (Retainage) pending Final Acceptance of the Work or as otherwise specified below.
Contractor may, as a condition precedent to any payment, require Subcontractor to submit for itself, its subcontractors, immediate and remote, and all material suppliers, vendors, laborers and other parties acting through or under it, complete waivers and releases of all claims against Contractor or Owner arising under or by virtue of this Subcontract. Upon request, Subcontractor shall in addition furnish acceptable evidence that all such claims have been satisfied.
Any amounts otherwise payable under this Subcontract may be withheld, in whole or in part, if:
3. Any claims are filed against Subcontractor by Contractor, Owner or third parties (for which Contractor or Owner is or may become liable);
4. Subcontractor is in material default of any Subcontract condition including, but not limited to, the schedule, quality assurance and health and safety requirements;
5. Subcontractor has not submitted:
a. Schedules as defined in the Special Condition titled "Subcontract Schedule,"
b. Proper insurance certificates, or not provided proper coverage or proof thereof, and
Required Performance and Payment Bonds or Contractor approved equivalent securities;
. Plans e.g. HSE, Security, Quality, etc., required prior to start of construction.
6. Adjustments are due from previous overpayment or audit result; or
7. Offsets in favor of Contractor in other transactions are asserted.
Contractor shall pay such withheld payments if Subcontractor:
8. Pays, satisfies or discharges any claim of Contractor, Owner, or third parties against Subcontractor under or by virtue of this Subcontract; or
9. Cures all defaults in the performance of this Subcontract.
If claims filed against Subcontractor connected with performance under this Subcontract, for which Contractor may be held liable if unpaid (e.g., unpaid withholding and back taxes), are not promptly removed by Subcontractor after receipt of written notice from Contractor to do so, Contractor may remove such claims and deduct all costs in connection with such removal from withheld payments or other monies due, or which may become due, to Subcontractor. If the amount of such withheld payment or other monies due Subcontractor under this Subcontract is insufficient to meet such costs, or if any claim against Subcontractor is discharged by Contractor after final payment is made, Subcontractor and its surety or sureties, if any, shall promptly pay Contractor all costs incurred thereby regardless of when such claim arose or whether such claim imposed a lien upon the Project or the real property upon which the Project is situated.
In the event a lien is filed, Subcontractor shall remove the lien, or see that it is removed or shall furnish a bond for the full amount thereof within seven (7) calendar days of notice by Contractor or as otherwise specified by applicable law. Upon Subcontractor's failure to promptly comply with the foregoing requirements Contractor may remove such liens. Subcontractor shall reimburse Contractor for all costs in connection with the removal of such liens and Contractor may deduct such costs from payments or other monies due, or which may become due, to Subcontractor.
Upon receipt by Subcontractor of Contractor's Notice of Final Acceptance of the Work under this Subcontract, Subcontractor shall prepare, as required above, an estimate of all remaining work satisfactorily completed under this Subcontract. Upon Contractor's approval of such estimate, Subcontractor shall prepare and submit its final invoice in accordance with the approved estimate.
Upon receipt by Subcontractor of Contractor's written notice of Final Acceptance of the Work under this Subcontract, Subcontractor shall prepare a written statement for Contractor's approval of the amount and value of all remaining Payment Milestones or other work satisfactorily completed under this Subcontract. Upon Contractor's approval of such statement, Subcontractor shall prepare and submit its final invoice in accordance with the approved statement.
Unless otherwise specified by applicable law, Contractor shall, within sixty (60) calendar days following Final Acceptance of the Work and after submittal of such final invoice, pay to Subcontractor the amount then remaining due, provided that, Subcontractor shall have furnished Contractor and Owner for itself, its subcontractors, immediate and remote, and all material suppliers, vendors, laborers and other parties acting through or under it, waivers and releases of all claims against Contractor or Owner arising under or by virtue of this Subcontract, except such claims, if any, as may with the consent of Contractor and Owner be specifically excepted by Subcontractor from the operation of the release in stated amounts to be set forth therein.
Contractor shall reduce the value of the Retainage to five percent (5%) of the final Subcontract value until expiration of the warranties provided under the General Condition titled "Warranty." However, upon Contractor's written approval all Retainage may be paid and an acceptable security substituted for this requirement.
No payments of invoices or portions thereof shall at any time constitute approval or acceptance of any work under this Subcontract, nor be considered a waiver by Contractor or Owner of any of the terms of this Subcontract. However, title to all equipment and materials which has vested in Contractor or Owner pursuant to the Special Condition titled "Title And Risk Of Loss" shall not be part of Subcontractor's property or estate, unless otherwise specified by applicable law, in the event Subcontractor is adjudged bankrupt or makes a general assignment for the benefit of creditors, or if a receiver is appointed on account of Subcontractor's insolvency, or if all or any portion of this Subcontract is terminated.
Subcontractor shall submit all invoices in original and two (2) copies to:
Eastern Co. Ltd.
Attention: - Accounts Payable
Reference: Subcontract No.
A copy of the invoice to be sent to:
Project Accounting Manager
Plant Project
Invoices shall be submitted and payment shall be made in the currency of this Subcontract
Each copy of the invoice shall be supported by copies of the full supporting documentation. Failure to specify the full Subcontract number or to submit full supporting documentation may be cause for invoice rejection or delay in payment.
Invoices shall be prepared and signed and shall show the following information: -
(a) Subcontract Number.
(b) Subcontractor 's full name and address.
(c) Subcontractor 's bank, bank addresses and account number.
Description of work performed in accordance with Exhibit "C" of this Subcontract.
Unique Invoice Number
SC-16 Pricing Of Adjustments
When costs are a factor in any determination of a subcontract adjustment pursuant to the General Conditions titled "Changes" or "Disputes," Subcontractor shall propose upward or downward price adjustments in one of the following methods as directed by Contractor:
1. Using unit prices from the Subcontract;
2. Estimating new unit prices where appropriate, subject to negotiation;
3. Estimating a lump sum price for the change, subject to negotiation; and
4. Establishing separate cost accounting records, subject to daily end-of-the-day written approval by Contractor of all allocable costs on a Force Account basis. Reimbursement of reasonable and approved incurred costs, plus specified rates for overhead and profit, as defined below, shall be the basis for Force Account adjustment of the Subcontract price.
When Subcontractor is directed to propose price adjustments pursuant to 2 or 3 above, it shall provide cost breakdown information for the purpose of and in sufficient detail to permit analysis and negotiation including but not limited to labor categories, jobhours and rates, equipment and material quantities, sources and calculations, overhead costs and allocations, profit computations and reference data upon which estimates are based. If for any reason Contractor and Subcontractor are unable to agree upon a Subcontract price adjustment the following provisions, which establish and define allowable costs and rates for Force Account work pursuant to 4 above, shall also define allowable costs and rates for a determination by Contractor.
1. Direct Labor. Incurred direct labor wages for technical, craft and manual labor for all classifications through lead engineer, foreman or equivalent are allowable for the period of performance of the change. General supervision and management above lead engineer, foreman or equivalent and indirect labor, e.g., surveyors, office personnel, timekeepers and maintenance personnel, are not allowable as direct costs but are recovered in the overhead and profit rates established by this clause. Payroll additives are allowable and include taxes, insurance premiums, paid absences, and social and retirement benefits required by law, labor agreements, published company policies applying uniformly to Subcontractor's work force or which are normal and customary.
Contractor shall have access to Subcontractor's certified payroll records for verification of labor costs.
2. Equipment. Approved incurred construction equipment, facilities and vehicle net rental costs plus five percent (5%) for subcontractor overhead and profit are allowable, except tools and equipment having original purchase prices of less than $500 each, which are deemed to be covered in the overhead and profit rates established by this clause. If operating costs are not included in rental rates they are also allowable.
Reasonable equipment charges for approved Subcontractor-owned construction equipment having original purchase prices of more than $500 each shall also be allowed, provided such charges are:
a. Agreed upon Subcontract unit rates; or
b. Based upon calculated values allocating ownership costs over the useful life of the equipment plus operating costs such as fuel, oil, lubricants, and maintenance and a profit of ten percent (10%) on such costs; or
c. Appropriately discounted to stand-by rates for idle time reasonably required.
When the operated use of equipment is infrequent and, as determined by Contractor, such equipment need not remain at the work site continuously, charges shall be limited to actual hours of use. Equipment not operating but retained at the location of changes at Contractor's direction shall be charged at the standby rate.
For the cost of both rented and owned equipment to be allowable, Contractor must agree in writing, prior to their being used, that the individual pieces of equipment are needed, are appropriate for the work, and that the mobilization and demobilization costs are allocable to the change and acceptable. This is in addition to the daily end-of-day approval of operating time for such equipment.
3. Materials. Approved incurred costs for material incorporated into the changed Work or required for temporary construction facilities made necessary by the change shall be allowable at net cost delivered to the Jobsite plus five percent (5%) overhead and profit for Subcontractor.
4. Subcontracts. Approved incurred costs for lower-tier subcontracted tasks shall be allowable plus five percent (5%) overhead and profit for Subcontractor; provided that Contractor has approved the lower-tier subcontract pursuant to the General Condition titled "Assignments And Subcontracts" before any work is performed.
5. Overhead, Profit and All Other Costs. In addition to the overhead and profit provided in 6 through 8 above, Contractor shall also pay an amount equal to fifteen percent (15%) of total direct labor as described in 5 above for changes resulting in a Subcontract price adjustment, excluding this percentage markup, of less than $25,000, or shall pay ten percent (10%) for changes resulting in adjustments of $25,000 or more.
This amount shall be deemed to be full consideration for all overhead, interest and profit, for all additional costs e.g., supervision and tools, and for all impacts of the change on all elements of the Work whether or not changed.
SC-17 Quality Assurance Program
Within thirty (30) calendar days after Subcontract award, Subcontractor shall submit a Quality Management System Documentation for approval by Contractor, consisting of the following documents or their Contractor determined equivalent:
1. Quality Management System Manual setting out Subcontractor’s corporate quality management system, or a copy of an independently approved ISO 9001:2000 Certificate
Project specific Quality Plan applicable to the Scope of Work or Services.
Index of relevant Project or Corporate Procedures
Draft Project Audit Schedule
The Project specific Quality Plan shall address all activities and locations relevant to the Work and shall demonstrate how all work performed by Subcontractor shall conform to the Subcontract requirements.
The plan shall define the documented quality system responsibilities and activities to be applied by Subcontractor throughout the Work, in accordance with the requirements of ISO9001/ISO:2000 and make reference to all relevant Subcontractor procedures and manuals.
The plan shall address the interfaces between Contractor, Subcontractor, and other relevant organizational entities. The plan shall include an organization chart showing Subcontractor’s corporate and Project organization responsible for managing, performing and verifying the Work. The organization chart shall be supported with a reporting and functional description of Subcontractor’s Project organization and identification of the quality related responsibilities of key positions.
The plan shall be updated as necessary throughout the Subcontract, to reflect any changes to Subcontractor’s documented quality system.
The Subcontractor’s documented plan shall identifiy that all quality documents are approved and that there are no outstanding corrective actions, technical queries or concessions which are not fully resolved or closed out.
Subcontractor’s documented quality system shall provide for the issuance of a “stop work” order by Subcontractor or Contractor at any time during the Work, when significant adverse quality trends and/or deviations from the approved Quality Program are found.
Contractor reserves the right to perform Quality Management System Audits of Subcontractor’s approved Quality Assurance Program, including suppliers and subcontractors of any tier, at any stage of the Work.
SC-18 Title And Risk Of Loss
Title to the Work, Project Documents and to all goods and other items supplied or to be supplied by Subcontractor or its subcontractors to Contractor or Owner to be incorporated as a permanent part of installations under this Subcontract shall pass to Contractor or Owner on whichever is earlier of the following dates:
a. when delivered to the Site;
b. when delivered to the custody of Subcontractor or its shipping agent;
c. when Subcontractor receives payment from Contractor for the Work, Project Documents or goods or other items by Subcontractor.
Materials or operating equipment of any kind left over or meant to be left over during and after the completion of the Work, as well as the construction special tools and erection equipment, temporary structures, forms supplied and any other incidental items not forming part of the Project, if furnished by Subcontractor or its subcontractors, shall remain the property of Subcontractor or its subcontractors, as the case may be, and shall be removed by Subcontractor prior to or upon the completion of the Work.
All construction plant, goods and other things provided by Subcontractor shall when brought on the Site be deemed to be exclusively intended for the purpose of the Work and Subcontractor shall not remove same or any part thereof while required at the Site.
SC-19 Component Warranties
In addition to the General Condition titled "Warranty" Subcontractor shall obtain or provide, for the benefit of Contractor and Owner and their successors in interest, warranties or guarantees for the equipment, materials and work furnished by suppliers and subcontractors of any tier. Such warranties or guarantees are to run for the period set forth in the applicable specification of this Subcontract or, when not specified, that period customarily provided by the supplier. Subcontractor shall use its best efforts to enforce such lower-tier warranties or guarantees on its own behalf or, if requested by Contractor or Owner, on behalf of Contractor or Owner. Subcontractor shall provide warranty documentation by Final Acceptance or as otherwise required by this Subcontract.
SC-20 Applicable Law
This Subcontract shall be interpreted under the laws nation.
All work performed in nation shall be subject to the laws, regulations and orders of the nation. Such laws include without limitation any law (national, state, municipal, local or other), requirement, ordinance, rule, decree, regulation or order of any governmental authority or agency of nation (state, national, municipal, local or other).
SC-21 Modifications To EXHIBIT “A”
None
SC-22 Release Of Consequential Damages
Neither party shall be liable to the other for consequential damages resulting from or arising out of this Subcontract, including without limitation, loss of profit, loss of business opportunity, idle facilities or resources, loss of property or mineral rights, or business interruption however caused.
SC-23 Nondisclosure
Subcontractor agrees that for a period of fifteen (15) years following the issue of the Final Acceptance Certificate it shall not, without the prior written consent of Contractor, disclose or make available to any third party (other than subcontractors, vendors or licensors) or use, directly or indirectly, except for the performance of its obligations under the Subcontract, the terms of the Subcontract, Project Documents or any information acquired directly or indirectly from Contractor or Owner in connection with the Project or the Subcontract before or after the effective date unless:
a. The information was known to Subcontractor (as evidenced by its written records) prior to obtaining the same from Contractor;
b. The information was in the public domain prior to the time of disclosure to Subcontractor; or
c. The information is disclosed to Subcontractor by a third party who did not receive the same, directly or indirectly, from Contractor or Owner and who has, to the best of Subcontractor’s knowledge, no obligation of secrecy with respect thereto.
Subcontractor shall take all steps, which may be necessary or appropriate including the obtaining of written confidentiality undertakings or agreements in order that its employees, agents and representatives adhere to the provisions of this clause. Appropriate clauses to carry out the purpose and intent hereof shall also be included in all subcontracts
SC-24 Measurement System
Subcontractor shall use the Metric (SI) system of measurement for all designs, specifications, drawings, plans and work except as otherwise directed in writing by Contractor.
SC-25 Liquidated Damages
The parties hereby agree that the damages which Contractor shall sustain as a result of Subcontractor's failure to meet key Subcontract Milestones are difficult or impossible to determine with certainty and, therefore, have in good faith estimated as fair compensation (and not as a penalty) the liquidated damages as set forth below. If Subcontractor fails to deliver the equipment or materials or perform the services within the time frames specified in the Subcontract for the Subcontract Milestones listed below, or any extensions evidenced by a Change Notice/Order or duly executed Subcontract Amendment, the Subcontractor shall pay to Contractor as fixed, agreed and liquidated damages for each calendar day of delay the sum(s) specified below, which amounts shall be independently calculated for each Subcontract Milestone indicated:
No. Subcontract Milestone Daily Liquidated Damage Amount
1. Mobilization $
2. Completion of Site Preparation $
3. Completion of Foundation Formwork $
4. Completion of Concrete Pour $
5. Completion of All Work $
The application of liquidated damages shall not effect a change in the Subcontract Milestones or relieve Subcontractor of its obligation to improve its progress, pursuant to the Special Condition titled "Commencement, Progress And Completion Of The Work," to achieve or mitigate the failure to achieve any Subcontract Milestone.
Payments of liquidated damages shall become due immediately upon failure to achieve a Subcontract Milestone. Contractor shall be entitled to withhold from payments due, offset against other obligations, deduct from Retainage, and draw down on letter(s) of credit or performance securities any and all liquidated damages due from Subcontractor.
Nothing in this clause shall operate to restrict any other rights and remedies available to Contractor or Owner at law or under this Subcontract.
SC-26 Key Personnel
Subcontractor shall not reassign or remove the key personnel listed below without the prior written authorization of Contractor.
Name Title/Position
Contractor’s organization charts together with deployment schedule and key personnel shall be subject to prior approval of Contractor.
SC-27 Language Requirements
Subcontractor shall prepare all Project Documents and drawings, and the Parties shall conduct all communications in connection with the Work, in the English language. Any documentation received by Contractor in any other language shall not be accepted and must be resubmitted in English unless it is an official certificate in which case it must be accompanied by an "approved" legal English translation. Any impact on cost or schedule relating to this requirement shall be Subcontractor’s sole responsibility.
SC-28 Drugs, Alcohol And Weapons
Subcontractor's personnel shall not bring onto the Jobsite, or any other location where the provisions of this Subcontract apply:
1. Any firearm of whatsoever nature, knife with a blade exceeding four (4) inches (100 millimeters) in length or any other object which in the sole judgment of Contractor is determined to be a potential weapon.
2. Alcoholic beverages of any nature.
3. Illegal or Contractor or Owner prohibited non-prescription drugs of any nature without exception.
Subcontractor shall abide by and enforce the requirements of this clause to include the immediate removal from the Work under this Subcontract of any employee who has violated the requirements of this clause or who Contractor, in its sole judgment, determines has violated the requirements of this clause.
SC-29 Right To Work Tools And Work Product
All drawings, reports, microfilms, software, results, studies, calculations, data and any other documents or information including as-built drawings, operating and maintenance manuals in respect of the systems, plant, installations or Project produced or prepared by or for Subcontractor or its subcontractors in physical or electronic form for and in the course of or as a result of performance of Work shall be the exclusive property of Owner and for the avoidance of doubt Owner may use and disclose the same freely without reference to or consent of Subcontractor or its subcontractors.
Subject to the provisions of the Special Condition “Nondisclosure”, Subcontractor is hereby granted a non-terminable, non-exclusive, royalty-free licence to copy and use the drawings, reports, microfilms, software, results, studies, calculations, data and any other documents or information including as-built drawings, operating and maintenance manuals referred to in above in connection with Subcontractor’s normal business development.
SC-30 Importation Of Equipment, Materials And Services
Subcontractor shall import into nation all equipment, materials and services not locally available and required for the performance of the Work, subject to all provisions which grant Contractor, Owner or Subcontractor an exemption from or reduction of any customs duties, import and export taxes, or other charges (Exemption). Subcontractor shall not perform or omit any act which results in prejudice to such Exemption.
Subcontractor shall be responsible for all clearances, fees, charges and requirements of whatsoever nature for the importation of such equipment, materials and services including all port dues, landing pilotage, lighterage and all other dues and charges whatsoever relating to the importation of equipment, materials and services.
In executing its obligations under the Subcontract, Subcontractor shall use the ports in the nation International Airport, for the import of all Goods, materials, equipment, machines, accessories, spare parts and tools as well as construction special tools and erection equipment and any other incidental items to be delivered to the Jobsite. Owner or Contractor shall not be responsible for payment of customs duty, if any, in the event import of Goods are made through a port other than a port in the nation. Subcontractor shall use the local means of transport available in nation.
If the Exemption accrues directly to Contractor or Owner as a rebate of Subcontractor's payment, Contractor shall reimburse Subcontractor for the documented cost of any such exemption paid by Subcontractor to a duly authorized governmental agency having jurisdiction over the equipment, materials or services, to the extent Contractor or Owner receives such rebate.
If the Exemption includes the obligation to re-export, Subcontractor shall diligently comply with such obligation.
Subcontractor shall provide only equipment and materials for which channels of supply and supplier representatives have been established in or are readily available within nation and upon which no undue restrictions of any nature exist for service, repair, or replacement (e.g., product line discontinued or excessive import/export clearances).
If Subcontractor's action or failure to act results in the loss of the full benefits of any available Exemption or otherwise prejudices Contractor, Owner or any third party, Subcontractor shall reimburse Contractor for the loss.
Owner, at its own discretion, reserves the right to make the final, unilateral and specific selection of any proposed carriers, insurers, suppliers of services to be performed within nation. or of specific products or components to be furnished.
SC-31 Provision Of Documents
Subcontractor shall provide and shall ensure that its subcontractors, vendors and licensors provide electronic and hard copies of all Project Documents for Contractor’s permanent files in accordance with the type, status and time requirements defined within the documents making up this Subcontract.
SC-32 Contractor Review Of Documents
For all documents submitted by Subcontractor to Contractor for its review/approval, Contractor shall respond within ten (10) working days of receipt unless a longer period is specified in the Exhibits, provided that the said documents are complete in every respect and have been subject to Subcontractor’s internal review and check process.
If any document is commented upon or rejected by Contractor, Contractor shall provide a written explanation of the reasons, whereupon Subcontractor shall re-submit such document within five (5) working days of receipt with such modifications as may be necessary to reflect Contractor’s requirements.
Any document resubmitted shall be reviewed/approved by Contractor within ten (10) working days of receipt, provided all of Contractor’s comments have been incorporated by Subcontractor in the revised document to Contractor’s satisfaction
SC-33 Labour
Except as otherwise specifically stated in this Subcontr5act, Subcontractor shall arrange for mobilization/demobilization of its personnel including visas, licenses, residence permits, work permits and applicable security passes for entry and egress of personnel in accordance with Project requirements.
Subcontractor shall be responsible for and provide at its sole cost and expense all messing, housing, working and living conditions of labour and all necessary accommodation and other facilities for its personnel as required for the performance of Work.
Subcontractor shall also be responsible for and provide at its sole cost and expense for all transportation for its personnel between their points of origin and the nation, if applicable, and all transportation as may be required for performance of the Work in and around the Site and to and from nation City as applicable.
Subcontractor shall at all times during the Subcontract conform in all respects with and carry out all obligations imposed on it by the provisions and requirements of any applicable law in the country where any part of Work is performed or regulation issued including without limitation all nation laws, regulations and requirements, including any labour laws and requirements to employ an nation agent or to enter into association with an nation partner.
or who are in possession of valid "No Objection Certificate(s)" entitling them to work in the nation for Subcontractor. Contractor shall assist Subcontractor in obtaining "No Objection Certificate(s)" by suitable letter of recommendation. Subcontractor shall submit this letter to the Department of Labour in order to receive such certificate(s). Contractor accepts no responsibility for obtaining "No Objection Certificate(s)" for Subcontractor’s personnel.
Contractor shall be at liberty to object to and require Subcontractor to remove forthwith any person employed by Subcontractor in or about the execution of Work, who in the opinion of Contractor has committed misconduct or whose employment is otherwise considered detrimental to the best interests of the Project. Such person shall not be re-employed on Work without the written permission of Contractor. Subcontractor shall, at its own cost, use its best endeavours to immediately replace such person with a competent substitute.
Subcontractor shall, in its dealings with labour for the time such labour is employed on or in connection with the Work, have due regard to all recognised festivals and religious days and other customs. Subcontractor shall also observe all relevant local customs.
Subcontractor shall not, other than in accordance with statutes, ordinances and government regulations or orders, import, sell, give, barter or otherwise dispose of any alcoholic liquor, or permit or offer any such importation, sale, gift, barter, or disposal by its subcontractors, agents or employees.
Subcontractor shall not give, barter or otherwise dispose of to any person or persons, any arms or ammunition of any kind or permit or offer the same.
In the event of an outbreak of illness of an epidemic nature, Subcontractor shall comply with and carry out such regulations, orders and requirements as may be made by the government or the local medical or sanitary authorities for the purpose of dealing with and overcoming the same.
All Subcontractor’s personnel visiting or working in the nation. must be in possession of valid inoculation certificates as required from time to time.
Upon the outbreak of any strike involving any of Subcontractor’s or its subcontractor’s employees and/or agents engaged in the Work, Subcontractor shall forthwith give details thereof to Contractor.
Subcontractor shall, without delay, inform Contractor of any accident at or around the Site or in connection with the execution of the Work or any injury, loss or damage to any personnel and/or property of Subcontractor indemnified parties, Contractor indemnified parties or of third party and report such occurrences to the competent authority whenever such a report is required by law.
Subcontractor shall be responsible for and to ensure the observance of all provisions of this Special Condition by its subcontractors employed in the execution of the Subcontract.
If Contractor so demands in writing, Subcontractor shall promptly remove from the Project, at Subcontractor’s own cost, any of its employees or employees of its lower tier subcontractors who, in Contractor’s sole and absolute discretion, are not co-operative, are careless or are not qualified to perform the work assigned to them, or for any other reasonable cause.
SC-34 Customs And Duties
In connection with the performance of this Subcontract, Subcontractor acknowledges that the import and customs laws and regulations of the nation shall apply to the furnishings and shipments of any goods, products or components thereof to the nation.
Subcontractor specifically acknowledges that the aforementioned import and customs laws and regulations of nation. prohibit, among other things, the importation into the nation of certain products or components.
Contractor, at its own discretion, reserves the right to make the final, unilateral and specific selection of any proposed carriers, insurers, suppliers of services to be performed within the nation or of specific products or components to be furnished in accordance with the terms and conditions of this Subcontract.
SC-35 Component Warranties
In addition to the General Condition titled Warranty Subcontractor shall obtain or provide, for the benefit of Contractor and Owner and their successors in interest, warranties or guarantees for the equipment, materials and work furnished by suppliers and subcontractors of any tier. Such warranties or guarantees are to run for the period set forth in the applicable specification of this subcontract or, when not specified, that period customarily provided by the supplier. Subcontractor shall use its best efforts to enforce such warranties or guarantees of any tier on its own behalf or, if requested by Contractor or Owner, on behalf of Contractor or Owner. Subcontractor shall provide warranty documentation by Provisional Acceptance or as otherwise required by this subcontract.
SC-36 Conflict Of Interest
Subcontractor shall conduct its operations in a lawful manner consistent with the highest ethical standards of the business community.
Each Party shall use all efforts to prevent a conflict of interest situation from arising. Such efforts shall include, but not be limited to, establishing precautions to prevent its employees, agents, or representatives from making, receiving, providing or offering gifts, entertainment, payments, loans or other considerations for the purpose of influencing individuals to act contrary to the best interest of the other Party.
Subcontractor shall promptly notify Contractor of the identity of any employee, agent, or representative of Contractor or Owner who has at any time either before, during or after performance of the Work acquired any financial interest in Subcontractor’s business or received any financial benefit, directly or indirectly, from or through Subcontractor.
SC-37 Arbitration
Any dispute, claim or difference arising out of or related to the Subcontract or any breach thereof shall first be resolved amicably between the Parties but if such resolution fails, such dispute, claim or difference shall be referred to and finally settled by arbitration in nation City under the Rules of Arbitration of the International Chamber of Commerce (ICC) by three arbitrators appointed in accordance with said Rules.
