PROJECT EXECUTION

PLAN REVIEW
Single Point of Failure (SPOF)
Phase 1 Project
Petrorabigh Complex, Rabigh, KSA

Furnace Tube Replacement EO Reactors Replacement Coil Replacement Heat Exchanger Replacement

Contract No. G-K073-C-3100-001 Project Completion 29 Feb 2016

 CONTENTS
1. Project Overview
2. Site Organization Chart
3. Work Schedule
4. Summary of Work Volume
5. Manpower/Equipment Mobilization Plan
6. Temporary Facilities Plan
7. Project Control Progress Monitoring and
Reporting (for Turn-around Projects)
8. HSE Execution Program
9. Quality Program Plan
10. Other Areas of Concern
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 1. Project Overview

Owner Rabigh Arabian Water and Electricity Co. (RAWEC)

EPC
JGC Gulf International Co. Ltd (JGC Gulf)
Contractor

Single Point of Failure (SPOF) Phase 1

Project
Procurement & Construction Project

Objective To improve and increase plant capacity

Contract No. G-K073-C-3100-001

Project
9 months including shutdown period
Duration

Location Petrorabigh Complex Rabigh, KSA

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2. Site Organization Chart

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 3. Work Schedule

Level 1 Master Schedule

Primavera Schedule Level 2

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Shutdown Window

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ARCC Preliminary Level 2 Schedule
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4. Summary of Work Volume

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 4. Summary of Work Volume
Quantities
Item Description Unit
Const'n Shutdown Total
1 Civil / Concrete
1.1 Excavation by Machine, Above Water Level cu.m. 30 30
1.2 Excavation by Hand cu.m. 84 84
1.3 Backfilling, Foundation & Trenches cu.m. 178 178
1.4 Disposal cu.m. 56 56
1.5 Rebars, Foundation & Trenches ton 0.56 0.56
1.6 Forms, Substructures sq.m. 30 30
1.7 Concrete - Piperack, Foundation, misc structure cu.m. 10 10
1.8 Guardrail M 45 45
1.9 Guard Post Nos 80 80
1.10 Others Civil Work ( Embeds, Coating, grouting, etc. ) LOT 1 1
2 Structural Works
2.1 Platform & Access Way Erection tons 5.21 5.21
2.2 Steel Support tons 0.45 0.45
2.3 Structural Demolition tons 0.20 0.20
Subtotal 5.86 - 5.86
3 Piping Works
3.1 Piping Demolition Ø-in 43 43
3.2 Piping Tie-in - RTR Pipe Ø-in - 44 44
3.3 Valve Lock Opening & Closing Nos 113 113
3.4 Valve ( New & Modification) Nos 21 21
3.5 Piping Fabrication Ø-in 854 854
3.6 Piping Erection Ø-in 611 611
3.7 Piping Tie-in (CS&SS) Ø-in - 2,494 2,494
3.8 Pipe Supports, CS (Fab/Erec) Ton 1 1

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4. Summary of Work Volume continuation…
Quantities
Item Description Unit
Const'n Shutdown Total

4 Electrical Works
4.1 Wires and Cables lm 550 550
4.2 Electrical Equipment set - 1 1
4.3 Minor electrical items set - 8 8

5 Instrumentation Works
5.1 Wires and Cables lm 8,220 8,220
5.2 Instrumentation Equipment set 5 - 5
5.3 Instrumentation Conduits / Piping / Tubing lm 1,323 882 2,205
5.4 Instruments, valves, etc set - 24 24
5.5 Loop Points pts - 26 26
5.6 Instrument / Valve Calibration ea - 9 9
5.7 Minor instrumentation items set/ea - 181 181
5.8 Demolition Works (Analyzer, Cabling, Static Mixer ) lot - 1 1

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5. Manpower Mobilization Plan

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Manpower Loading (Direct Labor)
Shutdown Period

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 Overall Manpower Mobilization Schedule
2015 2016
Peak October Man
Item Department
(Nos) Jun Jul Aug Sep Nov Dec Jan Feb Mos.
2Oct 9Oct 16Oct 23Oct 30Oct

I Common Manpower (Field Management)

