Itb - CCW Crane Upgrade Rev

Area: Smelter, RAK
Instruction to Bidders Department: Central Projects

CCW CRANE UPGRADE Revision #:00 Sub-Area: CCW
Date Published:
Document No: MD-402-

Revision: 00
Date of Issue: [Abstract]
REVISION HISTORY / INDEX
Instruction to Bidders
CCW CRANE UPGRADE FROM 16.5 T TO 20 T

MAC REVIEW/APPROVAL
Project Name: CCW CRANE UPGRADE FROM 16.5 T TO 20 T

Project No: SM-CP-2021-6000-0030
MOC No: MOC-SM-2021-6000-1773
Area: CCW
Project Engineer: Sajid Barey
Sign: Date: 27/11/2022
Project Engineering Superintendent:
Sign: Date: 27/11/2022
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Area: RAK Port
Department: Central Projects
Revision #: 00
Sub-Area: CCW
Date Published: 27 Nov 2022
Table of Contents:
1. Project Background
2. Project Introduction & Scope
3. Detailed Description of work
4. Codes and Standard
5. Procurement
6. EHS (Environment, Health, Safety Standard) Requirements for construction Bidder.
7. Planning and Progress Measurement
8. GENERAL CONSTRUCTION REQUIREMENTS
9. Quality Assurance and Quality Control
10. GENERAL NOTES TO BIDDER
11. Pre-commissioning and Mechanical Completion
12. GUARANTEE
13. Attachment
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1. Project Background: Ma’aden Aluminum Company (MAC) is one of the largest

integrated mining and Bauxite-processing complex in the world. The mine is located
at Al-Ba’itha, 450 km northwest of Riyadh in Saudi Arabia. The chemical processing
facility is located at Ras Al Khair (formerly known as Ras Az Zawr), 130 km through Abu
Hadriyah Highway north of Jubail.
The project type classification is LSPB (Lump Sum Procure and Build) which includes
all necessary activities such as supply, change, modifications and dismantling
whenever applicable in all LSPB contract deliverables and needed to meet Ma’aden
Aluminium (MA) acceptance and execute the project agreed scope. The Scope of Work
of the Contractor is to cover the, Structural, Electrical, Automation and Structural
scope of work involved in upgrading the CCW facility from 16.5T Cranes ( 2 Nos ) to 20
T Cranes ( 2 Nos ) of the Smelter Crucible Cleaning Workshop (CCW). Scope also
includes necessary inspection, shop testing, painting, transport, supply, loading &
unloading at site, erection & commissioning of the proposed two ( 2 ) new cranes
including all raw material, consumables, manpower, construction equipment to
commission & hand over at MA site in totality and shall include but not be necessarily
limited to the following:
2. Project Introduction & Scope:

The MA complex in Ras-Al-Khair (RAK) include Aluminum Smelter, Aluminum Refinery
and rolling mills. Smelter unit has Crucible Cleaning Workshop which receive the dirty
metal crucible from REEDUCTION, REMELT & CANREC dept. adhered with Crucible
scale (CH scale) which is cleaned at Crucible cleaning workshop (CCW) on Crucible
cleaning machine (CCM). The metal crucible is handled by 02 over head crane Tag #
4441-MQKC-0001 & 4441-MQKC-0002 of capacity 16.5 ton each, called as LADLE
HANDLING CRANE. On an average utilization for each crane is around 65 number of
cycles/day.
During the operation of Ladle handling crane while handling the crucible, the crane
4441-MQKC-0002 wire rope failed, resulted in crucible falling. RCA was done and as
an outcome, it has been recommended to replace the existing 16.5-ton cranes with
20-ton crane along with change in class of structure A6 to A8 and utilization class from
M6 to M8.
For the stated tonnage capacity & class of structure with utilization class, structure
analysis of CCW performed and as an outcome re-enforcement/retrofit of existing
structure is required to sustain the 20ton capacity crane.
Berkeley Engineering Consultancy has provided the Basic and Detail Engineering for
this project , and this document explains the scope of work to be done by the
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Construction Contractor with supervision of Crane OEM.
2.1 Project Scope of Work

All work shall be done as per the IFC design drawings. List of which is attached with
this document.
The crane upgradations work shall comply in design, materials of construction,

manufacture, assembly, inspection, shop testing and performance conforming with
this ITB / Scope of Work, drawings, all relevant MA & International standard of latest
edition, Specification, applicable codes as a minimum and as per good engineering
practice where specifications are not available. Work shall include the provision of all
supervision, labor, tools, equipment, materials, consumables, testing &
commissioning, technical and professional services including shop drawings,
documentation and manuals, spare part list etc.
Work shall be performed in accordance with the conditions of the contract, contract
documents, approved procedures, applicable standards, codes of practice and plant
regulations, including all temporary supports, access platforms, safety devices MA EHS
Stipulations, all installations, and activities necessary to complete the Work.
Major Component within scope of the Project:
a) Crane Upgradation by replacing the existing 16.5 T Cranes with 20 T Cranes (2 Nos )
b) Structural Retrofitting
c) Electrical
d) Automation
2.2 ENGINEERING SCOPE OF WORK

2.2.1 GENERAL
Although detail engineering has been completed, the Vendor of the crane
may have to engineer miscellaneous items pertaining to the crane
requirements as explained in the subsequent articles.
3. Detailed Description of work: The Work shall be performed in compliance with this
Scope of Work, Engineering drawings, technical specifications, MA'ADEN Standards,
local codes as a minimum and as per good engineering practice where specifications
are not available. The Bidder Scope of Work Lump sum rate of project, but not limited
to the following:
3.1 CONSTRUCTION SCOPE OF WORK
3.1.1 Mechanical Works
a) The two existing 16.5 T Cranes shall be removed and replaced with
new heavy-duty Cranes of 20 T ( 2 Nos ) .
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b) The cranes shall be procured from Micheletto Only with below

requirements
SN ITEM DESCRIPTION UNITS REUIREMENTS
1 CRANE TYPE - OVERHEAD

2 KIT TYPE - DOUBLE GRIDER
3 CAPACITY SWL (TON) 20 TON
4 SPAN (MAX) M 20 M
°C (Tmin -
5 WORKING TEMPERATURE RANGE Tmax) 0 - 55
6 STRUCTURE CLASSIFICATION - A8
7 MECHANISM CLASSIFICATION - M8
8 HEIGHT OF LIFT M 10 M
9 MAIN HOIST SPEED M/MIN 6/1.5
10 TROLLEY SPEED M/MIN 20/5
11 LONG TRAVEL SPEED M/MIN 40/10
12 SERVICE TYPE - INDOOR
13 HOIST TYPE - OPEN WINCH
14 TOTAL WEIGHT OF CRANE KG 27,400 kg
15 MAIN HOIST MOTOR kW 30 kW
16 TROLLEY MOTOR kW 3 kW
17 BRIDGE MOTOR kW 2x2.8 kW
18 MAIN SUPPLY VOLTAGE VOLT/HZ 460/60
19 CONTROL VOLTAGE VOLT 24V D.C
DEGREE OF PROTECTION
20 (ELECTRICAL) IP IP 55
180 DAYS FROM ORDER
21 DELIVERY TIMES - CONFIRMATION
18 MONTHS FROM
22 WARRANTY - COMMISSIONING
c) The Contractor shall be responsible for the removal of existing

16.5 tons crane ( 2 Nos ) and other accessories as required as
per design details.
d) Construction Contractor shall install new 2 nos. of 20-ton cranes
in place of existing demolished cranes as per B-2022259-STR-
MS-001.
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e) The crane vendor must ensure there are two ropes and
balancing plate as hoisting mechanism, as actual configuration.
f) The Rope safety factor to be considered shall be in the range of
11.2 with no compromise on the flexibility.
g) The crane head beam / girder plate thickness shall be in line
with higher incremental factors - ref. FEM 1.001 - dimensioning
following the principle of the low tensions and higher fatigue
resistance.
h) The crane vendor must ensure that the crane would be
continuous use-type.
i) The temperature to be considered shall be 450°C and the
maximum weight 18000 Kg.
j) New crane should be equipped with a weight measurement
system (alphanumeric LED display).
k) The cranes should be equipped with emergency breaks in
addition to normal breaks.
l) To consider HMI device on crane – connected with level 2
screen on floor (connected with existing process domain).
m) Construction Contractor shall ensure the new crane is upgraded
with class of structure from A6 to A8 and utilization class from
M6 to M8.
n) The crane class shall be T9-L3 based on the past history and the
production forecast. The structural class shall be U9.
o) Construction Contractor shall coordinate with vendor for the
supply and delivery of 20-ton cranes at site and shall be
responsible for the procurement of complete material and
technical documents as per the specifications.
p) Construction Contractor shall submit technical submittals and
material submittals for approval before execution of work at
site as per B-2022259-STR-MS-001.
q) Construction Contractor shall submit method statement and
risk assessment report before execution of work at site as per
B-2022259-STR-MS-001.
r) Construction Contractor shall perform third party load testing
before handing over the crane to operation and management
team.
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s) The execution strategy to be provided for the removal of the

