<Operation Readiness Management Plan for Jetty 2 Tower Replacement Project>

OPERATION READINESS MANAGEMENT

PLAN

JETTY 2 TOWER CRANE REPLACEMENT

EXECUTE PHASE

Revision Record

Document Life Cycle APPROVAL

Rev Description Originator Reviewer. Approver Date
0 Initial Issue P.O E.I K.I

All signed originals will be retained by the Project Document Control Centre and an electronic copy
will be stored in Livelink

Signatures for Revision

Originator Peter Ohwerhi (TPC/4C8)

Custodian Innocent Ekpu (TPC/4)
Verified by Adebayo Ola (TPC/1) Oluwole Pelemo Godpower Olungwe (POS/41)
Signature (TPC/3)
Date
Authorised by Kenneth Azike (TPC) Signature Date
Authorised by Adekunle Signature Date
Arogunmati (POS)

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<Operation Readiness Management Plan for Jetty 2 Tower Replacement Project>

Contents

1. Introduction.............................................................................................................................. 4

2. The Scope of work…………………………………………………………………………………....5

3. OR/CSU Management............................................................................................................. 8

4. Flawless Project Delivery....................................................................................................... 16

5. Pre-Commissioning and Commissioning...............................................................................16

6. Project- To-Owner Transfer (P2O) Plan.................................................................................17

6. Spare parts............................................................................................................................ 17

7. Handover Documentations..................................................................................................... 17

8. Asset Owners Readiness / Asset Readiness Review (ARR).................................................17

8.1Performance & Reliability Test………………………………………………………………….

9. Preservation........................................................................................................................... 18

10. Asset Disposal....................................................................................................................... 18

11. RACI...................................................................................................................................... 19

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<Operation Readiness Management Plan for Jetty 2 Tower Replacement Project>

1.0 INTRODUCTION

1.1 Asset Readiness & Assurance Plan

The operations readiness management (ORMP) plan is a forward-looking document structured for the Jetty 2 Tower
Crane Replacement. It describes the activities that must be accomplished to achieve a right first-time commissioning of
the project and ascertains the state of preparedness of the asset owners to confidently take over the project to operate
and maintain it throughout its lifecycle. The overall objective of the ORMP is to assure future readiness and ensure
flawless project delivery.

1.2 Objective of the ORMP

To apply the principles of asset readiness and assurance for the optimal delivery of the Jetty 2 Tower Replacement in a
safe and environmentally friendly manner. The ORMP serves to ensure quality delivery of projects, risk mitigation,
accurate documentations that comply with the standard Asset Information requirements at handover to asset owners,
and training of end-users in readiness to operate and maintain the asset to ensure lifecycle benefits are realized.

1.3 Project Description

This project relates to the replacement of the tower crane in NLNG Jetty 2. Upgrade signifies demolition and removal of
existing jib systems and installation of new jib, and refurbishment of the mast to support a 20-year life extension.

This is to restore the integrity, reliability, and availability of the tower crane at Jetty 2 on the NLNG Bonny Island LNG
plant.

The existing Tower Crane was commissioned in 2004. In 2016, the tower crane failed a load capacity test due to the level
of deterioration and was later derated from allowable load of 8.0 Tons to 5.9 Tons. Due to obsolescence and
unavailability of OEM support, the tower crane was tagged out of service in 2020 after being assessed and considered
unsafe for use with compromised integrity.

A project was initiated by NLNG to investigate options for replacing or restoring the existing tower crane. The concept
select phase has been completed and is documented in a separate Concept Selection Report.

Replacement of the jib was selected as preferred option based on the criteria for evaluation set out in the Jetty 2 Tower
Crane Replacement Project Concept Select Report. The viability of this option is based on an NDT assessment carried out
by a specialist vendor, which confirmed that the mast has a remaining life of more than 20 years and thus did not need
to be replaced.

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2.0 THE SCOPE OF WORK

2.1. Project Scope Summary

The scope of project covers for the following:
 Design and supply of a fit-for purpose jib.
 Demolish existing tower crane jib.
 Installation of new jib.
 Commissioning of the New Tower crane.
 Rehabilitation and modification of tower crane mast. The table below demonstrate the scope summary.
The table below demonstrate the scope summary.

Figure 1 - Scope Illustration

2.2 Preparatory Work

Pre-work scope should be completed prior to NLNG management approval. The overall scope of work to include:
 Pre-qualification and certification of demolition and installation tools and equipment including crane barge.
 Approval of method statements and risk assessments.
 Preparation of work permits required to execute the work.
 Mobilization of construction equipment, tools, and material.
 Erection of barriers and signage to prevent entry of unauthorized personnel to the construction area.
 Electrical isolations for executing work.
 Provision of safe access at the work fronts for demolition of the existing jib.
 Demolition of existing jib.
 Corrosion control and grating & bolts replacement of the mast as indicated in the mast NDT report.
 Fabrication and installation of steel work required to support mast repair and jib replacement.
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 Scaffold erection (if eventually it will be required in place of rope access).