Subcontractor shall not at any time suspend performance of the Work or any of its obligations under the Subcontract pending resolution or settlement of a dispute and shall proceed with all due diligence with the Work and its other obligations in full compliance with the Subcontract.
The arbitration proceedings and all papers in connection therewith shall be in the English language. The arbitrators’ decision shall be final and binding on the Parties and the award may be enforced by any court of competent jurisdiction.
SC-38 Hazardous Substance Handling
In the event that Subcontractor encounters any pre-existing hazardous waste, Subcontractor shall immediately contact Contractor.
Subcontractor shall be responsible for the proper containerization, labeling, manifesting, storage and transport of hazardous waste. Subcontractor shall also be responsible for ensuring that all waste profile work and land ban disposal notifications required at recycling, treatment, storage and/or disposal facilities have been properly completed in a timely manner and in accordance with national law.
All Subcontractor equipment, debris and used or surplus materials must be fully decontaminated prior to removal from designated work areas. Subcontractor shall submit decontamination and contaminated material control procedures for Contractor review and acceptance. Subcontractor shall obtain Contractor's authorization to remove any such equipment, debris and used or surplus materials from the Jobsite.
SC-39 Deficient Works
If, from commencement of the Works up until expiry of the Warranty Period, any part of the Works performed by Subcontractor or its Lower Tier Subcontractor’s is found to be defective, deficient or in any respect does not conform to Specifications for any reasons, including but not limited to, Subcontractor’s failure to :-
execute the Works in a good and workmanlike manner with diligence and dispatch, orcorrect or cause to be corrected any defect in the Works, or
comply with any other provisions of the Subcontract, or
deliver the goods in conformity with the Subcontract,
then without detracting from any other rights of Contractor under this Subcontract or at law, Contractor shall have the power to require Subcontractor, and Subcontractor shall, upon receipt of written notice from Contractor and at the expense and for the account of Subcontractor re-perform, remedy or cause to be remedied such deficient part of the Works, remove from Site any goods which, in the opinion of Contractor, are not in remove and properly re-execute (notwithstanding any previous test thereof or interim payment therefore) any Work which is not in accordance with the Subcontract. (whether in respect of Goods or workmanship or otherwise Immediately after the replacement of defective goods or work, Subcontractor shall remove said defective goods or work from Site without cost to Contractor.
All replacements and/or repairs and/or alterations shall be made by Subcontractor at such times and in such a manner that they shall cause the minimum of interruption in the operation of the Works or Installations by Owner and/or Contractor. Contractor and Subcontractor shall agree on the schedule for such remedial work. Contractor and Subcontractor shall agree on the schedule for such work, which shall be undertaken without additional cost to Contractor, save where the additional work is not the result of a failure by Subcontractor to conform with this Subcontract and Contractor has accordingly authorised a Change Notice for the performance of such remedial work.
SC-40 Goods And Services
In procuring Goods and services, Subcontractor shall give preference to nation subcontractors and Vendors and to such Goods and services as are available in the local market of a suitable type and quality and provided that their prices are competitive or equal to others.
All lubricants shall be procured from operator Distribution, if available, except where they contradict or conflict with technical specifications or manufacturer’s recommendations.
EXHIBIT B
APPENDIX B-1
Company Furnished Insurance
Appendix 1
Technical Services Contract
Contractor’s Project Health Safety And Environmental Plan (Including Owner’s Commitment To Health, Safety and the Environment & Owner’s Health, Safety And Environmental Policy)
Eastern Contractor Co. Ltd.
Plant Development Phase Project
Section "B"
Technical Services Subcontract
Special Conditions
Table Of Contents
SC Title
1 Definitions
2 Insurance
3 Progress The Work
4 Rights To Work Tools And Work Product
5 Payment
6 Quality Management System
7 Non-disclosure
8 Release Of Consequential Damages
9 Applicable Law
10 Modifications To Section "A"
11 Procedures And Documents
12 Reports
13 Language Requirements
14 Subcontractor Mobilisation / Demobilisation Responsibilities
15 Provision Of Documents
16 Contractor Review Of Documents
17 Labour
18 Title
19 Customs and Duties
20 Dispute Resolution
21 Utilities, Facilities and Services
22 Security and Property
23 Work Week, Overtime and Crew Rotation Schedule
24 Administrative Assistance
SECTION "B"
Technical Services Subcontract
Special Conditions
SC-1 Definitions
Contractor means Contracting Co. Ltd, and all of its authorised representatives acting in their professional capacities.
Final Acceptance means the stage at which Subcontractor has fulfilled its obligations under the Purchase Order including the expiration of warranty period.
Installations means the permanent facilities constituting the Plant Development Phase Project of which the Products are a portion.
Owner means Company and its successors-in-interest and assigns.
Purchase Order means the purchase order between Contractor and Subcontractor for the supply of the Products being installed at the Jobsite. Purchase Order is an entirely separate agreement to this subcontract.
Provisional Acceptance means the stage when the Installations have been accepted by Owner in accordance with the terms of Contractor’s prime contract and the commencement of the warranty period provided in the Purchase Order General Condition entitled “Warranties and Guarantees” shall start upon issuance of the last Provisional Acceptance Certificate.
Products mean/s the goods, materials, articles, equipment, supplies, drawings, data, processes, all other property, services, including design, expediting, inspection, delivery, installation and testing, specified or required to furnish under the Purchase Order.
Project means the Onshore Gas Development Project for Owner located in Plant Area for whom the Work under this subcontract is being performed.
Project Documents mean/s the subcontract, all hard copy, electronic versions of Project documents which shall include but not be limited to all documents, drawings, P&ids, pfds, isometrics, plot plans, general arrangements, specifications, materials requisitions, data sheets, calculations, indices, manuals, reports, procedures, estimates, accounts, summaries, compilations, agreements including SubContractors agreements, related materials and any other document defined or described in any of the foregoing.
Subcontractor means ABC or its authorised representatives, successors, and permitted assigns.
Warranty Period means twenty-four (24) months from the effective date of the last Provisional Acceptance Certificate
Work means all the stated or implied activities to be performed by Subcontractor as required by the Subcontract Documents.
Jobsite means those locations as specified in the Scope of Work, Plant Area
Subcontract Milestone(s) means the established completion date(s) set forth in the Special Condition titled "Commencement, Progress and Completion of the Work."
Subcontract Schedule means the Work execution schedule developed and approved pursuant to the Special Condition titled "Commencement, Progress and Completion of The Work."
SC-2 Insurance
Insurance to be provided by Subcontractor
Without limitation to its obligations and responsibilities under this subcontract, Subcontractor during the performance of this Subcontract, shall at its own expense obtain and thereafter maintain in full force and effect (or cause to be obtained and maintained) the insurance policies set forth below to be effected in the name of Subcontractor. Subcontractor shall cause the insurers or underwriters thereof, to waive their rights of subrogation against Contractor and Owner indemnified parties and wherever feasible, to include the names of Contractor and Owner as additional assured parties.
Subcontractor shall require the same insurance from its SubContractors under the same conditions as required herein.
A. Worker’s Compensation (Employer's Liability)
Worker’s Compensation and Employer's Liability Insurance covering the employees of Subcontractor for all compensation and other benefits required of Subcontractor by Worker’s Compensation or similar statutory insurance laws of any nation or political subdivision thereof, to which Subcontractor’s operations under this subcontract are subject in respect of liability for bodily injury by accident or disease including death resulting therefrom, sustained by any employee of Subcontractor arising out of and in the course of his / her employment. The limit of liability under Employers Liability Section shall be not less than United States Dollars one million (US$ 1,000,000/-) per occurrence or as required according to relevant national laws.
B. Motor Vehicle Third Party and Passenger Liability
Motor vehicle Third Party and passenger liability insurance in respect of death of or injury to persons and / or loss or damage to property in respect of motor vehicles used by Subcontractor in connection with the execution of the Work and shall ensure that SubContractors maintain such insurance in respect of motor vehicles used by them.
Such insurance shall provide an unlimited indemnity for death of or injury to persons and the equivalent of not less than United States Dollars one million (US$ 1,000,000/-) or according to the relevant law of nation per occurrence for loss of or damage to property, which shall be extended as may be necessary to cover any additional protection necessary by applicable statutory requirements in the country of location of the Work.
C. General Third Party Risks Insurance
General third party liability, insurance covering liabilities arising out of any activities of Subcontractor. Such insurance shall have a limit of liability not less than United States Dollars two million (US$ 2,000,000/-) or according to the applicability of the relevant national law.
Evidence of insurance
Subcontractor shall furnish Contractor within thirty (30) days from the effective date with certificates of insurance issued by the relevant insurers or underwriters providing evidence of the risks insured against as well as pursuant to the provisions of this clause also showing all parties assured and levels of indemnity.
Deductibles
All deductibles provided under the insurances arranged by Subcontractor as required under this clause (the amounts of which Subcontractor acknowledges to have seen), shall be for the account of and paid by Subcontractor accordingly.
Notice to contractor and remedy on subcontractor's failure to insure
Subcontractor shall provide Contractor with timely advance notice of any changes in the terms of the policies, which are to be carried out by Subcontractor under this clause including any cancellation notices.
If Subcontractor fails to keep in force the insurance which may be required to effect under the terms of this clause then Contractor may effect that, keep in force any such insurance, pay the premium as may be necessary for that purpose, which premium amount paid to the insurer by the Contractor from time to time, the contractor shall deduct the paid premium amount from any money due or which may become due to Subcontractor or recover the same as a debt due from Subcontractor.
Protection of contractor’s rights
Approval by Contractor of any insurer or terms of insurance proposed by Subcontractor shall not relieve Subcontractor from any obligation or liability under or arising from this subcontract or under the mandatory provisions of the applicable law.
Costs and incidental expenses
All costs and incidental expenses incurred in relation to the preparation of claims under the insurance policies arising out of matters connected therewith for which Subcontractor is responsible under the subcontract, shall be borne by Subcontractor
Notifications: In accordance with the submittal requirements outlined above, Subcontractor shall deliver two (2) copies of the Certificate(s) of Insurance required by this clause and all subsequent notices of cancellation, termination and alteration of such policies to:
Contracting Co. Ltd.
Attention: Project Subcontracts Manager
Reference: Subcontract No.
SC-3 Progress of the work
Subcontractor shall furnish sufficient personnel, equipment and facilities who shall work such hours so as to assure prosecution of the Work to completion. Timely performance of the Work is essential to this Agreement and Seller shall perform the Work with all due diligence and expedition to meet the contract requirement helping achieve the milestones strictly.
If the progress of the Work is behind schedule due to delays including but not limited to low productivity, default and / or negligence, Seller shall immediately take such steps as Buyer considers sufficient to expedite the rate of progress of the Work including but not limited to working overtime and mobilising additional manpower, resources & explore every possibility needed in the interest of jobs to achieve the completion date.
Subcontractor shall from time to time be required to provide to Contractor for approval an original and subsequently updated Subcontract Schedule showing all activities and necessary sequence of operations needed for the orderly performance and completion of the Work. Subcontractor shall adhere to the approved Subcontract Schedule submitting periodic progress reports and / or proposed schedule changes in form and manner directed by Contractor.
SC-4 Rights to work tools and work product
All drawings, reports, microfilms, software, results, studies, calculations, data and any other documents or information including as-built drawings, operating and maintenance manuals in respect of the systems, plant, installations or Project produced or prepared by or for Subcontractor or its SubContractors in physical or electronic form for and in the course of or as a result of performance of Work, shall be the exclusive property of Owner and for the avoidance of doubt, Owner may use and disclose the same freely without reference to or consent of Subcontractor or its SubContractors.
Subject to the provisions of the Special Condition “Nondisclosure”, Subcontractor is hereby granted a non-terminable, non-exclusive, royalty-free licence to copy and use the drawings, reports, microfilms, software, results, studies, calculations, data and any other documents or information including as-built drawings, operating and maintenance manuals referred to in foregoing in connection with Subcontractor’s normal business development. The documents in either form should be used only for the works purpose by anybody connected directly or indirectly to the works.
SC-5 Payment
Subcontractor shall submit one only invoice at defined intervals after satisfactory completion and approval of the Work as contained herein.
Subcontractor shall submit its invoice in the form and format directed by Contractor in original and two (2) copies to:
Contracting Co. Ltd
Attention of ----- Accounts Payable
A further copy of the invoice should be sent to:
Project Accounting Manager- XY
The invoice shall be submitted and payment made in the currency as exhibited within this Subcontract
The invoice shall be supported by Contractor approved timesheets, originals of receipts, invoices for any reimbursable items and by such other supporting documentation that Contractor may require or consider necessary. Each copy of the invoice shall be supported by complete documentation as original.
Failure either to specify the full Subcontract number or to submit full supporting documentation may be a cause for invoice rejection or delay in scrutinizing the correctness of the contents as well as ratification of payment.
Invoice shall be prepared and signed including the following information as well
Subcontract Number -- Number.
Subcontractor 'S full name and address.
Subcontractor 'S bank, bank addresses and account number.
Description of work performed in accordance with Exhibit "C" of this Subcontract.
Any amount otherwise payable under this Subcontract may be withheld in whole or in part if, Subcontractor is in default of any condition of this Subcontract.
Contractor reserves the right to recover any overpayments made to Subcontractor either by an error or due to any other reason.
Subcontractor shall submit a copy of draft invoice fifteen (15) days before actual invoice submission date to enable expedition of queries to the invoice if applicable. This invoice may be handles on perusal level with relevant officer.
Subcontractor shall certify in the invoice that there are no known outstanding liens, that all due and due bills have been paid or are included in the application for payment.
Within sixty (60) calendar days after receipt of the correct invoice, Contractor shall pay Subcontractor one hundred percent (100%) of the approved invoice amount.
Subcontractor shall promptly pay all claims of persons or firms furnishing labour, equipment or materials used in performing the Work under this subcontract as a condition precedent to any payment by Contractor.
Contractor may require Subcontractor to submit all satisfactory evidences of payment made and release to the genuine beneficiaries of all such claims.
No payment of Subcontractor’s invoice or portions thereof, shall at any time constitute approval or acceptance of work under this subcontract nor be considered a waiver by Contractor or Owner of any of the terms of this subcontract. However, title to all equipment and materials for which payment has been made which whether or not, have been installed in the Work as well as title to all completed work whether paid for or not, shall vest in Contractor or Owner as the case may be by automatic application of the provision of the subcontract. Subcontractor's property or estate in the event Subcontractor is adjudged bankrupt or makes a general assignment for the benefit of creditors or if a receiver is appointed on account of Subcontractor's insolvency or if this subcontract is terminated, the titles of the items procured as well as installed for the permanent inclusions shall stand transferred to the contractor but all other items belonging to the subcontractor procured for the temporary purposes shall remain in subcontractor’s title but could be used for the purposes of this subcontract by the contractor until the works are completed .
SC-6 Quality management system
Within fourteen (14) calendar days after subcontract award, Subcontractor shall submit Quality Management System package containing a minimum of the following intending documents or their Contractor determined equivalent: for approval,
Quality Assurance Manual giving in full Subcontractor’s corporate quality management system with an updated copy of an independently approved ISO 9001:2000 Certificate.
Project Specific Quality Plan giving all descriptions proposed to be followed for the quality profiles on the project including all formats intended to be used for the practical purpose of inspections, checks, tests etc. The plan shall also include organization chart, staffing responsibilities, duties & about materials, procurement & whatever else is feasible to be included within to elaborate the proposal leading to a confirmation that the works shall definitely be prosecuted according to the provisions of quality assurance management.
Index of relevant Project or Corporate Procedures.
Project Internal Audit Schedule for the whole currency of the project.
The plan shall define the documented quality system to be applied by Subcontractor throughout the Work in accordance with the requirements of ISO9001:2000 and make reference to all relevant Subcontractor procedures and manuals.
Subcontractor’s documented quality system shall provide for the issuance of a “stop work” order by Subcontractor or Contractor at any time during the Work when significant adverse quality trends and / or aberrations from the approved Quality Management System are observed.
Contractor reserves the right to perform Quality System Audits of Subcontractor’s approved Quality Programme including lower-tier suppliers and SubContractors at any stage of the Work.
SC-7 Nondisclosure
Subcontractor agrees that for a period of fifteen (15) years following Final Acceptance of the Project under the Owner/Contractor Contract, it shall not without the prior written consent of Contractor, disclose or make available to any third party (other than SubContractors, vendors or licensors) or use, directly or indirectly except for the performance of its obligations under the subcontract the terms of the subcontract, Project Documents or any information acquired directly or indirectly from Contractor or Owner in connection with the Project or the subcontract before or after the effective date unless:
The information was known to Subcontractor (as evidenced by its written records) prior to obtaining the same from Contractor;
The information was in the public domain prior to the time of disclosure to Subcontractor or
The information is disclosed to Subcontractor by a third party who did not receive the same directly or indirectly from Contractor or Owner and who has to the best of Subcontractor’s knowledge no obligation of secrecy with respect thereto.
Subcontractor shall take all steps that may be necessary or appropriate including the obtaining of written confidentiality undertakings or agreements in order that its employees, agents and representatives adhere to the provisions of this clause. Appropriate provisions shall be included in this regard within all further subcontracts executed between the subcontractor & other lower tier subcontractors.
SC-8 Release of consequential damages
In no event shall either party be liable to the other party in contract, tort (including but not limited to negligence) or otherwise, for any of the following categories of damages, costs, losses, or expenses: (a) loss of profit, loss of revenue, loss of goodshall, loss of use, loss of opportunity, down time costs, costs of obtaining or maintaining finance; and (b) indirect or consequential damages, costs, losses or expenses of whatsoever nature.
SC-9 Applicable law
This Subcontract shall be interpreted under the laws of the nation
All work performed in Plant Area shall be subject to the laws, regulations and orders of the nation. Such laws include without limitation any law (national, state, municipal, local or other), requirement, ordinance, rule, decree, regulation or order of any governmental authority or agency of state (state, national, municipal, local or other).
All work performed in nation shall be subject to the laws, regulations and orders of the nation. Such laws include without limitation any law (national, state, municipal, local or other), requirement, ordinance, rule, decree, regulation or order of any governmental authority or agency of nation
Subcontractor shall maintain in full force and effect its trade license, commercial registration and other requisite licenses allowing to legally do business in the nation as well as to perform its obligations under this Subcontract. Subcontractor shall provide Contractor with such evidence as Contractor may require to make sure or ascertain that such licenses, permits, temporary permits and authorisations are in full force and effect & could be passed on to the client.
SC-10 Modifications to section "a"
The following modifications to Section "A" apply to this subcontract:
None
SC-11 Procedures and documents
Subcontractor shall prepare and submit to Contractor for approval, co-ordination, for other procedures documents expressly required under the Subcontract or which are otherwise deemed necessary by Contractor to be submitted for the execution of the Subcontract.
All O&M Manuals, manufacturing record books shall be provided in the originals and defined number of copies with best quality hard copy and electronic software format specified in the Purchase Order. All documents required for commissioning shall be provided under the Purchase Order six (6) months prior to commissioning.
Under the Purchase Order Subcontractor shall be responsible for ensuring that all information supplied by Contractor for use in connection with the Products is sufficient, adequate and accurate. If however, during performance of the Work under, Subcontractor finds any deficiency in said information, it shall promptly notify Contractor in writing of any discrepancy or of any deficiency in said information. Failure of Subcontractor so to notify Contractor shall not relieve Subcontractor of any of its responsibilities or liabilities under this Subcontract or at law.
SC-12 Reports
On a weekly basis Subcontractor shall provide to Contractor a concise summary report in agreed format at n appointed day or time or as directed by Contractor, describing the work accomplished during the reporting period, work forecasted to be completed during the next reporting period including a summary of problem areas.
On completion of Work, Subcontractor shall submit a final report outlining the Work performed and the status of the Products. This report should be submitted within ten (10) calendar days of completion of Work. The final report must be accepted and approved by Contractor before Subcontractor 's invoice is submitted.
SC-13 Language requirements
The official status for language use on this contract is in English. Subcontractor shall prepare all additional Project Documents, drawings and the involved Parties conduct all communications in connection with the Work in the English language. Any documentation received by Contractor in any other language shall not be accepted unless, it is an official certificate in which case it must be accompanied by an "approved" legal English translation. Any impact on cost or schedule relating to this requirement shall be Subcontractor’s sole responsibility.
SC-14 Subcontractor mobilization / demobilization
Responsibilities
Except as otherwise stated, Subcontractor shall arrange and provide for mobilization / demobilisation of its equipment and work forces including but not limited to provisions for temporary facilities, customs clearance and customs claims, work permits, applicable licenses, immigration and emigration of all personnel.
SC-15 provision of documents
Subcontractor shall provide and ensure that its SubContractors, vendors and licensors provide electronic and hard copies of all Project Documents for Contractor’s permanent record files in accordance with the type, status and time requirements defined within the contract documents.
SC-16 Contractor review of documents
For all documents submitted by Subcontractor to Contractor for its review / approval, Contractor shall within ten (10) working days of receipt unless a longer period is specified in the Exhibits, review / approve the documents failing which response, it shall be presumed that the approval is granted, provided that the said documents are complete in every respect and have been subject to Subcontractor’s internal review and check process.
If any document is commented upon or rejected by Contractor, Contractor shall provide a written explanation of the reasons whereupon, Subcontractor shall re-submit such document within five (5) working days of receipt incorporating amendment or modifications as may be necessary to fulfill Contractor’s requirements.
Any document resubmitted shall be reviewed / approved by Contractor within ten (10) working days of receipt provided all of Contractor’s comments have been incorporated by Subcontractor in the revised document satisfactorily
SC-17 Labour
Subcontractor shall be responsible for and provide at its sole cost and expense all messing, housing, working and living conditions of labour with all necessary accommodation / other facilities for its personnel as necessary / required for the performance of Work.
Subcontractor shall also be responsible for and provide at its sole cost and expense for all transportation for its personnel between their points of origin and the jobsite if applicable, all transportation as may be required for performance of the Work in and around the Jobsite / to and from jobsite.
Subcontractor shall at all times during the Subcontract conform in all respects with, carry out all obligations imposed on it by the provisions and requirements of any applicable law in the nation where any part of Work is performed or regulation issued.
Subcontractor shall only employ in the jobsite nation such persons who are nationals or who are in possession of valid "No Objection Certificate(s)" entitling them to work in the jobsite nation for Subcontractor. Contractor shall assist Subcontractor in obtaining "No Objection Certificate(s)" by suitable letter of recommendation. Subcontractor shall submit this letter to the Department of Labour in order to receive such certificate(s). Contractor accepts no responsibility for obtaining "No Objection Certificate(s)" for Subcontractor’s personnel.
Contractor shall be at liberty to object to and require Subcontractor to remove forthwith any person employed by Subcontractor in or about the execution of Work who in the opinion of Contractor has committed misconduct or whose employment is otherwise considered detrimental to the best interests of the Project. Such person shall not be re-employed on Work without the written permission of Contractor. Subcontractor shall at its own cost use its best endeavours to immediately replace such person by a competent one.
Subcontractor shall not give barter or otherwise dispose of to any person or persons any arms or ammunition of any kind or permit or offer the same as aforesaid.
In the event of an outbreak of illness of an epidemic nature, Subcontractor shall comply with all such regulations, orders and requirements as applicable / may be made by the Government or the local medical or sanitary authorities for the purpose of dealing and overcoming the community health issues.
Subcontractor shall in its dealings with labour for the contract duration time ensure that the workforce is given due regard respecting their all recognised festivals and religious days and other customs. The workers shall be allowed to celebrate their festivals etc, under the rules of the job nation. Subcontractor shall also observe all relevant local customs.
All Subcontractor’s personnel visiting or working in the jobsite or in the nation must be in possession of valid inoculation certificates as required from time to time according to the provisions by the national health authorities.
The subcontractor shall take all necessary steps to avoid any expected labour unrest but in the event of its occurrence, Subcontractor shall promptly give this information with relevant details thereof to Contractor.
Subcontractor shall without delay inform Contractor of any accident in connection with the execution of the Work or any injury, loss or damage to any personnel and / or property of Subcontractor indemnified parties, Contractor indemnified parties or of third party and report such occurrences to the competent authority as required by law.
Subcontractor shall be responsible for and to ensure the observance of all provisions of this Special Condition by its other lower tiers SubContractors employed in the execution of the subcontract.
SC-18 Title
Title to the Work, to Project Documents, to all Products and other items supplied or to be supplied by Subcontractor or its SubContractors to Contractor or Owner to be permanently included for installations under this subcontract, shall pass to Contractor or Owner on the earlier of the following dates:
When delivered to the Jobsite;
When delivered to the custody of Subcontractor or its shipping agent;
When Subcontractor receives payment from Contractor for the Work, Project Documents or goods or other items by Subcontractor.
Materials or operating equipment of any kind left over or meant to be left over during and after the completion of the Work if furnished by Subcontractor or its other SubContractors, shall remain the property of Subcontractor or its subContractors as the case may be and be removed from the jobsite by Subcontractor or its other subcontractors prior to or upon the completion of the Work.
SC-19 Customs and duties
In connection with the performance of this subcontract, Subcontractor acknowledges that the import of items / customs laws and regulations of the nation shall be complied with fully for all shipment pertaining any good/s, product/s or component/s thereof.
Subcontractor specifically acknowledges that the aforementioned import and customs laws and regulations of the nation prohibit among other things the importation into the nation of certain products or components.
Contractor at its own discretion reserves the right to make the final, unilateral and specific selection of any proposed carriers, insurers, suppliers of services to be performed within the nation or of specific products or components to be furnished in accordance with the terms and conditions of this subcontract.
SC-20 Dispute resolution
Any dispute, claim or difference arising out of or related to the Subcontract or any breach thereof shall first attempted to be resolved amicably between the Parties but if such resolution fails, the dispute, claim or difference shall be referred to be finally settled by arbitration in Plant City under the Rules of Arbitration of the International Chamber of Commerce (ICC) by three arbitrators appointed in accordance with said Rules.
Subcontractor shall not at any time suspend performance of the Work or any of its obligations under the Subcontract pending resolution or settlement of a dispute and proceed with all due diligence with the Work / all its other obligations in full compliance with the Subcontract.
The arbitration proceedings and all papers sent or presented in connection therewith shall be in the English language. The arbitrators’ decision shall be final and binding on the Parties followed by adjudication of the award by any court of competent jurisdiction.
SC-21 Utilities, facilities and services
The following utilities, facilities and services may be provided for Subcontractor's use unless otherwise indicated herein at existing outlets at Jobsite or at points to be selected by Contractor subject to Subcontractor requesting such utilities, facilities and services prior to mobilisation.
Raw and potable water in limited quantities.
Local support labour required as well as any necessary erection, installation or service equipment, instruments, rigging and standard maintenance tools (to be itemised by Subcontractor prior to mobilisation) and office space where necessary in the opinion of Contractor for the performance of Subcontractor's Work and obligations under this Subcontract.
Sanitary facilities.
Limited use of telephone and fax services at the Jobsite for purposes connected with this Subcontract and subject to prior Contractor approval. Personal use of telephone and fax services shall be to Subcontractor’s account.
Limited reproduction facilities for photocopies and blue lines for purposes connected with this Subcontract.