existing cranes and replacing them with new ones with least
interruption to production. Before submitting the proposal, an
on-site technical inspection to be conducted by the vendor ,
evaluating the available the spaces, daily production , crucible
movement , etc and propose a formal strategy, complete with
a day by day operational plan with timings, means and
manpower required. Vendor may explore using the existing
cranes for lifting the proposed new cranes!
t) Vendor must have his representative during the existing crane
removal, installation of new ones , pre-commissioning and
commissioning ; his visa-processing , accommodation , food ,
transportation ( International and local ) , etc all to be
considered.
u) Vendor shall provide 18 months written warranty with effect
from commissioning of the cranes.
v) Vendor must consider below improvements
✓ Rope inclination detection device, which will stop the
lifting operations in case the operator should lift the
ladle and the ropes had an angle larger than the
maximum allowed.
✓ Ropes detection overlap system: in case the ropes, while
unwinding/winding, should overlap, a system made of
rotating rollers and dedicated sensors will stop the
operation
✓ Semi-automatic positioning system: encoders will be
installed on every movement and PLC logic will be
implemented so that the operator, while operating the
working cycles, will be supported in all the movements
by the machine itself. This system is highly customizable.
✓ Crane monitoring system: the PLC will be installed with
a software which will allow the Maintenance and
Production Dept. to monitor all the cranes parameters,
such as cycles, weight lifter, hours of activities, current
absorptions and all the datas that could be read by the
PLC. This system is highly customizable and can be used
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to support the Maintenance Team to implement a

predictive maintenance system.
✓ VDF on the rotating hook system: the rotating hook
motor will be controlled by VFD.
✓ The weight of the crucible will be either shown on
remote control or a panel and linked with MES.
w) Vendor must provide FAT/SAT/Load Test procedures along with
their proposals in addition to considering the same in the SOW.
x) The Vendor must consider One year spares in the proposal to
be shipped along with the cranes.
3.1.2 Structural Works

a) All material shall be of new stock (less than 5 years from
manufacturing) and shall comply with the requirements of
the Eurocodes or equivalent accepted standards, as defined
by the contractual documents. Alternate proposed
materials shall contain all the minimum EN requirements for
chemical composition.
b) All supplied steel and each fabricated component shall be
covered by, and be traceable to, a CMTR - Certified Material
Test Report.
c) The CCW structural columns to be retrofitted as per the
detail engineering drawings attached along with the
drawing
d) The retrofitting to be done by procuring, fabricating and
installing flange plate (32 mm Thk. ) and web plate ( 8 mm
Thk. )
e) All plates shall comply with the requirements of EN 10025
grades S355JR or S275JR (or equivalent).
f) Alternative structural steel certified to Chinese steel
specifications GB 700 or GBT 1591 shall meet the following
requirements:
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Table 5.1
Tensile Test Charpy V-Notch

Impact Test
Max.
Max.
Grade Plate Yield Ultimate Tested
Tested
Thicknes Strength Tensile Ultimate Energy
Yield Elongation Temp. °C
s MPa Strength Tensile Joules
Strength
mm MPa Strength
MPa
MPa
< 16 > 345 515 470
> 21%
Q345B 16~35 > 325 485 470
610 For Grade
35~50 > 295 440 470
> 22% B +20 > 27
50~100 > 275 410 470
< 16 > 235 > 350 375 485 > 26%

Q235B
16-40 > 225 > 335 375 485 > 26%
g) The protective coatings shall be in accordance with the
requirements of 25457-0000-3PS-G000-0002 Painting of
Mechanical Equipment, Piping and Structural Steel.
h) All Welding, shall comply with the requirements of EN ISO
3834; and shall be in accordance with 25457-0000-3PS-
SS01-0001 Rev 000
i) The contractor shall ensure that this would be the first
activity in terms of on-site construction. The effort towards
procurement and installation of plates/retrofitting shall be
completed 100% before the new cranes are delivered on
site.
j) Construction Contractor shall install additional web and
flange plates of thickness and dimensions as per 25457-
40AZ-SS-4441-0002r002, 25457-40AZ-SS-4441-0003r002,
25457-40AZ-SS-4441-0004r002, 25457-40AZ-SS-4441-
0005r003, 25457-40AZ-SS-4441-0006r003.
k) Contractor must consider scaffoldings/man-lift for installing
the plates along the columns
l) Al above must comply to MSHEM requirements appended
along with the ITB
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3.1.3 Electrical
a) Construction Contractor shall dismantle the power & cables
of 2 nos. of existing 16-ton cranes.
b) Construction Contractor shall utilize the existing Circuit
Breaker and existing cables for the supply of power to the
cranes, as per Single Line Diagram, 25457-20AZ-E1-2162-
0002r004_2162-ECK1-0001 & 0002 and Schematic Diagram
25457-2100-V1A-ESL1-0062r007_2162-ECK1-0001 & 2,
indicating new feeder for the crane.
c) The Hoist Motor Rating for proposed new cranes shall be 30
KW.
d) The rating for the of Bridge Motor (Long Travel ) shall be
2.2kW/50Hz while that for Trolley Motor ( Cross Travel )
shall be 1.5kW/50Hz.
e) Platform for the Hoist motor, Terminal box and encoder to
be designed and installed specifically for motor for better
maintainability.
f) Radar Anticollision system should be integrated into PLC
with alarm generation.
g) Electrical panel fully enclosed in a room/enclosure on
walkways as most of the electrical break down occurs due
to high temp and vibration. The enclosure could be
designed with welded metallic sheets and shall be IP rated
for outdoor type.
h) There Should be provision for raising and Lowering
Mechanism in case of Motor Failure.
i) 1 VFD to control both Bridge motors, instead of 2 VFDs
controlling individually (also for trolly motors).
j) It is proposed to have Energy chain type arrangement for
Trolley main electrical supply type instead of festoon, in
order to have maintenance free or less maintenance cable
arrangement.
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k) HMI Display to be supplied. Installed, and Integrate to Level

2 Network.
3.1.4 Automation
a) Crane must include PLC control (Must be on Rockwell
Platform for software & Hardware) Others.
b) Control Supply Voltage should be 24V.
c) Ethernet network should be used for all the networking with
I/O & VFD's. DLR (Device Level Ring) network configuration
should be included at device level.
d) Local HMI at Crane panel should be included. L2 screens
must be provided by vendor & should be integrated with
crane using wifi access point.
e) Tilt angle sensor should be included as safety for hoist
motion.
3.2 General:
• BIDDER shall be responsible for all field activities covered by the Scope of
WORK as described in the CONTRACT including all Schedules and its
attachments.
• BIDDER shall liaise and coordinate with MAC, all other SUBBIDDER(S) and
third parties involved in the implementation of the project.
• The generic term EHS is used throughout this document as an abbreviation
for “Health Safety and Environmental”.
• BIDDER shall comply with all MAC Construction Safety Manual for all
construction activities as applicable to its nature of works.
• BIDDER shall provide qualified manpower, tools, construction equipment,
facilities, indirect materials, direct materials, consumables, supervision,
management, technical and professional services and each and every other
item necessary for the completion of the work.
• This Project is critical in terms of Smelter operation and time constraint.
BIDDER to prioritize the activity and plan in such a way those overlapping
and parallel activities can be performed as much as possible. During
execution wherever there is a possibility of schedule improvement, BIDDER
to analyses and implement by resources or by any other suitable means.
• Material storage shall be as per Hazard classification and according to MAC
standards. BIDDER to develop and submit a Resource allocation plan.
• Temporary power requirements for site facilities shall be in BIDDER scope.
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• All site work will be carried out only after approval of EHS docs,
Construction docs and Quality docs for all discipline.
• BIDDER to continuously check and inspect the work during the
construction in accordance with approved Inspection Test Plan (ITP) to
ensure it is completed in compliance with approved drawings,
specifications and quality requirements.
• Construction BIDDER to liaison with its QC team and MAC for inspection
work.
• BIDDER to clearly specify in the proposal and get approval in written in case
of any Sub- Contracting scope of work/ strategy. Sub- BIDDER needs to
have very good experience and relevant project work summary (more than
10 years of experience)
• Ensure BIDDER employees observe all site safety rules; e.g. Speed limit, PPE
requirements.
• Ensure that MAC Aluminum Lock, Tag, verify (LTV) safety Procedure is
followed.
• Maintain, coordinate and track all deviations from approved construction
drawings.
• Supervision of the installation work for the construction of the system
inclusive of all items necessary for safe and efficient
construction/installation of piping and components.
• BIDDER to generate and submit daily work progress report to MAC.
• BIDDER to generate and submit 2 weeks look ahead construction and
resource plan to MAC. BIDDER to arrange additional resources to mitigate
the work delay.
• BIDDER to Follow safe working practices and using proper Personal
Protective Equipment (PPE), safety clothing & harness as per MAC for
Health and Safety.
• Deputation of a Project Manager responsible for overall project during the
entire duration of EPC works.
• Deputation of a Site Supervisor for each discipline during the entire
duration of installation & commissioning work.
• Testing kit/skid used under project shall be well designed and third party
certified. Carrying out periodical Safety Audits and maintenance of audit
records and safety records.
• Communication co-ordination Coordinator/Engineer on a regular basis for
the duration of the Project. Attend the construction kick-off meeting to be
held at MAC before starting the work.
• Attend clarification meetings and any other meetings at MAC as required.
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• Co-ordination with the Project/ Construction Engineer regarding any