1.1 Project Manager 1 1 1 1 1 1 1 1 1 1 5
1.2 Construction Manager 1 1 1 1 1 1 1 1 1 1 1 1 7
1.3 Project Control Department: 1 1 1 1 1 1 1 1 1 1 5
1.4 Field Engineering & Supports: 7 1 5 6 6 6 7 7 7 6 25
1.5 QA/QC Department: 20 1 3 6 8 14 20 20 20 14 1 1 40
1.6 Administration/Personnel: 3 1 3 3 3 3 3 3 3 3 13
1.7 Information Technology Group 1 1 1 1 1 1 1 1 1 4
1.8 Safety Group: 28 1 3 4 7 17 28 28 28 17 1 1 45
1.9 Project Payroll/Accounting: 1 1 1 1 1 1 1 1 1 1 5
1.10 Warehouse & Materials: 11 4 11 11 11 11 11 11 11 11 48
1.11 Procurement: 1 1 1 1 1 1 1 1 1 1 5
1.12 Survey Group: 2 2 2 2 2 2 2 2 2 2 10
1.13 CEMD Department: 21 3 9 11 12 15 21 21 21 15 1 1 58
Total Common Staff 98 18 42 49 55 74 98 98 98 74 4 4 270
II Direct Staff (Supervision Staff)
2.1 Superintendent 3 1 2 3 3 3 2 4
2.2 Supervisor 13 1 1 2 5 9 13 13 13 9 1 1 24
Total Direct Staff 16 1 1 2 6 11 16 16 16 11 1 1 28
IV Direct Labor
3.1 Civil Works 6 5 5 6 6 5 5 5 5 5 27
3.2 Structural & Piping 353 48 208 353 353 353 80 401
3.3 Electrical & Instrument 62 28 28 43 62 62 62 28 28 174
Total Direct Labor 420 5 5 34 82 256 420 420 420 85 28 28 602
Grand Total Manpower 534 24 48 85 143 341 534 534 534 170 33 33 900
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Equipment Mobilization Plan

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 Equipment Mobilization Plan
2015 2016
Item Peak October Total E
Description
No. Nos. Jun Jul Aug Sep Nov Dec Jan Feb Mos.
2-Oct 9-Oct 16-Oct 23-Oct 30-Oct

I Indirect Equipment
1 Material Handling Equipment:
50 Tonner Crane 1 1 1 1 1 1 1 1 1 1 5
40 Tonner High Bed Trailer 1 1 1 1 1 1 1 1 1 4
5 Tonner Forklift 1 1 1 1 1 1 1 1 1 4
5 Tonner Boom Truck 1 1 1 1 1 1 1 1 1 1 5
6 Tonner Elf Truck 1 1 1 1 1 1 1 1 1 4
2 Generators:
500 KVA Genset 2 1 2 2 2 2 2 2 2 2 9
3 Transport / Other Vehicles:
50 Seater Bus (Shuttle) 8 4 8 8 8 8 4 1 1 14
30 Seater Coaster (Shuttle) 26 7 26 26 26 26 18 33
Ambulance 8 8 8 8 8
3000 Gal. Water Truck 2 2 2 2 2
Fuel Truck 52 52 52 52 52

II Direct Equipment
1 Civil Works
Backhoe 1 1/2 cy 1 1 1 2
Dumptruck 18 cy ( 16 m³ ) 1 1 1
Roller compactor 1 ton 1 1 1
Concrete Vibrator High Frequency ,
2 2 2 4
7.5 HP
2 Struc/Piping/Pipe Support
Crane, 200 Ton Capacity 1 1 1 1 1 1 1
Crane, 90 Ton Capacity 1 1 1 1 1 1 1
Crane, 50 Ton Capacity 1 1 1 1 1 1 1 1 1
Manlift 9 4 5 5 9 9 9 2 18
Welding Machine, 400/600A DD 67 8 40 40 67 67 67 12 115
Air Compressor, 375 cfm 3 1 1 1 3 3 3 1 5
Air Compressor, 600 cfm 2 1 1 1 2 2 2 1 4
Water Truck, 3000 Gals. 2 1 1 2 2 2 1 3
Tower Lights 3 3 3 3 3
Hydrotest Pump 1 1 1 1 1
Dewatering Pump 1 1 1 1 1
Fill Pump 1 1 1 1 1
3 Electrical & Instrumentation
Air Compressor, 125 cfm 1 1 1
50 KVA Generator Set 1 1 1
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6. Temporary Facilities Plan

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 Temporary Facilities Plan

ARCC plan to share its existing temporary

facilities (i.e. offices, warehouse, etc.) in its
ongoing project “Rabigh 2 IWSPP”.