Limited electric power.
The timing of the use of such utilities, facilities and services shall be subject to Contractor's approval.
SC-22 Security and property
A security force to guard the perimeter and patrol the interior of the Jobsite shall be provided by Contractor. The provision of this security force shall in no way be construed to be an assumption of responsibility by Contractor with respect to the safety & security of Subcontractor's employees or Subcontractor's property or in respect of any damage or loss thereto, which shall remain Subcontractor's sole responsibility.
SC-23 Work week, overtime and crew rotation schedule
Subcontractor shall perform its Work on a schedule commensurate with applicable labour laws and as agreed with Contractor. Subcontractor’s normal work schedule shall be 60 hours per week (6 days – 10 hours/day). Subcontractor may with Contractor approval if requested by Contractor, work such incidental overtime as be deemed practicable and necessary for the proper execution of the Work.
Subcontractor’s work cycle for its personnel is as follows:
As defined in relevant exhibit
Travel time associated with work cycle rotation if any, is included in the specified time off.
SC-24 Administrative Assistance
Owner shall, if required upon the request of Contractor provide assistance to Subcontractor to apply for necessary licenses, visas, work permits, other documentation and approvals necessary for its operations in nation in connection with performance of its obligations under this Subcontract including but not limited to immigration and egress of personnel. The said assistance shall be limited to the provision to Subcontractor by Owner through Contractor, letters addressed to government departments responsible for these matters. All further actions necessary to obtain the required permits and approvals shall be Subcontractor’s sole responsibility which being understood that neither Owner nor Contractor be liable for any costs or delays whatsoever due to obtaining of such licenses, visas, work permits or other documentation and approvals or due to non-obtaining of the same for any reason whatsoever.
Contracting Co. Ltd.
Onshore Gas Development Project
Seller technical services agreement
Exhibit "C"
Statement of work and compensation
Table of contents
S # Title
1 Statement Of Work 2
2 Compensation And Payment
1. Statement of work
Subcontractor undertakes to provide Contractor with the services of personnel qualified to provide technical assistance during installation and/or pre-commissioning and commissioning, performance, initial operations & maintenance of Products supplied under the Purchase Order at Owner's Jobsite at Plant nation
The following information should be properly tabulated
Required number of personnel for various stages of the job
Estimated commencing date at jobsite
Estimated work duration
Number of visits
The above quantities and durations are estimated only that may change as the commencement date approaches. Contractor shall give Subcontracto---- days (Subcontractor to insert) notice for mobilisation of Subcontractor’s personnel.
Subcontractor's personnel shall report to the Contractor Construction Manager or his representative and comply with the instructions for all such matters concerning work schedule, labour relations, working conditions and the like. Contractor Construction Manager or representative shall administer this Subcontract and prepare any necessary amendments including but not limited to amendment of the statement of Subcontractor’s Work during installation and/or pre-commissioning and commissioning, performance, initial operations & maintenance of Products described in the Purchase Order referenced herein.
2. Compensation and payment
Contractor shall provide construction equipment, normal construction tools, labour assistance, accommodation, food, laundry, transportation to and from accommodation to Jobsite and transportation to and from XY airport or nation City to Jobsite.
Subcontractor understands that labour and equipment provided by Contractor shall be fully supervised by Contractor, while Subcontractor representatives shall only direct and advise Contractor supervision if so required for the optimum utilization of the contractor’s resources. Contractor shall be responsible for job schedule.
Should Subcontractor demobilise at request of Contractor and be asked to remobilise, the round trip rate in Section 2.4 shall apply.
Should additional work be required, the daily rates in Section 2.4.6 shall apply.
2.1 Agreement Price
Provided always that Subcontractor shall perform and observe all its obligations under the terms and conditions of the Subcontract, Contractor shall pay in the manner set forth in the Subcontract the Subcontract prices defined/detailed below which shall be deemed to be full and total compensation for the execution of the Work in accordance with the Subcontract to the satisfaction of Contractor.
2.2 Firm Price
The lump sum prices, daily rates and hourly rates stated herein for the performance of the Work shall remain firm in respect of all works performed and services provided to perform the Works and shall be deemed to provide for any and all fluctuations in costs of salaries, wages, materials, fees, rentals, taxes and insurances & all unforeseen.
The lump sum prices, daily rates and hourly rates together with any additional sums or provisions specifically included in the Subcontract are all inclusive and include without limitation salaries and wages, travel allowances, bonuses, travel expenses, vacation, public holiday pay and allowances, sick pay, medical expenses, insurances, the cost of home office support services, overheads, head office costs and profit for Subcontractor's representatives at Jobsite and any of its SubContractors employees. Contractor shall supply transport to and from site to city, camp accommodation, meals, laundry, etc., for personnel provided by Subcontractor. SubContractor shall take care for the welfare of its employees according to the requirement of the labour contracts provisions defined by the national laws.
2.3 Declaration By Subcontractor
Subcontractor certifies that it has carefully examined and is fully familiar with all the provisions of the Subcontract documents; and that it has satisfied itself as to the nature and location of all the Works, the general and local conditions to be encountered and all other matters which can in any way affect the Work, the costs or the schedule thereof. Subcontractor further certifies that it has carefully checked all the words and figures in the schedule of prices, that it has carefully reviewed the accuracy of all the statements made in the Subcontract and that it is solely responsible for all omissions on its part in the preparation of the Subcontract, that it understands & interprets correctly the contract implications & impacts very well as well as the quantum of works covered within the scope of SubContract.
2.4 Lump Sum Prices, Daily Rates And Hourly Rates
As full consideration for the satisfactory performance by Subcontractor of the Work and subject to the payment provisions of this Subcontract, Contractor shall pay to Subcontractor compensation in accordance with the following:
2.4.1 Subcontractor shall be paid a lump sum in respect of installation support and pre-commissioning work for the Products. The lump sum shall include for all costs of whatsoever nature incurred by Subcontractor at the Jobsite including but not limited to labour and any necessary materials, tools and equipment. Total lump sum price for Installation and Pre-Commissioning work _________________ (US Dollars) / national currency
2.4.2 Subcontractor shall be paid a lump sum in respect of commissioning, start up and two months’ operation of the Products. The lump sum shall include for all costs of whatsoever nature incurred by Subcontractor at the Jobsite including but not limited to labour and any necessary materials, tools and equipment.
Total lump sum price for Commissioning, Start Up and two months’ operation ________ (US Dollars) / national currency
Subcontractor shall be paid a lump sum in respect of mobilising each Subcontractor’s representative following Contractor’s written approval of the proposed representative(s). The lump sum shall include for all costs of whatsoever nature incurred by Subcontractor in mobilising and demobilising the representative including any necessary materials, tools and equipment and including all transportation to Jobsite/ travel time to and from the Jobsite.
Total lump sum price for mobilisation/demobilisation each round trip ________ (US Dollars) / national currency
2.4.4 Not to Exceed Value
The not to exceed value of this Subcontractor Technical Services Subcontract is ________ (US Dollars) / national currency. This is based upon the total of items 2.4.1, 2.4.2. and 2.4.3.
2.4.5 If in any subsequent amendment to this Subcontract, work is released against daywork rates, it is the responsibility of the Subcontractor to notify the Contractor in writing when the cumulative value of Work carried out reaches 75% of any not to exceed value. A maximum “not to exceed” value may be varied only by the issue by Contractor of a formal amendment to the Supplier Technical Services Subcontract. Should Subcontractor provide services in excess of the not to exceed value, Contractor shall not be liable for payment for those excess services unless a formal amendment to the Subcontractor Technical Services Subcontract has been issued.
2.4.6 Subcontractor is requested on the basis of the above quoted lump sum costs to advise rates for approved working hours during normal work days for each representative (6 days per week/10 hours per day – Friday is deemed a non-working day).
Category of Personnel Daily Rate (US Dollars)
Technical Supervisor
2.4.7 Subcontractor is requested on the basis of the above quoted lump sum costs to advise overtime hourly rates for approved overtime hours (i.e. Hours worked in excess of 10 hours a day or 60 hours a week)
Category of Personnel Friday and Local Holiday Hourly Overtime Rate (US Dollars)
Technical Supervisor
Category of Personnel Other Overtime in Excess of 10 hours/day 6 days per week including Night Shifts (US Dollars)
Technical Supervisor
3 Orientation:
If it has not already been issued to the Subcontractor prior to execution of this Subcontract, the Subcontractor must familiarise itself with the relevant orientation information by contacting Mr.[AB] TBA – Construction on site on Mobile telephone number 00-911.[AB] TBA, Fax number 00-911-.[AB] TBA or E Mail .[PN] TBA @ on site and for obtaining the necessary orientation information pack no less than three (3) weeks prior to departure for Jobsite in order for all necessary permits, visas and project clearances to be confirmed prior to departure.
Contents
GC-1 Entire Agreement
GC-2 Changes
GC-3 Price And Payment
GC-4 Force Majeure
GC-5 Title And Risk Of Loss
GC-6 Testing, Inspection And Expediting
GC-7 Quality Standards
GC-8 Warranties And Guarantees
GC-9 Infringement
GC-10 Compliance
GC-11 Assignment
GC-12 Suspension
GC-13 Termination For Convenience
GC-14 Termination For Default
GC-15 Non-Waiver
GC-16 Governing Law
GC-1 Entire agreement:
This Instrument/Document embodies entire Agreement between Buyer and Seller. Either Party shall not be bound by or liable for any statement, representation, promise or understanding not set forth herein. Nothing contained in proposals, correspondence, discussions, order acknowledgments or others of Seller’s forms has any effect on this Agreement unless specifically incorporated herein formally or by supplementary documentation.
GC-2 Changes:
Buyer shall not consider any requests for a change where the scope of Work and concept of overall objectives of this Agreement are not changed or are merely a closer definition or change in detail of the technical specifications. Buyer through its authorized Procurement representative, may at any time direct in writing changes including but not limited to changes in any one or more of the following:
(1) drawings or specifications;
(2) additions to or deletions from quantities ordered;
(3) delivery schedule;
(4) method of shipment or packing;
(5) place of delivery. If any such change causes an increase or decrease in the cost of or timing required to provide the Product(S) an equitable adjustment actually reflecting the negotiated effect of such changes may be made in the price or delivery schedule or both and this Agreement may be modified by written amendments or revisions executed by authorized representatives. Any notification by the Seller for adjustment under this Changes clause must be asserted as soon as reasonably practicable, but in no event later than seven (7) days from the date of receipt by the Seller of the notification of change. The burden of demonstrating that such directions constitute a change shall be upon Seller. If Seller fails to so notify Buyer then any work or services carried out pursuant to such directions shall not be construed as a change. If it is subsequently shown that any Seller proposed change was not well founded then all costs associated with such proposed change shall be to Seller’s account Not withstanding any dispute between Buyer and Seller as to whether Buyer’s instructions constitute a change, Seller shall forthwith proceed with carrying out the Work in accordance with Buyer’s instructions.
If this Agreement requires Buyer to review and comment on Seller’s technical documents, Seller shall submit within 10 working days from the date of Seller’s receipt of such comments any request for adjustment which would result from implementation of Buyer’s comments. No adjustment shall be made hereunder unless Buyer through its authorized procurement representative confirms the change in writing.
GC-3 Price and payment:
The prices herein specified unless otherwise expressly stated shall include all taxes and duties of any kind which either party is required to pay with respect to the sale of Products covered by this Agreement, but shall include all charges and expenses in connection with the packing of the Products and their carriage to the place of delivery to the Buyer unless specifically excluded. Seller shall be paid except as otherwise stated in this Agreement upon submission of correct invoices the prices stipulated herein for Products delivered and accepted; however, payment may be withheld or portions thereof may be deducted if in Buyer’s reasonable opinion, Seller is not performing work in accordance with the provisions of this Agreement or if proper set-offs in favor of Buyer in other transactions are asserted. Buyer reserves the right to make payments due hereunder directly to Subcontractor(S) of Seller whenever Buyer has reason to believe that Seller has not paid or is likely not to pay such Subcontractor amounts due to them on a timely basis. Correct invoices shall include documentation as reasonably agreed between Buyer and Seller sufficient to cover the provisions of each payment milestone and sufficient to allow Buyer to certify in writing to Company that all liens relating to or arising out of the Works covered by the invoices have been released or discharged.
Seller shall maintain at all times an adequate, complete, correct and confidential set of records and accounts pertaining to all the financial and non-financial performance of Seller under the Agreement. Buyer and Company shall have the right to examine with advance notification such records and accounts of Seller for all activities of Seller related to its performance of the Agreement. All reimbursable amounts paid to Seller are subject to justification and audit during the course of the Agreement and up to and including a period of five (5) years after the end of the calendar year in which the final invoice was submitted by Seller to Buyer provided that Buyer may not audit the components of any lump sum prices under this Agreement. Buyer's claims for errors may be presented to Seller anytime within the time period mentioned above. In the event such audit(s) reveal any discrepancy or error, a written response to Buyer's claim shall be made by Seller as soon as practicable and in no event later than twenty (20) working days from the date of such claim. Any payment determined to be due to Buyer shall be paid promptly by Seller. Seller agrees that Company shall have the right to enforce the audit rights contained in this Article 3 directly against Seller.
Buyer and Company shall have the right to examine with advance notification such records and accounts for the limited purpose of verifying requests for payment when progressive advancement of the works forms the basis for such payment or for evaluating the reasonableness of proposed price adjustment requests.
Payment terms are net sixty (60) days from receipt of correct invoice subject to any limitations as provided elsewhere in this Agreement. Invoices shall be mailed at the time of shipment or achievement of specific milestones as defined in this Agreement and any cash discount period offered by Seller shall be computed from the date the Products are transferred to Buyer or the correct invoice is received whichever is later/ provided, any required supporting certification documents are received by Buyer. The foregoing payment and cash discount periods shall be extended by the period of any delay caused by an error in the invoice requiring correction. Buyer may elect to pay Seller through Buyer’s electronic disbursement system (EDS). Seller shall advise Buyer in writing within twenty (20) working days prior to the due date of the first invoice of the bank and account number into which EDS payments may be made to Seller.
No payment made under this Agreement shall constitute a waiver by Buyer of the performance by Seller of any of its obligations hereunder and in no event shall any such payment affect the warranty obligations of Seller as set forth in General Condition Article 8, “Warranties and Guarantees.
No later than thirty (30) working days after the date of Provisional Acceptance, Seller shall lodge with Buyer a final payment claim and endorse it “Final Payment Claim” (the “Final Payment Claim”). Seller shall include in that claim all amounts that Seller considers to be due from the Buyer under this Agreement.
GC-4 Force Majeure:
4.1 The term Force Majeure as employed herein shall be defined as strikes (excluding strikes occurring among the employees of Seller or Seller Group or Seller other industrial disturbances of a general nature), acts of the public enemy, wars, undeclared wars, acts of governments including the governments of the nation, blockades, insurrections, riots, epidemics, landslides, earthquakes, lightning, civil disturbances, explosions and any other cause or event which is unavoidable, insurmountable and similar to the kind herein enumerated or equivalent forces, not within control of the Party affected thereby and which that Party is unable to overcome by the exercise of due diligence. Force Majeure shall not include financial distress of either Party and late delivery of Products or late performance by Seller or Seller’s Subcontractor unless such late delivery or performance is itself caused by Force Majeure.
Delays attributable to and within the control of Seller’s Subcontractors of any tier shall be deemed delays within the control of Seller.
4.2 Notice of Occurrence. If due to Force Majeure, Seller is temporarily rendered unable, wholly or in part to comply with its obligations under this Agreement and is claiming that a Force Majeure condition has arisen then Seller shall, within twenty-four hours of becoming aware of such condition, notify the Buyer of the same, act diligently to overcome, remove and/or mitigate the effects of the event of Force Majeure, notify Buyer on a continuing basis of its efforts to overcome, remove and/or mitigate the event of Force Majeure and notify Buyer immediately when aforesaid disrupting condition has ceased.
4.3 Notice of Impact. In addition to its obligations under General Condition Article 4.2, “Notice of Occurrence” if Seller claims there is a Force Majeure condition, Seller shall (i) within three days of becoming aware of such condition notify Buyer in writing of the nature and cause of such Force Majeure condition (ii) state up to what extent the condition shall delay Seller’s performance of the contractual Work.
Immediately upon termination of the Force Majeure occurrence, Seller shall
Notify Buyer of resumption of work and Submit a plan to minimize and mitigate the adverse effect by the Force Majeure occurrence on the contractual works.
4.4 Effect. Any Work or any portion thereof, that is impacted by Force Majeure, shall be deemed suspended for the duration of the Force Majeure. Any claim on the part of Seller for any extension of time by reason of a suspension under this clause shall be made within a reasonable time but no later than ten (10) working days after the end of the suspension. Seller shall promptly submit for review a revised schedule for performance of Work. Subject to the provisions of this General Condition as set forth below, such extension shall be the sole remedy for the delay.
If a suspension of any obligation by virtue of this clause lasts for a continuous period of Thirty (30) days, Buyer may terminate this Agreement forthwith in whole or in part by so notifying Seller in writing. Such termination by Buyer shall take effect on receipt by Seller of the written notice. Upon such termination, both Parties shall be released from any further obligations under the Agreement but both Parties retain all rights and claims arising out of such termination of the contract prior to the effective date of the termination.
If Buyer elects not to terminate the Agreement as stated above then the Work shall be deemed suspended with effect from the expiry of the said thirty (30) day period. Thereafter, the provisions of the General Condition titled ‘Suspension’ shall apply save that extra cost if any, of Seller’s standby and any other additional costs incurred by Seller in giving effect to Buyer’s instructions under this Article to be borne and paid by Seller.
Any delays in or failure of performance by the affected Party other than the obligations to pay monies hereunder, shall not constitute a default hereunder if and to the extent such delays or failures of performance are caused by Force Majeure events that impact Seller’s ability to achieve the promised ship date(s) specified in this Agreement.
GC-5 Title and risk of loss:
Buyer and Seller agree that the title of Products shall be transferred to Buyer at the earlier of (1) Equipment released by Buyer’s inspectors or (2) the time that Seller receives payment from Buyer for the Products or (3) delivery to the Jobsite. Buyer may request Seller to provide temporary storage which Seller agrees to do so at no additional charge until the revised date of delivery to the delivery point specified in the Agreement
Seller hereby confirms that title remains with Buyer though the Equipment is stored in Seller’s facilities and said Equipment shall not be subject to any liens or bankruptcy
Transfer of title shall not relieve Seller of its obligations to fulfil the data and document requirements according to Agreement
Seller hereby confirms that the Equipment shall be stored safely and properly in Seller’s facility with maintaining full value insurance coverage for the Equipment for fire, theft and third party liability.
Seller shall be responsible for loss or damage to Buyer’s Equipment while in Seller’s care, custody and control regardless of any transfer of title.
The warranty duration of the Equipment in custody at Seller facility shall carry the same warranty provision as stated elsewhere in this Agreement.
Seller shall indemnify Buyer and Company against any damages, injury or death, which may occur as a result of Buyer owned Equipment being located at the Seller’s facility
Seller shall be responsible for every risk of loss to the Products until delivery of all Products to the delivery point(s) specified in this Agreement is affected, even if title transfer and payment have occurred.
Seller shall be responsible for maintaining the Equipment in accordance with the Seller’s storage procedures while in Seller’s care, custody and control.
GC-6 Testing, inspection and expediting:
Seller shall notify Buyer with fifteen (15) working days written notice in advance of the date and place of any inspection or testing so that Company and Buyer may witness those tests. Irrespective of whether or not, Buyer witnesses such tests, Seller shall provide Buyer copies of those test results as soon as such information becomes available. Should any postponement become necessary, Seller shall provide at least ten (10) working days written notice prior to the originally scheduled date. In the event that any part of the Equipment fails to comply with the specifications detailed in this Agreement and Seller has to re-perform the Work, all costs associated with this re-inspection shall be to Seller’s account. Seller shall allow Buyer, Company or Company’s authorized representatives access to any place where Products are being manufactured or such Products are being prepared for incorporation into the FACILITY for the purpose of inspecting production and observing tests on such Products.
No shipments of Products shall be permitted prior to release for shipment by Buyer. Any Products requiring inspection or quality surveillance by Buyer if shipped before such inspection or quality surveillance has affected/taken place, shall automatically be considered as rejected.
The Products including all warranty work shall be subject to expediting by Buyer. Buyer’s representatives shall be afforded free access during working hours to Seller’s plants. Seller agrees to procure a similar right for Buyer and Company for expediting purposes with respect to Seller’s Subcontractors. As required by Buyer, Seller shall supply schedules, progress reports and un-priced copies of Seller’s purchase orders and subcontracts for Buyer’s use in expediting. Seller shall notify Buyer in writing of any actual or anticipated delays immediately upon discovery. Such notice shall include an estimated period of delay, cause, and corrective actions being taken. Slippage in Seller’s schedule may be deemed to be reasonable grounds for insecurity in which event, Buyer may demand in writing that Seller provide adequate assurances that Seller shall deliver Products in accordance with the requirements of the Agreement.
If requested by Buyer, Seller shall allow Company or its authorized representative to be present at any tests, observations or inspections that Buyer is given the right to witness or conduct pursuant to this Article “Testing, Inspection and Expediting.”
GC-7 Quality standards:
Seller shall ensure that the Products comply with the standards of quality specified by this Agreement or those customary/conventional in the industry if no requirement is specified. Buyer’s quality surveillance representative shall be afforded free access during working hours to plants of Seller. Seller agrees to procure a similar right for Buyer for quality surveillance purposes with respect to Seller’s Subcontractors in order to monitor compliance with quality requirements. Buyer’s right to inspect, examine and test the Products shall extend through the manufacturing process, the time of shipment and a reasonable time after arrival at the final destination. Seller’s failure to adhere to the standards of quality required under this Agreement shall be deemed to be reasonable grounds for insecurity. Buyer may demand in writing that Seller provide adequate assurances of Seller’s ability to meet said standards.
The Products shall not be deemed accepted until finally inspected and accepted by Buyer’s representative at final destination. The making or failure to make an inspection, examination or test of or payment for or acceptance of the Products shall in no way relieve the Seller from its obligation to conform to all of the requirements of this Agreement/ and shall in no way impair Buyer’s right to reject or revoke acceptance of nonconforming Products or to avail itself of any other remedies to which Buyer may be entitled, notwithstanding Buyer’s knowledge of the nonconformity, its substantiality or the ease of its discovery. If requested by Buyer, Seller shall allow Company or its representative to be present at any surveillance, inspection, examination, or testing that Buyer is given the right to conduct or observe pursuant to this Article “Quality Standards.”
GC-8 Warranties and guarantees:
Seller warrants that the Products shall be free from liens and from defects in design, material, workmanship, title and shall conform in all respects to the terms of this Agreement as well as to the applicable drawings issued for manufacture, produced new of the best quality if no quality is specified. Seller shall require such warranties or guarantees that be included in all of Seller’s subcontracts and material purchase orders. Unless the warranty period is otherwise specified in this Agreement, the following warranty shall apply: Twelve (12) months after the effective date of the last Provisional Acceptance Certificate issued by Company pursuant to the Company-Contractor Contract, or with respect to liens, title or latent defects at any time, it appears that the Products or any part thereof, do not conform to these warranties and Buyer so notifies Seller within the warranty period. Seller shall promptly correct such nonconformity to the satisfaction of the Buyer at Seller’s sole expense failing which Buyer may reject or revoke acceptance, cover by making any reasonable purchase of Products in substitution for those rejected and the Seller be liable to the Buyer for any additional costs for such substituted Products, or Buyer may proceed to correct Seller’s nonconforming work by the most expeditious means available and the costs for such correction to Seller’s account or Buyer may retain the nonconforming Products and an equitable adjustment reducing the order price to reflect the diminished value of such nonconforming Products to be made by written revision.
Any Work re-performed, replaced, remedied or rectified shall itself be warranted for a single period of twelve (12) months commencing from the date of acceptance of such re-performed, replaced, remedied, or rectified Work provided however, that the warranty period shall not in aggregate exceed twenty four (24) months from the effective date of the last Provisional Acceptance Certificate issued by Company pursuant to the Company-Contractor Contract but without prejudice to any extended painting warranty (as detailed below).
Seller warrants that any paint and coatings used in the Products provided under this Agreement shall be free from defects, fit for purpose and its preparation and application shall be carried out in conformity with specifications in a professional and workmanlike manner by certified personnel. Seller shall be considered to have discharged the painting warranty on expiry of a period 5 years from the date of issuing of the last Provisional Acceptance Certificate by Company.
Seller’s liability hereunder shall extend to all damages proximately caused by the breach of any of the foregoing warranties including incidental damages such as disassembly, removal, inspection, re-installation, re-testing, costs of transportation to and from the point of repair or warehousing.
GC-9 Infringement:
Seller shall protect, defend, release, indemnify and hold harmless Buyer and Company Group from and against any / all claims, demands, liabilities, losses, damages, proceedings, causes of action and expenses (including court costs, attorneys' fees and other litigation costs) on account of or by reason of any claim or suit for alleged infringement or misappropriation of any Intellectual Property arising from the manufacture, sale, use or other disposition of any article or material furnished hereunder by Seller including the Products (Seller Furnished Items) or the performance of any WORK or part thereof. Provided that Buyer itself receives notice promptly (e.g. From the Company, etc.) and receives all necessary authority, information and assistance for the Company, Buyer shall notify Seller promptly in writing and render Seller all necessary authority, information and assistance. If, by reason of any such suit or threatened action concerning Intellectual Property, Buyer or Company is enjoined from using any Seller Furnished Items or part thereof. Seller at its own expense shall diligently procure the right to use such Seller Furnished Items or infringing or misappropriating operation or substitute equivalent but non-infringing or non-misappropriating Seller Furnished Items or operation or modify the Seller Furnished Items or operation to make such items or operation non-infringing or non-misappropriating but at least equivalent to the infringing or misappropriating equipment and/or operation. Seller hereby grants Buyer and Company an irrevocable, perpetual, royalty-free license to use all Intellectual Property contained in any Work or Products with respect to the Project.
GC-10 Compliance:
Seller warrants that all Products shall have been produced, sold, delivered and furnished in strict compliance with all applicable laws and regulations to which the Products are subject. Seller shall execute and deliver to Buyer any documents as may be required to effect or to produce evidence for such compliance. All laws and regulations required to be incorporated in agreements such as this one are hereby incorporated herein by reference.
Seller hereby agrees to indemnify, defend and hold Buyer, Company and its respective affiliates harmless from and against any / all claims, legal actions, final judgments, reasonable attorneys' fees, civil fines and any other losses which any of them may incur as a result of the sale or delivery to Buyer hereunder of Products which do not meet all requirements of such laws and regulations.