connections to existing equipment/systems/ Electrical and pipe work
before commencement of work.
• Providing any relevant certificates, documents and other related
requirements required by MAC
• Ensuring that all work is carried out carefully and as per MAC
approved/issued drawings and specifications.
• Since the Project is in a live Operation area, Bidder shall develop a transport
and traffic management plans in such a way that personnel movement
wherever possible separated from material traffic vehicles, to ensure safe
working conditions.
• Installation Spread (Personnel & Equipment) to be pre-approved by the
MAC prior to mobilization to the site.
• Bidder shall plan construction works inside the existing facility in close
conjunction with the MAC and shall include in the schedule a staged
construction approach per area.
• Bidder shall plan his labour force and supervision such that the same
personnel are working in these live areas during the execution of these
works.
• In case of any conflict in the requirements, the Bidder shall bring this to the
attention of the MAC Project team shall obtain such applicable
requirements for this PROJECT in writing from the MAC.
• The Bidder shall get approval of all the drawings and documents from the
MAC for construction before starting the construction activities.
• All WORK, including services for testing and inspections required by the
MAC, shall be furnished by the Bidder.
• Preparation and reinstatement in respect of the work area as follows;
• Returning the work area to a safe condition, correctly disposing of waste
materials, Completion of all necessary documentation.
• BIDDER shall perform all the WORK required for FINAL ACCEPTANCE by
MAC. MAC will not perform any part of the WORK except review,
monitoring and approval of BIDDER's performance of the WORK in
accordance with CONTRACT.
• Construction BIDDER to develop the following:
• Project Execution Plan (PEP)
• Interface Management Plan (IMP)
• Environmental, Health, and Safety Management Plan (EHS)
• Quality Plan (QP)
• Risk Register for overall project.
• Project Controls Plan (PCP)
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• Construction Execution Plan (CEP)

• Temporary Facilities Plot Plan
• Mobilization / Demobilization plan
• Traffic Management Plan
3.3 Bidder’s Construction Site Office and Facility:

• Construction BIDDER to develop site facility for worker food, water,
material storage. Office should be equipped per industrial standards
• Providing food, transportation, welfare and all other facilities and
amenities to personnel during tenure of work. Ensuring proper
behavior of personnel during tenure of the work.
• A lay-down area designated by the MAC representative where the
BIDDER shall provide at his own expense the following as minimum:
➢ Temporary fences
➢ Barricades and lights
➢ Storage shed
➢ Workshops
➢ Toilet facilities
➢ Temporary power
➢ Temporary telephone
➢ Water and sewer provisions
➢ First aid cabinet
➢ Portable fire extinguishers, type ABC, 30 lbs.
➢ Housekeeping and cleanliness
➢ Fire Protection plan for site
• BIDDER shall remove the temporary facilities after the completion of
the project to the satisfaction of the MAC representative.
3.3.1 Housekeeping and Clean Up

• BIDDER shall maintain good housekeeping throughout the
execution of the project.
• In the event BIDDER encounters on the construction site material
reasonably believed to be a toxic or hazardous material, or a toxic
or hazardous waste, BIDDER shall immediately stop WORK in the
affected area and notify MAC, BIDDER shall not resume WORK in
the affected area.
• After completion of construction, BIDDER will dispose of all
construction debris, non- hazardous waste, oily waste and
hazardous waste to location as designated by the MAC
Representative.
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• Clean-up work shall immediately follow completion of

construction. BIDDER shall conduct clean-up work so that it shall be
finished as soon as possible after commissioning the system.
• Throughout performance of the WORK, BIDDER shall conduct all
operations in such a way as to minimize impact upon the natural
environmental and comply with all laws, regulations, and rules
applicable to the SITE.
• BIDDER shall provide: Dust control of all material sites, roads, and
disposal areas within its assigned WORK areas of responsibility
• BIDDER shall provide a dump for waste material and haul away the
same in as per MAC’s instructions.
• BIDDER shall remove excess construction material from site prior to
demobilizing. Demolished or obsolete materials shall be removed
from site in an expedient manner.
• BIDDER shall dispose-off all non-contaminated excavated Soil,
Concrete and debris (nonstructural/steels) to designated dumping
area as advised by the MAC.
• Suitable equipment, facilities, and precautions shall be taken to
prevent the discharge of contaminants which may pollute the
atmosphere, any body of water, or land areas, or which may harm
fish or other wildlife.
• All other materials remain property of MAC, such as obsolete
equipment, piping materials and obsolete cabling and shall be
transported from Site to designated location as advised by the
MAC.
3.4 Statutory Regulations and Authority Approvals: BIDDER shall comply with all statutory
regulations and authority approvals obtained for the project by MAC.
In certain instances, it may be the BIDDER responsibility to obtain authority
approvals.
All permits outside Ma’aden promises (e.g.: RC road) is BIDDER responsibility. Ma’aden
will provide all necessary support required.
3.5 Engineering Specifications and Standards: The BIDDER shall comply with all
engineering specifications and standards issued with or referenced in the CONTRACT.
With regards to Construction and Commissioning activities BIDDER shall execute this
work in compliance with the MAC standards & specifications.
3.6 Engineering Specifications and Standards: The BIDDER, including all SUBBIDDER(S),
shall comply with all relevant employment legislation and work in conjunction with
recognized entities in existence, to support the interests of the work force.
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4 Codes & Standards
SN Document Number Description

1. 25457-0000-3PS-SS01-0001r000 Structural Steel Work Supply &
Fabrication
2. 25457-0000-3PS-SS02-0001r000 Structural Steel Erection Work
3. 25457-0000-3PS-G000-0002 Painting of Mechanical Equipment
Piping and structural Steel
4. ASTM A36/A36 M Standard for Carbon Structural Steel
5. ASTM A325 Standard for Hot Dip Galvanized

Bolts
6. ASME B30.16 and ASME HST-2M Standard for Hoist
7. Ladle & tube Cleaning LV S/S-2162

25457-20AZ-E1-2162-0002r004_2162-ECK1-
Utility Distribution Board-1 Single Line
0001
Diagram
8. Ladle & tube Cleaning LV S/S-2162
25457-20AZ-E1-2162-0003r004_2162-ECK1-
Utility Distribution Board-2 Single Line
0002_
Diagram
9. 25457-2100-V1A-ESL1-0062r007_2162-ECK1- Schematic Diagram of Utility
0001_ Distribution Board-2162-ECK1-0001
10. 25457-2100-V1A-ESL1-0063r007_2162-ECK1- Schematic Diagram of Utility
0002_ Distribution Board-2162-ECK1-0002
ACI 305 Specifications for Structural Concrete

ACI 318/318R Building Code requirements for structural concrete
AISC 303-05 Code of Standard Practice for Steel Buildings and Bridges
AISC 360-10 Specification for Structural Steel Buildings
ASCE 7-05 Minimum design loads for buildings and other structures
ASCE Guidelines for Seismic Evaluation and Design of Petrochemical
ASTM A36/A36M Facilities Specification for Carbon Structural Steel
Standard
ASTM A775/A775M Standard Specification for Epoxy-Coated Steel Reinforcing Bars
ASTM A992/A992M Standard Specification for Steel for Structural Shapes
ANSI American National Standard Institute Process Piping
ASME American Society of Mechanical Engineers
ASTM A193 Stud Bolt with A194 Nuts
ASME B16.10 Face-to-Face and End-to-End Dimension of Valve
ASME B16.11 Forged Fittings, Socket-Welding and Threaded
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ASTM B16.20 Metallic Gasket for Pipe Flanges

ASME B16.5 Pipe Flanges and Flanged Fittings NPS ½” Through NPS 24
ASME B31.3 Metric/Inch
Chemical Standard
Plant and Petroleum Refinery Piping.
ASME B36.10 Welded and Seamless Wrought Steel Pipes
IEC 61439-3 Distribution Boards
IEC 61439-4 Assemblies for Construction Sites
IEC 61439-4 Assemblies for power Distribution
IEC 60947-2 Low Voltage Switchgear & Control Gear – Part 2: Circuit
BS 6004 Breakers Cables PVC Insulated, non-armoured cables
Electrical
IEC 60287, IEC60059 Determination of current ratings of power cables
The applicable local, international / national standards and specifications, Ma’aden