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 7. Project Control
Progress Monitoring and Reporting
(For Turn-around Projects)
7.1 Shutdown Progress Accomplishment Report
7.2 Daily Progress Percent Report
7.3 Shutdown Three (3) Part Curves
7.4 Daily Progress Quantity Monitoring

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 o n l y
m p l e
S a
7.1
 o n l y
m p l e
S a
7.1
 o n l y
m p l e
S a
7.2
 o n l y
m p l e
S a
7.3
 o n l y
m p l e
S a
7.4
8. HSE Execution Program

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 HSE Performance Record
As of 05 December 2014

Lost Time Injury

0
MANPOWER
Restricted Work Case
1
11,107 Medical Treatment Case
3
SAFE MANHOURS FY 2014 First Aid Case

5
28,368,136 Near Miss Incident

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Property Fire Motor Environmental

Damage Incident Vehicle Incident

9 5 3 1

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 Health, Safety & Environmental Execution Program
 Contractor Site Safety Program (CSSP) shall be prepared and submitted to SAUDI
ARAMCO for their approval. The Loss Prevention Program shall be implemented all
through out the duration of the project.
 A Job Safety Analysis shall be prepared for every activity to determine HSE control
measures that are to be implemented.
 ARCC shall comply with SAUDI ARAMCO GI 2.100 Work Permit System for activities
carried out in the project.
 ARCC shall conduct HSE Trainings for its employees to continuously educate them on
HSE requirements at the project.
 HSE Meetings (i.e. toolbox, weekly subcommittee, and monthly steering committee)
shall be conducted by HSSE Representative and Project Management Team to
communicate to employees HSE issues, programs, and client requirements.
 Safety Talk
 HSSE Dept. will provide topic for the week to continuously education project
employees.
 HSE Inspection Program
 A daily and weekly HSE inspection conducted by HSSE Representative at the
work area to determine deviations and its corrective action.
 Monthly HSE inspection shall also be conducted to mobile construction
equipment, fire protection equipment, rigging hardware, hand & power tools

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 Safety Talk

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9. Quality Program Plan

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 Quality Program Plan
 ARCC is accredited and certified of the following : ISO 9001:2008 – QMS Requirement
Certifications by TUV NORD, ASME and NBIC Certifications by OneCIS Insurance
Company

 ARCC identifies the inspection and testing activities in a systematic flow in accordance
with construction process thru approved Inspection and Test Plan

 ARCC uses approved Work Method Statement / Special Process Procedures which are
predominantly used in construction to describe an activity / work that gives specific
instructions on how to comply with quality and safely perform a work related task, or
operate a piece of plant or equipment. It is mandatory implemented at work site to
have a work method statements in place to advise employees and contractors on how
to work safely and with quality

 ARCC as of to date, has 183 total no. of Quality Inspection Personnel and out of these,
76 have Special Skills Certification :
 25 - Welding Inspectors (CSWIP/AWS)
 1 - RTFI
 10 – Coating Inspector (BGAS/NACE)
 4 - QMS Lead Auditor (IRCA)
 46 – ISO 9001:2008 Internal Auditors

 ARCC QA/QC has 377 Quality forms used in construction that covers all disciplines
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 ARCC Documentation Levels
ARCC QA/QC plan, organize, control and execute all WORK of the Project in
accordance with the four (4) levels of documentation:

1ST LEVEL
PQP DOCUMENT

2ND LEVEL
Project Procedures DOCUMENT

Technical Specification, Inspection 3RD LEVEL

and Test Plan, Work Instructions DOCUMENT

Quality Verifying Documents (QVD’s) 4TH LEVEL

DOCUMENT

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 Management of Subcontractors

ARP-QA-009
VENDOR SURVEY AND
QUALIFICATION
PROCEDURE

ARP-006
SUBCONTRACT
PROCEDURE

ARP-OP-008
SUBCONTRACTOR
EVALUATION
PROCEDURE

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10. Other Areas of Concern

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 10. Other Areas of Concren
SN Concerns Mitigation
1. Issuance of the following deliverables: ARCC and JGC to
a) IFC Drawings discuss and align the
b) Availability of materials work schedule with the
issuance of drawings
and delivery dates of
materials during the
pre-planning or
2. Underground utilities, if any Immediate remedial
constructability review.
action from JGC in
order not to delay the
Construction activities.

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End of Presentation
THANK YOU!

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