All Applicable Laws and regulations relating to the export and import of any work shall apply to Seller. When required by the Agreement shipping/delivery terms, Seller shall obtain any necessary export license in a timely manner to avoid shipment delays. If Buyer is required by the Agreement to obtain any necessary export license or to meet the import rules and regulations of the destination country, Seller is to timely provide all necessary compliance assistance to Buyer and its authorized representatives. To the extent required by Applicable Laws, Seller shall register with any applicable governmental entity of the nation if any. Failure to so register may result in cessation of the Work and/or fines or penalties being levied against Seller by the applicable governmental entity and any fines and/or penalties shall be tor Seller’s account. Seller shall indemnify, defend and hold harmless Buyer from any penalties, suits, liabilities or costs (including attorney fees) proximately caused by Seller’s failure to comply with applicable export and import rules and regulations or other Applicable Laws or to comply with its export and import obligations set forth in this Agreement
GC-11 Assignment:
Unless a benefit is expressly conferred on a third party herein or is derived through assignment as provided for in this Article 11, it is not intended that a third party should have the right to enforce a provision of the Agreement pursuant to the Contracts (Rights of Third Parties) Act 1999. Buyer and Seller may by agreement rescind or vary the Agreement without the consent of a third party to whom the right of enforcement of any of its terms has been expressly provided.
11.1 Assignment by seller
Seller shall not assign, pledge or declare any trust of the whole or any part of the Agreement nor any benefit, burden, interest, right or cause of action arising under the Agreement. Any assignment of this Agreement or of any rights hereunder in any manner in whole or in part by operation of law or otherwise without prior written consent of Buyer shall be void. Upon ten (10) working days written notice to Buyer and upon approval by Buyer, Seller may assign monies due or to become due under this Agreement.
11.2 Subcontracting of Whole
Seller shall not subcontract the whole nor substantially the whole of the scope of Work under this Agreement.
11.3 Subcontracting of Part
Seller shall provide Buyer with details of any major part of the Work or Products it intends to subcontract along with a list of its proposed Subcontractors for Buyer’s approval. Seller shall not subcontract any major part of the Work to any person or third party without the prior written consent of Buyer (which consent shall not be unreasonably withheld or delayed). Neither such consent if given nor any subcontracting shall relieve Seller from any liability under the Agreement. Seller shall be responsible for the acts, defaults and omissions of any subContractor, its agents, employees or workmen as fully as if those are the acts, defaults or omissions of Seller, his agents, employees or workmen.
Seller shall make its best efforts to include in its suborders and subcontracts with its Subcontractors provisions to secure all rights and remedies of Buyer provided under this Agreement. Seller must impose upon the Subcontractors all of the general duties and obligations required to fulfill its scope of Work. Seller shall provide Buyer with copies of all suborders and subcontracts (excluding details of pricing) upon execution of such suborders and subcontracts.
11.4 Assignment Provision in Subcontracts
All suborders and subcontracts shall contain provisions that Seller shall not waive, release or impair, giving Seller an unrestricted right to assign the relevant suborder or subcontract and all benefits, interests, rights and causes of action arising under it to Buyer and provisions whereby Buyer may subsequently assign the suborder or subcontract as it requires.
11.5 Assignment of Subcontracts
Seller if so requested by Buyer, shall make its best efforts to assign the relevant suborder or subcontract and all relevant rights and obligations, including the benefit of any guarantee or warranty from SubContractors to Buyer or as Buyer may direct.
11.6 Assignment by BUYER
This Agreement together with any benefit, burden, interest, right or cause of action arising under the Agreement shall be assignable to the Company and upon written notice from Buyer to Seller, shall be assigned to Company. In the event of such assignment, this Agreement shall remain in ‘full force and effect’ be enforceable by Company or its agents designated in writing pursuant to the terms hereof. In addition, in the event of such assignment, Seller shall if required by Buyer, enter into a novation of the Agreement with Buyer and with the assignee.
In addition, Buyer may assign this Agreement or may pledge or otherwise deal with the benefit and/or burden of the Agreement and any benefit, burden, interest, right or cause of action arising under the Agreement to any of its Affiliates or to any other party, provided that the financial situation of the assignee is reasonably acceptable to Seller. In such a case, Seller shall be entitled to request financial information on assignee. In the event that Seller is not reasonably satisfied with the financial standing of such assignee, Seller shall have the option to request the Buyer to remain ultimately jointly and severally liable for the payment obligations under the Agreement.
GC-12 Suspension:
Notwithstanding any other provisions of this Agreement, Buyer may at any time suspend or extend the time for Seller’s performance upon ten (10) working days prior written notice of such suspension or extension. Thereafter, Seller shall resume performance as directed by Buyer. In the event of such suspension or extension, Seller shall be entitled to reimbursement for additional costs reasonable and necessarily incurred by Seller in implementing/effectuating such suspension or extension period. Seller shall have the right to seek accordingly an equitable adjustment to the time for completion to an extent that such additional costs are actually incurred if claimed within thirty (30) calendar days after resumption of performance. Should said suspension last in excess of 180 calendar days, Buyer and Seller shall meet to mutually agree whether or not, to terminate this Agreement under the provisions of General Condition Article 13 provided if the Parties are unable to agree, this Agreement shall continue in ‘full force and effect’.
GC-13 Termination for convenience:
Seller’s performance under this agreement may be terminated by the Buyer for its convenience in accordance with this clause in whole or from time to time in part whenever the Buyer shall elect. Any such termination shall be effected by delivery to Seller of a notice of termination specifying the extent to which performance under the Agreement is terminated and the date upon which such termination becomes effective. Upon receipt of any such notice, Seller shall, unless the notice requires otherwise: (1) immediately discontinue work on the date and to the extent specified in the notice; (2) place no further orders for materials other than as may be necessarily required for completion of any portion of the work that is not terminated; (3) promptly make every reasonable effort to either obtain cancellation on terms satisfactory to Buyer of all orders to sub-suppliers or assign those orders to Buyer; (4) assist Buyer upon request in the maintenance, protection and disposition of property acquired by Buyer under this Agreement.
If requested in writing within thirty (30) calendar days after notice of termination, the Buyer shall pay to Seller as full compensation: (1) all amounts due and not previously paid to Seller for Products completed in accordance with this Agreement prior to such notice and for work thereafter completed as specified in such notice; (2) a reasonable amount for any Products then in production; provided that no such adjustment shall be made in favour of Seller with respect to any Products which are Seller’s standard stock; (3) reasonable costs of settling and paying claims arising out of the canceled orders; (4) a reasonable profit for costs incurred in the performance of the work terminated; provided however, if it appears that the Seller would have sustained a loss on the entire Agreement had it been completed, no profit shall be included.
The total sum to be paid to Seller under this clause shall not exceed the total Agreement price as reduced by the amount of payments otherwise made and as further reduced by the Agreement price of Work or Products not terminated. It shall not include any consideration for loss of anticipated profits on the terminated Work or Products all claims for which Seller agrees to waive.
GC-14 Termination for default:
BUYER may terminate the whole or any part of Seller’s performance under this Agreement in any one of the following circumstances: (1) If Seller or its creditors seek relief under any bankruptcy law or if Seller should become insolvent or make an assignment for the benefit of creditors or file a voluntary petition of bankruptcy or if receivership proceedings should be instituted against Seller (2) if Seller fails to make delivery of the Products or to perform within the time specified herein or any extension thereof; or (3) if Seller delivers nonconforming Products; or (4) if Seller fails to provide adequate assurance of Seller’s ability to meet the quality standards or the delivery date(s) of this Agreement; or (5) if Seller fails to perform any of the other provisions of this Agreement in accordance with its terms or so fails to make progress as to endanger or jeopardize performance of this Agreement. In the event of (1) above, buyer shall have an immediate right to terminate for default. In the event of (2), (3), (4) or (5) above, Buyer shall provide Seller with written notice of the nature of the failure expressing Buyer’s intention to terminate for default. In the event, Seller does not cure such failure within ten (10) working days of such notice, Buyer may by written notice, terminate this Agreement.
In the event Buyer terminates this Agreement in whole or in part as provided in this clause, Buyer may procure upon such terms and in such manner as Buyer may deem appropriate, Products similar to those so terminated and Seller shall be liable to Buyer for any additional costs for such similar Products provided, that Seller shall continue the performance of this Agreement to the extent not terminated under the provisions of this clause.
Seller agrees to assist Buyer in the event that re-procurement action is necessary as a result of default by co-operation in the transfer of information, in the disposition of work in progress or residual material and in the performance of other reasonable requests made by Buyer.
If after notice of termination of this Agreement, it is determined for any reason that Seller was not in default under the provisions of this clause or that the default was excusable under the provisions of this agreement, the rights and obligations of either Party shall be the same as if the notice of termination had been issued pursuant to the Termination for Convenience clause.
GC-15 Non-waiver:
Failure by Buyer to insist upon strict performance of any of the terms and conditions hereof or failure or delay in exercising any rights or remedies provided herein or by law or to properly notify Seller in the event of breach or the acceptance of or payment for any Products hereunder or review of design, shall not release Seller from any of the warranties or obligations of this Agreement and not be deemed a waiver of any right of Buyer to insist upon strict performance hereof or a waiver of any of its rights or remedies as to any such Products regardless when shipped, received or accepted or as to any prior or subsequent default hereunder nor shall any termination of this Agreement by Buyer operate as a waiver of any of the terms hereof. A requirement that a Seller furnished document is to be submitted for or subject to "Authorization to Proceed", "Approval", "Acceptance", "Review", "Comment" or any combinations of such words or words of like importance shall mean unless the Agreement clearly indicates otherwise, that the Seller shall before implementing the information in the document submit the document to obtain resolution of any comments with Buyer’s authorization to proceed. Such review shall not mean that a complete check shall be performed. Authorization to proceed shall not constitute an acceptance or approval of design details, calculations, analyses, tests or construction methods or materials developed or selected by Seller and shall not relieve Seller from full compliance with requirements of this Agreement.
Those provisions of this Agreement that by their very nature survive payment, final acceptance or termination under the Agreement shall remain in full force and effect after such acceptance and payment.
GC-16 Governing law:
The validity, construction, interpretation, and effect of this Agreement shall be governed by the laws of nation excluding any choice of law rules which would refer the matter to the laws of another jurisdiction.
No modifications of these General Conditions shall be valid unless reduced to writing and signed by both Parties.
Special Conditions
Contents
SC-1 Definitions-
SC-2 Confidentiality Agreement-
SC-3 Backcharges
SC-4 Safety For Buyer And Company Representatives
SC-5 On-Site Services Of Seller’s Representatives
SC-6 Release Against Liens And Claims
SC-7 Completion And Delivery
SC-8 Compliance With Laws And Hazardous And Toxic Substances Requirements
SC-9 Health, Environment , Safety And Indemnity
SC-10 Buyer Furnished Equipment (Including Materials)
SC-11 Taxes & Duties
SC-12 Laws And Regulations
SC-13 Dispute Resolution
SC-14 Intellectual Property
SC-15 No advertising
SC-16 Ethical business Consideration
SC-17 Language
SC-18 Survivability
SC-19 Subcontractor Relations
SC-20 Retention Of Documents
SC-20 Contract Validation
SC-22 Order of Precedence
SC-23 United Nations Convention On Contracts
SC-1 Definitions:
"Affiliate" shall mean any corporation or other entity that directly or indirectly, through one or more intermediaries, controls or is controlled by or is under common control with another corporation or entity. The term "control" with respect to any entity means the possession directly or indirectly of the power to direct or cause the direction of the management and policies of such entity whether through the ownership of voting, securities by contract or otherwise.
"Agreement" means this purchase order including General Conditions, Special Conditions, Technical Services Agreement, all exhibits, schedules, and supplements hereto (each of which is hereby incorporated herein by reference) as amended from time to time.
"Applicable Laws" means laws, regulations and orders of the nation and all other laws applicable to the FACILITY, the Work, the Agreement, the Jobsite or any Work Site or Company, Seller or Buyer as appropriate.
"Contractor" means the Contractor entity executing this Agreement.
"Buyer" means Contractor-To the extent that Buyer is not the ultimate consumer of the Products being herein purchased. All rights, benefits and remedies conferred upon Buyer by this Agreement shall also accrue on and be available to and are for the express benefit of Company/Client/Facility Owner for whom the Products are purchased.
“Buyer Group” means Buyer, its Affiliates, its joint venturers, its Sub Contractors of any tier but excluding Seller and its and their respective directors, officers, employees (including agency personnel), servants, agents and Invitees but does not include any member of Seller Group or Company Group.
“Data” means ideas, know-how, inventions, designs, models, drawings, prints, samples, transparencies, specifications, reports, manuscripts, working notes, documentation, manuals, photographs, negatives, tapes, discs, electronic files, software or any other similar terms.
"Dispute" means any dispute, controversy or claim arising out of or relating to the Agreement or breach thereof including any question regarding its existence, validity or termination which the Parties shall address in accordance with Special Condition Article 9, “Dispute Resolution”.
“Effective Date” means the date of this Agreement
"Equipment" means any and all materials, supplies, equipment and facilities, of whatever nature, specified in the Agreement, intended to become a permanent part of the FACILITY.
"FACILITY" means the facility to be constructed/built at the Jobsite including all types of buildings, interconnections and utilities.
"Force Majeure" means an occurrence of the type and impact as more fully described in General Condition Article 4, “Force Majeure”.
“Intellectual Property” means patents, trademarks, services marks, copyrights, trade secrets and other forms of comparable property rights protected by an Applicable Law.
“Invitees” mean a third party invited to the Worksite by a Party in connection with the Work. Company Invitees exclude any members of Buyer Group and Seller Group and excludes any other Company Contractors. Buyer and Seller Invitees exclude any members of Company Group.
“Jobsite” means the location where the FACILITY is to be constructed.
"Notice Of Dispute" means the notice set forth in Special Condition Article 13, “Dispute Resolution” which may be served by one Party to the other Party in connection with a Dispute.
"Company" means xxxxxxxxxxxxxx and/or other successor and assigns in interest for whose benefit the PRODUCTS are purchased.
“Company-Contractor Contract” means that certain contract entered into between Company and Contractor entitled “Facility Plant Onshore Phase, Agreement No 12345678
“Company Group” means Company, its Affiliates, Company’s’ Other Contractors carrying out work in connection with the Project and its and their respective directors, officers, employees (including agency personnel), servants, agents and Invitees, but does not include any member of Buyer Group or Seller Group.
“Company’s Other Contractors” means all Contractors of Company other than Buyer that have executed a contract with Company.
“Party” means singularly Buyer or Seller and collectively Buyer and Seller. "Products" means the goods, materials, articles, equipment, supplies, drawings, data, processes and all other property and services, including design, expediting, inspection, delivery, installation, and testing, specified or required to furnish the items ordered hereunder specified in the Agreement.
"Project" means the design, procurement, construction, commissioning, testing ownership and initial operation & maintenance of the FACILITY with carrying out all activities incidental thereto pertaining to the Onshore Plant Project Phase according to the provisions within this contract or agreement.
“Project Documentation” means this Agreement and all hard copy with electronic versions of Project documents including but not be limited to drawings, P&IDs, PFDs, Isometrics, plot plans, general arrangements, materials requisitions, data sheets and calculations, indices, manuals, reports, procedures, estimates, accounts, summaries, compilations, agreements including Subcontractor agreements, related materials and any other document defined or described in any of the foregoing.
“Provisional Acceptance” has the meaning set out in the Company-Contractor Contract.
“Punch List Items” means those items identified as incomplete work under the Company-Contractor Contract in accordance to the latest approved drawings and specifications under such contract but which shall not prevent the safe operation of the plant or equipment and be rectified by Buyer.
“Seller Group” means Seller, its Affiliates, its joint venturers, its Subcontractors and its and their respective directors, officers, employees (including agency personnel), servants, agents and Invitees but does not include any member of Buyer Group or Company Group.
“Start Up Date” means the day on which feedstock is introduced into the FACILITY or part thereof with the intent to operate the FACILITY or part thereof.
“Subcontractor” means any company, individual or entity with whom Seller or any of Seller’s suppliers or SubContractors of any tier enter(s) into an agreement to perform any of the Work or to whom, Seller otherwise delegates performance of any of the Work.
"Taxes" means income or profits tax, employment tax, withholding tax, social security tax, Contractor tax, sales tax, property tax, consumption tax, value added tax, use and excise tax, turnover tax, capital tax, customs duties, import and export tax and all other taxes that are based on the revenues and compensation for services derived under this Agreement.
"Warranty Period" means the period of time set forth in General Condition Article 8, “Warranties and Guarantees" for all or any of the items & works..
"Work" means the work, jobs, services, goods, deliverables, and activities to be performed or provided by or on behalf of Seller under the Agreement as more fully defined in Section 1, “Scope of Work” including all necessary ancillary equipment, personnel and tools of trade to effect such work, jobs, services, goods, deliverables and activities.
“Work Site” means the locations where the Work is performed including all & every / any applicable locations through which the Work shall be manufactures, assembled, processed or transported.
SC-2 Confidentiality agreement:
Seller agrees to keep and maintain strict confidentiality about all Project Documentation and affairs of Buyer and Company, their Affiliates, the details Products and Work which may be revealed to Seller as a result of its performance of the Agreement respecting to all data collected, analyses made and reports or material prepared by Seller hereunder (“Confidential Information”). Seller shall discuss the business of Buyer or Company/their Affiliates only with representatives of Buyer or Company respectively. Seller shall not disclose to or discuss with a third party any affairs of Buyer or Company or their Affiliates without specific authorization of Buyer or Company respectively.
The provisions of this Article 2 shall expire twenty-five (25) years after the Agreement Effective Date and shall not apply to information that is or becomes publicly available without fault of Seller, its Affiliates or their respective Subcontractors, directors, officers, employees, servants, agents or Invitees or
is disclosed to Seller by a party who is not under any legal obligation to Buyer or Company, their Affiliates or prohibiting such disclosure or
is known by Seller as evidenced by written record before disclosure under the Agreement,
The information is disclosed to Seller by a third party who did not receive the same, directly or indirectly, from Buyer, Company or its respective affiliates and who has, to the best of Seller’s knowledge, nothing is developed by Seller without benefit of any information of the Buyer, Company or its respective Affiliates, or
is required to be disclosed by a court of competent jurisdiction or by a governmental agency, provided that if Seller is required to disclose any such Confidential Information pursuant to this Article 2.6, Seller informs Buyer prior to such disclosure in sufficient time to enable Buyer to seek an appropriate protective order.
is required to be disclosed in an arbitration, mediation or court proceeding in order to enforce or defend Seller’s rights after taking reasonable steps to maintain confidentiality in such proceedings
The Parties acknowledge that the disclosure of any Confidential Information, except as expressly permitted by this Agreement, shall cause irreparable injury for which Buyer does not have an adequate remedy at law. Accordingly, Buyer may seek injunctive relief against the breach or threatened breach of any of the undertakings in the Agreement regarding confidentiality, in addition to any other legal remedies that may be available.
Buyer and Company shall have no obligation of confidentiality with respect to any information disclosed to Buyer by Seller Group and Buyer and Company shall be free to use or disclose any or all of such information contained in any drawing, record or other document to third parties without accounting to Seller. Therefore, unless, any such information is specifically and clearly identified in writing as requiring confidentiality, provided however, that any disclosure of the product of Seller’s Work by Company to third parties shall be represented to the third party as Company’s own work product, with no reference to Buyer or Seller.
SC-3 Backcharges:
In the event the Products or Work are found to be defective as to workmanship or materials or not to be in conformance with this Agreement, it is the responsibility of Seller to promptly correct any deficiency when so directed. Buyer shall take reasonable measures to discover such noncompliance as quickly as practical; however, failure to do so shall in no way relieve Seller of its responsibility during the term of this Agreement and for the warranty period to promptly make such modifications as are required.
If upon being notified by Buyer of deficient Work or Products and having been directed to correct the deficient Work or Products by a specific date, Seller states or by its actions indicates its inability or unshallingness to comply then Buyer shall proceed to accomplish the corrective work by the most expeditious means available to it and backcharge Seller for the cost of the required work. The cost categories for which Seller is liable hereunder are the same as those prescribed in the General Conditions Article titled "Warranties and Guarantees".
The cost of such back charge work shall be computed as follows:
Labour shall be charged at actual cost plus 60% to cover payroll additives.
Material shall be charged at net delivered cost.
Equipment and Tool Rentals shall be charged at prevailing rates in the area.
50% shall be added to items A, B and C for Buyer’s indirect costs, overhead, supervision and administration.
Before proceeding on such backcharge work, if available, Buyer shall furnish the Seller with a written estimate of the cost of performing the work and solicit Seller’s signed authorization to proceed. Regardless of Seller’s shallingness to provide such written authorization, the Buyer when forced to proceed with the work, upon completion of the work shall invoice the Seller for actual costs incurred, computed as shown above or withhold such sum from funds still due the Seller.
In the event the Buyer has to expend additional time performing expediting, inspection or engineering activities because the Seller states (or by its actions indicates) inability or unshallingness to complete the work in accordance with the terms of this agreement, the Buyer shall proceed to perform additional expediting, inspection or engineering to facilitate completion. This action shall be taken using Buyer’s personnel or agents and Buyer shall backcharge Seller for the cost of the work at a rate of US ---- Dollars/other currency per hour plus actual and reasonable expenses.
SC-4 Safety for buyer and company representatives
Seller shall ensure the safety of Buyer and Company representatives while present at or in Seller’s plants and the plants of Seller’s Subcontractors for any purpose in connection with the Products or any part thereof, being furnished by Seller under this Agreement. If at any time, a Buyer representative deems that the conditions at Seller’s plants or the plants of Seller’s Subcontractors are unsafe and promptly notifies Seller accordingly, Buyer’s representative(s) shall be entitled to suspend their activities (including but not limited to any activities relating to expediting, quality surveillance and delivery) at such plants until such time as the unsafe conditions are resolved by Seller to Buyer’s reasonable satisfaction.
If any Buyer activities are suspended under this clause, Seller shall promptly reschedule any work required to be conducted in the presence of a Buyer representative and Seller to be fully liable for any resulting delay(s). Seller shall also be liable for all costs (including but not limited to costs for labor, transportation and lodging) incurred by Buyer due to any such suspension and subsequent resumption of Buyer activities at Seller’s plants or the plants of Seller’s Subcontractors under this Agreement.
SC-5 on-site services of seller’s representatives:
Seller agrees that the terms and conditions of the attached Technical Services Agreement shall apply upon Buyer or one of its Affiliates requiring the services of Seller’s representative(s) at the Jobsite to provide guidance during erection/start-up or operator training. The representative shall be subject to Jobsite safety and procedure requirements inclusive of but not limited to insurance requirements. A technical service subcontract shall be issued by Buyer or one of Buyers’s Affiliates which Seller hereby agrees that it shall execute such a technical service subcontract upon the request of Buyer or one of its Affiliates.
5.1 Scope of Services
Seller’s representative(s) is required to provide technical assistance, expert guidance and direction to Buyer during installation of Seller’s Products so as to ensure that the Products become fully operational in accordance with the requirements of this Agreement.
5.2 Seller's tax obligations.
Except as otherwise set forth in this Article, Seller assumes full and exclusive ‘responsibility and liability’ for and shall make its Affiliates and Subcontractors similarly responsible for timely filing all applicable returns with promptly paying when due all Taxes, levies, fees, duties, assessments including other similar charges that are levied on Seller by any country.
5.3 Registration with Tax Authorities.
If required by the country in which Work is being performed, Seller undertakes to register with the relevant tax authorities of such country.
SC-6 Release against liens and claims:
Seller shall be solely responsible for payment of all its obligations and the payment by its Subcontractors of their obligations. Seller shall keep Company’s property free of liens filed by its Subcontractors. If any such lien is filed against Company’s property, Seller shall within ten (10) working days of such filing, commence appropriate action to remove such lien and shall thereafter, diligently pursue the release of such lien. Seller shall defend any action arising from its actions which result in the assertion of a lien including a worker’s, mechanic’s, vendor’s or materialman’s lien or other similar remedy. Buyer may audit Seller’s relevant records if a worker’s, mechanic’s, vendor’s or materialman’s lien or other similar remedy is asserted and Seller does not as soon as practical secure the release of or bond the same. Seller’s obligations set forth herein shall apply to such worker’s, mechanic’s, materialmen’s and vendor’s lien and related items as result from Seller’s failure to pay its employees and Subcontractors. Seller further agrees to use its best efforts to incorporate the substance of this provision into all of its agreements with Subcontractors
Seller and not Buyer or Company, shall be solely responsible and liable for all injury to or death of persons or damage to or loss of property of Seller or any of its Subcontractors occurring in or about any of its shops or factories or other places where the Work under this Agreement is performed including any injury or death to employees of Seller or any of its Subcontractors and Seller releases Buyer and Company for all liability therefrom.
SC-7 Completion And Delivery
The Products shall be completed by the date(s) specified in the Agreement except as varied by any change order. Strict compliance with such date(s) shall be the essence of the Agreement.
Seller shall provide at its own expense such reports, bar charts, schedules or data as Buyer deem necessary from time to time during the performance of the Agreement to confirm that the Products be completed by the required date(s).
If Seller fails to commence performance of the Work on receipt of the Agreement or if it appears that Seller may not be able to complete the Products by the required date or Seller fail so to do, Buyer may terminate the Agreement in accordance with General Conditions Clause 14 “Termination for Default” or take other actions as appropriate.
Any part of the Products ready for delivery before Buyer has authorised delivery shall be stored by Seller at its own risk and expense.
Performance
In the event Products fail to meet performance guarantees contained within the material requisition or elsewhere in this Agreement then Seller shall make good such failure in order to meet the required guarantee in a time frame acceptable to Buyer.
SC-8 Compliance With Laws And Hazardous And Toxic Substances Requirements:
In the performance of this Agreement, Seller shall (i) comply with and perform the Work in accordance with all Applicable Laws, rules, requirements and ordinances including but not limited to those relating to environmental law, toxic or hazardous materials, occupational health and safety (ii) remove and dispose of any pollutants, contaminants and other chemicals released upon or around the Jobsite or other Work Site arising from performance of the Work (if any), to the extent such release is due to such performance. If this Agreement calls for the transfer to Buyer/Company by Seller of any chemical substance or mixture or any material which may generate or release a chemical substance or any hazardous agent, Seller shall provide before or with said transfer a Material Safety Data Sheet (Federal OSHA Hazard Communication Standard, 29 CFR 1910.1200) and label which are current, accurate and complete, which include but are not limited to a statement of Product hazards and precautions for safe use. Copies of the Material Safety Data Sheet shall include the Purchase Order number, shipping location, and be sent to the shipping location identified in this Agreement.
SC-9 Health, Environment And Safety And Indemnity:
Seller shall protect, defend, release, indemnify and hold harmless Buyer / Company Group from and against any and all health, environmental and safety claims, demands, liabilities, losses, damages, proceedings, causes of action and expenses (including court costs, attorneys' fees and other litigation costs) on account of or by reason of any and all citations, notice of violations or complaints, abatement obligations, assessments, fines and penalties which may be assessed by any and all federal, state, local or other government health, environmental and safety enforcement agencies arising out of the execution of WORK and to the extent based upon any and all violations of law by Seller Group.
SC-10 Buyer Furnished Equipment (Including Materials):
If Buyer furnishes Products to Seller for Seller’s use in performing the Work under this Agreement, title of said Products shall remain with Buyer. Seller shall have full responsibility for Buyer owned Products including but not limited to risk of loss while at Seller’s or Seller’s Subcontractor’s facilities.
Seller shall acknowledge receipt of Buyer owned Products in good order.