rules, regulations, specifications and standards, etc. for this project shall be applicable.
A list of applicable code, standards and specifications is provided with this document
for reference. However, any other standards and specifications which are considered
to be relevant and applicable for the subject work shall be used with the prior consent
of Ma’aden.
The more stringent requirement of the specifications, standard drawings and
international codes, standards and regulation shall always prevail.
Attached the Index of Ma’aden Standards
5 Procurement:
5.1 General:
• BIDDER has to procure the Long Lead items and Bulk items required including
consumables to complete the project, as specified below and elsewhere in this
document. This project is critical and time constraint. BIDDER to prioritize and
procure material accordingly as per below, but not limited to:
• BIDDER to review, verify the bill of quantity of material with drawings notify to
MAC in case of discrepancy and update the Bill of quantity docs accordingly.
However, BIDDER is fully responsible to procure the required quantity for
successful execution under the same contract.
• BIDDER to procure material as per Project scope specification and standards.
• BIDDER to consider and procure required consumables to execute the project
successfully
• BIDDER to submit the Material approval form prior to procurement for all
material along with the drawing specification and product catalogue/ manual.
• BIDDER to procure material from Ma’aden approved Supplier.
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• BIDDER to submit the MTC, test reports and attach along with RFI for material
inspection. No inspection entertained without supporting vendor/
manufacturer document.
• Procured material should be fresh (not older than 06 months from current
month, free from dirt, defect, etc.)
• BIDDER to consider and procure operating/ maintenance spare parts for the
equipment. Similar to be developed for Civil, Electrical and other disciplines.
• BIDDER to procure fresh (not older than 6 months) and good quality material
for the project work. Material should not be older than 6 months than the
manufacturing date. BIDDER to notify to MAC and get written approval prior
to procurement.
• BIDDER to mention the material procurement plan (Country of origin, material
specification, delivery time, etc.).
• Valves, pumps should be same manufacturer of existing facility in order to
minimize the spares and plant reliability. Or BIDDER to specify in the proposal
and get written approval from MAC in case of deviation.
• BIDDER to store and preserve the material as per vendor recommendation or
under shed to avoid any damage/ defect.
• BIDDER to develop and update the material procurement status and take
necessary actions to meet project objectives.
• Bidder to submit the Material approval form prior to procurement for all
material along with the drawing specification and product catalogue/ manual.
• BIDDER to propose the local material supplier list to MAC. MAC will have right
to select from the suppliers from the list.
• BIDDER to procure material from Ma’aden approved Supplier only.
5.2 MAC Approval: MAC approval shall include all items in the BIDDER’s scope - After
approval of datasheet/specification and approval of proposed vendor ordering can be
done. Also, approval of the following materials and equipment shall be obtained before
placement of orders.
• Field Instruments
• Process Control System Hardware, Software and Panels
• Cable
• MCC
• All Bulk Items, including but not limited to Electrical, I&C, CSA and Piping Items
• Requests for procurement approval shall include full, clear and un-ambiguous details of
the proposed materials and equipment.
6 EHS (Environment, Health, Safety Standard) Requirements for construction Bidder.

6.1 Safety training and ID requirements:
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5.1 Safety training and ID requirements:
• Bidder to undergo Ma’aden general trainings such as safety induction,

LOTOV-I, LSR, work at height, confined space, etc. Bidder must deploy
qualified and experienced manpower for work permit and safety
training and certification.
• These trainings have been outsourced to MEIRC in Jubail and that
contractor shall bear all the expenses towards such general trainings.
• Plant specific trainings such as Chlorine, DC Hazard, etc shall be

provided by MA free of cost.
• Safety officer shall with minimum 5 years of GCC industrial experience
in the project and should pass MA central EHSS interview prior to
mobilization on site.
• Safety officer shall with minimum 5 years of GCC industrial experience

in the project and should pass MA central EHSS interview prior to
mobilization on site.
• Bidder to assign Saudi GRO to co-ordinate these activities with ISD &
PORT department for employee ID and Material gate pass.
• Bidder to prepare and submit EHS plan, JSA, Risk assessment and other
safety relevant document in Ma’aden prescribed Format for Ma’aden
EHS approval prior to start the work.
• Bidder shall verify that its personnel are full fit for duty to medical,
physical and substance abuse consideration as per Pre-Placement
Medical evaluation (MA-EHS-HP-08).
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• Bidder shall ensure all their employees, sub-contractors, visitors,

delivery vehicles to register at security department and obtain
Ma’aden Aluminium security ID badge.
• No one should work on site without successfully completing the
Ma’aden Induction and other required training based on the scope of
work and affiliate requirements.
• Bidder to follow Safety ratio requirements for Safety management on
site as per Contractor EHS Requirements ( MA-EHS-S-009.1).
6.1.1 Requirement for MA ID for Contractor Employees

• Duly filled request form
• Copy of valid National ID/Iqama/Passport
• Copy of Contract
• Medical Report from approved Clinics
• Recent photographs
• Safety Induction attendance verification
• Return old ID for renewal
• Iqama profession shall be same as applied
• Approval from EHSS Dept. for Safety officers
• 3rd party training card copy for scaffolder technicians
• Saudi License for mobile equipment operation for Operators
• Additional for Sub-contactors
• Service Agreement attested by Chamber of Commerce
• AJEER documents
6.2 SAFETY:
• The Bidders responsible for compliance with applicable local legislation
and regulations for Safety and Health of their employees, facilities for
their employees including medical care facilities and emergency
transportation at worksite, waste disposal, and other environmental
rules and regulations.
• The Bidder Management is held accountable for any violation to EHS
rules, Work Practices and applicable government laws / regulations by
their employees.
• Maintain an adequate safety record that to tracks all the potential
incidents, including near misses, take 5s, HP form, etc.
• Taking due care that personnel are fit for work, e.g. no excessive
overtime. (Max. 60 hours per week/ max. 6 days). Working Patterns
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Current and future practices allow for routine work to as per Ma’aden
EHS policy.
• The Bidder shall adhere to Ma’aden ALUMINUM safety regulations and
shall be equipped with all required Personnel Protective Equipment
(PPE) for the job. Monogoggles, Hot metal clothes and 6” long sleeve
safety shoes are mandatory in Smelter
• The Bidder communications while on site is the responsibility of the
Bidder and use of mobile communication equipment shall conform to
both Ma’aden and Royal Commission requirements.
• For all site jobs, Bidder will designate a site manager, as the point of
accountability and contact for all matters related to the project(s)
completion) in charge (not the site supervisor) who will be completely
responsible for completion of the jobs.
• Permit Receiver shall pass Maaden Aluminium centralized PTW
receiver course and should have minimum 4 years’ previous
experience.
• A Ma’aden qualified dedicated technical person for collecting and
returning of the work permits, safety requirements and for conduct of
Bidder’s people within the premises of Ma’aden. He will be
coordinating and taking necessary work instruction from the user
department on routine basis.
• The working area shall be kept cleaned of all unwanted materials daily
basis as per the Ma’aden Environmental policy.
• LOTOV (Lock out tag out verification) Procedure.
• Ensure that Ma’aden Aluminum Lock, Tag, verify (LTV) safety Procedure
is followed.
6.3 Permit to Work
• All activities on the project shall require a permit to work.
• Work Permit is required to perform the Work in Restricted areas and
Work Permits shall be issued as detailed in the MAC procedures and
standards.
• BIDDER shall have sufficient qualified Work Permit Receiver to receive
Work Permit as required to perform their Works to meet their target
Schedule.
• Work permit certification training and exam for employees takes longer
time. Therefore, BIDDER to schedule their employees for training &
apply for certification class as soon as possible after signing the
CONTRACT.
• BIDDER shall consider that the MAC permit issuing authority will have
dual responsibilities for production and project activities and therefore
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sufficient time should be allowed between issuing the permit request

and the planned start date.
• Proper deployment of permit receivers, fire watch, standby men, safety
officers aside from the craftsmen and supervisory staff to the skill level
of MAC requirement shall be BIDDER responsibility throughout the life
cycle of the project.
• A Permit to Work shall not be issued without an approved method
statement and risk assessment in place.
6.4 Scaffolding
• BIDDER shall allow for the provision of a common user scaffolding
service for all construction and pre-commissioning, commissioning
activities, including but not limited to Inspection, Demolition,
Construction, Suppliers scope of work for modifications and
inspections.
• Maaden shall provide laydown down area and bidder to maintain the
area for scaffolding materials.
• BIDDER shall provide sufficient qualified scaffolding supervisors &
inspectors to ensure that scaffolds are erected and maintained in
accordance with safety requirements and planned to meet the project
schedule.
• Scaffolding shall only be erected, modified and dismantled by
scaffolders certified in accordance with MSHEM standards and
procedures.
• A SCAFFTAG system for control of scaffolding use shall be implemented
by BIDDER as per MSHEM Standards & Procedures.
6.5 Mobile Equipment

• BIDDER shall make provision for all mobile equipment required for the
duration of the project.
• All the mobile equipment’s required for the Project should be
inspected by MAC Mobile Equipment department.
• BIDDER shall provide qualified riggers to co-ordinate all crane
requirements, review of method statements, preparing lift plan and
crane movements.
• Crane operators shall be fully qualified and certified for the equipment
they are responsible for.
• The crane supplier will be required to establish a workshop for the
project capable of providing routine service, inspection and testing
facilities.
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• All cranes, slings, shackles etc. shall have the appropriate valid test
certification and the crane provider shall maintain a register of all
inspections and tests carried out during the project.
• BIDDER shall provide sufficient Rigger I, II, III to perform their lifts. All
Critical lift plans shall be prepared and reviewed by Rigger I and duly
Reviewed by MA’ADEN.
6.5.1 Requirement for Vehicle Sticker for bidders Vehicle

