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Build
ingsPra
ctice

Plan ts
F
acility
Petrochemicals
Industrial Projects
O nsho re
AnOve
rview

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P
reface
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
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.

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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
feasible..

Author – IEI Professional Engineer Suraj Singh August 15, 2009

---------------------------------------
Refer to the various photographs appended somewhere else.Source Google

Index Headin
g
Industrial development,
1 Chapter 1 policy, components
Project Design, Contract
2 Chapter 2 award&Miscellaneous

3 Chapter 3 Engineering

Construction&Controls
4 Chapter 4
Testing- Pre
5 Chapter 5 Commissioning,
commissioning, start up,
performance &
maintenance

Project management
6 Chapter 6
Detailed Engineering
7 Chapter 7 Requirements
BuildingDesignConcept
8 Chapter 8
9 Chapter 9 Procurement

10 Chapter 10 Construction

11 Chapter 11 Pre-Commissioning

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12 Chapter 12 ExecutionPlan

13 Chapter 13 Environmental clauses for


plant Industrial city in
ConstructionContracts

14 Chapter 14 HSES

15 Chapter 15 Commercial
Contracts
Sub

16 Chapter 16 References

Chapter 1
G e
n
e ra
l
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.

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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

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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,
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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
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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
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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.

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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
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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
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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
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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

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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.

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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).
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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
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(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.
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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.
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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)
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 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
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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
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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.

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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
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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
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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.

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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


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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
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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
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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
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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.
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For once through system, the water is supplied & returned after cooling the industrial
systems into the returned headers without any circulations.
In some cases a combination of both could be adopted for economy.

----------------------------------
Chapter 2
Project Design, Contract award & Miscellaneous
Abbreviations
Some useful abbreviations generally used on the design documents for references:-
A / G - above ground, AFC-approved for construction, AFD-approved for design, 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 &

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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.

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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
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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:
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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)-
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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
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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
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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
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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


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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
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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,

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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

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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.

---------------------------------------
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

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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
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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
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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
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not be known. Systems generally involve safety against fire, gas explosion & electric
default. Therefore, these import application of all precautionary measures selection of
which depend on the detailed requirement as obtained from the risk analysis & details of
equipment operations.
OPTAN- Operator task Analysis-Control & field Operator-This part also involves
detailed study as well as precise applications. No slackening should be allowed.
Attempts should be made to take due measure to prevent accident in hot work as well
as cold work areas & also in restricted & confined entry areas. Permit to Work PTW
must be applied to work in such areas of the facility.

---------------------------------------
Quality Assurance, QA / QC Briefs
Quality plans-Training-Induction-Regular courses-Special courses- Audits-
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

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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
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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.

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---------------------------------------
Chapter 3
E
ng
ine
er
ing
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

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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.
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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,


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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
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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
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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

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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
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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
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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
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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.

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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
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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
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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
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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.
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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
C
ons
tru
ctio
n&Co
ntro
ls -
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
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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.

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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.
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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
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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.
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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
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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
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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.
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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.

---------------------------------------
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

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 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.

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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.
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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
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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-
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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.

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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
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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
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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"

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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.
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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-
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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
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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


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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
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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
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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
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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
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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
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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
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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.

--------------------------------------
Chapter 6
Pro
jectmanagement
Various facilities at Construction Site
Contractor shall be responsible to arrange to acquire all the service logistics required at
Plant Industrial City for the performance of the Works. The costs of such services shall
be included in the Lump Sum Portion of the Contract Price.
Examples of the required services are:
 Land rental for Accommodation / office camp and lay down area.
 Gate pass of personnel and vehicles, equipment, plant
 H2S, BA Certificate courses.
 Fresh water etc

All these facilities shall be managed by the contractor sufficient in advance so as to


meet the schedule requirement. It should be noted that the procedure for the lease of
the planned land for the camping consumes considerable time by the municipality or the
industrial city authorities as well as other authorities. Also, the application procedures
for the security gate passes based on its own regulation take certain hours for the
issues. All these points should be kept in notice to initiate the application quiet in
advance to meet the schedule requirement.
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Construction Accommodation Camp and Other Construction Facilities


Contractor shall choose from option 1 or 2 (below) for its accommodation camp.
Option 1 - Accommodation facilities Inside the Fence of Plant Area.
Contractor may utilize accommodation facilities provided by Plant inside the fence of
Plant area. Charges and fees to be paid by Contractor to Plant for such
accommodation if so preferred & available. Contractor notes that Plant accommodation
facilities shall be subject to availability at the time of request and be provided to
Contractor or other parties on the basis of first come first served.
In the event that the Plant accommodation facilities are not available, Contractor shall
utilize an approved Plant designated area and construct, operate and maintain his own
accommodation facilities.
Option 2 - Accommodation facilities Outside the Fence of Plant Area.
Notwithstanding the above, Contractor may elect to have his accommodation facilities
outside the Plant area fence. In such case Contractor shall obtain necessary approval
from local authorities as mentioned in the foregoing.