Title remains with Buyer though the Products is stored in Seller’s facilities and said Product shall not be subject to any liens or bankruptcy proceedings.
The Products shall be stored safely and properly in the Seller’s facilities and have full value insurance coverage for fire, theft and third party liability provided by the Seller.
Seller shall indemnify Buyer/Company against any damages, injury or death which may occur as a result of the Buyer owned Products being located in the Seller’s facilities.
SC-11 Taxes & duties
Seller shall be liable for and shall indemnify Buyer against all taxes, imports, duties, withholding taxes, charges or other dues or assessments of whatsoever nature levied on or chargeable to Seller or its Subcontractors in the nation of jobsite or elsewhere and payable on or in respect of anything done under the Agreement or in connection therewith.
SC-12 Laws and regulations:
Seller acknowledges that all Applicable Laws and regulations shall apply to the manufacture, sale and delivery of the Products. Seller shall execute and deliver to Buyer any documents as may be required to effect or to evidence such acknowledgment. All laws and regulations required to be incorporated in agreements such as this one are hereby incorporated herein by reference.
SC-13 Dispute resolution:
Resolution by Parties
In the event of any dispute, controversy or claim arising out of or relating to the Agreement or breach thereof including any question regarding its existence, validity or termination (a "Dispute"), the Parties shall attempt to settle such Dispute by mutual discussions between the Parties. Either Party may deliver to the other Party a written notice setting forth the nature of the Dispute and the relief or remedy requested (a "Notice Of Dispute") to commence this process of mutual discussions. If the Dispute has not been resolved by execution of a written agreement within thirty days (30) of delivery of a Notice Of Dispute, the Dispute may be referred to mediation by agreement of both Parties.
Mediation
The Parties shall jointly select a neutral mediator and schedule the mediation. The mediation contemplated by the Parties is intended to be a voluntary process to promote understanding and where possible, to arrive at a mutually acceptable resolution of their Dispute. A Party may withdraw from the mediation at any time. The mediation process shall be confidential and all information disclosed in the mediation shall be treated as compromise and settlement information for the purposes of any applicable rules of evidence. The Parties shall jointly share the cost of the mediation services.
Binding Arbitration
In the event a Dispute is not resolved by execution of a written agreement within sixty of delivery of a Notice Of Dispute, the Dispute shall be settled by binding arbitration in accordance with the Rules of Conciliation and Arbitration of the International Chamber of Commerce. The arbitration shall be held in nation or anywhere as agreed. The proceedings shall be in the English language. The Parties undertake to carry out the award without delay and waive their right to any form of appeal of the award insofar as they may validly waive such rights. Awards shall be final and binding on the Parties and judgment on any award may be entered in any court having jurisdiction. The arbitrator(s) may award attorneys’ fees and expenses and the cost of arbitration including administrative, arbitrator and expert witness fees and expenses to the prevailing Party. Each Party waives any defense to arbitration, suit, pre- or post-judgment execution or attachment based on sovereign immunity.
Selection of Arbitrator(s)
The Parties shall agree on the number of arbitrators to be appointed to resolve a Dispute. In the event the Parties agree to appoint a single arbitrator, this arbitrator shall be jointly selected by both Parties and be neutral and knowledgeable in the subject matter of the Dispute and experienced in arbitral proceedings. In the event the Parties agree to appoint three arbitrators, each Party shall select one arbitrator and these Party-appointed arbitrators shall select a third neutral arbitrator who shall be knowledgeable in the subject matter of the Dispute and experienced in arbitral proceedings. In the event the Parties cannot agree on the number of arbitrators or on a specific arbitrator, or a Party or the Party-appointed arbitrators fails to appoint an arbitrator, then the International Chamber of Commerce shall specify the number of arbitrators and/or nominate an arbitrator or arbitrators as the case may be.
Joinder of/in Related Arbitration
For purposes of this Special Condition, Seller hereby agrees upon the request of Buyer to be joined (as either a third, fourth or further party as the case may be) to any arbitration proceedings between Company and Buyer that arise out of or in any way relate to the Work, the Products, or the Agreement (a “Related Arbitration”). Seller hereby agrees that any such Related Arbitration to which Seller may be joined pursuant to this Article shall continue under the same arbitration rules as those under which it was commenced and with the same arbitration tribunal.
Tolling of Limitation Periods
Upon delivery of a Notice Of Dispute, all applicable statutes of limitation, prescriptive periods and defenses based on the passage of time shall be tolled while negotiation, mediation and/or arbitration are conducted pursuant to Special Condition Articles through The Parties shall take such action, if any, required to effectuate tolling.
SC-14 Intellectual property
All Project Documents required to be delivered to Buyer in respect of the Products produced or prepared by or for Seller or Subcontractor in physical or electronic form for and in the course of or as a result of performance of Work shall be the exclusive property of Buyer.
Subject to the provisions of this clause, Seller is hereby granted a non-terminable, non-exclusive, royalty-free license to copy and use the drawings, reports, microfilms, software, results, studies, calculations, data and any other documents or information including as-built drawings, operating and maintenance manuals in connection with Seller’s normal business development.
SC-15 No advertising:
Without Buyer’s prior written approval, Seller shall not publish or permit to be published or supplied to the press or other news media (including in-house magazines and speeches) any information regarding or photographs of the Work, including the award of this Agreement or Company’s business,
SC-16 Ethical business considerations:
No member of Seller Group shall enter into any business arrangement with any director, employee or agent of Buyer or Company without prior written notification to Buyer and Company
No member of Seller Group or Buyer Group as the case may be, shall pay any fee, commission, material remuneration or other value to or for the benefit of any government official in connection with the Agreement for the purpose of influencing an act or decision in such government official’s capacity or inducing such government official to influence the government in violation of the National Corrupt Practices Act / any Applicable Law. If such payments are made by Seller, Buyer or Company shall have the right to require Seller to pay Buyer the amount of the prohibited payment and Buyer shall have the right to terminate the Agreement forthwith for default.
SC-17 Language:
All notices, directions, documents, drawings and other information provided by the Parties to each other and to Subcontractors shall be in English. The language for the day-to-day conduct of business pursuant to the Agreement also shall be English.
SC-18 Survivability:
All provisions necessarily requiring survival beyond any termination of the Agreement including but not limited to those relating to audit, choice of law, confidentiality, dispute resolution, indemnity, insurance, taxation, title and warranty shall survive any such termination.
SC-19 Subcontractor relations:
Seller shall provide Buyer with a complete list of all Products that Seller intends to procure from Subcontractors and a list of all proposed Subcontractors. Seller shall secure Buyer’s approval for any proposed major Subcontractor at any tier prior to suborder placement. Such approval shall not be unreasonably withheld. Determination of major Subcontractors shall be at Buyers sole discretion based on the consistency as well as authenticity of the proposal. All Work performed by any Subcontractor is to be performed in strict accordance with the requirements of the Agreement pertaining to conduct of the Work.
Company shall have no obligation to pay or to cause the payment of any monies to Seller or any Subcontractor or any other person acting through, under or on behalf of Seller or any Subcontractor.
SC-20 Retention of documents:
Seller shall, at no additional cost to Buyer, retain all project documentation for a minimum period of ten (10) years from the effective date the Agreement.
SC-21 Contract Validation
Additional provisions:- The invalidity or non-enforceability of any portion or provision of this Agreement shall in no way affect the validity or enforceability of any other portion or provision hereof. Any invalid or unenforceable portion or provision shall be deemed severed from this Agreement and the balance of the Agreement be construed and enforced as if the Agreement did not contain any such invalid or unenforceable provision.
SC-22 Order of precedence:
All Agreement documents and subsequently issued Revisions are essential parts of this Agreement making mandatory the implication of a requirement occurring in one to be binding as though occurring in all. In resolving conflicts, discrepancies, omissions, misrecital or errors, the following order of precedence shall be used:
Agreement amendments
Agreement
Agreement terms
Section 11 - Special Conditions
Section 10– General Conditions
Data Sheets and drawings
Specifications
SC-23 United Nations convention on contracts
The United Nations Convention on Contracts for the International Sale of Goods shall not apply to this Agreement. All the provisions mandated according to the said convention shall be disclaimed in and excluded from any further contract, subcontract or purchase order entered into by Seller in connection with this Work or Project in any form.
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Chapter 16
References
Softwares List in General
OLGA 2000-dynamic/slugging study, INFOWORKS-drainage network modeling, FRED- Shell fred (fire, risk, explosion & dispersion) software, Fault tree+ Fault tree, event tree & markov analysisi software. T hazop- Hazop software, T risk- QRA tool, SACS- offshore structural analysis, CAESAR II- pipe stress analysis, WANDA- liquid network simulation program incl. Unsteady hydraulic behavior, WATNET- water network analysis, TWO PHASE- steady state hydraulic analysis, PIPE PHASE- steady state hydraulic analysis & complex network analysis, TRANSIM- transient & dynamic analysis, HYSYS-process simulation & modeling, GAS- pressure drop calculation in gas pipeline, calculation of control valves, SENSYCALC- calculation of orifices, VALTEC- valve sizing program, NELSIZE- valve sizing program, EDSA- electrical systems analysis & simulation, LOADFLOW- calculation of electric load flow s/c & motor starting conditions, CABLE- calculation of electric cable sizes, VABI- calculation of lighting levels, A/C LOAD- air conditioning calculation program, TECHNOSOFT- structural calculation program, MICROFEAP-finite element analysis program-structural engineering, DECIDE- structural design of reinforced concrete, STAAD PRO- structural analysis & design, STRESS- 3 D structural calculations, CONCRETE –concrete calculations, CORSUR- corrosion data base, MATHCAD- mathematical calculations- all disciplines, MANIFOPRO v.5- GIS data processing
International
Codes & Standards Contractor to note that Client shall not provide these or any other International and National Codes/Standards/Specifications.
Survey and Investigation Works As provided in the documents
Process
API 520 Part I and II Recommended Practice for Sizing, Selection and Installation of Pressure Relieving Devices in Refineries
API 521 Guide for Pressure Relieving and Depressurising Systems.
API STD 610 Centrifugal Pumps for Petroleum, Chemical and Gas Industry Services
API STD 613 Special Purpose Gear Units for Petroleum, Heavy Duty Chemical and Gas Industry Services
API STD 617 Centrifugal Pumps for Petroleum, Chemical and Gas Industry Services
ASME Section VIII, Div. 1 Rules for Construction of Pressure Vessels. NACE MR 01-75 Standard Material Requirements, Sulphide Stress Cracking Materials for Oil Field Equipment.
API 2000 Venting Atmospheric and Low Pressure Storage Tanks, fourth edition, September, 1992.
API 2610 Design, Construction, Operation, Maintenance and Inspection of Terminals and Tank Facilities
Mechanical
National Standards Not provided Construction Standards Instrumentation & Control (ICA)
International Standards
BS 5308 Part 1 Instrument Cables – Polyethylene Insulated Cables
BS 5308 Part 2 Instrument Cables – PVC Insulated Cables
BS 5345 Installation and Maintenance Requirements for Electrical Apparatus – Type of Protection (I)
BS 6121 Cable Glands BS 7405 Guide to the Selection of and Application of Flowmeters for Measurement of Fluid Flow in Closed Conduits
ISO 5167-1 Specification for Square-Edged Orifice Plates, Nozzles and Venturi Tubes
ISO 5168 Methods of Measurement of Fluid Flow Estimation of Uncertainty of a Flow Rate Measurement
ISO 5210 Industrial Valves – Multi-Turn Valve Actuators
ISO 5211 Industrial Valves – Part-Turn Valve Actuators TS/AS/009 Technical Standard on Non-Relieving over Pressure Protection (The Netherlands Steam Institute)
NACE MR-01-75 Material Requirements Sulphide Cracking Resistant Metallic Material For Oil Field Equipment
IEC 60051 Direct Acting Indicating Analogue Electrical Measuring Instruments
IEC 60079 Electrical Apparatus for Explosive Gas Atmosphere
IEC 60227 Specification for PVC Insulation and Sheath of Electrical Cables IEC 60331 Fire Resisting Characteristics of Electrical Cables
ASTM A106Standard specification for carbon steel pipes
ASTM D695Standard test method for compressive properties of rigid plastics ASTM D1599Standard test method for short time hydraulic failure pressure of plastic pipe, tubing and fittings
ASTM D2105Standard test method for longitudinal tensile properties of “fiberglass” (glass fiver reinforced thermosetting resin) pipe and tube
ASTM D2290Standard test method for apparent tensile strength of ring or Tubular plastics and reinforced plastics by split disk method
ASTM D2412Standard test method for determination of external loading characteristics of plastic pipe by parallel plate loading
ASTM D2992Standard practice for obtaining hydrostatic or pressure design basis for “fiberglass” pipe and fittings
ASTM D3517Standard specification for “fiberglass” pressure pipe ASTM D3567Standard practice for determining dimensions of “fiberglass” Pipe and fittings
ASTM D3681Standard test method for chemical resistance of “fiberglass” pipe in a deflected condition
ASTM D4161Standard specification for “fiberglass” pipe joints using Flexible elastomeric seals
ASTM F412Standard terminology relating to plastic piping systems
ASTM D883Standard terminology relating to plastics
ASTM D1600Standard terminology for abbreviated terms relating to plastics ASTM D2310Standard classification for machine made “fiberglass” pipe ASTM D2517Standard specification for reinforced epoxy resin gas pressure pipe and fittings
ASTM D2996Standard specification for filament wound “fiberglass” pipe ASTM D2997Standard specification for centrifugally cast “fiberglass” pipe ASTM D3262Standard specification for “fiberglass” sewer pipe
ASTM D3754Standard specification for “fiberglass” sewer and industrial pressure pipe
ASTM D4024Standard specification for machine made “fiberglass” flanges ASTM F1173Standard specification for thermosetting resin fiber glass pipe and fittings to be used for marine applications
ASTM D3839Standard practice for underground installation of “fiberglass” Pipe
ASTM D790Standard test method for flexural properties of un-reinforced And reinforced plastics and electrical insulating materials
ASTM D2925Standard test method for beam deflection of “fiber glass” Pipe under full bore flow
ASTM D2143Standard test method for cyclic pressure strength of reinforced, thermosetting plastic pipe
ASTM D1598Standard test method for time to failure of plastic pipe under constant internal pressure
ASTM D2924Standard test method for external pressure resistance of “fiberglass” pipe
ASTM C581Standard practice for determining chemical resistance of thermosetting resins used in glass fiber reinforced structures intended for liquid service
ASME B31.3Process piping
ASME B31.4 Pipeline transportation systems for liquid hydrocarbons and Other liquids
ANSI B16.5Steel Pipe Flanges and Flanged Fittings
ANSI B16.9Steel Butt Welding Fittings
ANSI B16.10Face-to-Face and End-to-End dimensions of Valves
ANSI B16.20Metallic Gaskets for Pipe Flanges - ring joint, spiral wound
ANSI B16.21Nonmetallic Flat Gaskets for Pipe Flanges
ANSI B16.47Large Diameter Steel Flanges - NPS - 26" to 60ANSI B36.10Welded and Seamless Wrought Steel Pipes
ANSI B36.19Welded and Seamless Austinitic Stainless Steel Pipe BS 1868Steel Check Valves for Petroleum Industry
BS 1873B Steel Globe and Check Valves for Petroleum Industry
S 5351Steel Ball Valves for Petroleum Industry
BS 5352Steel Gate, Globe and Check Valves, smaller than 2" NB
BS 6755Testing of valves
BS EN 10204Metallic products – type of inspection
NACE MR0175Sulfide Stress Cracking Resistant Metallic
Materials for Oilfield Equipment
NACE RP0286The Electrical isolation of Cathodically protected pipelines ISO 14692EJMA STD Standards of the expansion joint manufacturers association, Inc Civil and Structural
National standards/specifications- QP shall not supply copies of these standards.
EPIC Contractor shall have to obtain his own copies from the Ministry of Municipal Affairs and Agriculture.The Qatar Construction Specifications (QCS).Qatar Highway Design Manual
Marine Breakwater
BS 6349- British Standard Code of Practice for the Design of Maritime Structure.
US Army Corps of Engineers Shore Protection Manual:
1984CIRIA Report 154: 1991 – Manual on the use of rock in coastal and shoreline engineering Delft Hydraulics Report no 483: 1983 –Conceptual design of rubble mound breakwaters HR Wallingford Ltd R&D Technical Report W178.
Overtopping of seawalls – Design and Assessment Manual Delft Hydraulics Computer Program ‘Breakwater’ Version 3.0 Conceptual Design Tool for Breakwater Structures
ES.2.14.0003 for Navigation Aids, Rev. A (listed under 5-B)
Telecommunication
CCWP FEED Phase- II: Mechanical specifications and references there to.
Also references have been to various tender documents during the professional experience used for collection of information purpose only
AASHTO - American Association of State Highways and Transportation Officials
ACGIH - American Conference of Governmental Industrial Hygienists
ACI - American Concrete Institute
AGA - American Gas Association
AGMA - American Gear Manufacturers Association
AISC - American Institute of Steel Construction
ALPEMA - Brazed Aluminum Plate-Fin Heat Exchanger Manufacturers Association
AMCA - Air Movement and Control Association
ANSI - American National Standards Institute
API - American Petroleum Institute
API (MPMS) - API Manual of Petroleum Measurement Standards
ASCE - American Society of Civil Engineers
ASHRAE - American Society of Heating, Refrigeration, Air Conditioning
ASME - American Society of Mechanical Engineers
ASTM - American Society of Testing and Materials
ATEX - Atmosphere Explosible
AWS - American Welding Society
BS - British Standards
CINI - Stichting Isolatie Nederlandse Industrie
CEB - Comite Euro-international du Beton
CICIND - International Committee on Industrial Chimneys
CONCAWE - European Organisation for Environment, Health and Safety
DIN - Deutsches Institut Fur Normung
EEMUA - Engineering Equipment and Materials Users Association
EIA - Electronics Industry Alliance
EJMA - Expansion Joint Manufacturers Association
EN - Comite European de Normalisation
ERA - Electronics Representatives Association
FCI - Fluid Control Institute
FEM - Federation Europeene de la manutention
FIP - Federation Internationale de la Precontrainte
HEI - Heat Exchange Institution
HTFS - Heat Transfer and Fluid Service
ICAO - International Civil Aviation Organisation
IEC - International Electrical Committee
IEEE - Institute of Electrical and Electronic Engineering
IP - Institute of Petroleum
ISA - Instrument Society of America
ISBN - International Standard Book Number
ISGOTT - International Safety Guide for Oil Tankers and Terminals
ISO - International Organisation for Standardisation
ISSMFE - International Society for Soil Mechanics and Foundation Engineering
ITU - International Telecommunications Union
MIL-HDBK - US Military Handbook
MSS - Manufacturers Standardisation Society
NACE - National Association of Corrosion Engineers NAMUR
NAS - National Standards Association
NEN - Nederlands Normalisatie-Institutuut
NFPA - National Fire Protection Association
OCIMF - Oil companies international marine forum
PrEN - Draft EN Standard
RAL - Deutsches Institut fur Gutesicherung und Kennzeichnung
SMACNA - Sheet Metal and Air Conditioning Contractors National Association
SSPC - Steel Structures Painting Council
TEMA - Standards of the Tubular Exchanger Manufacturers Association
TIA - Telecommunications Industry Association
UBC - Uniform Building Code
UL - Underwriters Laboratories Inc
USEPA - United States Environmental Protection Agency
VDE - Verband Deutscher Elektrotechniker
VDI - Verein Deutscher Ingenieure
WRC - Welding Research Council APPENDICES
AASHTO Guide for design of pavement structures
ACGIH Threshold limit values for chemical substances and physical agents, an biological exposure indices
Advisory Circular Obstruction Marking and Lighting (issued by Aviation Administration)
AC70/7460-1K
AGA-9 Report 9, Measurement of Gas: Ultrasonic Meters
AGMA 6011 Specification for High speed helical gear units
AISC Steel Construction manual
ALPEMA Plate-fin heat exchangers
AMCA Publication 203 Field performance measurement of fan systems
ANSI/ASME B1.1 Unified inch screw threads
ANSI/ASME B1.20.1 Pipe threads, General purpose (inch)
ANSI/ASME B16.3 Malleable iron threaded fittings classes 150 and 300
ANSI/ASME B16.5 Pipe flanges and flanged fittings NPS ½” to NPS 24”
ANSI/ASME B16.9 Factory-made wrought steel butt welding fittings
ANSI/ASME B16.10 Face-to-face and end to end dimensions of valves
ANSI/ASME B16.11 Forged steel fittings, socket-welding and threaded
ANSI/ASME B16.20 Metallic gaskets for pipe flanges - Ring-joint, spiral-wound, and jacketed
ANSI/ASME B16.21 Non-metallic flat gaskets for pipe flanges
ANSI/ASME B16.24 Cast copper alloy pipe flanges and flanged fittings
ANSI/ASME B16.25 Butt welding ends
ANSI/ASME B16.34 Valves: flanged, threaded and welding ends
ANSI/ASME B16.36 Orifice flanges
ANSI/ASME B16.47 Large diameter steel flanges NPS 26” to NPS 60”
ANSI/ASME B16.48 Steel line blinds
ANSI/ASME B16.104 Control valve seat leakage
ANSI/ASME B31.1 Power piping
ANSI/ASME B31.3 Process piping
ANSI/ASME B31.4 Pipeline transportation systems for liquid hydrocarbons and other liquids
ANSI/ASME B31.5 Refrigeration piping
ANSI/ASME B31.8 Gas transmission and distribution piping systems
ANSI/ASME B36.10M Welded and seamless wrought steel pipe
ANSI/ASME B36.19M Stainless steel pipe
ANSI/ASME B46.1 Surface texture
ANSI B133.8 Gas Turbine Installation Sound Emissions
ANSI/FCI 70.2 Quality control standard for control valve seat leakage
ANSI/ISA S51.1 Process instrumentation terminology
ANSI/ISA S75.02 Control valve capacity test procedures
ANSI MC 96-1 Temperature measurement thermocouples
API (MPMS) Chapter 12 Calculation of petroleum quantities
API (MPMS) Chapter 2 Cylindrical Tanks
API (MPMS) Chapter 4 Proving systems
API (MPMS) Chapter 5 Metering
API (MPMS) Chapter 6 Metering assemblies
API 5L Replaced by ISO 3183
API 6D Specification for pipeline valves
API 6FA Specification for fire test for valves
API 15LE Specifications for polyethylene (PE) line pipe
API 510 Pressure Vessel Inspection Code: Maintenance Inspection, rating, repair and alteration
API RP 520 Part 1 Sizing, selection, and installation of pressure relieving devices in refineries
API RP 520 Part 2 Sizing, selection, and installation of pressure relieving devices in refineries
API RP 521 Guide of pressure relieving and depressurizing system
API 526 Flanged steel pressure relief valves
API 527 Seat tightness of pressure relief valves
API 530 Refer ISO 13704 (Calculation of heater tube thickness in petroleum refineries)
API 536 Post combustion NOx control for fired equipment in general refinery services
API 541 Form-wound squirrel cage induction motors – 250 HP and larger
API 546 Form-wound brushless synchronous motors – 500 HP and larger
API 551 Process measurement instrumentation
API 552 Transmission systems
API 554 Process instruments and control
API 555 Process analysers
API 560 Refer ISO 13705 (Fired heaters for general refinery services)
API 582 Welding guidelines for the chemical, oil and gas industries
API 594 Check valves; wafer, wafer-lug and double flanged type
API 598 Valve inspection and testing
API 600 Steel gate valves – flanged and butt welding ends, bolted and pressure seal bonnets
API 601 Replaced by ANSI/ASME B 16.20
API 602 Compact carbon steel gate valves – Flanged, threaded, welding and extended body ends
API 608 Metal Ball valves – Flanged, threaded and welding ends
API 609 Butterfly valves; double flanged, lug and wafer type
API 610 Centrifugal pumps for petroleum, petrochemical and natural gas Industries – not used – refer to BS EN ISO 13709
API 611 General purpose steam turbines for petroleum, chemical and gas industry services
API 612 Special purpose steam turbines for petroleum, chemical and gas industry services
API 614 Lubrication, shaft-sealing, and control-oil systems and auxiliaries for petroleum, chemical and gas industry services
API 616 Gas turbines for petroleum, chemical and gas industry services
API 617 Axial and Centrifugal compressors and expanders - Compressors for petroleum, chemical and gas industry services
API 618 Reciprocating compressors for petroleum, chemical and gas industry services
API 619 Rotary-type positive displacement compressors for petroleum, chemical and gas industry services
API 631M Measurement of Noise from Air-Cooled Heat Exchangers
API 650 Welded Steel Tanks for Oil Storage
API 662 Plate heat exchangers for general refinery services
API 670 Machinery protection systems
API 671 Special purpose couplings for petroleum, chemical and gas industry services
API 672 Packaged, integrally geared centrifugal air compressors for petroleum, chemical and gas industry services
API 673 Centrifugal fans for petroleum, chemical and gas industry service
API 674 Positive displacement pumps - Reciprocating
API 675 Positive displacement pumps - Controlled volume
API 676 Positive displacement pumps - Rotary
API 677 General purpose gear unit for petroleum, chemical and gas industry services
API 681 Liquid ring vacuum pumps and compressors
API 682 Shaft sealing systems for centrifugal and rotary pumps
API RP 686 Machinery installation and installation design
API 934 Materials & Fabrication Requirements for 2-1/4Cr-1MO & 3Cr-1Mo Steel Heavy Wall Pressure Vessels for High Temperature, High Pressure Hydrogen Service, 1st Edition, 2000
API 945 Avoiding Environmental Cracking in Amine Units- Third Edition.
API 2000 Venting atmospheric and low-pressure storage tanks, non refrigerated and refrigerated
API 2218 Fireproofing practices in petrochemical processing plant
API 2510 Design and construction of LPG installations
API 2550 Method for measurement and calibration of upright cylindrical tanks
API RP 500 Classifications of locations for electrical installations at petroleum facilities classified as Class 1, Division 1, Division 2
API RP 505 Classifications of locations for electrical installations at petroleum facilities classified as Class 1, Zone 0, Zone 1, and Zone 2
API RP 572 Inspection of Pressure Vessels
API RP 576 Inspection of Pressure-relieving Devices
API RP 651 Cathodic protection of aboveground petroleum storage tanks
ASCE Design of blast resistant buildings in petrochemical facilities
ASCE 7-95 Minimum design loads for buildings and other structures
ASHRAE Handbooks - Refrigeration
ASHRAE Handbook- HVAC applications
ASHRAE Handbook - Fundamentals
ASHRAE Handbooks - HVAC systems and equipment
ASHRAE 16 Method of testing for rating room air conditioners and packaged terminal air conditioners
ASHRAE 23 Methods of testing for rating positive displacement refrigerant compressors and condensing units
ASHRAE 30 Methods of testing liquid chilling package
ASHRAE 37 Methods of testing for rating unitary air-conditioning and heat pump equipment
ASHRAE 40 Methods of testing for rating heat operated unitary air-conditioning equipment for cooling
ASHRAE 52.1 Gravimetric and dust spot procedures for testing air cleaning devices used in general ventilation for removing particulate matter
ASHRAE 55 Thermal environmental conditions for human occupancy and addendum
ASHRAE 62 Ventilation for acceptable indoor air quality
ASHRAE 63.1 Method of testing liquid line refrigerant driers
ASHRAE 70 Method of testing for rating the performance of air outlets and inlets
ASHRAE 79 Methods of testing for rating room fan-coil air conditioners
ASHRAE 111 Practices for measurement, testing, adjusting and balancing of building heating, ventilation, air conditioning and refrigeration systems.