2.3. DEFINE Phase Scope of Work
The DEFINE phase scope of work shall be focused on three parallel work streams related to the jib replacement:
 Vendor supply of standard solutions (Liebherr/IPESL (OEM) supply).
 Brownfield scope.
 Secure approval for the various contractors to carry out their responsibilities.

2.4. DEFINE Phase objectives are to:

 Develop a detail design sufficiently defined to enable a type 3 cost estimate and level 3 schedule to support FID.
 Deliver an installation methodology to enable detailed method of the new jib replacement and demolition of the old jib to
progress seamlessly and in a safe manner.
 Define vendor packages and support procurement to the point of package ready to award following project sanction
Due to the nature of this project which is predominantly procurement of standard equipment and installation with relatively marine and
little brownfield scope shall be carried out.

2.5. Vendor Supply

PMC via Vendor to firm up the standard solution that meets company functional requirements as well as scope of supply for the
vendor/OEM (Liebherr).
The new jib to be replaced shall be designed to be installation in as few numbers of lifts as possible onto the existing mast. Vendor (IPESL)
shall work with construction Contractor (DEP) in the identification and resolution of logistical and site constructability constraints during
DEFINE Phase.
2.6. Brownfield Scope
Contractor shall identify and address logistical and site constructability constraints during Define phase.
The following are excluded from the vendor scope of supply and shall be designed by the FEED Contractor:
 Demolition of existing jib
 Existing mast modification.
 Civil works and erection activities.
 Electrical cable isolation and connection.
 Any modifications/repairs to ladders, external lighting, etc
 Commissioning of the installation.

2.7. Project Location

The location of the tower crane is shown in the figure below. It is a brownfield location with limited access via road due to load
requirement on the bridge. Being a marine environment with product loading jetty infrastructural installations, access through water is
also burdened by pipe-racks. Work shall be performed using lay barge barges with long reach. Below is the layout area of the Tower Crane.

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Figure 2: Project locations.

System Tag Name of Systems Location

Number
A-3436-01 Slewing Platform System

A-3436-01.01 Slewing gear

A-3436-01.02 Switchgear Cabinet

A-3436-01.03 Slipring assembly

A-3436-01.04 Slewing gear

A-3436-01.0 5 Cabinet

A-3436-01.06 Slewing ring Support

A-3436-02 Counter Jib System

A-3436-02.01 Counter- ballast A& B or C

A-3436-02.02 Toolbox

A-3436-02.03 Tower section

A-3436-02.04 Hoist rope

A-3436-02.05 Tie bar Counter-Jib

A-3436-03 JIB System

A-3436-03.01 Trolley

A-3436-03.02 Load Hook

A-3436-03.03 Hoist Rope

2.8 The main components of the tower crane are:

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2.9 System work Deliverables.

Deliverables includes, but not limited to:

 System and Subsystems break down.

 FAT & SAT procedure.
 Bill of Materials/ Construction Execution Plan.
 As Built Documentation.
 Site procedures and work instructions.
 ITR Check sheet (A and B).
 Punch list.
 Training Materials/training of Ops/Maintenance/Asset Teams.
 List of commissioning spares and two years running spares.
 Pre-commissioning inspection test plan Commissioning Test Plan.
 Certifications.

Note that this list is not exhaustive and design contractor can update as necessary

2.10 The systems scope of work

The detail scope of work will include both static and dynamic aspects of commissioning and will to a greatest extent
possible represent a complete testing of systems and subsystems of the project.

These documents comprise the various steps that will be provided to demonstrate that the system is fit for purpose,
assembled correctly, tested completely, and preserved correctly and hand over to Operations.

3. OR/ CSU MANAGEMENT

 (Key Deliverables and Activities)

Operations Readiness and Assurance deliverables relevant to the project Roadmap 3 were agreed
by the project lead and the OR/CSU coordinator. This includes asset information requirements
compatible with TEA requirements, identification of novelties and complexities, operability
and maintainability, training requirements, CSU plan and stakeholder engagement.

 Operations Readiness Management Plan (ORMP)

The ORCSU/PMF deliverables/activities for the define phase have been performed by the
assigned action party in line with the ORCSU/PMF RACI. As the project transits into the Execute
phase, the ORMP shall be updated with the outcome of operations readiness review sessions that
will be held with all stakeholders.

 Organization / Roles & Responsibilities

The Project Organization encompasses all parties responsible for each role as enshrined in
Project Controls and Assurance Plan (PCAP). This is to ensure flawless project delivery is
achieved in the Operate Phase.

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 Lessons learnt

Project team Lessons learnt focal point liaison with ORCSU coordinator will plan and execute lessons for the
define phase and share the outcome to project team and BOM for inclusion in the PEP and NLNG lessons
learnt database.

 Competency Required (Training)

This new e q u i p m e n t a n d i t s subsystem will be collated by vendor as part of the training
package for maintenance technicians, asset representatives and operators. This training is needed
to impact the knowledge required to manage the new asset by the Owner after all activities have
completely handover.

 Operations /Maintenance Philosophy

The operation and maintenance philosophy shall be updated to reflect current realities. This shall
be led by the Production Integrity Instrumentation (PII/3) Team.