• Duly filled request form
• Vehicle Registration card copy
• Vehicle Insurance Copy
• Driver’s Saudi ID/Iqama/Passport copy
• Driver’s Saudi License copy
• Driver’s MA ID copy
• Lease agreement for rental vehicle.
6.5.2 Requirement for Industrial Vehicle/ Mobile Equipment Sticker for Bidders equipment
• Apply through MEI System
• ME Inspection check list filled by Approved Inspector
• Copy of Registration Card issued by Saudi Traffic Dept.
• If not, Ownership Certificate issued by equipment owner
• Copy of Equipment Insurance Document
• Copy of Equipment 3rd Party Inspection Report
• Copy of Operator’s Saudi License for Equipment operation
• Copy of Operator’s Saudi ID/Iqama
• Copy of Operator’s MA ID
• Copy of Operator’s 3rd party training card
• Copy of Lease agreement for rental equipment
• Copy of TAMM documents for rental equipment
6.6 Method Statement and Risk Assessment

• All activities in the field shall require a method statement and risk
assessment regardless of location or impact on operations.
• BIDDER shall be responsible for ensuring that all SUBBIDDER(S) and
vendors produce method statements and risk assessments.
• As a minimum the method statement shall fully describe the task
planned, name of responsible person, identify plant and equipment to
be used, scheduled start/end dates, risks, control measures, mitigation
of risks and reference to relevant procedures. The method statement
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and risk assessment shall be submitted well ahead of the actual start of
site activities.
• As a minimum, the method statement and risk assessment shall be
reviewed and approved by the BIDDER and the MAC as required.
Approval shall be obtained a minimum of 2 weeks before start of site
activities.
• The content of an approved method statement and risk assessment
shall not be changed without the agreement of all parties. For example,
revisions to method statements and risk assessments shall be reviewed
and approved before the work may continue. This shall be done within
the minimum possible time frame to ensure smooth flow of work.
6.7 Job Safety Analysis
• BIDDER shall perform a Job Safety Analysis (JSA) at the planning stage
for all work activities, which involve a significant risk, which are not
adequately controlled by existing control measures, such as operating
procedures, and safe work practices, etc. as per MA-EHS-S-037.1
• Activities requiring JSA shall include:
• Jobs that are routine and have frequent accidents or near misses, even
if the degree of injury or damage is low.
• Jobs that are non-routine and have a potential for a very serious loss.
• Jobs those are new or repetitive, and not covered by an operating
procedure.
• Other activities for which a JSA is deemed necessary by the area OME
team.
• The preparation of JSA’s shall, where possible, involve personnel
actually doing the job.
• JSA’s shall be documented and the documents filed appropriately by
the responsible workgroup.
6.8 Waste Removal and Disposal
• A WMP (Waste Management Plan) shall be prepared by the BIDDER
and approved by the MAC, prior to the production of any waste
material, this plan shall identify types and volumes of waste and how
this waste will be handled, stored, managed, treated, disposed of and
controlled. The WMP shall be incorporated in the overall
Environmental Management Plan (EMP) prior to construction and
operation.
• Waste management for all materials, including hazardous waste, shall
be provided by BIDDER.
• During the removal and transportation of hazardous materials BIDDER
shall employ suitably qualified sub-BIDDERS and shall comply with the
appropriate legislation.
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• BIDDER shall ensure that all records for the transportation and disposal
of hazardous waste are maintained (and kept available for random
inspection) and handed over to MAC on completion of the project.
EHS Documents Reference:

• MA-EHS-S-009 CONTRACTOR Safety process
• MA-EHS-SP-037 Permit to work program.
• MA-EHS-S-004-Industrial and Earth Moving Mobile Equipment
• CONTRACTOR Program (MA EHS.S8.12.001)
• EHS CONTRACTOR Safety Process (MA EHS.S8.12.001)
• Contractors EHS Requirements
• MA-EHS-MS-02 EHS ASPECTS RISK & IMPACT ASSESSEMENTS.
• MA-EHS-S-009 CONTRACTOR Safety process
• MA-EHS-SP-037 Permit to work program.
• CONTRACTOR Program (MA EHS.S8.12.001)
• EHS CONTRACTOR Safety Process (MA EHS.S8.12.001)

• MA-EHS-S-009 Contractor Safety process
• MA-EHS-SP-037 Rev 05 Permit to work program.
7 Planning and Progress Measurement

7.1 The Control Schedule shall include a Control Network for Procurement, Construction
and Mechanical Completion and Practical Completion. The Control Schedule shall be
supplemented with Progress ‘S’-Curves, Manpower Schedules and Histograms and a
Construction Plant / Equipment Deployment Schedule. The control schedule shall
support the Employer’s overall schedule for the completion of this project
7.2 The Control Network shall be in enough detail to show milestones, sequence and
inter-relationships between various activities and sub-activities to the lowest level.
7.3 The Control schedule shall, after approval by Employer/Project Manager, serve as the
schedule for controlling the time and resource utilization, productivity requirements.
The approved schedule shall be considered as the “Baseline Schedule” and shall not
be changed without appropriate approvals by Employer/Project Manager.
7.4 Progress Measurement: Progress measurement shall be based upon the physical
progress against each of the activities / sub-activities and deliverables according to a
set of weighted values allocated according to the effort required to complete. Bidder
shall submit, to Employer/Project Manager for review and approval, its detailed
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system for measuring the progress of construction, pre-commissioning,

commissioning and start up, prior to implementation. The following basis will be used
for working out the weighted values of various activities within each Facility.
7.5 Progress and Status Reports: Bidder shall prepare a Daily and weekly Progress Reports
in accordance with General Conditions. Daily Progress Report (DPR) – BIDDER shall submit
Daily Progress Report on or before 08:00 Hours daily to the MAC. This report should also
include the activities, which will be carried out next day, along with the daily issues (if
any). Weekly Progress Report (WPR) – BIDDER shall also submit Weekly Progress Report
on or before 08:00 Hours as per mutually agreed day with the MAC. Weekly progress
report should capture the activities completed for the current week and planned for next
week. BIDDER shall also highlight the delay/risks and submit the Catchup plan.
7.6 The following shall also be included:
• Safety Report
• Weather report
• Daily Activities & Plan activity for next day
• Two (2) week "look ahead plan.
• Manpower & construction equipment planned versus actual
deployment
• Project Progress
• Project Status (procurement, subcontracts, construction,
Mechanical Completion and Practical Completion)
• Invoice Status and Log
• Risk Mitigation plans for catch up (Area of Concern)
• Quality assurance / Control
• Non-Compliance reports/ corrective/ preventive actions
status.
• S-Curve
7.7 During the construction stage daily meetings shall be held at the end of each working
day. The meeting comprised from Bidder project manager, MA Project engineer, MA
construction engineer and MA planning leader. The agenda will be all area of concern
related to this project, progress monitoring and planned activities. The person or
persons designated by BIDDER to attend the meetings shall have all the required
authority to make decisions and commit BIDDER to solutions agreed upon during any
meetings.
8 General Construction Requirements

7.1 Construction Documents:
• Bidder to submit the construction package documents prior to start of any site
activity for the approval.
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• Bidder to depute experienced and qualified site supervisor for project supervision
to achieve good quality, safe work and within the schedule.
• Bidder to submit Resume/ CV for the construction supervisor for Maaden review/
interview and approval.
Sr. No. Document Description

1 Project Execution Plan
2 Mobilization plan
3 Construction safety Document: JSA, Risk assessment
4 List of Mobile Equipment, machine, tools
5 Site and Waste Material Management Plan
6 All Sub-Bidder MAC profiles
7 Resumes of all Project Engineer, Construction manager,
construction Engineers / supervisors/ Safety Officer with all
relevant certificates.
8 Method of statements for all construction activities.
09 Emergency Plan
8.1.1 Technical Proposal minimum requirements, but not limited to:
Scope compliance, proposed project schedule, Previous work experience
related to similar projects & in Maa’den. Bidders shall compile and
arrange the Technical Proposal as per the below 13 sections.
Minimum requirements (documents & information) in each section shall be as

mentioned below.
No. Bid Sections Requirements in the section
Bidder shall prepare and submit a brief scope of
work of the project. The Technical Proposal shall
cover the highlights of the project, major
equipment, systems.
1 Technical Proposal
and services.
Previous work experience related to similar
projects & in Maa’den, List of projects executed in
last 3 years
Bidder shall prepare a discipline-wise list of Long
Long Lead Items (LLI)
Lead Items (including equipment catalogs) along
2 & Bill of Quantities
with preliminary BOM. Bidder to state any free-
(BOQ)
issue items
Bidder to attach a copy of the Commercial
Unpriced Commercial
3 Proposal (as per MA Procurement instructions to
Proposal
Bidders) without mentioning any prices / costs.
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Unpriced Contract Price breakup and Unit Rates

shall also be included.
MA’ADEN’s Bidders Compliance / Deviation Log
Bidder’s Compliance (Form# XXXXX) which is attached with ITB shall be
4
/ Deviation Log filled, signed & stamped by Bidders then
submitted with Technical Proposal
Bidder to attach the Pre-Bid Technical Queries (if
Pre-Bid Technical any) raised by Bidder during the pre-bid meeting
5
Queries or site visits. Bidder to also attach the responses
received from Ma’aden to these queries.
Bidder to prepare and submit Level-2 Project
6 Project Schedule
Schedule highlighting key milestones.
Bidder to attach a list of its Sub-CONTRACTORs
and Vendors proposed for this project. All Sub-
Sub- CONTRACTORs
CONTRACTORs / Vendors shall be Ma’aden
7 / Vendors
approved. Sub-CONTRACTORs include:
List
Engineering, Inspection, Painting, Insulation,
Heavy Lifting etc.
The Project Organization Chart shall be prepared
Proposed Project by Bidder and shall include the name &
8 Organization designations of assigned personnel. Also, resumes
Chart of key personnel assigned for this project shall be
attached.
Bidder to prepare and submit Manpower Schedule
(high level) as per the requirements of the
9 Manpower Schedule
project’s scope and
schedule.
Bidder to prepare and submit the Equipment List
10 Equipment List as per the requirements of the project scope and
schedule.
Bidder to submit HSE Plan and Policy. Safety
11 HSE Plan & Policy
records for last 3 years
QA/QC Bidder to submit QA/QC Plan, Policy, ISO
12
Plan & Policy certificates
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Documents, Drawings, Datasheets, Manuals,