ASHRAE Guideline 1 The HVAC Commissioning Process
ASHRAE Guideline 4 Preparation of operating and maintenance documentation for building systems
ASHRAE Guideline 5 Commissioning of smoke management systems
AASHTO GDPS 4 Guide for design of pavement structures
AASHTO T180 Standard Method of testing for moisture-density relations of soils using a 4.45 kg rammer and 457 mm drop
ASME B16.3 Malleable iron threaded fittings, classes 150# & 300#
ASME PTC 1 General instructions for performance test codes
ASME PTC 4.1 Steam generating units
ASME PTC 4.4 Gas turbine heat recovery steam-generating units
ASME PTC 6 Steam Turbines
ASME PTC 9 Displacement compressors
ASME PTC 10 Performance test code : compressors and exhausters
ASME PTC 16 Gas Generators
ASME PTC 19.3 Temperature measurement – Instruments and apparatus
ASME PTC 22 Performance test code : gas turbines
ASME PTC 26 Speed governing systems for internal combustion engine/generator sets
ASME Section I Power Boilers
ASME Section II Material specifications Part A, B, C and D
ASME Section III Creep design basis fatigue analysis
ASME Section IX Qualification standard for welding and brazing procedures
ASME Section V Non-destructive examination
ASME Section VIII Div. 1 and 2, Boiler and vessel code
ASME RTP-1 Reinforced thermoset plastic corrosion resistant material
ASTM A 48 Standard specification for gray iron castings
ASTM A53 Standard Specification for Pipe, Steel, Black and Hot Dipped, Zinc Coated, Welded and Seamless
ASTM A 105/105M Forgings, carbon steel, for piping applications
ASTM A 106 Seamless carbon steel pipe for high temperature service
ASTM A 123/A123M Standards - Specification for zinc (hot dip galvanised) coating on iron and steel products, version A
ASTM A 167 Standard specification for stainless and heat resisting chromium-nickel steel plate, sheet and strip
ASTM A 179/A179M Seamless cold-drawn low-carbon steel heat-exchanger and condenser tubes
ASTM A 182/A182M Forged or rolled alloy-steel pipe flanges, forged fittings, and valves and parts for high-temperature
ASTM A 193/A193M Standard specification for alloy steel, stainless steel and stainless steel bolting materials for high temperature service
ASTM A 194/A194M Standard specification for carbon alloy and steel nuts for bolts for high pressure or high temperature service, or both
ASTM A 213/A213M Seamless ferritic and austenitic alloy - steel boiler, superheater and heat-exchanger tubes
ASTM A 216/A216M Specification for carbon steel castings, suitable for fusion welding, for high temperature service
ASTM A 234/A234M Pipe fittings of wrought carbon steel and alloy steel for moderate and elevated temperatures
ASTM A 240/A240M Standard specification for heat resisting chromium nickel stainless steel plate, sheet, and strip for pressure vessels
ASTM A 262 Standard practices for detecting susceptibility to intergranular attack in austenitic stainless steels
ASTM A 269 Standard specification for seamless and welded austenitic stainless steel tubing for general service
ASTM A 276 Standard specification for stainless steel bars and shapes
ASTM A 285 Standard Specification for Pressure Vessel Plates, Carbon Steel, Low and Intermediate-Tensile Strength
ASTM A 307 Standard Specification for Carbon Steel Bolts and Studs, 60,000 P.S.I. Tensile Strength
ASTM A 312/A312M Seamless and welded austenitic stainless steel pipes for general service
ASTM A 320/A320M Alloy-steel bolting materials for low-temperature service
ASTM A325 Standard Specification for Structural bolts, steel, heat treated, 120/105 ksi minimum tensile strength-AASHTO no:M164.
ASTM A 333/A333M Seamless and welded steel pipe for low-temperature service
ASTM A 334/A334M Seamless and welded carbon and alloy - Steel tubes for low-temperature service
ASTM A335 Standard Specification for Seamless Ferritic Alloy-Steel Pipe for High-Temperature Service
ASTM A 350/A350M Forgings, carbon and low-alloy steel, requiring notch toughness testing for piping components
ASTM A 351/A351M Specification for steel castings, austenitic, for high temperature service
ASTM A 352/A352M Specification for steel castings, ferritic and martensitic, for pressure containing parts suitable for low temperature service
ASTM A 353/A353M Pressure vessel plates, alloy steel, 9% nickel, double normalised and tempered
ASTM A 358/A358M Standard specification for electric-fusion-welded austenitic chromium-nickel alloy steel pipe for high temperature service
ASTM A 388/A388M Practice for ultrasonic examination of heavy steel forgings
ASTM A 392 Standard specification for zinc coated steel chain link fence fabric
ASTM A395 Standard Specification for Ferritic Ductile Iron Pressure-Retaining Castings for Use at Elevated Temperatures
ASTM A 403/A403M Wrought austenitic stainless steel piping and fittings
ASTM A 420/A420M Piping fittings of wrought carbon steel and alloy steel for low-temperature service
ASTM A 450/A450M Standard specification for carbon, ferritic alloy and austenitic alloy steel tubes
ASTM A 453/A453M Standard specification for high temperature bolting materials, with expansion coefficients comparable to austenitic steels
ASTM A 463/A463M Standard specification for steel sheet, aluminium-coated by hot-dip process
ASTM A 491 Standard specification for aluminium coated steel chain link fence fabric
ASTM A 516/A516M Pressure vessel plates, carbon steel, for moderate and lower-temperature service
ASTM A 522/A522M Forged and rolled 8 and 9% nickel alloy steel flanges, fittings, valves and parts for low-temperature service
ASTM A 525/A525M Specification for general requirements for steel sheet, zinc coated (galvanised) by hot dip process
ASTM A 530 Standard specification for general requirements for specialized carbon and alloy steel pipe
ASTM A 537/A537M Pressure vessel plates, heat treated, carbon-manganese-silicon steel
ASTM A 553/A553M Pressure vessel plates, alloy steel, quenched and tempered 8 and 9 percent nickel
ASTM A 609 Specification for Longitudinal-Beam Ultrasonic Inspection for Carbon and Low-alloy Steel Castings
ASTM A671 Standard Specification for Electric-Fusion-Welded Steel Pipe for Atmospheric and Lower Temperatures
ASTM A672 Standard Specification for Electric-Fusion-Welded Steel Pipe for High Pressure Service at Moderate Temperature
ASTM A 765/A765M Carbon steel and low-alloy steel pressure-vessel-component forgings with mandatory toughness requirements
ASTM A 770/A770M Specification for through-thickness tension testing of steel plate for special applications
ASTM A 790/A 790M Standard specification for seamless and welded ferritic/austenitic stainless steel pipe
ASTM A961 Standard Specification for Carbon and Alloy Steel Pipe, Electric-Fusion-Welded for High Pressure Service at High Temperature
ASTM B 148 Specification for aluminum bronze sand castings
ASTM B 165 Standard specification of nickel-copper alloy
ASTM B 209 Standard specification for aluminium and aluminium alloy sheet and plate
ASTM B 418 Standard specification for cast and wrought galvanic zinc anodes
ASTM B 423 Standard specification for seamless and electric welded low-alloy steel tubes
ASTM B 574 Standard Specification for Low-Carbon Nickel-Molybdenum-Chromium, Low-Carbon Nickel-Chromium-Molybdenum, Low- Carbon Nickel-Molybdenum-Chromium-Tantalum, Low-Carbon Nickel-Chromium-Molybdenum-Copper, and Low-Carbon Nickel-Chromium-Molybdenum-Tungsten Alloy Rod
ASTM B 637 Standard specification for precipitation-hardening nickel alloy bars, forgings, and for going stock for high temperature service
ASTM B 668 Standard specification for UNS N08028 seamless pipe and tube
ASTM B 695 Standard Specification for coatings of zinc mechanically deposited on iron and steel
ASTM B 764-04 (Includes change to title) Test Method for Simultaneous Thickness and Electrode Potential Determination of Individual
Layers in Multilayer Nickel Deposit Step Test (R)
ASTM B 839-04 Test Method for Residual Embrittlement in Metallic coated, externally threaded articles, fasteners, and rod – inclined Wedge Method (R)
ASTM B 851-04 Specification for automated controlled shot peening of metallic articles prior to Nickel, autocatalytic nickel, or chromium plating, or as final finish
ASTM C 27 Standard Classification of Fireclay and High-Alumina Refractory Brick
ASTM C 155 Standard Classification of Insulating Firebrick
ASTM C 165 Standard test method for measuring compressive properties of thermal insulation
ASTM C 167 Standard test method for thickness and density of blanket or batt insulations
ASTM C 177 Standard test method for steady-state heat flux measurements and thermal transmissions properties by means of the guarded hot plate apparatus
ASTM C 240 Standard test method of testing cellular glass insulating block
ASTM C 273 Test for shear properties in flatwise plane or flat sandwich constructions or sandwich cores
ASTM C 303 Standard test method for dimensions and density of performed block-type thermal insulation
ASTM C 390 Criteria for sampling and acceptance of pre formed thermal insulation lots
ASTM C 401 Standard Classification of Alumina and Alumina-Silicate Castable Refractories
ASTM C 461 Standard test method of mastic and coating used in conjunction with thermal insulation
ASTM C 518 Standard test method for steady state heat flux measurements and thermal transmission properties by means of the heat flow meter
ASTM C 533 Standard specification for calcium silicate block and pipe thermal insulation
ASTM C 547 Standard specification for mineral fibre pipe insulation
ASTM C 552 Standard specification for cellular glass thermal insulation
ASTM C 585 Standard practice for inner and outer diameters of rigid thermal insulation for nominal sizes of pipe and tubing (NPS system)
ASTM C 591 Standard specification for unfaced pre formed rigid cellular polyisocyanurate thermal insulation
ASTM C 592 Standard specification for mineral fibre blanket insulation and blanket-type pipe insulation
ASTM C 612 Specification for mineral fibre block and board thermal insulation
ASTM C 623 Standard test method for Young’s modulus, shear modules and Poisson's ratio for glass and glass ceramics by resonance
ASTM C 680 Standard practice for the determination of heat gain or loss and the surface temperatures of insulated pipe and equipment
systems by the use of a computer program
ASTM C 795 Standard specification for thermal insulation for use in contact with austenitic stainless steel
ASTM C 871 Standard test methods for chemical analysis of thermal insulation materials for leachable chloride, fluoride, silicate and sodium ions
ASTM C 876 Standard test method for half cell potentials of uncoated reinforcing steel in concrete
ASTM C 892 Standard specification for high temperature fibre blanket thermal insulation
ASTM C 1497-04 Specification for cellulosic fiber stabilized thermal insulation (R)
ASTM D 312 Standard specification for asphalt used in roofing
ASTM D 420 Guide to site characterization for engineering, design and construction purposes
ASTM D 511 Test method for calcium and magnesium in water
ASTM D 512 Test method for chloride ion in water
ASTM D 513 Test methods for carbon dioxide, total and dissolved, in water
ASTM D 516 Test method for sulphate ion in water
ASTM D 5162 Standard practice for discontinuity (holiday) testing of non-conductive protective coating on metallic substrates
ASTM D 610 Test methods for evaluating degree of rusting on painted steel surfaces
ASTM D 635 Test method for rate of burning and/or extent and time of burning of self-supporting plastics in a horizontal position
ASTM D 653 Terminology relating to soil, rock and contaminated fluids
ASTM D 790 Standard test methods for flexural properties of un-reinforced and reinforced plastics and electrical insulating materials
ASTM D 1066 Practice for sampling steam
ASTM D 1126 Test methods for hardness in water
ASTM D 1248 Specification for polyethylene plastics moulding and extrusion materials
ASTM D 1250 Standard guide for petroleum measurement tables
ASTM D 1293 Test method for pH of water
ASTM D 1426 Test methods for ammonia nitrogen in water
ASTM D 1452 Practice for soil investigation and sampling by auger borings
ASTM D 1557 Standard Test methods for laboratory compaction characteristics of soil using modified effort
ASTM D 1587 Practice for thin-walled tube geotechnical sampling of soils
ASTM D 1621 Standard test method for compressive properties of rigid cellular plastics
ASTM D 1622 Standard test method for apparent density of rigid cellular plastics
ASTM D 1623 Standard test method for tensile adhesion properties of rigid cellular plastics
ASTM D 2487 Standard practice for classification of soils for engineering purposes
ASTM D 2563 Practice for classifying visual defects in glass reinforced plastic laminate parts
ASTM D 2583 Standard test method for indention hardness of rigid plastics by means of barcol impressor
ASTM D 2856 Standard test method for open cell content of rigid cellular plastics by the air pycnometer
ASTM D 3014 Standard test method for flame height, time of burning and loss of mass of rigid thermoset cellular plastics in a vertical position
ASTM D 3039/3039M Test method for tensile properties of polymer matrix composite materials
ASTM D 3370 Practice for sampling water from closed circuits
ASTM D 3441 Deep, quasi-static cone and friction cone penetration tests of soil
ASTM D 3744 Test method of aggregate durability index
ASTM D 3764 Standard practice for validation of process stream analysers
ASTM D 4541 Standard test method for pull and off strength of coating using portable adhesion testers.
ASTM D 5162 Standard practice for discontinuity (holiday) testing of non-conductive protective coating on metallic substrates
ASTM D 6122 Standard practice for the validation of multivariate process infrared spectrophotometers
ASTM E 162 Standard test method for surface flammability of materials using a radiant heat source
ASTM E 21 Elevated temperature tension test of metallic materials
ASTM E 84 Standard test method for surface burning characteristics of building materials
ASTM E 94 Standard guide for Radiographic Testing
ASTM E 96 Standard test method for measurement of water vapour transmission of materials
ASTM E 110 Standard test method for indentation hardness of metallic materials by portable hardness testers
ASTM E 165 Standard test method for liquid penetrant examination
ASTM E 413-04 Classification for Rating Sound Insulation (R)
ASTM E 446 Reference Radiographs for Steel Castings up to 2in. (51mm) in Thickness
ASTM E 709 Standard guide for magnetic particle examination
ASTM E 966-04 Guide for field measurement of airborne sound insulation of building facades and façade elements (R)
ASTM E 1687-04 Test method for Determining Carcinogenic Potential of Virgin Base Oils in Metalworking Fluids (R)
ASTM E 1972-04 Practice for Minimizing Effects of Aerosols in the Wet Metal Removal Environment (R)
ASTM E 2235-04 Test method for determination of decay rates for use in sound insulation test methods (R)
ASTM F 552 Standard terminology relating to chain link fencing
ASTM F 567 Standard practice for installation of chain link fence
ASTM F 668 Standard specification for polyvinyl chloride (pvc) and other organic polymer-coated steel chain link fence fabric
ASTM F 1043 Standard specification for strength and protective coatings on metal industrial chain link fence framework
ASTM F 1249 Test method for water vapour transmission rate through plastic film and sheeting using a modulated infra red sensor
ASTM G 57 Standard test method for field measurement of soil resistivity using Wenner four electrode method
ASTM G 93 Cleaning methods for material and equipment used in oxygen enriched environments
ASTM SI-10 Practice for the use of the International System of units (SI)
ASTM Volume 04.03 Traveled surface characteristics
ASTM Volume 04.08 Natural building stones; Soil and rock
ASTM Volume 11.01 Water (I)
ASTM Volume 11.02 Water (II)
ATEX Directives Protective equipment and systems intended for use in potentially explosive atmospheres;
AWWA M45 Fibreglass Pipe Design- First Edition
AWS A5.1 Specification for covered carbon steel arc welding electrodes
AWS A5.11A5.11M Nickel and nickel alloy welding electrodes for shielded metal arc welding
AWS A5.14/A5.14M Nickel and nickel alloy bare welding electrodes and rods
AWS A5.17/A5.17M Specification for carbon steel electrodes and fluxes for submerged arc welding
AWS A5.18 Specification for carbon steel filler metals for gas shielded arc welding
AWS A5.4 Specification for stainless steel electrodes for shielded metal-arc welding
AWS A5.5 Specification for low alloy steel covered arc welding electrodes
AWS A5.9 Bare stainless steel welding electrodes and rods
AWS D1.1/D1.1M Structural welding code steel
BS 88 Cartridge fuses for voltages up to and including 1000V AC and 1500V DC
BS 171D Identification of Pipe Lines and Services. BSI, UDC (621.643/644) – 777.6
BS 336 Specification for Fire hose couplings and ancillary equipment
BS 381C Colours for Identification, Coding and Special Purposes
BS 417 Specification for galvanised low carbon steel cisterns, cistern lids, tanks and cylinders
BS 449 The use of structural steel in buildings
BS 466 Specification for Power Driven Overhead Travelling Cranes, semi goliath and goliath cranes for general use
BS 476 Fire tests on building materials and structures
BS 476-3 Fire tests on building materials and structures – Part 3: classification and method of test for external exposure to roofs
BS 599 Methods of testing pumps
BS 709 Methods of destructive testing fusion welded joints and weld metal steel
BS 729 Hot dip galvanized coatings on iron and steel articles
BS 743 Specification for Materials for Damp Proof Courses
BS 747 Specification for Reinforced Bitumen Roofing
BS 750 Specification for underground fire hydrants and surface box frames and covers.
BS 812 – 123 Testing aggregates - Method for the determination of Alkali-Silica reactivity - Concrete prism method
BS 848 Fans for general purpose
BS 952 Glass for Glazing
BS 1113 Specification for design and manufacture of water-tube steam generating plant etc
BS 1133 Packaging code
BS 1184 Specification for Copper & Copper Alloy Traps
BS 1188 Ceramic Wash Basins and Pedestals
BS 1191 Specification for Gypsum Building Plasters
BS 1230 Gypsum – Plasterboard
BS 1245 Specification Metal Door Frame (steel)
BS 1253 Gullies for Buildings
BS 1376 Specification for colours of light signals
BS 1377 Methods of tests for soils for civil engineering purposes – parts 1 to 9
BS 1377 Methods of test for soils for civil engineering purposes. Part 3 Chemical and Electrochemical tests, Part 9 In-situ tests.
BS 1414 Specification for steel wedge gate valves (flanged and buttwelding ends) for the petroleum, petrochemical and allied industries
BS 1449 Specification for steel plate, sheet and strip
BS 1494 Specification for fixing accessories for Building Purposes. Fixing for Sheets, Roof and Wall Coverings
BS 1501 Steel for pressure purposes
BS 1503 Specification for steel forgings for pressure purposes
BS 1521 Specification for waterproof building papers
BS 1635 Recommendations for graphical symbols and abbreviations for fire protection drawings
BS 1640 Steel butt-welding pipe fittings for the petroleum industry
BS 1722 Part 10 Fences - Part 10: Specification for anti-intruder fences in chain-link and welded mesh
BS 1726 Coil springs
BS 1787 Steel Windows for Industrial Windows
BS 1868 Specification for steel check valves (flanged and butt welding ends) for the petroleum, petrochemical and allied industries
BS 1873 Specification for steel globe and globe stop valves (flanged and butt welding ends) for the petroleum, petrochemical and allied industries
BS 1876 Specification for Automatic Flush Cisterns for Urinals
BS 1881 Testing concrete
BS 1990-1 Wood poles for overhead power and telecommunications lines
BS 2000 – Part 72 'Methods of test for petroleum and its products Part 72 - Determination of viscosity of cutback bitumen'
BS 2080 Specification for face to face, centre to centre, end to end and centre to end dimensions of valves
BS 2573 Rules for the design of cranes
Part 1 Specification for classification, stress calculations and design criteria for structures
Part 2 and AMD 3952 and AMD 5013 Specification for classification, stress calculations and design of mechanisms
BS 2654 Specification for manufacture of vertical steel welded non-refrigerated storage tanks with butt welded shells for the petroleum industry
BS 2690 Methods of testing water used in industry
BS 2853 The design and testing of steel overhead runway beams
BS 2972 Methods of test for inorganic thermal insulating materials
BS 2997 Specification for Aluminium Rainwater Goods
BS 3083 Specification for Hot Dipped and Hot Dipped Aluminium/Zinc Coated corrugated steels sheets for general purposes
BS 3148 Methods of test for water and making concrete
BS 3165 Specification for rubber and plastics suction hoses and hose assemblies for fire-fighting purposes
BS 3381 Spiral Wound Gaskets for Steel Flanges to BS 1560
BS 3402 Specification for Quality Vitreous China Sanitary Appliances
BS 3505 Specification for unplasticized polyvinyl chloride (U-PVC) pressure pipes for cold potable water
BS 3573 Specification for polyolefin copper conductor telecommunication cables
BS 3602 Specification for steel pipes and tubes for pressure purposes; carbon and carbon manganese steel with specified elevated temperature properties
BS 3603 Specification for carbon and alloy steel pipes and tubes with specified low temperature properties for pressure purposes
BS 3605 Austenitic Stainless steel pipes and tubes for pressure purposes
BS 3606 Specification for steel tubes for heat exchangers
BS 3621 Specification for Thief Resistant Locks
BS 3790 Specification for endless wedge belt drives and endless V-belt drives
BS 3958 Thermal insulating material
BS 3974 Specification on pipe supports
BS 4022 Specification for pre-fabricated gypsum plasterboard
BS 4027 Specification for sulphate resisting Portland cement
BS 4076 Steel Chimneys
BS 4082 External dimensions for vertical in-line centrifugal pumps.
BS 4131 Terrazzo Tiles
BS 4211 Specification for ladders for permanent access to chimneys, other high structures, silos and bins
BS 4320 Specification for metal washers for general engineering purposes
BS 4346 Joints and fittings for the use with unplasticized PVC pressure pipes
BS 4370 Methods of test for rigid cellular materials
BS 4449 Carbon steel bars for the reinforcement of concrete
BS 4483 Steel fabric for the reinforcement of concrete
BS 4514 Un-plasticised PVC Soil and Ventilation Pipes of 82.4mm mean outside diameter and accessories of 82.4mm and other sizes
BS 4721 Specification for Ready Mixed Building Mortars
BS 4735 Laboratory methods of tests for the assessment of the horizontal burning characteristics of specimens no larger than 150mm x 50mm x 13mm of cellular plastics and cellular rubber materials when subjected to a small flame
BS 4787 Internal and External Wood door sets, door leaves and frames
BS 4800 Schedule of paint colours for building purposes
BS 4868 Profiled Aluminium Sheet for Buildings
BS 4880 Urinals, Stainless Steel Slab Urinals
BS 4882 Specification for bolting for flanges and pressure containing purposes
BS 4991 Specification for propylene copolymer pressure pipe
BS 4999-140 General requirements for rotating electrical machines
BS 4999-144 General requirements for rotating electrical machines Part 144: Specification for the insulation of bars and coils of high
voltage machines, including test methods
BS 5041-1 Fire hydrant systems equipment-Specification for landing valves for wet risers
BS 5041-2 Fire hydrant systems equipment-Specification for landing valves for dry risers
BS 5051 Specification for Security Glazing
BS 5135 and AMD 5172 Specification for arc welding of carbon and carbon manganese steels
BS 5224 Masonry Cement
BS 5234 Partitions (including Matching Linings)
BS 5250 Code of Practice for the Control of Condensation in Buildings
BS 5262 Code of Practice for External Rendered Finishes
BS 5306 Part 0 Guide for the Selection of Installed Systems and Other Fire Equipment
BS 5306 Part 1 Hydrant Systems, Hose Reels and Foam Inlets
BS 5306 Part 2 Specification for Sprinkler Systems
BS 5306 Part 4 Specification for Carbon Dioxide Systems
BS 5306 Section 6.1 Specification for Low Expansion Foam Systems
BS 5306 Section 6.2 Specification for Medium and High Expansion Foam Systems
BS 5306 Part 7 Specification for Powder Systems
BS 5308 Instrumentation cables
BS 5351 Specification for Steel Ball Valves for the Petroleum, Petrochemical and Allied Industries
BS 5352 Specification for steel wedge gate, globe and check valves 50mm and smaller for the petroleum, petrochemical and allied industries
BS 5353 Steel plug valves
BS 5357 Code of Practice for Installation of Security Glazing
BS 5368 Methods for Testing Windows
BS 5385 Code of Practice for the Design and Installation of Ceramic Floor, Wall Tiles and Mosaics
BS 5395 Part 2 Code of Practice for the Design of Helical & Spiral Stairs
BS 5395 Part 3 Code of Practice for the Design of Industrial Type Stairs, permanent ladders and walkways
BS 5422 Methods for specifying thermal insulating materials on pipes, ductwork and equipment (in the temperature range-40°C to+700°C)
BS 5427 Code of Practice for use of profiled sheet for roof and wall cladding on buildings
BS 5492 Code of Practice for Internal Plastering
BS 5499 Code of Practice for Escape Signs, Route Signage, Safety Signs including Fire Safety Signs
BS PD 5500 Specification for unfired fusion welded pressure vessels
BS 5503 Specification for Vitreous China washdown WC pans with horizontal outlet
BS 5504 Specification for wall hung WC pans
BS 5506 Specification for wash basins
BS 5520 Specification for Vitreous chain bowl urinals (rimless type)
BS 5588 Fire Precautions in the Design, Construction and Use of Buildings
BS 5628 Code of Practice for the structural use of Masonry
BS 5642 Sills and Copings, Specification for Sills and Copings of Pre-Cast Concrete, Cast Stone, Clay ware, Slate & Natural Stone
BS 5713 Specification for Hermetically sealed flat double glazing units
BS 5731-4 Specification for aluminium and aluminium alloy
BS 5744 Code of practice for safe use of cranes
BS 5750 Quality systems
BS 5872 Specification for locks and latches for doors in Buildings
BS 5977 Lintels – Method of Assessment of Loads
BS 5930 Code of practice for site investigation
BS 5950 Structural use of steelwork in building
BS 5970 Code of practice for thermal insulation of pipework and equipment (in the temperature range of -100oC to +870oC)
BS 5996 Ultrasonic testing and specifying quality grades of ferritic steel plate
BS 6072 and AMD 3960, Method for magnetic particle flaw detection 4542 and 4843
BS 6073 Pre-cast Masonry Units
BS 6100 Part 1 Glossary of building and civil engineering terms - Part 1: General and miscellaneous
BS 6100 Part 2 Glossary of building and civil engineering terms - Part 2: Civil engineering
BS 6150 Code of Practice for Painting of Buildings
BS 6031 Code of practice for earthworks'
BS 6121 Specification for mechanical cable glands
BS 6217 Code of Practice for Built up felt roofing
BS 6218 Code of Practice for Mastic Asphalt Roofing
BS 6229 Code of Practice for Flat Roofs with continuously supported covering
BS 6231 Specification for PVC-insulated cables for switchgear and control gear wiring
BS 6259 Code of Practice for the design, planning, installation, testing and maintenance of sound systems
BS 6262 Code of Practice for Glazing of Buildings
BS 6290-4 Lead-acid stationary cells and batteries
BS 6349 Code of practice for maritime structures - Part 1 through Part 7
BS 6364 Specification for valves for cryogenic service
BS 6375 Performance of Windows
BS 6387 Specification for performance requirements for cables required to maintain circuit integrity under fire conditions
BS 6398 Specification for Bitumen Damp-proof Courses for Masonry
BS 6399-1 Loading for buildings – Part 1 Code of Practice for dead and imposed loads
BS 6399-2 Loading for buildings – Part 2 Code of Practice for wind loads
BS 6399-3 Loading for buildings – Part 3 Code of Practice for imposed roof loads
BS 6431 Ceramic Floor and Wall Tiles
BS 6437 Specification for polyethylene pipes (type 50) in metric diameters for general purposes
BS 6452 Beads for Internal Plaster & Dry Linings
BS 6467 Electrical Apparatus with protection by enclosure for use in the presence of combustible dusts
BS 6510 Specification for steel windows, sills, window boards and doors
BS 6510 Steel sub-frames, sills & window boards for metal windows
BS 6515 Specification for Polyethylene Damp Proof Courses for Masonry
BS 6572 Specification for Blue Polyethylene pipes up to nominal size 63 for below ground use for portable water
BS 6651 Code of practice for protection of structures against lightning
BS 6656 Guide to prevention of inadvertent ignition of flammable atmosphere by radio frequency radiation
BS 6701 Telecommunications equipment and telecommunications cabling – specification for installation, operation and maintenance.