Other Construction Temporary Facilities


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
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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
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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
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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.
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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


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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
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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.

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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.
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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
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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
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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

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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.
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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.

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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
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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
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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
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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
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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.
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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
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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
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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.

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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
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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
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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
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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:
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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

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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
---------------------------------------
Chapter 7
DetailedEngineeringRequirements
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

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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
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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
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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
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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
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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
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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
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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.
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 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.
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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
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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.
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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.

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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
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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,
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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.

---------------------------------------
Chapter 8
B
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DesignGeneral 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
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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
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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
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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.

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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
1 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
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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.

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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
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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. For general notes, see Drawing No. ......
b. This detail drawing refers to Drawing No. ......
c. For bar bending list(s), see No. ......, sheet 1 to .......
d. For weight list(s), see No. ........, sheet 1 to ........
e. Quantity of concrete (for each quality of concrete separately)
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.

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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
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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
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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
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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
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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
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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 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
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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-

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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
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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

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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

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#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
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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
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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
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 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
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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
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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. 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. 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. 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,
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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:
bb. Surface Friction Coefficient
cc. Steel-to-steel (corroded) 0.35
dd. Steel-to-concrete 0.50
ee. Teflon-to-teflon
ff. 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
gg. 0.08
hh. Graphite-to-graphite 0.15
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ii. For computing friction loads due to the effects of pipe expansion in pipe racks,
use the following friction coefficients:
jj. Number of Lines on Support
kk. Friction Coefficient
ll. 1 – 3 0.3
mm. 4 - 6 0.2
nn. 7 or more 0.1
oo. 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.

pp. 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.

qq. 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.
rr. Foundations and structures which are subject to temperature effects shall be
designed for the various loading conditions and also for any temperature
difference which may occur in parts of structural members.
a. Anchor and guide forces shall be obtained from the Designers Piping
Engineering Department.
b. Structural Steel Pipe Supports shall be designed in accordance with
Industry

Standard Structural Design Methods.


Erection Dead Load
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


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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
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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

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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.
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Weight of Structure DL
Empty Weight of Vessels and Equipment DLempty
Operating Load LLop
Hydrostatic Test Load Test
Live Load LL
Moving / Truck Load LLmove
Wind Load WL
Earthquake Load EQ N/A
Crane / Impact Load CR
Dynamic Load DY

Thermal Load TL
Erection Load ER
Maintenance Load ML
Differential Settlement DS
Earth / Water Pressure HY
Blast Load BL

Loads shall be combined as specified below. Concrete bund walls shall be designed for
accidental load condition when the bund is completely filled with water to the crest. Only
the hydrostatic fluid acting in the outward direction and gravity loading need to be
considered. The factor of safety shall not be less than 1.3 for this loading condition.
Load Combinations A through G:
Primary Operation Test Erection Earthquake Maintenance Blast
Loads without wind with wind
ABCDEFG
DL x x x x x X x
DLempty x x1 x x x X x
Test x
LL x x x x x X
Crane x x x X
LLop x x 1 x
LLmove x x x X
WL x x 3,4 x 4
EQ N/A
DY x x x2 X
TL x x X
ER x
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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
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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
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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
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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
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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
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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
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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
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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


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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.
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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
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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
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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

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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.

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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.

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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
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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 /
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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
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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
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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
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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.
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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
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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
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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.
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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
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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.
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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
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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
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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.
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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
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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
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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.
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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.
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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
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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
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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
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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;-
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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.
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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.

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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

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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
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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
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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,
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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
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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.
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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
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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
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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
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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.
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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,
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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
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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.
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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
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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.
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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-
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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
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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.

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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”
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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
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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
---------------------------------------
Chapter 9
P
roc
ure
m e
nt
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-
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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.