Catalogs, etc. which are specifically requested by
Ma’aden to submit in Bid Proposal in ITB, If Any.
Details of LLI within Bidder’s scope.
13 Attachments Reference list of execution of similar projects in
Ma’aden, KSA & abroad.
Execution plan, location of laydown area and a list
of required site facilities.
Documents which Bidder wants to submit in Bid
Proposal but are not covered in above sections.
7.2 Bidder’s Organization

• The BIDDER, in conjunction with all SUBBIDDER(S) and vendors, shall provide a
site management organization sufficient to execute the work in a safe, timely
and cost-efficient manner to the overall satisfaction of MAC.
• BIDDER to provide Organization Chart for all manpower and equipment at site.
• BIDDER shall provide a detailed and quantified overview of his proposed
WORKSITE Management Team, including accurate job descriptions, with defined
roles and responsibilities. The plan shall demonstrate sufficient management,
supervision and control of all site related activities that address as a minimum:
➢ Overall Site Management
➢ HSE, Medical First Aid Faculties.
➢ Waste Management
➢ Liaison with MAC, Third Parties, SUBBIDDER(S) and suppliers
➢ Construction Supervision
➢ Field Inspection (Pre-Construction) including Radiation Protection Safety Officer
➢ Pre-commissioning, Commissioning, Hand-Over and Start-up
➢ Field Engineering, Document Control and Administration
➢ Project Control, including Planning, Progress and Cost control
➢ QA/QC and Inspection
➢ Field Procurement, Materials Management and Field Fabrication
➢ Interface Management Plan (where applicable)
➢ Detailed Inspection, Construction and Commissioning planning documents.
➢ Detailed Pre-Commissioning and Commissioning documents
➢ WORKSITE Management Plan
➢ WORKSITE reports (Daily / Weekly / Monthly)
➢ Material Control, WORKSITE Procurement, Warehousing and Material
Distribution
➢ WORKSITE QA/QC Systems, Inspection Plans and Procedures, QA/QC
Organization
➢ Detailed Pre-commissioning, Commissioning and Hand-Over plan
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• The appropriate levels of supervisors and foremen shall need to be available to

ensure that the labor force is efficiently organized and managed.
• Qualified and Certified Crane operators, Riggers, Scaffolding supervisors and
inspector shall be supplied by BIDDER.
• Fire Watchers shall be supplied by BIDDER, to ensure that sufficient HSE trained
staff are available at each and every location, specifically where permits for hot
works and works in confined spaces are applicable, in order to execute the works
in a safe and controlled manner.
• BIDDER shall ensure that sufficient management and supervisory personnel are
present at WORKSITE during any construction activity. These personnel shall
also, as necessary, be in attendance outside normal working hours, to ensure
efficient direct hands on management of his sub-BIDDER and suppliers.
• BIDDER shall be responsible for the work assigned to the Sub-Bidders. BIDDER to
propose a minimum of 3 Bidders for any Sub-Contract scope / service. Any
subcontract for this project shall be placed only after receiving approval from
the MAC.
• BIDDER will not change any person from Organization without Ma’aden written
approval. However, Ma’aden will have right to release any person from
Organization due to non-performance/misbehavior/ non-compliance/ violation,
etc.
7.3 Bidder’s Construction Site Office and Facility

• The BIDDER shall install a temporary site office prior to mobilization of any
construction activity pertaining to the PROJECT. Proposal with layout sketch of
the site office shall be submitted for approval to the MAC.
• Construction BIDDER to develop site facility for project team, project meeting,
worker food, water, material storage. Office should be equipped per industrial
standards. Separate room for Project Meeting and site office for MAC team with
all basic needs shall be arranged.
• Providing food, transportation, welfare and all other facilities and amenities to
personnel during tenure of work. Ensuring proper behavior of personnel during
tenure of the work.
• A lay-down area designated by the MAC representative where the BIDDER shall provide at his
own expense the following as minimum:
➢ Temporary fences
➢ Barricades and lights
➢ Temporary site office
➢ Storage shed
➢ Workshops
➢ Toilet facilities
➢ Temporary power
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➢ Temporary telephone
➢ Water and sewer provisions
➢ First aid cabinet
➢ Portable fire extinguishers, type ABC, 30 lbs.
➢ Housekeeping and cleanliness
➢ Fire Protection plan for site
• BIDDER shall remove the temporary facilities after the completion of the project to
the satisfaction of the MAC representative
7.4 Third Party Inspection Requirement’s:
7.4.1 Mechanical
Requirements to be clearly defined and described
7.4.2 Welding
7.4.3 Tie-In
7.4.4 Painting and Coating

7.4.5 Civil
7.4.6 Electrical
7.5 Mobilization: BIDDER mobilization shall include but not be limited to all transport,
equipment, machinery, tools, personnel, supply, installation and erection of temporary
offices, work sheds, storage sheds, lay down areas, site perimeter marking, and any other
support facilities required for the performance of the work. BIDDER shall pay particular
attention to and allow sufficient time for obtaining from the MAC, all identity cards and
permits for his personnel and equipment.
7.6 Construction Work: BIDDER shall make field measurements and corrections necessary to
complete the job in a workmanlike manner. Work shall be carried out on 24 hour per
day and seven days a week basis, if required during the shutdown window.
7.7 Equipment and Material Handling:
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• BIDDER shall supply all equipment to load, transport, and off-load all equipment and
materials, and will also supply all warehousing or storage to protect the materials.
BIDDER shall provide lifting plan of all equipment/piping/structure and ensure the
safety of lifting operation as per MAC/RC guidelines.
• The BIDDER shall ensure that all tools and equipment used throughout the duration
of the project are of good quality, fit for purpose and carry the appropriate
certification where required. Tools and equipment’s shall be inspected and
certified for use at regular intervals complying with project safety and quality plan.
7.8 Checking and Testing: BIDDER shall provide the MAC with a complete set of test
records for all tests performed.
7.9 As Built Drawings