BS 6730 Specification for black polyethylene pipes up to nominal size 63 for above ground use for cold potable water
BS 6755 Inspection and testing of valves. Parts 1 and 2
BS 6883 Elastomer insulated cables for fixed wiring in ships and on mobile and fixed offshore units
BS 6941 Specification for electrical apparatus for explosive atmospheres with type of protection N
BS 6925 Specification for Mastic Asphalt for Building & Civil Engineering
BS 7121 Code of practice for safe use of cranes.
Part 1 and AMD 9093 General
Part 2 Inspection testing and examination
BS 7281 Specification for polyethylene pipes for the supply of gaseous fuels
BS 7354 Code of practice for design of high-voltage open terminal stations
BS 7357 7.5 litre WC flushing cistern
BS 7361-1 Cathodic Protection
BS 7364 Specification for Galvanised Steel Studs and Channels for Stud and Sheet Partitions using Screw Fixed Gypsum Wallboard
BS 7953 Entrance Flooring Systems, Selection, Installation and Maintenance
BS 8004 Code of practise for Foundations
BS 8007 Code of practice for design of concrete structures for retaining aqueous liquids
BS 8102 Code of Practice for the Protection of Structures Against Water from the Ground
BS 8110 Structural use of concrete
BS 8203 Code of Practice for Installation of Resilient Floor Coverings
BS 8204 Screeds, Bases and In-situ Flooring, Concrete Bases and Cement Sand, Screed to Receive Flooring
BS 8207 Code of Practice for Energy Efficiency in Buildings
BS 8212 Code of Practice for Dry Lining and Partitions using Gypsum Plasterboard
BS 8214 Fire Door assemblies with non-metallic leaves
BS 8215 Code of Practice for Design and Installation of Damp-proof Courses in Masonry Construction
BS 8217 Code of Practice for Built-up Felt Roofing
BS 8218 Code of Practice for Mastic Asphalt Roofing
BS 8290 Code of Practice for Suspended Ceilings
BS 8300 Design of Buildings and their approaches to meet the needs of Disabled People
BS 8500-1 Concrete - Complimentary British Standard to BS EN 206-1 - Method of specifying and guidance for the specification'
BS 8500-2 Concrete - Complimentary British Standard to BS EN 206-1 - Specification for constituent materials and concrete
BS DD IEC TS 60695 Fire Hazard Testing – Part 7-3: Toxicity of Fire Effluent – Use and Interpretation of Test Results
BS EN 179 Building Hardware – Emergency Exit Device Operated by a Lever or Push Pad
BS EN 196 Method for testing concrete
BS EN 197-1 Cement, specification and conformity for common cements
BS EN 206 Concrete, specification, performance, production and compliance and conformity
BS EN 274 Waste Fitting for Sanitary Appliances
BS EN 295 Vitrified Clay Pipes and Fittings
BS EN 329 Sanitary Tapware Waste Fittings for Showers
BS EN 403 Respiratory protective devices for self-rescue – Filtering devices with hood for escape from fire – requirements, testing, marking
BS EN 411 Sanitary Tapware Waste Fittings for Sinks
BS EN 508 Roofing Products for Metal Sheet – Specification for Self Supporting Products of Steel, Aluminium or Stainless Steel Sheet
BS EN 593 Specification for butterfly valves
BS EN 607 Eaves gutters and fittings made from PVC-U
BS EN 612 Eaves gutters and rainwater down pipes of metal sheet
BS EN 649 Resilient Floor Coverings – Homogeneous & Heterogeneous Polyvinyl Chloride Floor Coverings
BS EN 654 Resilient Floor Coverings – Semi-flexible Polyvinyl Chloride Tiles
BS EN 764-1 Pressure Equipment Part 1: Terminology – pressure, temperature, volume, nominal size
BS EN 806 Specification for Installation inside buildings conveying water for human consumption
BS EN 837-1 Specification for bourdon tube pressure and vacuum gauges
BS EN 877 Cast Iron Pipes and Fittings, their joints and accessories for the Evacuation of Water from Buildings
BS EN 934 Admixtures for concrete
BS EN 997 WC Pans and WC Suites with Integral Traps
BS EN 998 Specification for Mortar for Masonry
BS EN 1008 Mixing water for concrete
BS EN 1011 Parts 1 & 2 Welding. Recommendations for welding of metallic materials.
Part 1 General welding for arc welding
Part 2 Arc welding of ferritic steels
BS EN 1057 Copper and Copper Alloys – Seamless Round for Water and Gas in Sanitary and Heating Applications
BS EN 1063 Glass in Buildings – Security Glazing – Testing and Classification of Resistance against Bullet Attack
BS EN 1125 Building Hardware – Panic Exit Devices Operated by a Horizontal Bar
BS EN 1154 Controlled Door Closing Devices
BS EN 1158 Building Hardware – Door Co-ordinator Devices
BS EN 1254 Copper and Copper Alloys – Plumbing Fittings or Capillary Brazing to Copper Tubes, Manufacturers Association
BS EN 1303 Building Hardware – Cylinders for Locks
BS EN 1329 Plastic Piping Systems for Soil and Waste Discharge
BS EN 1451 Plastic Piping Systems for Soil and Waste Discharge within Buildings
BS EN 1452 Plastic Piping Systems for Water Supply
BS EN 1455 Plastic Pipe Systems for Soil and Waste (Low and High Temperature) Within the Building – Acrylonitride Butadiene-Styrene
(APS) Specification for Pipes, Fittings and the System
BS EN 1492-4 Textiles Slings – Safety Part 4: Lifting Slings for general service made from natural and man made fibre ropes
BS EN 1514-7 Flanges and their joints – Gaskets for PN-designated flanges Part 7: covered metal jacketed gaskets for use with steel flanges
BS EN 1519 Plastic Piping Systems for Soil and Waste Discharge (Low and High Temperature) Within the Building Structure –
Polyethlene (PE) Specification for Pipes, Fittings and the System
BS EN 1527 Building Hardware – Hardware for Sliding and Folding Doors
BS EN 1565 Plastic Piping System for Soil and Waste Discharge (Low and High Temperature) Within the Building. Styrene Copolymer
Blends (SAN + PVC) Specification for Pipes Fittings and the System
BS EN 1566 Plastic Piping Systems for Soil and Waste (Low and High Temperature) within the Building Structure – Chlorinated Poly
(Vinyl Chloride) (PVC-c) Specification for Pipes, Fittings and the System
BS EN 1670 Building Hardware – Corrosion Resistance
BS EN 1634 Fire Resistance Tests for Door and Shutter Assemblies, Fire Doors and Shutters
BS EN 1906 Building Hardware – Lever Handles and Knob Furniture
BS EN 1935 Building Hardware – Single Axis Hinges
BS EN 1982 Specification for copper alloy ingots and copper alloy and high conductivity copper castings
BS EN 10160 Ultrasonic testing of steel flat product of thickness equal to or greater than 6mm(reflection method)
BS EN 10223 Specification for zinc-coated hexagonal steel wire netting
BS EN 12051 Building Hardware – Door and Window Bolts
BS EN 12056 Gravity Drainage Systems Inside Buildings BS1184 Specification for Copper and Copper Alloy Traps
BS EN 12056 Part 3 Gravity drainage systems inside buildings – roof drainage layout and calculation
BS EN 12350 Testing fresh concrete
BS EN 12350-2 Testing fresh concrete – slump test
BS EN 12390 Testing Hardened Concrete
BS EN 12390-3 Testing hardened concrete – strength of test specimens
BS EN 12445 Industrial, Commercial & Garage – Doors and Gates
BS EN 12620 Aggregates for concrete
BS EN 12635 Industrial, Commercial and Garage Doors and Gates – Installation and Use
BS EN 12639 Liquid Pumps and Pump Units – Noise Test Code/Grade 2 and grade 3 of Accuracy
BS EN 12680-2 Founding. Ultrasonic examination of Steel castings for highly stressed components
BS EN 12810-1 Façade Scaffolds made of Prefabricated Components – Part 1: Products Specifications
BS EN 12810-2 Façade Scaffolds made of Prefabricated Components – Part 2: Particular Methods of Structural Design
BS EN 12811-1 Temporary Works Equipment – Part 1: Scaffolds – Performance Requirements and General Design
BS EN 12825 Raised Access Floors
BS EN 12952 Water-tube boilers
BS EN 13024 Glass in Building – Thermally Toughened Borosilicate Safety Glass
BS EN 13124 Windows, Doors and Shutters Explosion Resistant
BS EN 13139 Aggregate for Mortar
BS EN 13162 Thermal Insulation products for buildings – Factory made mineral wool
BS EN 13163 Thermal Insulation products for buildings – Factory made products of expanded polystryrene
BS EN 13164 Thermal Insulation products for buildings – Factory made products of extruded polystyrene
BS EN 13310 Kitchen Sinks
BS EN 13553 Resilient Floor Coverings – Polyvinyl Chloride Floor Covering for use in special wet areas
BS EN 13586 Cranes - Access
BS EN 13813 Screed Material and Floor Screeds
BS EN 13892-3 Methods of Test for Screed Materials Part 3: Determination of Wear Resistance
BS EN 14329 Inland Navigation Vessels – Installation of Berths and Loading Areas
BS EN 50054 Electrical apparatus for the detection of combustible gases, general required test methods
BS EN 50055 Electrical apparatus for the detection of combustible gases, performance requirements for group I apparatus indicating up to 5% (V/V) methane in air.
BS EN 50056 Electrical apparatus for the detection of combustible gases, performance requirements for group I apparatus indicating up to 100% (V/V) methane in air.
BS EN 50174 Part 2 Information Technology – Cable Installation – Installation Planning and Practices inside Buildings
BS EN 55022 Radio disturbance characteristics information technology equipment
BS EN 60076-10 Determination of transformer and reactor sound levels
BS EN 60534-8 Industrial - process control valves Part 8: Noise considerations
BS EN 60651 Specification for Sound Level Meters
BS EN 60849 Sound systems for emergency purposes
BS EN 60947 Specification for degrees of protection of enclosures of switchgear and control-gear for voltages up to 1000V AC and 1200V DC
BS EN 61000 Electromagnetic compatibility (EMC)
BS EN 61496-1 Safety of Machinery – Electro-Sensitive Protective Equipment – Part 1: General Requirements and Tests
BS EN ISO 1461 Hot dip galvanised coatings on fabricated iron and steel articles – Specifications and test methods
BS EN ISO 4126-1 Safety devices for protection against excessive pressure – Part 1: Safety valves
BS EN ISO 5667-19 Water Quality – Sampling – Part 19: Guidance on sampling in marine sediments
BS EN ISO 9000 Quality management systems – Fundamentals and vocabulary
BS EN ISO 9001 Quality management systems - Requirements
BS EN ISO 9002 Quality assurance
BS EN ISO 10204 Metallic Products – Types of Inspection Documents
BS EN ISO 14692 Parts 1-4 Petroleum and Natural Gas Industries – Glass Reinforced Plastics (GRP) Piping
BS EN ISO 15465 Pipework – Strip Wound Metal Hoses and Hose Assemblies
BS EN ISO 15614-1 Specification and Qualification of Welding Procedures for Metallic Materials – Welding procedure test Part 1: Arc and Gas
Welding of Steels and Arc Welding of Nickel and Nickel Alloys
BS ISO 4308 Cranes and lifting appliances-Selection of wire ropes
BS ISO 15175 Soil Quality – Characterization of Soil Related to Ground Water Protection
BS PD 5304 Safe use of machinery
CEB-FIP Model code for concrete structures
CEMA 300 Screw conveyor dimensional standards
CEMA 350 Screw conveyors
CEN EN 1822-1 High Efficiency Air Filters (HEPA & ULPA)
CGA/GAS 02-DIR Directory of cleaning agents for oxygen service
CICIND Manual for inspection and maintenance of brickwork and concrete chimneys
CICIND Model code for steel chimneys
CINI Handbook for insulation - Issued by: Commission of the Dutch insulation industrie, Ceintuurbaan 182, 1403 AK, Bussum, The Netherlands
CONCAWE No. 2/79 Method for Determining the Sound Power Levels of Flares Used in Refineries, Chemical Plants and Oilfields
CONCAWE No. 3/77 Test Method for the measurement of noise emitted by furnaces for use in the petroleum and petrochemical industry
CONCAWE Report 87/59 The predictions of noise radiated from pipe systems, an engineering procedure for plant design.
CSA 22.2 – 157 Intrinsincally safe and non-incendive equipment for use in hazardous locations
CSA 22.2 – 30 Explosion-proof enclosures for use in Class 1 hazardous locations general instruction No 1-2R
DIN 0875 Radio interference suppression of electrical appliances and systems
DIN 3852 Part 2 Stud-ends and tapped holes with pipe thread for use with compression couplings
DIN 4030 Evaluation of liquids, soils and gases aggressive to concrete
DIN 19234 Measurement and control; electrical distance sensors; DC interface for distance sensor and signal converter
DIN 45635-22 Measurement of Airborne Noise Emitted by Machines; Enveloping Surface Method, Flares
DIN 45635-47 Measurement of noise emitted by machines: Airborne noise emission Enveloping surface method Chimneys
DIN 45681 Detection of tonal components of noise and determination of a tone adjustment for the assessment of noise emissions
DIN 50129 Testing of metallic materials, testing of welding filler materials for liability to cracking
DIN EN 1870-12 Safety of Woodworking Machines – Circular Sawing Machines – Part 12. Pendulum Cross-cut Sawing Machines EURO 123.30
DIN EN 10204 Inspection documents for the delivery of metallic products
DIN EN 50277 Measurement and control, electrical distance sensors, DC interface for distance sensor and signal converter
DIN EN ISO 15607 Specification and Qualification of Welding Procedures for Metallic Materials – General Rules supercedes DIN EN 288-1 Edn. EURO 94.70
DIN RP-B401 Cathodic Protection Design
DIN V 19250 Control technology; Fundamental safety aspects to be considered for measurement and control equipment
DIN VDE 0801 Principle for computers in safety related systems
DIN VDE 0101 Erection of power installations with rated voltages exceeding 1 kV
EEMUA Pub. 106 General specification for silencers and acoustic enclosures
(Formerly OCMA NWG-4, 1979), replaced by EEMUA Pub. 161
EEMUA Pub. 132 Specification of 3 phase cage induction motors
EEMUA Pub. 140 Noise procedure specification (Formerly OCMA NWG-1, Rev. 2, 1980)
EEMUA Pub. 142 Acoustic insulation of pipes, valves and flanges (formerly OCMA NWG-5, 1982)
EEMUA Pub. 143 Recommendations for tube-end welding, tubular heat transfer equipment. (Formerly OCMA specification No. TEW 1)
EEMUA Pub. 161 Guide to selection and assessment of silencers and acoustic enclosures
EEMUA Pub. 201 Process plant control desks utilising human-computer interfaces – A guide to design, operational and human interface issues.
EIA RS 232,422 & 485 Interface between data terminal equipment and data communication equipment employing serial binary data
EIA/TIA 222 Structural standards for steel antenna towers and antenna supporting structures
EIA/TIA 232 Interface between data terminal equipment and data communication equipment
EIA/TIA 422 Electrical characteristics of balanced voltage digital interface circuits
EIA/TIA 423 Electrical characteristics of unbalanced voltage digital interface circuits
EIA/TIA 455 Standard Test procedures for fibre optic fibres, cables, transducers, connecting and terminating devices
EIA/TIA 568 Commercial building telecommunications cabling standard
EIA/TIA 569 Commercial building standard for telecommunications pathways and spaces
EIA/TIA 606 Administration standard for the telecommunications infrastructure of commercial buildings
EJMA Standards of the Expansion Joint Manufacturers Association
EN 54 Fire protection and fire alarm system
EN 81 Safety rules for the construction and installation of lifts and service lifts
EN 287 Approval testing of welders for fusion welding
EN 288 Approval of welding procedures for metallic materials
EN 292 Safety of machinery - Basic concepts, general principles for design
EN 294 Safety of machinery - Safety distances to prevent danger zones to be reached by upper limbs
EN 349 Safety of machinery - Minimum gaps to avoid crushing parts of the human body
EN 563 Safety of machinery - Temperature of touchable surfaces - Ergonomics data to establish temperature limit values for hot surfaces
EN 571 Part 1 Non destructive testing – penetrant testing Part 1: General principles
EN 614 Safety of machinery - Ergonomic design principles
EN 837 -1 Pressure Gauges, Part 1: Bourdon tube pressure gauges. Dimensions, metrology, requirements and testing
EN 1043-1 Destructive tests on welds in metallic materials. Hardness testing. Hardness test on arc welded joints
EN 1418 Welding personnel. Approval testing of welding operators for fusion welding and resistance weld setters for fully mechanized and automatic welding of metallic materials
EN 1964 Transportable gas cylinders - Specification for the design and construction of refillable transportable seamless steel gas cylinders of water capacities from 0,5 litre up to and including 150 litres
EN 10028 Flat products made of steel for pressure purposes
EN 10164 Steel products with improved deformation properties perpendicular to the surface of the product; technical delivery conditions
EN 10204 Metallic products - Type of inspection documents
EN 41003 Particular safety requirements for equipment to be connected to telecommunications networks
EN 50014 Electrical apparatus for potentially explosive atmospheres - General requirements
EN 50015 Electrical apparatus for potentially explosive atmospheres - Oil immersion
EN 50016 Electrical apparatus for potentially explosive atmospheres - Pressurized apparatus
EN 50017 Electrical apparatus for potentially explosive atmospheres - Powder filling
EN 50018 Electrical apparatus for potentially explosive atmospheres - Flameproof enclosure
EN 50019 Electrical apparatus for potentially explosive atmospheres - Increased safety
EN 50020 Electrical apparatus for potentially explosive atmospheres - Intrinsic safety
EN 50021 Type of Protection ‘n’
EN 50028 Electrical apparatus for potentially explosive atmospheres - Encapsulation 'm'
EN 50039 Electrical apparatus for potentially explosive atmospheres – intrinsically safe electrical systems ‘I’
EN 50057 Electrical apparatus for the detection and measurement of combustible gases; performance requirements for group II apparatus indicating up to 100% lower explosive limit
EN 50058 Electrical apparatus for the detection and measurement of combustible gases; performance requirements for group II apparatus indicating up to 100% (v/v) gas
EN 50081 Electromagnetic compatibility - Generic emission standard
EN 50082 Electromagnetic compatibility - Generic immunity standard
EN 50091-2 Uninterruptible Power Systems (UPS)
EN 50160 Voltage characteristics of electricity supplied by public distribution systems
EN 50174 Information technology cable installation
EN 50209 1999 Test of Insulation of Bars and Coils of High-Voltage Machines Supersedes BS 4999-144; 1987 (F)
EN 55011 Limits and methods of measurement of radio interference characteristics of industrial, scientific and medical (ISM) radiofrequency equipment
EN 55011M Limits and methods of measurement of radio disturbance characteristics of industrial, scientific and medical radio frequency equipment
EN 55022 Limits and methods of measurement of radio interference characteristics of information technology (ITE) equipment
EN 61000-4-5 Electromagnetic compatibility (EMC) Part 4: Testing and measurement techniques – Section 5: Surge Immunity Test
EN 61779 Parts 1 to 5 Electrical apparatus for the detection and measurement of flammable gases. Part 1: General requirements and test methods
Part 2: Performance requirements for group I apparatus indicating a volume fraction up to 5 % methane in air
Part 3: Performance requirements for group I apparatus indicating a volume fraction up to 100 % methane in air
Part 4: Performance requirements for group II apparatus indicating a volume fraction up to 100 % lower explosive limit
Part 5: Performance requirements for group II apparatus indicating a volume fraction up to 100 % gas
EN 187101 Optical telecommunications cables to be used in ducts or direct buried application
ERA 69-30 Current rating standards for distribution cables
FM 3610 Intrinsically safe apparatus and associated apparatus for us n Class 1, 11 & 111, Division 1, and Class 1, Zone 0 & 1
Hazardous (classified) locations
FM 3615 Explosion-proof electrical equipment – general requirements
FIP Guide to good practice grouting of tendons in pre stressed concrete
FIP Recommendations for the acceptance of post-tensioning systems
HEI Steam surface condensers and addendum 1 Steam Jet Vacuum Systems
HTFS Handbook sheet JMI Allowing for fouling in heat exchanger design
ICAO Annex 14 Regulations
ICAO July 1990 Annex 14 to the Convention on International Civil Aviation Aerodromes
IEC 34-9 Rotating Electrical Machines – Part 9: Noise Limits
IEC 225 Specification for Octave-Band and Fractional-Octave-Band-Analogue and Digital Filters
IEC 651 Recommendations for Sound Level Meters
IEC 60034 Rotating electrical machines
IEC 60038 IEC standard voltages
IEC 60044 Current Transformers
IEC 60044-1 Current Transformers
IEC 60044-2 Voltage Transformers
IEC 60050 International electrotechnical vocabulary - Electrical installations of buildings
IEC 60051 Direct acting indicating analogue electrical measuring instruments and their accessories
IEC 60056 High voltage alternating-current circuit-breakers
IEC 60060 High voltage test techniques
IEC 60068 Environmental testing
IEC 60071 Insulation coordination
IEC 60072 Dimensions and output ratings for rotating electrical machines
IEC 60073 Basic and safety principles for man-machine interface, marking and identification, indicating devices and actuators
IEC 60076 Power transformers
IEC 60079 Electrical apparatus for explosive gas atmospheres
IEC 60085 Method for Determining the Thermal Classification of Electrical Insulation
IEC 60096 Radio Frequency Cables
IEC 60099-1 Lightning arresters Part 1 – Non linear resistor type arrestor for a.c systems
IEC 60112 Method for determining the comparative and the proof-tracking indices of solid insulating material under moist conditions
IEC 60113 Diagrams, charts, tables
IEC 60120 Dimensions of ball and socket couplings of string insulator units
IEC 60137 Bushing for alternating voltages above 1000V
IEC 60146 Semiconductor converters
IEC 60156 Method for the determination of the electric strength of insulating oils
IEC 60157 Low Voltage Switchgear and Control Gear
IEC 60158 Specification for Control Gear for Voltages up to and including 1000VAC &1200VDC
IEC 60168 Tests on indoor and outdoor post insulators of ceramic material or glass for systems with nominal voltages greater that 1000V
IEC 60204 Electrical equipment of industrial machines
IEC 60214 On-load tap-changers
IEC 60225 Octave, half-octave and third-octave band filters intended for the analysis of sound and vibrations, replaced by IEC 61265
IEC 60227 Polyvinyl chloride insulated cables of rate voltages up to including 450/750 V
IEC 60255 Electrical relays
IEC 60265 High-voltage switches
IEC 60269 Low voltage fuses
IEC 60282 High voltage fuses
IEC 60289 Reactors
IEC 60296 Specification for unused Mineral Oils for Transformers and Switchgear
IEC 60292 Low Voltage Motor Starters
IEC 60298 AC metal-enclosed switchgear and control-gear for rated voltages above 1kV and up to and including 52kV
IEC 60300 Reliability and maintainability management
IEC 60304 Standard colours for insulation for low-frequency cables and wires
IEC 60309 Plugs, socket-outlets and couplers for industrial purposes
IEC 60317 Specifications for particular types of winding wires;
IEC 60331 Fire resisting characteristics of electric cable
IEC 60332 Tests on electric cables under fire conditions
IEC 60364 Electrical installation of buildings
IEC 60383 Tests on insulators of ceramic material or glass for overhead lines with a nominal voltage greater than 1000 V
IEC 60398 General test conditions for industrial electroheating equipment
IEC 60408 Low Voltage Air-Break Switches, Air-Break De-connectors, Air-Break Switches, De-connectors and Fuse-Combination Units
IEC 60422 Maintenance and supervision guide for insulating oils in service
IEC 60433 Characteristics of string insulator units of the long rod type
IEC 60439 Low voltage switchgear and control gear assemblies
IEC 60445 Identification of apparatus terminals and general rules for a uniform system of terminal marking, using an alpha-numeric notation
IEC 60470 High voltage a.c contactors
IEC 60473 Dimensions for panel mounted indicating and recording electrical measuring instruments
IEC 60478 Stabilized power supplies, DC output
IEC 60493-1-1992 Low voltage switchgear and control gear assemblies, Part 1: Type tested and partially type tested assemblies
IEC 60521 Class 0.5, 1 & 2 alternating current watt hour meters
IEC 60529 Electrical apparatus ingress protection
IEC 60534 Industrial process control valves – Part 8 noise considerations
IEC 60542 Application guide for on load tap changers
IEC 60549 High voltage fuses for the external protection of shunt power capacitors
IEC 60551 Determination of transformer and reactor sound levels
IEC 60584 Thermocouples
IEC 60593 Internal fuses and internal overpressure disconnectors for shunt capacitors
IEC 60605 Equipment reliability testing
IEC 60617 Graphical symbols for diagrams
IEC 60623 Vented nickel-cadmium prismatic rechargeable single cells
IEC 60654 Operating conditions for industrial-process measurement and control equipment
IEC 60688 Electrical measuring transducers for converting a.c electrical quantities to analogue or digital signals
IEC 60694 Common specifications for high voltage switchgear and control gear standards
IEC 60695 Fire Hazard Testing –Part 7-1: Toxicity of Fire Effluent – General Guidance
IEC 60721-2-1 Classification of Environmental Conditions
IEC 60726 Dry-type power transformers
IEC 60742 Isolating transformers and safety isolating transformers
IEC 60751 Industrial platinum resistance thermometer sensors
IEC 60794 Optical fibre cables
IEC 60801 Electromagnetic compatibility for industrial process measurement and control equipment
IEC 60815 Guide for the selection of insulators in respect of polluted conditions
IEC 60831 Shunt power capacitors of the self-heating type for a.c systems having a rated voltage up to and including 1kV
IEC 60849 Sound Systems for Emergency Purposes
IEC 60851 Winding wires – test methods
IEC 60871 Shunt capacitors for a.c power systems having a rated voltage above 1kV
IEC 60894 Guide for test procedure for the measurement of loss tangent on coils and bars for machine windings
IEC 60896 Stationary lead-acid batteries, general requirements and methods of test
IEC 60898 Electrical accessories - Circuit-breakers for overcurrent protection for household and similar installations
IEC 60902 Industrial process measurement and control terms and definitions
IEC 60905 Loading guide for dry-type power transformers
IEC 60909 Short-circuit calculation in three-phase AC systems
IEC 60947 Low voltage switchgear and control gear
IEC 61000 Electromagnetic compatibility (EMC)
IEC 61024 Protection of structures against lightning
IEC 61078 Analysis techniques for dependability – Reliability block diagram method
IEC 61089 Round wire concentric lay overhead electrical stranded conductors
IEC 61099 Specification for unused synthetic organic esters for electrical purposes
IEC 61131 Programmable controllers
IEC 61241 Electrical apparatus for use in the presence of combustible dust
IEC 61285 Industrial-process control - safety of analyser houses
IEC 61293 Marking of electrical equipment with ratings related to electrical supply - Safety requirements
IEC 61481 Live Working – Portable Phase Comparators for Use on Voltages from 1kV to 36 kV a.c
IEC 61508 Functional safety of electrical/electronic/programmable electronic safety related systems
IEC 61511 Functional safety: safety instrumented systems for the process industry sector
IEC 61518 Mating dimensions between differential pressure (type) measuring instruments and flanged-on shut-off devices up to 413 bar
IEC 61634 High voltage switchgear and control gear - Use and handling of sulphur hexafluoride (SF6) in high voltage and control gear
IEC 61641 Guide for testing under conditions of arcing due to internal fault
IEC 61850 Communications networks and systems in substations
IEC 62086-1IEC 62086-1 Electrical apparatus for explosive gas atmospheres
IEC/CISPR 11 Limits and methods of measurement of radio disturbance characteristics of industrial, scientific and medical (ISM) radiofrequency equipment
IEC/CISPR 14 Limits and methods of measurement of radio disturbance characteristics of electric motor-operated and thermal appliances
for household and similar purposes, electric tools and similar electric apparatus
IEC/CISPR 22 Limits and methods of measurement of radio interference characteristics of information technology (ITE) equipment
IEEE 80 Guide for Safety in AC Substation Grounding
IEEE 115 Guide: Test procedures for synchronous machines
IEEE 421.2 Guide for identification, testing, and evaluation of the dynamic performance of excitation control systems
IEEE 421.5 Recommended practice for excitation system models for power system stability studies
IEEE 519 Recommended practices and requirements for harmonic control in electrical power systems
IEEE 802 Standards for local and metropolitan area networks
IGC 33/97/E Cleaning of equipment for oxygen service (EIGA – European Industrial Gases Association)
IP Code Part 2 Design, Construction and Operation of Distribution Installations
IP Code Part 7 Petroleum Measurement Manual - Density, continuous density measurement
IP Code Part 9 Liquefied petroleum gas, Vol I large bulk pressure storage and refrigerated LPG
IP Code Part 13 Petroleum Measurement Manual - Fidelity and security of measurement data transmission systems, electric and/or
electronic pulsed data cabled transmission for fluid metering systems
IP Code Part 15 Area classification code for installations, handling flammable fluids
ISA 5.1 Instrument symbols and identification
ISA 5.2 Binary logic diagrams for process operation
ISA 5.3 Graphic symbols for distributed control shared display instrumentation, logic and computer systems
ISA 18.1 Annunciator sequences and specifications
ISA 55.1 Hardware testing of digital process computers (codes of BS-588 practice for testing computer based systems)
ISBN 92-67-10188-9 ISO guide to the expression of uncertainty in measurement 1995
ISGOTT International safety guide for oil tankers and terminals
ISO 15 Rolling bearings – radial bearings – boundary dimensions
ISO 31 Quantities and units
ISO 281 Rolling bearings – dynamic load ratings and rating life
ISO 636 Welding Consumables – Rods, Wires and Deposits for Tungsten Inert Gas Welding of Non-alloy and Fine-grain Steels – Classification
ISO 888 Bolts, screws and studs: nominal lengths and thread length for general bolts
ISO 898-1 Mechanical properties of fasteners made of carbon steel and alloy steel – Part 1: Bolts, screws and studs
ISO 1000 SI units and recommendations for the use of their multiples and of certain other units
ISO 1101 Technical drawings; Geometric tolerancing, tolerancing form, orientation, location and run out; Generalities, definitions, symbols, indications on drawings
ISO 1109 Refractory products -- Classification of dense shaped refractory products
ISO 1132 Rolling bearings – tolerances - definitions
ISO 1461 Metallic coatings: hot-dip galvanised coatings on fabricated ferrous products: requirements.
ISO 1461 Galvanised coatings on fabricated iron and steel articles
ISO 1680-Parts 1 & 2 Acoustics – Test code for the measurement of airborne noise emitted by rotating electrical machinery
ISO 1813 Belt-drives – V–ribbed belts, joined v-belts including wide section belts and hexagonal belts – Eletrica conductivity of antistatic endless V-belts – electrical conductivity – characteristics and methods of test
ISO 1927 Prepared unshaped refractory materials (dense and insulating) -- Classification
ISO 1940 Mechanical balancing of rotating bodies
Part 1 - Mechanical vibration – balance quality requirements of rigid rotors
ISO 1996 Part 1 Acoustics – Description, assessment and measurement of environmental noise
ISO 2063 Metallic and other coatings thermal spraying zinc aluminium and their alloys
ISO 2186 Fluid flow in closed conduits – Connections for pressure signal transmissions between primary and secondary elements.
ISO 2204 Acoustics – Guide to International standards on the measurement of air-borne acoustical noise and evaluating its effects on human beings
ISO 2245 Shaped insulating refractory products -- Classification
ISO 2314 Gas turbines - Acceptance tests
ISO 2372 Mechanical vibration of machines with operating speeds from 0-200 r/s – Basis for specifying evaluation standards
ISO 2409 Paints and varnishes - Cross cut test for adhesion
ISO 2548 Acceptance tests for centrifugal, mixed flow and axial pumps
ISO 2715 Liquid hydrocarbons; Volumetric measurements by turbine meter systems
ISO 2808 Paints and varnishes - Determination of film thickness
ISO 2954 Mechanical vibration of rotating and reciprocating machinery
ISO 3046 parts I to VI Reciprocating, internal combustion engines
ISO 3170 Petroleum liquids – Manual sampling
ISO 3171 Petroleum liquids – Automatic pipeline sampling
ISO 3183 Petroleum and natural gas industries -- Steel pipe for pipelines -- Technical delivery conditions
Part 1: Pipes of requirement class A
Part 3: Pipes of requirement class C
ISO 3511 Process measurement control functions and instrumentation - symbolic representation
ISO 3549 Zinc dust pigments for paint – Specifications and test methods
ISO 3582 Cellular plastics and cellular rubber, laboratory assessment of horizontal burning characteristics of small specimens subjected to a small flame
ISO 3601 Part 1 Fluid systems Sealing devices – O rings
Part 1: Inside diameters, tolerances and size identification code
ISO 3690 Welding and allied processes – Determination of hydrogen content in ferritic steel arc weld metal
ISO 3743 Acoustics - Determination of sound power levels of noise sources - Engineering methods for special reverberation test rooms
ISO 3744 Acoustics – Determination of sound power levels of noise sources using sound pressure – Engineering method in an essentially free field over a reflecting surface
ISO 3746 Acoustics – determination of sound power levels of noise sources using sound pressure. Survey method using an enveloping measurement surface of a reflecting plan
ISO 4021 Hydraulic fluid power - Particulate contamination analysis - Extraction of fluid samples from lines of an operating system
ISO 4032 Hexagon nuts style 1: products grade A & B
ISO 4200 Plain end steel tubes, welded and seamless - General tables of dimensions and masses per unit length
ISO 4406 Hydraulic fluid power - Fluids - Method for coding level of contamination by solid particles
ISO 4624 Paints and varnishes-pull off test for adhesion
ISO 4628 Paints and varnishes - Evaluation of degradation of paint coatings -designation of intensity, quantity and size of common types of defects
ISO 5024 Petroleum liquids and gases -Measurement - Standard reference conditions
ISO 5167 Measurement of fluid by means of orifice plates, nozzles and venturi tubes inserted in circular cross-section conduits running full
ISO 5199 Industrial pumps – Technical specification for centrifugal and rotary pumps
ISO 5211 Part-turn valve actuator attachment
ISO 5752 Metal valves for use in flanged pipe systems – Face-to-face and centre-to-face dimensions
ISO 6141 Gas analysis - Calibration gas mixtures - Certificate of mixture preparation.
ISO 6142 Gas analysis - Preparation of calibration gas mixtures - Weighing methods
ISO 6143 Gas analysis - Determination of composition of calibration gas mixtures – Comparison methods
ISO 6326 Part 1 Natural gas – Determination of sulphur compounds – Part 1: General introduction
ISO 6327 Gas analysis - Determination of the water dew point of natural gas - Cooled surface condensation hygrometers
ISO 6385 Ergonomic principles in the design of work systems
ISO 6570 Parts 1, 2 & 3 Natural gas – Determination of potential hydrocarbon-liquid content Part 1: Principles and general requirements
Part 2: Weighing method
Part 3: Volumetric method
ISO 6974 Natural gas – Determination of hydrogen inert gases and hydrocarbons up to C8 - Gas chromatographic method
ISO 6975 Natural gas – Extended analysis – Gas chromatographic method
ISO 6976 Natural gas – Calculation of calorific values, density, relative density and Wobbe index from composition
ISO 6978 Natural gas – Determination of mercury
ISO 7235 Acoustics – Measurement procedures for ducted silencers – Insertion loss, flow noise and total pressure loss
ISO 7411 Hexagon headed bolts – product grade A & B
ISO 7415 Plain washers for high strength structural bolting, hardened and tempered
ISO 7730 Determination of the PMV and PPD indices and specifications of conditions for thermal comfort
ISO 7731 Ergonomics – Danger signals for public and work areas – Auditory danger signals
ISO 8297 Acoustics - Determination of sound power levels of multisource industrial plants for the evaluation of sound pressure levels in the environment
ISO 8501 Preparation of steel substrates before application of paints and related products - Visual assessment of surface cleanliness
ISO 8502 Preparation of steel substrates before application of paints and related products - Tests for the assessment of surface cleanliness
ISO 8503 Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast cleaned steel substrates
ISO 8504 Preparation of steel substrates before application of paints and related products - Surface preparation methods
ISO 8995 Principles of visual ergonomics – the lighting of indoor work systems
ISO 9002 Quality systems – Model for Quality Assurance in Production, Installation, and Servicing
ISO 9606 Approval testing of welders. Fusion Welding
ISO 9613 Part 1 Acoustics – Attenuation of Sound During Propagation Outdoors” – Part 1 Calculation of the Absorption of Sound by the Atmosphere
ISO 9613 Part 2 Acoustics – Attenuation of Sound During Propagation Outdoors” - Part 2 General Method of Calculation
ISO 9614 Part 1 Acoustics – Determination of sound power levels of noise sources using sound intensity. Part 1 – Measurement at discrete points
ISO 9614 Part 2 Acoustics – Determination of sound power levels of noise sources using sound intensity. Part 2 – Measurement by scanning
ISO 9951 Measurement of gas flow in closed conduits – Turbine meters
ISO 10012 Quality assurance requirements for measuring equipment
ISO 10081 Classification of dense shaped refractory products
ISO 10101 Parts 1, 2 & 3 Natural gas–Determination of water by the Karl Fischer method
Part 1: Introduction
Part 2: Titration procedure
Part 3: Coulometric procedure
ISO 10303 Standard for the exchange of Product Data (STEP)
ISO 10441 Petroleum and natural gas Industries – Flexible couplings for mechanical power transmission – Special purpose applications
ISO 10474 Steel and steel products - Inspection documents
ISO 10494 Gas Turbines and Gas Turbine sets – Measurement of emitted airborne noise – Engineering/survey method
ISO 10715 Natural gas–Sampling guidelines
ISO 10723 Natural gas–Performance evaluation for on-line analytical systems
ISO 10816 Mechanical vibration – Evaluation of machine vibration by measurements on non-rotating parts
ISO 11014 Safety data sheet for chemical products - Content and order of selection
ISO 11064 -2 Ergonomic design of control centres – Part 2: Principles for the arrangement of control suites
ISO 11124 Preparation of steel substrates before application of paints and related products. Specifications for metallic blast-cleaning abrasives
ISO 11126 Preparation of steel substrates before application of paints and related products. Specifications for non-metallic blastcleaning abrasives
ISO 11127 Preparation of steel substrates before application of paints and related products. Test methods for non-metallic blastcleaning abrasives
ISO 11546 Part 2 Sound Insulation Performance of Enclosures – Measurement In-Situ
ISO 11691 Acoustics – Measurement of insertion loss of ducted silencers without flow – Laboratory survey method
ISO 12213 Parts 2 & 3 Natural gas – Calculation of compression factor –
Part 2: Calculation using molar–composition analysis
Part 3: Calculation using physical properties
ISO 12944 Paints and varnishes. Corrosion protection of steel structures by protective paint systems.
ISO 13443 Natural gas–Standard reference conditions
ISO 13686 Natural gas–Quality designation
ISO 13691 Petroleum and natural gas Industries – High speed special purpose gear units
ISO 13704(API 530) Calculation of heater tube thicknesses in petroleum refineries
ISO 13705 Fired Heaters - general refinery service
ISO 13706 Air-cooled heat exchangers for general refinery services
ISO 13709 Centrifugal pumps for petroleum, petrochemical and natural gas Industries
ISO 14001 Environmental management systems - specification with guidance for use
ISO 14313 Petroleum and natural gas industries – pipeline transportation systems – pipeline valves
ISO 14691 Petroleum and natural gas Industries – Flexible couplings for mechanical power transmission – General purpose applications
ISO 15156 Petroleum and natural gas industries -- Materials for use in H2S-containing environments in oil and gas production, petroleum and natural gas Industries Part 1: General Principles for Selection of Cracking-Resistant Materials - Part 2:
Cracking-Resistant Carbon and Low Alloy Steels, and the use of Cast Irons - Part 3: Cracking-Resistant CRAs (corrosionresistant alloys) and other alloys
ISO 15175 Soil Quality – Characterization of Soil related to Ground Water Protection
ISO 15607 Specification and qualification of welding procedures for metallic materials – General rules
ISO 15613 Specification and Qualification of Welding Procedures for Metallic Materials – Qualification based on pre-production welding test
ISO 15614-1 Specification and Qualification of Welding Procedures for Metallic Materials – Welding Procedure Test –
Part 1: Arc and Gas Welding of Steels and Arc Welding of Nickel and Nickel Alloys
ISO 17846 Welding and Allied Processes – Health & Safety – Wordless precautionary labels for equipment and consumables used in Arc welding and cutting
ISO 19011 Guidelines for quality and/or environmental management systems auditing
ISO/DIS 9241 Ergonomic requirement for office work with visual display terminals (VDT's)
ISO/DIS 9857 Petroleum and liquid petroleum products - Continuous density measurement
ISO/DIS 11429 Safety of machinery – system of auditory and visual danger and information signals
ISO/DIS 11064 Ergonomic design of control centres
ISO/DIS 14532 Natural gas – Terminology
ISO EN 10168 Steel Products – Inspection Documents – List of Information and Description
ISO/IEC 3352 Acoustics – assessment of noise with respect to the intelligibility of speech
ISO/IEC 11801 Generic cabling system for customer premises
ISO TR 5168 Measurement of fluid flow – Evaluation of uncertainties
ISO/TR 7849 Estimation of airborne noise emitted by machinery using vibration measurement
ISO/TR 10465 Parts 1-3 Underground installation of flexible glass-reinforced thermosetting resins (GRP) Pipes
ISO/TR 12765 Measurement of fluid flow in closed conduits - Methods using transit-time ultrasonic flow meters
ISO/TR 15608 Welding – Guidelines for a metallic material grouping system
ISO/TR 17671-5 Welding – Recommendations for Welding of Metallic Materials – Part 5: Welding of Clad Steels
ISO/TR 17671-7 Welding – Recommendations for Welding of Metallic Materials – Part 7: Electron Beam Welding
ISO/TR 18569 Safety of Machinery – Guidelines for the understanding and use of safety of machinery standards
ISSMFE Report of the sub-committee on standardisation of penetration testing in Europe
ITU-T G.175 Transmission planning for private/public network interconnection of voice traffic
ITU-T G.611 Characteristic of symmetric cable pairs for analogue transmission
ITU-T G.621 Characteristic of 0.7/2.9 mm coaxil pairs
ITU-T G.651 Characteristic of 50/125 micrometre multimode graded index optical fibre cable
ITU-T G.652 Characteristic of a single mode optical fibre cable
ITU-T K.8 Separation in the soil between telecommunications cables and earthing system of power facilities
ITU-T K.11 Principles of protection against over voltages and over currents
ITU-T K.12 Characteristics of gas discharge tubes for the protection of telecommunications installations
ITU-T K.19 Joint use of trenches and tunnels for telecommunication and power cables
ITU-T K.20 Resistibility of telecommunications switching equipment to over voltages and over currents
ITU-T K.21 Resistibility of subscriber’s terminal to over voltages and over currents
ITU-T K.25 Protection of optical fibre cables
ITU-T K.34 Classification of electromagnetic environmental conditions for telecommunication equipment: basic EMC requirements
ITU-T K.51 Safety criteria for telecommunication equipment
ITU-T L.3 Armouring of cables
ITU-T L.10 Optical fibre cables for duct, tunnel, aerial and buried application
ITU-T L.12 Optical fibre joints
ITU-T L.13 Sheath joints and organisers of optical fibre cable in outside plant
ITU-T L.14 Measurement method to determine the tensile performance of optical fibre cables under load
ITU-T L.36 Single mode optical fibre connectors
ITU-T P.54 Sound level meters
ITU-T T.6 Facsimile coding schemes and coding control functions for Group 4 facsimile apparatus
MIL-A-18001K Anodes, sacrificial zinc alloy
MIL-HDBK-217 U.S. Military Handbook: Reliability prediction of electronic equipment
MSS SP 44 Steel pipe line flanges
MSS SP 58 Pipe hangers and supports - Materials, design and manufacture
MSS SP 69 Pipe hangers and supports - Selection and application
MSS SP 75 Specification for High Test Wrought Butt welding Fittings
MSS SP 97 Integrally reinforced forged carbon steel - Branch o/let fitting
NACE MR 0103 Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments
NACE MR 0175 Replaced by ISO 15156
NACE RP 0177 Mitigation of alternating current and lightning effects on metallic structures and corrosion control sytems
NACE RP 0178 Fabrication details, surface finish requirements and proper design considerations for tanks and vessels to be lined for
immersion service
NACE RP0186 Application of cathodic protection for external surfaces of steel well casings
NACE RP 0188 Discontinuity (holiday) testing of protective coatings
NACE RP0193 External cathodic protection of on-grade carbon steel storage tank bottoms
NACE RP0196 Galvanic anode cathodic protection of internal submerged surfaces of steel water storage tanks.
NACE RP0285 Corrosion control of underground storage tank systems by cathodic protection.
NACE RP0290 Impressed current cathodic protection of reinforcing steel in atmospherically exposed concrete structures
NACE RP0387 Metallurgical and inspection requirements for cast galvanic anodes for offshore applications
NACE RP0388 Impressed current cathodic protection of internal submerged surfaces of carbon steel water storage tanks.
NACE RP0492 Metallurgical and inspection requirements for offshore pipeline bracelet anodes
NACE RP0572 Design, installation, operation and maintenance of impressed current deep groundbeds
NACE RP0575 Internal cathodic protection systems in oil-treating vessels
NACE TM 01-77 Laboratory testing of metals for resistance to sulphide stress cracking in H2S environment
NAMUR NE 43 Recommendation for signal levels to extract failure information from digital transmitters with analogue output.
NAS 1638 Cleanliness requirements of parts used in hydraulic systems
NEMA 250 Enclosures for electrical equipment (1000 volts maximum)
NEMA SM23 Steam Turbines for Mechanical Drive Service
NEN 547-2 Safety of machinery – human body dimensions, principles for determining the dimensions required for access openings
NEN 1005-3 Manual handling
NEN 3410 Safety requirements for high voltage and low voltage installations in potentially explosive gas atmospheres
NEN-EN 457 Safety of machinery – auditory danger signals, general design requirements, design and testing
NEMA MG 1 Motors and Generators
NFPA 10 Portable fire extinguishers
NFPA 11 Low expansion foam systems
NFPA 11A Medium and High expansion foam systems
NFPA 11C Mobile foam apparatus
NFPA 12 Carbon dioxide extinguishing systems
NFPA 15 Water spray fixed systems for fire protection
NFPA 20 Installation of stationary pumps for fire protection
NFPA 58 Standard for the storage and handling of liquefied petroleum gases
NFPA 70 National electrical code
NFPA 72 National fire alarm code
NFPA 90A Installation of air conditioning and ventilation systems
NFPA 496 Standard for purged and pressurised enclosures for electrical equipment in hazardous (classified) locations
NFPA 750 Water mist protection systems
NFPA 2001 Clean agent extinguishing systems
NPR 2760 Mutual influence of pipelines and high voltage circuits
OCIMF Design and construction specification for marine loading arms
OCIMF Recommendations for oil tanker manifolds and associated equipment
PrEN 1005 Safety of machinery - Human physical performance
PrEN 12437 Safety of machinery - Permanent means of access to machines and industrial plants
RAL Colours from Deutsches Institut fur Gutesicherung und Kennzeichnung e.V.
S.34 Engineering recommendation S.34 A guide for assessing the rise of earth potential at substation sites
SFA 3009 Special protection
SMACNA HVAC systems - Testing, adjusting and balancing
SMACNA HVAC systems - Duct design
SMACNA HVAC air duct leakage test manual
SMACNA HVAC systems - Applications
SSPC SP1 Surface preparation specification No 1 – Solvent cleaning
SSPC PA 2 Paint application specification No 2 – Measurement of dry paint thickness with magnetic gauges.
TEMA Standards of the Tubular Exchanger Manufacturers Association
TNO Green Book Method for determination of possible damage to people and objects resulting from releases of hazardous materials (CPR 16E – 1992)
UBC 1997 Volume 2 1997 Uniform Building Code: Volume 2; Structural Engineering design provisions
UL 698 Safety standard for electrical industrial control equipment for use in hazardous (classified) locations, Class I, Groups A,B,C and D and Class II, Groups E, F and G
UL 698UL 698 UL standard for safety industrial control equipment for use in hazardous (classified) locations.
UL 886 Outlet boxes and fittings for use in hazardous (classified) locations
UL 913 UL standard for intrinsically safe apparatus and associated apparatus for use in Class I, II and III, division I, hazardous (classified) locations
UL - 1709 Rapid rise fire test of protection materials for structural steel
USEPA 40 CFR Part 60 40 Code of federal regulations-Protection of the environment Part 60- Standards of performance for new stationary sources
VDE 0510 Specification for electrical storage batteries and battery plants
VDI 2055 Thermal insulation for heated and refrigerated industrial and domestic installations
VDI 3733 Noise in pipes
VDI/VDE 3845 Industrial process control valves; interfaces between valves, actuators and auxiliary equipment
VGB R-450-Le Guideline for Boiler Feedwater, Boiler Water and Steam of Steam Generators with a Permissible Operating Pressure of >68 bar
WRC 107 Local stresses in spherical and cylindrical shells due to external loadings
WRC 297 Supplement to WRC bulletin 107
drmala66/A-MethodStatementWaterReservoir.pdf
drmala66/A-FacilitiesPhotos.doc
Dear Reader,
Thanks indeed for taking interest in reading the above work intended to provide projects practical information exchange to those who aspire to develop their professional skills to a level making themselves more useful in the professional fields fitting conveniently within the industry environment. by getting a fast opportunity for learning the professional aspects to some extent. The purpose of the above work is to bring to the young engineers projections of necessary operations and activities conducted by various professionals on industrial projects. I am basically a civil engineer by formal education experienced on reinforced concrete buildings & similar heavy structures in general. It is a fact that during experience in the profession one does not confine to one’s discipline only as multidiscipline projects are involved in profession & by virtue of interface exposures, professional is forced to grasp some knowledge of the other disciplines otherwise the problem solving shall be near impossible. This envisages every practicing engineer to accept the criteria that hesitation to interact with the relative disciplines should be discarded by being ready to adapt that with full involvement. This kind of approach & conduct shall provide multi facet of coordinated know how through discussions, meetings, report preparations, statement preparations, exposure to data sheets, reading design basis, FEED documents, contract conditions etc.
It is also suggested that should any of you have any descriptive experience on any of the projects, must share that experience by documentation on web or otherwise for transferring the learning to juniors. The world has been changing & developing extremely fast in science and technology forcing us to accept the facts as well as update or face obsolete status. University knowledge helps confined to the understanding engineering & technology principles without exposing to the world of real applications. The students should not expect also that type of knowledge to be imparted by the professional teachers of engineering universities who in fact unfortunately, have never been exposed to virtuality of the profession. I have seen many managers on the projects who had no engineering formal degrees but occupied senior managers positions in particular from the western nations but having considerable exposure & grasp as well as capability of application in fields successfully.
I have done some other works on writing as follows
Civil Engineering Buildings Practice published in 1996 by CBS publishers 11 Darya Ganj, New Delhi 110002, India
This book contains various aspects of building engineering from site management viewpoint, contract administration viewpoint, design philosophy & general engineering in the field as well as in design office
RCCBDS 2003
Buildings design application software based on Kani’s rotation contribution method giving calculations on excel format. The super macro formats are available on web @ following URL
suraj_engineer
rccbuildings
rccbuildings1
This application covers the scope of RCC frames from 1 bay 1 storey to 5 bays 8 storey by using links, interlinks, hyperlinks etc
Further volume RCCBDS 2004 & 2005 were also commenced but could not be completed due to the reason that engineering community did not take any interest in Kani’s rotation contribution methods but shall be continued later when I have free time in future.
I also had worked on a volume of civil engineering home plans in nineties but unfortunately that is still in cold box without publication.
Also I conceived a township project schematically in nineties that could not take off due to lack of provision of financing by the promoter.
In addition to aforesaid, many other useful files are available on the web for practical purposes.
I have also personal interest in using date of birth numbers interpretations using spiritual movements within the body that work also is available on web though it is not relevant to engineering. Only educated persons can understand the philosophy of this subject.
By this note I conclude.
Regards & Thanks once again for your valuable time as well as interest shown. Hope the work has been useful to you. Please write suggestions.
Author
Eng Suraj Singh
Professional Engineer PE 28
Institution of Engineers India
Member Engineers Mobiity Forum
Cracking Furnaces Ethylene Cracking Plant
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