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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 Contractor 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 /

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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.

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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 above.

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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
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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. 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
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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


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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
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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 Contractor shall give preference to Plant Port while importing materials. Plant
Port is a modern port and has necessary FACILITY like exclusive heavy load
berth, cargo berths etc. To facilitate Project import materials.

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. 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.

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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
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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
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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.

----------------------------------
Chapter 10
C
on
st
ruc
ti
o n
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

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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,
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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
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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
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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.
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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
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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
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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.`

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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
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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
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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.
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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.
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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
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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
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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
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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.
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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
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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.
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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.
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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
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satisfactory performance under the final design operating conditions. For


Physical modelling scope of work Refer to Appendix- (Hydraulic Study Report)

---------------------------------------
Chapter 11
P
re
-co
mmis
sio
nin
g(P
C)
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

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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.
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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
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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
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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.
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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
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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,
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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 .

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

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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.

---------------------------------------
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

EXECUTI
O N PLAN
(PROJECT IMPLEMENTATION STRATEGY)
P
ro
ces
sBu
ild
in
gsP
ack
age

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 &

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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,


CONTRACTOR 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 CONTRACTOR)
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 CONTRACTOR 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

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Cabling System

1. Liaison, co-ordinate & lead CONTRACTOR services subcontractors’ design &


engineering efforts
2. (CONTRACTOR 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 CONTRACTOR at Bechtel offices / officials at UK, Abu Dhabi and / or


Habshan as CONTRACTOR’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 CONTRACTOR


head office. All field interfaces shall be conducted from site offices in
collaboration with CONTRACTOR field engineers
6. All other remaining functional descriptions shall be conducted by CONTRACTOR
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. CONTRACTOR 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 CONTRACTOR 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
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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 CONTRACTOR 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,

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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 & CONTRACTOR 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 CONTRACTOR & Bechtel head office
This part shall be conducted by regular interaction among CONTRACTOR
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 CONTRACTOR & Bechtel site office
This part shall be conducted by regular interaction among CONTRACTOR & Bechtel
site representatives to help resolve all pre & post award issue of Engineering services &
monitoring project controls
Coordination between CONTRACTOR & Firm
This part shall be conducted by frequent interaction between CONTRACTOR & 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

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Coordination between CONTRACTOR / 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 CONTRACTOR / 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 CONTRACTOR 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
CONTRACTOR internal Coordination among various sections
CONTRACTOR 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
CONTRACTOR 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 CONTRACTOR 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 CONTRACTOR for
further necessary CONTRACTOR action. All documentation shall be carried out
adhering to the CONTRACTOR 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
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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
CONTRACTOR to Firm. The Firm shall then work on the revision, its calculations &
advise to CONTRACTOR & 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


CONTRACTOR 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. CONTRACTOR 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 CONTRACTOR & 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 CONTRACTOR that all changes are recorded on contract
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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 CONTRACTOR 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

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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

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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 CONTRACTOR procurement
procedures document

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11. International and local transportation and customs clearance


12. 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 CONTRACTOR adequately in advance of the required date of
delivery adhering to schedule date, so that the delivery is shipped in time from
original source. CONTRACTOR 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, CONTRACTOR 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 CONTRACTOR procurement
procedures document.

13. Procurement and provision of construction spares, commissioning spares,


insurance spares and special tools
14. These shall be processed applying the same methods of procurement & delivery
received by CONTRACTOR / its services or specialist sub contractors. Most
probably, the spares shall form part of the order package. Elaborate details have
been given on the CONTRACTOR procurement procedures document

15. Recommendation for two-year operating spares for approval by Company in


accordance with the G-SPIR format requirements
16. This provision shall be followed & spares delivered according to contract &
Company requirement by CONTRACTOR / its services sub contractors.
Elaborate details have been given on the CONTRACTOR procurement
procedures document

17. Procurement and provision of two-years operating spares, (at cost and extra over
Lump Sum Subcontract Price)
18. Similarly this provision shall be effected & spares delivered according to
Bechtel/Company instruction to CONTRACTOR subject to the approval of the
procurement cost prior to the purchase order placement by CONTRACTOR

19. Source inspection


20. If so required by Bechtel / Company, arrangement shall be made by
CONTRACTOR 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

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Company. Representatives from Bechtel and/or Company, CONTRACTOR,


services sub contractor & vendor shall constitute an inspection at source team.
Proper record of inspection shall be made.