• BIDDER shall maintain one set of drawing prints specifically for marking up with as-
built information. All changes shall be recorded on the drawings, and on completion
of construction work, BIDDER shall update construction drawings and provide
them to the MAC.
• Prepare and issue "As-Built" drawings/documents in hardcopy and soft copy as
per the Project Documents submittal requirements. Submitted as built
drawings need to be verified by BIDDER, before submitting to the MAC for
review & acceptance.
• The work under this scope of work shall not be considered complete until all as-
built Documents and drawings are submitted to Ma’aden Representatives. All as-
built drawings softcopy to be submitted as MicroStation format (DGN).
7.10 De-Mobilization
• BIDDER demobilization shall include removal from the site of all waste, and the
site shall be left finished in accordance with the drawings.
• BIDDER shall return & acknowledgement of all ID issued for this project,
including sub-BIDDER IDs.
• BIDDER to get the demobilization / clearance letter from Ma’aden prior to any
demobilization. Any demobilization without Ma’aden approval will considered
as violation and necessary action taken to responsible authority.
7.11 Vehicle Permit
• BIDDER shall submit a complete “BIDDER Vehicle Sticker Application” for each
vehicle prior to mobilization. The vehicle and its equipment shall be subject to
inspection by the MAC for safety and operability.
7.12 Work Area
• BIDDER shall keep his personnel and equipment within designated work areas
and only enter operating areas with an authorized work permit.
8 Quality Assurance and Quality Control. (QA/QC):
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Revision #: 00
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• Bidder shall ensure that they have a valid ISO Certifications or equivalent related to
project requirements.
• Bidder shall submit their pre-qualification Quality documents as per PQC (Pre-
Qualification Checklist) form to Ma’aden for review and approval.
• The intention of the Ma’aden QAQC for the above said pre-qualification requirements
is to ensure that well qualified, skilled, experienced personnel are employed on
assigned project.
• Bidder shall perform Quality Assurance and Quality Control (QAQC) functions for all
parts of the work, including its subcontractor’s, manufacturers’ and supplier’s work as
specified in the bidder’s approved Quality Manual and as per MA standards and
specifications.
• Bidder shall ensure that the all QAQC requirements are clearly specified during Kickoff
meeting (KOM) and all documents will be submitted for MA as per QAP (Quality
Assignment package) form.
• QAQC Personnel Qualification (CV’s) shall be submitted by the Bidder along with
contractor proposal for Ma’aden approval.
• Bidder shall provide backup QC Inspector, if changes required due to vacation,
emergency leave, illness or other reasons as necessary to maintain required QAQC
coverage.
• Bidder shall send the minimum 03 working days advance notice for assigning new QC
Inspector qualification for Ma’aden approval
• Bidder shall submit the Quality documents as per Ma’aden QAP (Quality Assignment
package) form prior to attend the PIM meeting.
• Project Quality Plan (PQP) shall be submitted by the Bidder prior to start any site
activities.
• Bidder shall prepare the Draft Inspection Test Plan (ITP) along with checklist and shall
submit to Ma’aden for further approval during PIM.
• Bidder Inspector shall be responsible for the daily site Quality activities to establish
and maintain the Project Quality program and Controlling the site inspection and test
activities.
• Bidder shall ensure to have the availability of Ma’aden approved IFC drawing including
Bill of Material (BOM) prior to commencement of any inspection activities.
• It is mandatory for Bidder QC to attend the PIM & shall Lead the quality concern issues
for whole project during PIM.
• Bidder’s QAP documents will be reviewed and approved by Ma’aden QAQC during PIM
meeting.
• Bidder to engage certified Third Party for external inspection whenever required.
• Bidder shall prepare 1-week look ahead inspection schedule shall be submitted to
Ma’aden QAQC for review.
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Area: RAK Port
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Sub-Area: CCW
Revision #: 00
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• Bidder QAQC to coordinate with Ma’aden QAQC representative for project inspection
activities.
• Bidder shall provide all instrument calibration certificate along with data sheet to
Ma’aden QAQC for inspection and review and prior to start any site activities.
• If Maaden QAQC found any inspection is closed or covered before the required
inspection or witnessing as per approved ITP, if required, Bidder must be re-schedule
or perform the inspection under bidder expense.
• For Project site activities, bidder shall submit the RFI within 24 hours prior to start any
Inspection activities as per Ma’aden RFI format.
• For Vendor shop activities, bidder shall submit the RFI within 05 working days for
inside kingdom & 14 working days for outside kingdom prior to start any Inspection
activities as per attached Ma’aden RFI format.
• Bidder shall to provide the proper justification with target date within 24hours after
the issuance of QI (Quality Issue)/NCR (Non-Conformance Report)/EDR (Equipment
Deficiency Report) to Ma’aden QAQC for review and approval. Please note that for
EDR/NCR closure date should not be more than 04 week.
• Prior to close any project, bidder shall verify the closure punch list, Inspection Release
Certificate (IRC) & Non-Conformance Report (NCR) either any quality issue open so
bidder shall notify to Ma’aden QAQC team after analysis.
• For issuance of IRC (Inspection Release Certificate), Bidder shall submit the Quality
dossier package as per Ma’aden FDR form to Ma’aden QAQC team for review and
approval.
• Ma’aden QAQC will issue the final IRC once the punch list items have been completely
closed and after the approval of QAQC dossier.
8.1 QAQC Deliverables:
Sr.
Deliverables:
No.
1 Pre-Qualification Quality checklist (PQC)
2 Quality Assignment package (QAP)
3 QA/ QC personal CV for Third party inspector
4 Third party inspections as per Ma’aden requirements
5 Material Approval submittal
6 Inspection test plan (ITP) and inspection checklist for all disciplines
7 Field inspection and testing procedure for all disciplines
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8 Consumable control, preservation& Handling procedure

9 Non-conformance handling procedure
10 Project Quality audit plan wherever applicable
11 TPI/ Contractor inspection Report, RFI, Welding, NDT report, etc.
12 QAQC Dossier package
8.2 List of QAQC Forms:
Sl. No Form Description Form No

1. PQC (Pre-Qualification checklist) CE&P-QAQC-PQC-001 Rev.00
2. QAP (Quality Assignment Package) CE&P-QAQC-QAP-001 Rev.00
3. RFI (Request for Inspection) CE&P-QAQC-RFI-001 Rev.00
4. FDR (Final Disposition Report CE&P-QAQC-FDR-001 Rev.00
Requirements)
5. IRC (Inspection Release Certificate) CE&P-QAQC-IRC-001 Rev.00
9 GENERAL NOTES TO BIDDER:

9.1 BILL OF QUANTITIES AND PRICES
• The quantities set forth in the Bill of Quantities and Prices have been estimated
only and are based on the Scope of Work set forth in the Project documents.
• Bidder, if awarded the Project, shall have no basis of claim or to an adjustment
of any of the unit prices arising out of any variation between the estimated
quantity for any units of Work and the final quantity for such units measured
in accordance with the terms of this Project.
• If Bidder considers that a Pay Item(s) for a part of the Work as defined in the
specifications and drawings has not been included in the Bill of Quantities and
Prices, he shall so notify the Client during the bidding period.
• Bidder shall insert prices for each Pay Item in the Bill of Quantities and Prices
and the aggregate of the amounts for each Pay Item shall equal the estimated
Project Price set forth in the Proposal Letter.
Note:
• Bidder is cautioned against changing the pay item quantities and descriptions
stated in the Bill of Quantities and Prices without the approval of the Client.
• Bidders are advised that in pricing the Bill of Quantities and Prices, the unit
rates should be to two (2) decimal places only, and the extended totals should
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also be to two (2) decimal places only. Neither the unit rate nor the extension
of the unit rate shall be rounded off.
• All rates and resultant prices shall include for all initial price escalation risk and
are not subject to any adjustment in respect of any pricing risk for the duration
of the Project.
9.2 PREPARATION OF BID
• SITE VISITS
Bidders are requested to visit and examine the site and its surroundings and
shall familiarize him with the existing facilities and environment, and shall
collect all the information, which he may require for preparing and submitting
the bid and entering into the Contract. Claims
change order and objections due to ignorance of existing conditions or
inadequacy of information will not be considered after submission of the bid
proposal, during and after execution of the project. Bidder is responsible for
his bid and no relief or consideration shall be given for errors and omission.
• GATHERING INFORMATIONS
Bidders shall be responsible for gathering and checking all the information and
data such as the terms and conditions for carrying out the Work. Preparation
of shop fabrication drawings, quantities and materials necessary to carry out
the Work. The laws and regulations of the Kingdom of Saudi Arabia, the
procedures and regulations of MA'ADEN ALUMINIUM MAC Operation, Safety
and Security shall be applicable to this Work. Any neglect on bidder’s part
and/or error in or incorrect evaluation of Work and the difficulties related to
the Work due to site conditions, which may contribute adversely to the
evaluation of the above, shall by no means absolve the bidder of any
Contractual obligation and shall not entitle him for any claim or shall not be
acceptable as reason for delay
• PRE- BID
MA'ADEN ALUMINIUM MAC will arrange a pre-bid technical presentation

explaining general overview and specific details of technical requirements of
the complete project.
9.3 KICK-OFF MEETING

• A kick of meeting will be held at MA'ADEN ALUMINIUM MAC shortly after
award of the Contract. This meeting will cover project team organization,
scope of Work, schedule, execution of the project, safety aspect, quality
control and the site project management etc. This meeting will also give the
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Bidder an opportunity to discuss all the matters related to carrying out his
responsibilities.
10 Mechanical Completion and Pre-commissioning:

10.1 Mechanical Completion: When Bidder considers that the integrity of the
installed facility is proven by way of tests and checks; Ready for Commissioning,
and Start-up. As a minimum below tests/checks have been performed, documented
and signed off, can declare the Mechanical Completion inviting Ma’aden Project
team and relevant stakeholder for joint walkthrough and inspection. As a result of
joint walkthrough either Ma’aden will advise the Bidder in writing acceptance of
Mechanical Completion or a Punch List of items that require rework/correction. Such
Punch List of items shall be made in two categories. One category of the Punch List
items that must be corrected and completed before the facilities are considered
Mechanically Completed. The other category of the Punch List items that can be
completed during course of commissioning; these deficiencies are limited to those
not undermining the operational safety of the installed facility.
10.1..1 All static and visual checks should have been completed.
10.1..2 All QA/QC dossiers have been fully updated.
10.1..3 Vendors O&M Manuals are available.
10.1..4 Commissioning spares are available.
10.1..5 Red markup drawings are ready.
10.1..6 Housekeeping carried out.
10.1..7 Non-operating alignment and adjustment of mechanical
equipment is done.
10.1..8 Checking and calibration of Safety Relieve devices is done
10.1..9
10.1..10 Cable terminations and torque tightening is done.
10.1..11 Insulation resistance check is done.
10.1..12 Earthing/Grounding checks is done.
10.1..13 Correctness check of cable tagging and wire ferrules is
completed.
10.1..14 Electrical polarity and resistance test is completed.
10.1..15 Circuit Breaker functional test is completed
10.2 Pre-commissioning: Pre-commissioning is under BIDDER scope of work. The plant

or any part of it as agreed between the MAC and the BIDDER shall be deemed to be pre-
commissioned and mechanically complete when it has been installed in accordance
with the specifications, drawings, manufacturer’s instructions and tested in
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Area: RAK Port
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Sub-Area: CCW
Revision #: 00
Date Published:
accordance with engineering requirements and all the appropriate documentation