 HSSE Management (Update Risk Register, HSE plans, HSE Case, etc.)

The Risk Register, HSE Plan and HSE Case have been developed and will be updated as required as we transit
from one phase of the project to another. HSE in transition from define phase to operate phase will also be
developed. The highest risk on the risk register. See Jetty 2 tower crane Replacement Risk register.

4.FLAWLESS PROJECT DELIVERY

 Key FPD Deliverables & Activities shall be applied to this headline size of project since project
is ranked as high risk/complex and could result in train trips or the turbines running without
fire-fighting protection.

 Project Quality plan shall suffice to focus on selected quality areas inclusive of tightness of the
flange, integrity of welded joints, Integration and correct installation of instruments
monitoring systems, maintainability, and operability of the installed Jetty 2 equipment.

5 PRE- COMMISSIONING AND COMMISSIONING

This project’s pre-commissioning, commissioning, start-up, testing and handover shall be tied to a
turnaround window progressed according to the ORCSU standard construction through
commissioning and start-up milestones. All quality areas shall be tested during pre-
commissioning activities to guarantee installed asset integrity.

Pre-commissioning and commissioning for the Various system shall be subject to the approved site
acceptance testing plan developed by Vendor. This document shall be reviewed by our SMEs in PII
and PIR and approved for use.
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Vendor’s will prepare site acceptance test document that will be used for pre commission and
commissioning. The acceptance criteria for each will be clearly defined and documented for audit
purpose.

6 PROJECT- TO- OWNER TRANSFER (P 2 O) PLAN

A project to owner transfer plan shall be integrated into the commissioning and start-up plan.
This shall be developed by the ORCSU Coordinator in conjunction with the asset team.

7 SPARE PARTS
The minimum spares required for the critical items as identified in the project Material take off
shall be procured and handed over to the central warehouse after it has been inspected by the
different maintenance disciplines. This is an essential part of reliability of the assets after
handover. MESC Codes shall be provided for these new spares and the methodology of storage as
advised by the OEM adhered to. Commissioning spares shall be provided independent of the
operational spares. Commissioning spares shall be replacements of failed components during
commissioning activities. The surplus of the commissioning spares shall be handed over to the
warehouse for coding and storage to be added to the operational spares inventory.

8 HANDOVER DOCUMENTATIONS
The following documentation should be made available during handover. Mechanical Completion
Certificate (MCC) signed after punch list is done and all A and B punch list items closed, Pre-
Commissioning Certificate (PCC), pre start-up audit (PSUA), Statement of Fitness (SoF) checklist,
Ready-For-Start-Up (RFSU), Pre-Start Up Safety Review (PSSR), Tag Register, as built drawings and
documentations, updated procedures, work instructions, Transfer of Custody, Factory Acceptance
Test (FAT), Site Acceptance Test (SAT), Site Integration Test (SIT), Transfer of Ownership
documentation etc.

9 ASSET OWNERS READINESS / ASSET READINESS REVIEW (ARR)

The operations readiness review shall be conducted by the operations readiness coordinator in
liaison with the project lead to bring the asset owners up to speed with the status of the project
and close any identified gaps that have the potential to hinder smooth start-up and ramp up to
steady state operation of the project. The outcome of this review shall be used to update the asset
readiness plan for the project to exit the Define phase into the Execute phase.

9.1 PERFORMANCE AND RELIABILITY TEST:

The asset owners’ preparedness to take over the project on completion the crane shall be tested to be sure
about its operating and performance ability. It is expected that all systems installed for this new asset shall
function as designed and it is expected that all systems installed for this new asset shall function as designed
and respond on demand without hiccups. This performance test is set by the ORCSU lead/engineer when the
asset assumes its KPIs’ at steady state operation. The following test must be carried-out to confirm the
installed equipment performance ability:

 Slewing functional test.

 Hoist functional test (Lifting of a Load).
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 Trolley functional test (Movement of the Trolley)

 Performing Safety device check.
 And finally, Perform calibration test with 60% of the crane SWL. (Safety working load.)

10 PRESERVATION
The Project Engineer shall ensure adequate preservation of all procured materials and equipment
in line with vendor’s advice to sustain asset integrity when they arrive site until time of installation.
The OEM shall provide a preservation manual/instruction to the Project Engineer prior to shipment
of the materials. On no account shall any procured materials and equipment be stored without
following OEM’s recommendation. A preservation audit will be carried out as part of the quality
plan.

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 12 Notes

R: Responsible
A: Accountable
C: Consult
I: Inform

POS/41
  TPC/4

POP/5
TFF/4

  POS
TPC

  TFF

PSS
Crane Step Activity Description

 
Develop and implement asset readiness
ARP
plan R A I I I C I I
Develop, review and implement flawless
FPD
project delivery plan NOT APPLICABLE
Develop and review Commissioning and
Jetty 2 Tower Crane CSU
Start-Up philosophy R A C I R R I I
Replacement
AOR Ensure asset owners readiness R A C I R R I I
SoF Prepare and endorse Statement of Fitness NOT APPLICABLE
Start-Up Start-up the system I A R I R I R I
P2O Handover completed project to asset I A R I R I I R

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