21. 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
22. 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

23. CONTRACTOR 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 CONTRACTOR. CONTRACTOR 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

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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

Contractor 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 CONTRACTOR 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,

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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.

CONTRACTOR Site Office

Actual ‘on site management’ would be from offices based on the site next to
Contractor and Company’s office. CONTRACTOR Site Office is fully supported by
CONTRACTOR 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 CONTRACTOR Head Office at Abu


Dhabi with input from CONTRACTOR 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:

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 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


CONTRACTOR 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


CONTRACTOR 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.
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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 CONTRACTOR regularly during the project
currency

2. Detailed services designs shall be prepared by CONTRACTOR services


sub contractors

3. CONTRACTOR 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


CONTRACTOR 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

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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.

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Organization
Corporate Organization

1. 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 is a registered company specifically set-up to target
the energy sectors and its clients. CONTRACTOR has been operating under 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 Contractor. 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 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 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.

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6. The Contractor 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.

7. Equipment Resourcing And Mobilization

8. Based on the project schedule the planning department shall generate the
construction equipment schedules.
9. The Contractor 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.

10. 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
CONTRACTOR 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.
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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 CONTRACTOR 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. CONTRACTOR 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

2. All activities necessary for Mechanical Completion, Pre commissioning,


commissioning, and Provisional Acceptance.
3. All activities for the buildings part have been described on the method statement
appended

4. All testing facilities required at Jobsite


5. CONTRACTOR 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.

6. Full responsibility for co-ordination with any Third Party Inspectorate


7. CONTRACTOR 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.

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Supply and coordination of lower tier subcontractor and vendor representatives


as necessary

CONTRACTOR 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, CONTRACTOR 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

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settlement & long-term consolidation controls. However, to verify the validity of


the soil report, CONTRACTOR 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
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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. CONTRACTOR 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
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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
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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.
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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
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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

42. WARRANTY OBLIGATIONS FINAL ACCEPTANCE SHALL be


THROUGH TO

submitted for the work scope items


43. For further details on the services method statements for the package, please refer to the CCTC
documentation (not attached within this proposal).

E
XECU
TIO
NPL
A N Method statement

(PROJECT IMPLEMENTATION STRATEGY)


Civ
il W orks
/SitePreparations
Cons tru
ctionM etho
dS tate
m ents

Sample Only
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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.
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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.

5. 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.
6. 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.

7. 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

8. The scope involves the sub titles & their description of constructions as follows,
which cover major portions of the Preparation & Civil Works for the project.

9. 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.

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10. Checking procedure- Profile should be within acceptable limits. Soft spots should
be removed.
11. 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.
12. 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.

SitePreparation&EarthworkTypical
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.
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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
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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.

Protectionof ExistingServices
1. From the provision of existing site drawings, provided by the relevant authorities
within ASAB, existing services shall be located, and exposed by hand

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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
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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.

F
enc eE rec tion .
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.

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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.

E
xca va tio n
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

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results, the area shall be released for consequent activities.

Backfill tostructures
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.

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
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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
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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
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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.
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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
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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
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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.

LayingKerbstonesTypical Sample

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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
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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

Roads, Yards, Paving(Asphalt)


RoadWorksTypical 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

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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

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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
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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.
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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
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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.

F
orm w o rkE rectionT yp ica
l
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
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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.

C
on cretin gT yp icalsa m ple
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.
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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
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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.

C
on creteP avingT yp ical
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
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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.

ConcreteLinedTrapezoidal 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.
ExpansionJointsbetweenditches
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.

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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.

ConcreteLinedRectangular 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.

ExpansionJointsbetweenditches
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

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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.

TerminationDetailstoprotectivemembrane
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
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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. CONTRACTOR 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

Groutingtopiperackbasestypical
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.
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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.

Water TightnessTest of RCCStructuretypical 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.

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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
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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.

ConcreteProtectionCoatingTypical
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.
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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.

LightingPolesFoundationsTypical
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

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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.
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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.

PullP itsT y pic


al
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
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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
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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. 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
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1. As dug compacted backfill shall be carried out above the sand fill to the
specifications.
2. 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.

Foundationsconnectedtopavingconcrete
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
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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.

CableTrenches
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

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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
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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.
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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.

UndergroundPiping
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.

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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

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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.

EpoxygroutingtovibratingmachinebasesTypical
 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 sho