has been completed as per Project requirements and is available to hand over to the
MAC. No fluids other than those used for pressure (leak) testing, flushing and
lubrication of equipment will be allowed into the systems.
The transition of the new facilities and equipment from construction, through pre-
commissioning to commissioning, and finally plant operation will be carefully planned.
BIDDER to develop the plan, forms, handing over and guarantee/ warranty docs as per and
in line with MAC Procurement guidelines.
• Participate in Pre-start up Safety Review (PSSR) and follow up for observations.
• Review and verify the Red- mark up drawing and submit to the MAC. The
Construction BIDDER shall maintain a set of mark-up drawings during performance
of the work to record all as-built changes that occur during construction of this
project.
• Verify the As-built drawing as per Red Mark up and notify to the MAC.
• Review of Handing over packages as per MAC Procedures.
• BIDDER shall prepare a pre-commissioning checklist. MAC Representative shall check all
the items listed in the pre-commissioning checklist.
• BIDDER should give a written notice before preparing a checklist that the work is
completed.
• Test at site during/after installation shall be carried out by BIDDER as per approved
Quality Assurance Plan (QAP). The test procedures (operating tests and acceptance
test) shall be included in the QAP.
• BIDDER supervisors I test engineer shall be fully familiar with all the relevant safety
standards and shall comply with MAC safety rules and regulations.
• After completion of installation, operating tests shall be witnessed by MAC to
ensure compliance with the QAP. Any adjustments shall be made as required and
test shall be repeated after adjustment.
• Testing/Pre-Commissioning of the completely new facilities shall be under
BIDDER responsibility.
• Final acceptance shall be subject to compliance report, to be determined after
inspection by MAC after acceptance tests.
• Construction materials, test instruments and tools required for the site tests shall be
available with BIDDER.
• Defects on any materials installed and observed in the test result shall be
replaced by the BIDDER at his own cost.
• Tests during/after installation and prior to acceptance shall be performed in the
presence of the authorized engineer from MAC.
• BIDDER shall make sure and inspect the installation has been carried out as per project
scope of work, codes and standards, and prepare punch list and this punch list should
be corrected by the BIDDER prior to commissioning /testing of the entire Project.
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• Testing/Pre-Commissioning of the complete piping system shall be under

BIDDER responsibility.
• BIDDER shall provide Ma’aden with a complete set of inspection and test records for
all test performed.
10.3 Handover of Care and Custody:

• The plant or any part of it shall be considered acceptable for Handover
to the MAC when the requirements of the CONTRACT have been fulfilled
and any punch list items are of such a nature (No item) that they do not
restrict the MAC ability to proceed with commissioning activities. BIDDER
shall produce Handover Dossier’s per system containing red line marked
up key engineering drawings, plus copies of key quality verification
documents per discipline. Discipline sign off shall be visible on each
system prior to signature of the BIDDER Project Management Team. The
system shall be deemed formally handed over to MAC when the
certificate inside the Handover Dossier has been signed.
• Once part of the plant has been formally handed over to and accepted
by the MAC, the BIDDER will have no control over that part of the plant
and will need permission from the MAC to complete any punch list items.
These items shall be performed under the MAC Permit to Work (P.T.W).
System.
• BIDDER shall note that the pre-commissioning and commissioning phase
are extremely high-risk phases of the project and detailed coordination
between commissioning and construction activities is of paramount
importance.
10.4 Activities after Handover: After handover is completed, BIDDER and MAC shall
produce a Safety Management System to ensure the safe operation of the plant
and safety of personnel involved in the commissioning process and completion of
construction activities.
10.5 Commissioning, Start Up and Operational Implementation Assistance:

Commissioning shall be by the Vendor for the supplied Equipment.
• BIDDER shall define, all commissioning systems, subject to approval by MAC,
allowing phased hand-over and commissioning activities (functionality
and performance testing). After approval of the systems, BIDDER shall
develop a detailed Commissioning Plan, identifying all required commissioning
activities. BIDDER shall submit a detailed level III and level IV commissioning
planning document, identifying all activities provided in the
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Area: RAK Port
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Sub-Area: CCW
Revision #: 00
Date Published:
commissioning plan as per CONTRACT.

• BIDDER shall provide details, plans and planning documents for vendor site
assistance. BIDDER shall co-ordinate all vendor site assistance.
• BIDDER shall be required to provide support to the MAC during the
commissioning and startup phase. This assistance shall include all required
services by a BIDDER supplied commissioning staff, including a fully
experienced Commissioning Manager, Commissioning Engineers,
Commissioning Specialists supplied by BIDDER vendors, experienced DCS
operators and sufficient qualified labour (including tools) and supervision in
all disciplines.
10.6 Completion and Acceptance of Work:

• Upon completion of all work under the contract, BIDDER shall give written
notice to the MAC that all work has been completed per the contract work
scope. After receiving the notice, MAC representative shall inspect/ check
all the work per the approved drawings/ specifications etc. and issue a note
to BIDDER certifying “Work Completion.”
• Final acceptance shall be reserved until all other contractual
requirements are met.
11 GUARANTEE
• Without prejudice to MA'ADEN/MA'ADEN ALUMINIUM MAC approval of
vendor's documents/procedures, vendor shall guarantee the materials, any
failure from normal use, Workmanship and performance of the new supplied
& installed by them after 18 months’ warrantee from date of commissioning
• Bidder shall be responding to emergency calls & provide technical support up
to one year after commissioning of the projector system at no extra cost.
Bidder’s failure to respond will be subject to penalties. MA'ADEN/MA'ADEN
ALUMINIUM MAC has the discretion for the penalty amount as the long-time
loss equipment causes operational trouble and can result in loss of plant
unrestand subsequent loss in production.
12 PROJECT MILESTONE
SN Milestone Achievement Date

1 KOM, preliminary L2 Schedule 1-week after PO award date
2 L3 Schedule, necessary plans 1-week after KOM
5 Cranes Procurement & Delivery 24-weeks after PO
6 Structural retrofitting, electrical and 16-weeks after PO
Automation works
6 100% Installation of cranes 32-weeks after PO
7 Mechanical Completion/QAQC dossier 34-weeks after PO
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8 Commissioning 36-weeks after PO

9 As-Built submission 40-weeks after PO
10 Project Close out 42-weeks after PO
13 Attachment
• Engineering Package
• MA Standards
• MSHEM standards
Page 41 of 41

Itb - CCW Crane Upgrade Rev

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Area: Smelter, RAK

Instruction to Bidders Department: Central Projects

Document No: MD-402-

CCW CRANE UPGRADE FROM 16.5 T TO 20 T

Project Name: CCW CRANE UPGRADE FROM 16.5 T TO 20 T

Sign: Date: 27/11/2022

Project Engineering Superintendent:

Sign: Date: 27/11/2022

1. Project Background: Ma’aden Aluminum Company (MAC) is one of the largest

2. Project Introduction & Scope:

Construction Contractor with supervision of Crane OEM.

2.1 Project Scope of Work

The crane upgradations work shall comply in design, materials of construction,

2.2 ENGINEERING SCOPE OF WORK

b) The cranes shall be procured from Micheletto Only with below

SN ITEM DESCRIPTION UNITS REUIREMENTS

1 CRANE TYPE - OVERHEAD

c) The Contractor shall be responsible for the removal of existing

s) The execution strategy to be provided for the removal of the

to support the Maintenance Team to implement a

3.1.2 Structural Works

Tensile Test Charpy V-Notch

< 16 > 235 > 350 375 485 > 26%

k) HMI Display to be supplied. Installed, and Integrate to Level

• Co-ordination with the Project/ Construction Engineer regarding any

• Construction Execution Plan (CEP)

3.3 Bidder’s Construction Site Office and Facility:

3.3.1 Housekeeping and Clean Up

• Clean-up work shall immediately follow completion of

4 Codes & Standards

SN Document Number Description

5. ASTM A325 Standard for Hot Dip Galvanized

7. Ladle & tube Cleaning LV S/S-2162

ACI 305 Specifications for Structural Concrete

ASTM B16.20 Metallic Gasket for Pipe Flanges

The applicable local, international / national standards and specifications, Ma’aden

Attached the Index of Ma’aden Standards

6 EHS (Environment, Health, Safety Standard) Requirements for construction Bidder.

5.1 Safety training and ID requirements:

• Bidder to undergo Ma’aden general trainings such as safety induction,

• Plant specific trainings such as Chlorine, DC Hazard, etc shall be

• Safety officer shall with minimum 5 years of GCC industrial experience

• Bidder shall ensure all their employees, sub-contractors, visitors,

6.1.1 Requirement for MA ID for Contractor Employees

sufficient time should be allowed between issuing the permit request

6.5 Mobile Equipment

6.5.1 Requirement for Vehicle Sticker for bidders Vehicle

6.6 Method Statement and Risk Assessment

EHS Documents Reference:

EHS Documents Reference:

7 Planning and Progress Measurement

system for measuring the progress of construction, pre-commissioning,

8 General Construction Requirements

Sr. No. Document Description

Minimum requirements (documents & information) in each section shall be as

Unpriced Contract Price breakup and Unit Rates

Documents, Drawings, Datasheets, Manuals,

7.2 Bidder’s Organization

• The appropriate levels of supervisors and foremen shall need to be available to

7.3 Bidder’s Construction Site Office and Facility

7.4 Third Party Inspection Requirement’s:

7.4.4 Painting and Coating

7.7 Equipment and Material Handling: