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Client
PETRODAR OPERATING
COMPAN Y LIMITED
CHINA PETROLEUM
DOCUMENT No.:
ENGINEERING &
PDOC-596-PEP-01
CONSTRUCTION CORPORATION
CONTRACT No: PDOC/23/08-596
Palougue Produced Water Project Phase I
Submission
Date
Revision Details
Prepared
By
Approved By
Jan 24 2008
Caihongwei
Gosong
Apr 19 2008
Caihongwei
Gosong
PDOC
1.
2.
3.
4.
CONSTRUCTION
DEPARTMENT PROCEDURE
DOCUMENT NAME:
PROJECT EXECUTION PLAN
CONTENTS
General.........................................................................................................................................................1
1.1 Contents of Execution Plan..................................................................................................................1
1.2 Purpose of Execution Plan....................................................................................................................1
1.3 Objectives of Project.............................................................................................................................1
1.4 Essentials and Measures.......................................................................................................................2
Engineering..................................................................................................................................................4
2.1 Introduction...........................................................................................................................................4
2.2 Project Mission Statement....................................................................................................................4
2.3 Staffing..................................................................................................................................................4
2.4 Engineering...........................................................................................................................................6
2.5 Procurement Support..8
2.6 Construction Support..........................................................................................................................11
2.7 Comunication/training Support.13
Procurement...............................................................................................................................................14
3.1 Introduction.........................................................................................................................................14
3.2 Organization and Responsibilities......................................................................................................14
3.3 Purchasing...........................................................................................................................................15
3.4 Requisition and Inquiry......................................................................................................................17
3.5 Bid Evaluation and Vendor Selection.................................................................................................18
3.6 Expediting...........................................................................................................................................19
3.7 Inspection & Testing.19
3.8 Shipment & Air Freighting..20
3.9 Inland Transportation..........................................................................................................................21
3.10 Logistic Support.22
3.11 Reciept of Material at Site24
3.12 Warehouse and Stock Pile Area .25
3.13 Spare Parts and Consumble.26
3.14 Tax Exemption Application..............................................................................................................27
3.15 Use of Local Products and Services.................................................................................................27
3.16 warranty from Manufaturer 27
3.17 Material Control................................................................................................................................28
3.18 Management of Surplus Materials....................................................................................................29
Construction..29
4.1 General................................................................................................................................................29
4.2 Construction Arrangement and Preparatory Work32
4.3 Construction Plan................................................................................................................................35
4.4 Statement of Labor Management and Industrial Relations................................................................43
4.5 Civil works..........................................................................................................................................44
4.6 16" Main Water Line.47
4.7 4000m3 .52
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5.
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4.8 6.6KV Water Injection Pump & Diesel Engine Mud Pump.55
4.9 Diesel Engine System57
4.10 Electrical Installation.58
4.11 Installation of Instrument Equipment.64
4.12 Cable Laying Down & Wiring65
4.13 Material Handling Storage & Delivery66
4.14 Construction Quality Management68
4.15 Construction Quality Control 69
4.16 Construction Quality Assurance Measure..70
4.17 Important Quality Control Measurement in Each Discipline.72
4.18 Safety Security Policies in Construction74
4.19 Construction Management..77
4.13 Camp Living Facilities and Temporary Construction Facilities Layout..........................................78
Commissioning..........................................................................................................................................82
5.1 Overview82
5.2 Pre-Commissioning 82
5.3 Commissioning Organization .83
5.4 Commissioning Responsibility .84
5.5 Commissioning Plan..84
5.6 Commissioning Schedule85
5.7 Commissioning Procedure Development.85
5.8 Provisional Acceptance 86
5.9 Performance Testing87
5.10 Line of Communication 87
5.11 Owner Involvement87
5.12 Hand Over.87
Appendix: Project schedule (P3)
Project Organization Chart
Progress Measurement Chart with weight ages
S-Curves
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1.
General
Commission 2 sets of water injection pumps and 4 sets of mud pumps .and to achieve
the Sectional Mechanical Completion of two(2) mud pumps within five (5)months
from the Contract Effective Date.
To provide and commission all equipment and facilities that will meet the functional
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To warrant that CPECC has fully performed the Scope of WORK as stipulated in the
CONTRACT.
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drawing for civil work, especially for those activities difficult to perform in wet condition.
CPECC understand piling drawing is critical to achieve two mud pump first operation
within 5 months. CPECC will also give the prioritized consideration to the issuance of
relevant engineering documents for expeditious procurement of long lead items.
1.4.3 Expeditious Procurement Activities
The timely delivery to site of Project equipment and materials is the basic condition for
ensuring the completion of construction activities on schedule. Therefore, the procurement
group shall maintain efficient performance in procurement activities, for which close
contact and collaboration with engineering group is necessary.
The procurement activities shall be planned around the overall Project phases so that timely
availability of materials for critical paths can be guaranteed. The long delivery, critical
items will be ordered on priority basis to meet their delivery at site as per Project schedule.
1.4.4 Quality and Safety
Quality Fundamental and Safety First shall be always kept in the mind of everybody of
CPECC throughout the Project execution.
Along with the effective operation of a certified Quality System, CPECC shall stick to
observation and implementation of all the standards, codes and specifications as required
by the Contract and no quality compromise is allowed. All the activities in different phases
shall be performed and completed in accordance with the approved procedures, and shall be
subject to supervision and quality inspection by CPECCs quality inspectors and PDOCs
representatives. Any non-compliance as found must be rectified.
CPECC will attach as well great importance to safety all the time to provide a safe
environment to CPECC employees, visitors, Owners and subcontractors personnel and
minimize the losses caused by unsafe acts, conditions or omissions. All the applicable
safety regulations are mandatory and personnel at all level of CPECC management shall be
held accountable for their safety responsibilities. All CPECC individual employees will be
trained and encouraged to understand and promote the safety standards all the time and to
cooperate with the company safety program in every aspect to ensure the Project is
executed safely and smoothly.
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2.
Engineering
2.1 Introduction
CPECC, as a Main Contractor, will provide the single source responsibility for all aspects
of the project execution, which involves overall project management, engineering,
procurement, construction, site coordination, quality assurance/quality control, HSE,
project controls, training, commissioning and reporting.
China Petroleum Engineering Co., Ltd (CPE), as an Engineering Subcontractor to CPECC,
will provide all services as may be required for smooth execution of this Project, mainly as
engineering design, procurement assistance, construction support as well as training and
commissioning instructions. CPECC will appoint a responsible person and some major
discipline engineers taking the function of supervision of engineering work and
coordination between the Engineering Subcontractor, CPECC and the Owner for the
purpose of ensuring all the engineering activities to be performed in conformity with the
requirements of the Contract and to timely satisfy the needs by procurement, construction
and commissioning, so as to achieve the final success of this Project in terms of quality and
schedule.
2.2 Project Mission Statement
To assist the main contractor, CPECC, as required to ensure the successful execution of this
project, complete the project within the budget and schedule constraints laid out in the
Contract, and to achieve a quality that meets or exceeds the requirements for accuracy and
presentation of Client.
2.3 Staffing
2.3.1 PDOC & CPECC Staffing
PDOC staffing will compose of the following:
Project Manager
Project Team Leader
Project Coordinator
The personnel who will be assigned to the above posts will be introduced during Kick-Off
Meeting. However, PDOC will appoint a CTS representative to be responsible for the
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Project Management role for this project who is the approving body for all the issued for
approval documents/drawings required on this project.
CPECC as the main contractor who will be responsible for the Engineering, Procurement,
Construction and Commissioning (EPCC) of this project will directly communicate with
CTS (PDOC). CPE will be reporting to CPECC for all engineering matter of this project.
2.3.2 CPECC Office
CPECC/CPEs proposed Engineering Office for the execution of this project is the office in
Khartoum, Sudan.
2.3.3 CPEs Responsibilities
CPE, as the Engineering Sub-contractor of CPECC, is overall responsible for the correct
and timely execution of the engineering work scope.
CPE will undertake the following activities:
Detailed Engineering
Project Controls on Engineering Work including planning & controls, and reporting
Support on Procurement Services such as preparation of MTOs and Technical
Evaluation of vendor proposal.
Technical Assistance during construction and commissioning activities
Prepare as-built documentation and project dossier
Co-ordination with CPECC
2.3.4 Organization
Project Organization Chart will be submitted to CPECC showing the Key Personnel and
Management Level. The following Key Positions serve in the Roles as described and are
accountable for the Responsibilities as briefly outlined below:
Project Manager
Project Engineer
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Project
Engineer
Control
QA
/
Representative
QC
The above personnel are identified on the Organization Chart with extensive work
experience and to be approved by CPECC.
2.4 Engineering
2.4.1 Front End engineering & Design (Feed ) Verification
The engineering team recognizes the value of providing a quality product , and confirms
that the technical document include the specification and drawings provided by PDOC .
Feed verification covers all disciplines, including electrical, civil/structure tank and CP etc.
During this stage the output of engineering activities can be summarized as follows:
Plot plan & tank equipment Lay outs
PFDs &P & I Ds
Piping GADs and isometrics
Line routing Plan
Piling lay out Plan
Substation Housing
Tank installation
Structure steel
Area Classification Drawing
Tank CP system
Load list
MCC single line diagram
Transformer
6.6 KV switchgear and soft start
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and review against CPEs obligations and requirements in the Agreement. The Project
Manager will decide whatever a Change Order Proposal needs to be submitted to CPECC;
The Change Order will not be implemented unless approved by the CPECC in the form of
Agreement amendment.
.
2.4.4 Vendor Data Submittals
Vendor drawings and data are reviewed for conformance with Material Requisition
specifications, annotated with comments, stamped and signed and returned to the vendor in
a timely manner. All Vendor deliverables shall be subject to Vendor Squad Check as
follows:
DCC prepares the Vendor Squad Check Form and informs through email the Lead
Discipline Engineers concerned.
Each Engineer shall properly review and mark-up the documentation indicating the
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Consider first the Clients reasonable interest and second CPE interest in all
Procurement activities.
Buy without prejudice, seeking to obtain the maximum, ultimate value for each dollar
of expenditure.
Follow practical and cost-effective methods for conducting procurement services.
Subscribe to, and work for, honesty in buying and selling, and denounce all forms of
bribery; do not accept gifts or hospitality other than minor items of promotional value.
Strive constantly to acquire up-to-date knowledge with regard to Vendors materials,
manufacturing processes, and available services.
Accord prompt and courteous reception to all those, who come on a legitimate
business mission.
Respect the confidentiality of suppliers, and vendors quotations and technical
information.
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Initiation and administration of and response to technically related queries from the
field.
It serves as a coordination point for all pertinent data relating to construction. It
provides an easy reference and an accurate information transfer mode for all members
of the project management team.
Throughout the course of project, CPE will closely monitor the progress of the engineering
works and will inform CPECC to continuously plan, monitor and control all construction
activities to ensure successful completion of the project in accordance with all approved
drawings, specifications, standards, schedules and project goals.
2.6.2 Engineering and Construction Interface
CPE will prepare and issue engineering design documents to CPECC for PDOC
constructability review and approval.
PDOC or CPECC will provide all mark-ups of documents that require to be as-built. This
information will be obtained from the start up. CPE will do all back drafting to update the
related drawings up to as built status based on the approved red line mark-up drawings.
CPE will provide material take-offs and requisitions as per construction requirements.
CPE Project Manager shall be responsible for coordination of jobsite activities with
CPECC Site Manager and PDOC.
2.6.3 Field Change Instruction (FCI)
Responsibility
FCIs shall be issued by CPECCs Construction Manager and or CPE Project Manager.
CPECC Construction Manager or his designate shall sign all FCIs.
CPE document controller will log all FCIs and distribute to obtain the necessary approvals.
Approval of home office generated FCIs will be by CPE Project Manager or his designate.
These documents will carry an identification number for reference purposes.
The amendment or addition defined in an approved FCI shall be executed by CPECC
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construction staff.
PROCEDURE
All reference is to be made to the latest, approved for construction drawings. Reference to
the latest drawing index.
No other revision to IFC drawings or documents will be made unless directed by CPECC
or PDOC.
All approved FCIs will be incorporated in the As-Built drawings at the completion of
construction. FCIs shall be employed to add or to amend IFC drawings or design. The FCI
shall then be attached to the master copy of the related drawings and incorporated in the
As-Built.
FCIs shall be employed to execute changes to IFC engineering drawings or design
documents that are necessitated by:
Vendor data received after the IFC drawing cut-off date.
The details of the design change shall be entered on the attached FCI form by CPE engineer
and or CPECC field engineer. Any necessary design sketches shall be prepared and
attached to FCI form and shall be referenced on the form. This should be marked with the
FCI reference number. FCIs logs will be maintained by CPECC site coordinator. If
additional materials are required for the approved changes, a referenced bill of materials
will accompany the FCI.
2.6.4 Field Queries
It is intended to ensure that all queries are initiated, identified, logged and responded to in a
timely and effective manner.
Either the CPECC field technical staff or CPE site representative during commissioning
period will raise the technical query.
CPE Project Engineer will be responsible for identifying the Field Query, assigning the
work and ensuring completion. CPE Project Secretary will be responsible for maintaining
an up-to-date Field Queries log and hard copy. The appropriate disciplines will be
responsible for providing technical content of the reply.
The recipient of the response in the field (CPECC Site Manager or CPE site representative)
shall ensure that the response is distributed to all appropriate parties.
2.6.5 Prepare As-Built
Following the complete construction of Project, all relevant drawings and associated
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3.
Procurement
3.1 Introduction
The procurement plan is figured out to guide the procurement work to be performed by
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CPECC to ensure that all material and equipment necessary to complete this project will be
procured in conformity to the requirements by CONTRACT in terms of quality and
schedule.
Procurement activities shall be planned around the overall project schedule to ensure timely
availability of materials as required by construction. CPECC shall prepare a Bill of
Materials and establish a procurement schedule. This schedule shall include appropriate full
duration for the Owner approval cycle for procurement documents.
After bid are awarded, CPECC shall prepare procurement procedures and submit to the
Owner for approval. The procedures shall detail all aspects of procurement as required by
the Scope of Work, including preparation of Request for Quotation or Proposal, proposed
manufacturers list, evaluation of quotations/proposals, Owner review/audit, placement of
purchase order or contract, expediting, third party inspection, marshalling/storage,
importation and transportation to Site.
3.2 Organization and Responsibilities
After contract award, a Procurement Department will be duly formed same as other
functional departments for execution of the project. A procurement manager will be
responsible overall procurement management. Under the manager are buyers, expeditors
and engineers at different posts working on various procurement related activities.
The Procurement Department shall take the functions and duties mainly at the following
aspects:
Purchasing
Expediting
Customs clearance
Storage
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To prepare bid requests, bid evaluations, requisitions and purchase orders in all
disciplines, and review, revise and accept vendor data in all disciplines and meanwhile
with the Owner review and acceptance. Requisitions, TBE and un-priced P.O.s that
has been accepted by vendors for the critical and long lead items will be submitted,
within 45 days after contract effective date., to Owner for review and approval.
To obtain the Owner acceptance of suppliers prior to issuance of Request for Quotation
for items supplied by the Contractor, including any changes or substitutions.
Transformer (supply power to 6.6 KV Water Injection PUMP) , Water Draw OFF, 16 main
water line are purchased by PDOC .CPECC shall only be responsible for the following
purchasing of these small items as indicate in the table as per Contract requirements.
S/No.
Equipment Description
Quantity
1.
33KV/400KV Transformer
1set
2.
MCC
1set
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S/No.
Equipment Description
Quantity
3.
Tank Plate
1 batch
4.
Tank CP Material
1batch
5.
Steel structure
1batch
6.
7.
Housing material
1batch
8.
Instrument
1batch
9.
1 batch
1batch
10.
Purchase of equipment and materials as per the Owner Approved Manufacturers List
(AML) and in accordance with the Project schedule requirements.
Processing of requisitions from Engineering, the inquiry and P.O. requisition shall include
all the techno-commercial requirements related with the items being procured, spares,
inspection and testing, documentation in line with the Contract;
Prepare inquiry status report, purchase order status report and procurement expediting
report and update the same and issue on a monthly basis;
Preparing purchase orders with purchase specifications complete with all attachments and
applicable inspection, testing and documentation requirements, spare parts requirements,
vendors field assistance requirements and the Owners specified requirements for
procurement related activities as applicable;
Ensure adequate inspection, verification of material & test certificates are performed and
release note is issued prior to packing and dispatch from vendors works as applicable;
Carry out Factory Acceptance Tests (FAT) for critical items if necessary and applicable.
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be placed prior to the completion of design for long lead bulk materials. Initial bulk
material orders may, therefore, represent a portion of the ultimate order quantity for earlier
delivery with balance amounts to be defined and delivered later on.
Approved Manufacturers List
Purchasing inquiry will be prepared and issued in accordance with the material and
equipment requisition provided by Engineering. The vendors/manufacturers to be invited to
bid will be selected from AML. CPECC has noted the Owner requires that only equipment
or material vendors listed on AML is to be purchased by the Contractor, subject to the
following clarification:
Use of equipment models with less than 5 years proven record, even listed on the AML,
shall be subject to the prior acceptance of the Owner.
In the event that CPECC is unable to purchase in accordance with the AML due to:
The required equipment or material is not listed in any of the AML categories, or
Inability of any listed AML manufacturer to supply in accordance with specification and
data sheets.
CPECC will propose to the Owner, in writing, an optional item, vendor or manufacturer
specification for approval, which shall be considered on a case-by-case basis by the Owner,
and shall secure the Owner written approval to the proposal prior to proceeding with
purchase. The requisitions and documentation of selected vendor for the critical path
equipment/material purchase orders will be submitted to Owner for review and approval.
Such critical P.O.s shall be identified by Owner in first five weeks of the project.
Inquiry will be international tendering except local procured materials. All quotations will
be by sealed bids. Quotation by fax will be only applicable to the small value inquiry.
Inquiry sent to bidders will be complete with all technical and commercial requirements,
including instruction to bidder, terms and conditions, site service agreement, and shipping
and marking instruction to vendor, engineering requisition with detail description of scope
of work, spares, inspection and testing, drawings, statutory approvals as applicable and
relative specifications, etc.
3.5 Bid Evaluation and Vendor Selection
CPECC shall procure all equipment and materials in accordance with the Contract
specifications and Contractor supplied and Owner accepted data sheets. CPECC shall
submit Technical Bid Evaluation Report of the proposed vendor for Owner review.
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All deviations and exceptions from the Contract requirements shall be clearly
highlighted.
Separate technical and commercial evaluation on bids will be made to ensure the materials
and equipment to be purchased satisfying the specifications and offered with competitive
price as well. The sealed bids received from vendors will be opened under presence of two
procurement staff. The procurement manager or deputy manager will be present in such
opening. The evaluation at least for three vendor offers will be secured.
The technical evaluation will consider such aspects as standardizing, technical capabilities
of equipment and materials offered, cost of operation, flexibility and ease of operation, cost
and ease of maintenance, service factor, interchange ability and spare parts availability.
After evaluation and comparison of the bids, the optimum one, viewed from both technical
wise and commercial wise, shall be accepted for contract award. Award to the lowest priced
bid shall be subjected to the technical acceptability of the bid.
CPECC will prepare a Requisition Status Report and a Purchase Order Status Report which
shall include the information as detailed in CONTRACT. CPECC shall update these reports
weekly and shall submit them to the Owner.
In addition, CPECC shall prepare a Vendor Information List (VIL) which shall include the
data as required in CONTRACT, and shall be updated and issued to the Owner monthly.
3.6 Expediting
CPECC shall undertake all expediting necessary to achieve or improve the required
delivery dates while maintaining the purchase order design specification and conditions.
Any actual or potential deviation or slippage from these requirements shall be immediately
informed to the Owner.
CPECC will prepare and submit expediting procedure for the Owner's review and approval.
The expediting work will be carried out in accordance with the approved procedure.
CPECC shall perform expediting of equipment, materials, vendors and manufacturers
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data, manufacturers technical assistance from bid invitation to delivery to Site for vendor
and manufacturers items including the materials on suborders.
CPECC shall similarly expedite all replacement materials and associated documents, which
are the subject of guarantee or insurance claims. Such expediting shall be performed, as
necessary, for the duration of the Contract.
Compliance with delivery schedules will be enhanced by assignment of desk expediters,
field expediters and/or by intervention of management as necessary. The expediters will
send and receive expediting information by means of telephone, fax, e-mail or letter. The
regular expediting actions and/or visits shall be performed to ensure the purchase order
commitments are being met. More frequent expediting actions and/or visits will be
arranged, if the order execution is lagging behind the schedule and is likely to affect the
delivery and overall Project schedule.
In order to meet the project schedule, CPECC will take appropriate remedial action with
vendors and suppliers in case they are behind schedule. CPECC will promptly recommend
appropriate alternative remedial action to the Owner and implement the same.
Regular status reports will be issued highlighting problems, concerns and corrective actions
taken.
3.7 Inspection and Testing
CPECC shall be responsible for inspection of equipment and materials, and will engage a
reputable third party inspection company acceptable to the Owner to perform inspection of
major equipment and materials procured by CPECC.
CPECC shall submit to the Owner for approval a proposed list of equipment and materials
subject to third party inspection. CPECC shall also submit to the Owner for approval an
Inspection and Test Plan which shall identify all witness and hold points as required during
manufacture, assembly, testing and final inspection. To facilitate the Owners planning,
CPECC shall issue to Owner a monthly look-ahead for all inspection visits. In addition,
CPECC shall send to the Owner 5 working days in advance a written notice for inspection
visit in Sudan and 10 working days in advance a written notice for inspection visit outside
Sudan.
Upon completion of inspection of material or equipment and/or review of the
Manufacturing Data Records, CPECC inspectors shall fill out an Inspection Release
Certificate indicating that it has been fully inspected. The Inspection Release Certificate
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shall be signed by CPECC inspectors. CPECC shall maintain a status log to be issued to
Owner for all Inspection Notice, Inspection Report and Inspection Release Certificate
issued on each Purchase Order.
3.8 Shipment and Air Freighting
CPECC will be responsible for approving the release of completed goods for shipment after
satisfactory completion of final inspections and will execute forwarding activities for all
equipment/material.
CPECC shall ensure that the methods of transportation and packing used are suitable for
the type of material and comply with environmental requirements. Packing shall take into
account the type of rough handling which may occur during operations such as loading on
or off ships, and shall be designed to prevent damage to the materials.
CPECC shall inform Owner every week with advance information on the arrival of
shipments and the nature of the material in every shipment. CPECC shall provide
information to Owner with 30 days notice on packing, handling, route survey and transport
of material involving special heavy lift and oversized cargo prior to shipment.
CPECC shall provide insurance for transportation in accordance with the Contract. CPECC
shall employ a registered forwarding agent at each entry point into the Republic of Sudan.
CPECC shall liaise closely with Sudan Port authorities and airport authorities and shall
agree on detailed procedures with them.
CPECC shall be responsible for air-freighting of materials and equipment in the event this
mode of transportation becomes necessary in order to meet the Project schedule
requirements as set forth in the Contract or as it may have been changed in accordance with
the Contract.
3.9 Inland Transportation
CPECC has acquired many successful transportation experiences from previous projects in
Sudan. CPECC is fully aware of the difficulty of inland transportation in Sudan. In order to
provide the better transportation service for this project, a full investigation on Sudans
custom requirements and inland transportation condition will be made by CPECC at the
project outset. This will be essential for future traffic management and performance
because Sudan has a long rainy season and the Site is located remotely from traffic centers.
Cargoes arrived from overseas locations to Port of Sudan / Khartoum Airport need to go
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through some regulatory and customs formalities. A local broker entrusted by CPECC will
handle, under instruction and supervision by CPECC responsible person on the following
issues:
Pre-notice ETA of concerned cargo and follow-up the updated ETA from local shipping
agent and make notification accordingly.
Prepare all required customs forms and complete the customs formalities within 3
days.
In emergency of shortage of original B/L, co-ordinate with shipping co. to get telex
release of concerned cargo.
Co-ordinate with the Port Authority and the local carrier for loading and delivering the
cargo to the site.
If any damage or loss or short landing happened prior to our acceptance of cargo, make
it clear which side should be responsible and arrange insurance survey in time and
obtain the short landing and/or discrepancy certificate from shipping agent/port
authorities.
Transfer the import certificate of concerned cargo and other custom documents to
consignee.
To guarantee the on-time and safe delivery, a qualified and experienced local forwarder
shall be selected through bidding evaluation, and the following requirements shall be
fulfilled:
Try to arrange all shipping cargo to be transported by direct way upon the vessel
arrival of Port Sudan.
For heavy or oversize cargo, after review with Owner, CPECC Logistic Coordinator
will make a use of handling facilities of port and arrange the direct transportation with
inland carrier. Such deliveries of special cargo are usually as a part of a master plan in
which all phases of transportation from the factory in origin to the jobsite are closely
intertwined.
A wireless communication and tracing system must be established for follow up the
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During rainy season some urgent cargo, if possible, will be delivered by air from Port
Sudan/Khartoum Airport direct to jobsite.
For sensitive and expensive cargo, prior to loading and off-loading, an expert of this
field must be present.
The CPECC Logistic Coordinator will issue regular reports concerning local customs
maters and port matters.
The international freight forwarder (having a local office) may also be utilized to
coordinate these activities.
3.10 Logistic Support
The logistic office set up at Port Sudan, Khartoum and worksite will be responsible for all
traffic, local purchasing & warehousing operations. All controls and procedures will be
updated periodically to ensure management and control is maintained to meet job
requirements. Local procurement will work closely with the Project Manager and
Engineering group to ensure adequate support to the Project.
Logistic offices will perform the following as minimum functions:
Prepare qualified bidders list of local companies for provision of equipment, materials,
supplies and services.
Purchase all necessary material required for support of construction including the items
listed above but not limited to.
Responsible for expediting and inspection, coordination of all local purchases and
material shipments, including expediting materials that may be purchased from local
vendors.
Responsible for coordinating all customs clearance work between CPECC and the
freight forwarder for all project related materials and equipment and the import
documentation required for the same.
Responsible for routing and tracing all local purchases and material shipments.
CONSTRUCTION
DEPARTMENT PROCEDURE
DOCUMENT NAME:
PROJECT EXECUTION PLAN
Responsible for the control and operation of the warehouse group and the maintenance
of equipment while in storage and the issuance and disbursement of all Project related
equipment, materials and supplies.
Customs
Customs clearances for all procured Project materials shall be processed through a local
customs broker entrusted by CPECC.
Traffic
The local traffic group shall be responsible for the following:
Monitor all shipments scheduled to arrive at local sea ports and airports to ensure the
necessary Customs documentation (commercial invoices, packing lists, ocean bills of
lading, certificates of origin, insurance certificates, etc.) to be available prior to the
arrival of the cargo.
Work closely with the Project customs broker personnel to ensure proper classification
of materials as to import category and tariff heading, and assist with the translation of
documents by providing technical definitions.
Maintain logs of inbound cargo shipments, assign control numbers for all documents,
packages and posting each step of the processing through final clearance and dispatch,
expedite the Project customs brokers personnel as may be necessary, to ensure the
expeditious release of all Project cargo and materials.
Ensure
the
expeditious
handling,
customs
clearance
and
movement
of
personal/household effects for all employees, including family and single status
personnel.
Liaison with local purchasing to route and trace locally procured materials.
Coordinate with the contracted trucker(s) including the maintenance, incoming freight
logs, both ocean and air, dispatch logs, preparation of shipping notices, load
inspections, tracing and processing of freight claims.
Obtain gate passes from Owner for all material and equipment deliveries.
Prepare and distribute of ocean and air cargo reports, also daily shipping reports to
other local procurement groups, construction group, engineering group or other
disciplines as required.
Ensure Owner receives advance notification of all heavy and oversized equipment.
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Coordinate with the local buyers/expediters and the personnel in charge for traffic and
customs affairs to receive and disburse all Project procured materials and supplies.
Supervise a warehouse that may be deemed necessary to receive and store Project
procured materials.
Verify received cargo, check the quantities against bills of lading, freight bills, airway
bills, including inspection of cargo for any visible in-transit damage.
Check in detail the materials to ensure conformance to packing slip(s) and purchase
orders. Construction, engineering and supplier quality personnel may assist in technical
inspection if required.
Prepare material receiving reports and any UOS&D reports, as may be required from
time to time and the notification of the field material requisition originator that
materials have arrived.
Store and protect procured materials, segregate and disburse as required, including
consumable supplies, small tools, etc., within the warehouse and storage yards.
A material withdrawal form shall be prepared for all disbursements and must bear the
necessary approval signatures prior to release of any materials.
Coordination with Traffic for damaged material returns for repair or replacement.
CONSTRUCTION
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DOCUMENT NAME:
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equipment and material being delivered direct to the Site will be inspected by CPECC
inspector and Owner engineer on arrival. CPECC quality inspector and Owner engineer
will indicate their acceptance or rejection of the equipment/material. Accepted material will
be notified to the material controller of a receiving inspection report. In the case of noncompliance equipment/material found, quality inspector will complete a non-compliance
report. Copies of the non-compliance report and the UOS&D report will be forwarded to
expeditor for liaison with the relevant disciplines to clear the UOS&D in the most
expeditious
manner.
Warehouseman
will
notify
quality
inspector
when
the
CONSTRUCTION
DEPARTMENT PROCEDURE
DOCUMENT NAME:
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These yards will be enclosed by fencing with gate to control all incoming and outgoing
traffic. Materials will be stored off the ground by use of pallets, rough lumber, cross ties or
a like.
polyethylene, tarps or temporary structures. All weather roadways will be provided around
and within receiving and storage areas and will be maintained with through space for trucks
and operation of lifting equipment. The area will be secured by fencing no lower than 2.5
meters with barbed wire on the top. There will be 6 meters wide traffic gates in at least two
points. There will be personal gates next to these and in other strategic locations that will
be approximately 1.5 meters wide and 2 meters clear height. There should be sufficient
loading/unloading areas to accommodate trucks, trailers, cranes, forklifts and C-Vans
simultaneously. There will be absolutely No Smoking in any of the material storage areas.
3.13 Spare Parts and Consumables
As part of Request for Quotation, all the vendors will be required to quote for
commissioning and start-up spare parts, capital spare parts and 2 years operation spare parts
in accordance with the Owner requirements.
CPECC will supply commissioning and start-up spare parts as necessary up to the
Provisional Acceptance by Owner, the cost of which is included in the Contract Price.
CPECC will provide a detailed list for 2 years normal operation, and the spare parts
information shall be submitted in the Spare Part Inter-Changeability Form (SPIR). CPECC
will also provide a list of parts of equipment, equipment assemblies or complete items of
equipment which are required for replacement of items not subject to deterioration by
normal use but whose failure is critical for continual operation of the facilities.
3.14 Tax Exemption Application
With the exception of import duties on materials and equipment to be incorporated into the
Work or to be supplied to Owner as ether spare parts or as consumables imported for
exclusive use under the Contract, CPECC shall be responsible for obtaining all necessary
documents and permits.
3.15 Use of Local Products and Services
CPECC will source materials and equipment locally so far as possible, providing that the
service, materials and equipment can be obtained on equally advantageous conditions
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without compromising safety, quality and the suitability of the purpose for which the
service, materials and equipment re intended.
As per CPECC experience, CPECC may procure some material from local market for civil
work, e.g., cement, reinforcement bar, concrete block, wood, etc. CPECC may also procure
most consumable gas, i.e. oxygen, acetylene, argon from local manufacturers and suppliers.
CPECC will subcontract all custom clearance and inland transportation to local companies
3.16 Warranty from Manufacturer
CPECC will secure warranties from manufacturers and vendors of equipment, machinery,
and materials or supplies purchased by CPECC and used in the Work. Such warranties will
be assigned to the Owner to the full extent thereof.
Each purchase order for equipment, materials or supplies will bear the following clauses:
All articles, materials and work supplied by sellers shall be of good quality and free from
any defects. However, purchaser's failure to inspect or reject any article, material or work
shall not relieve seller of any warranties or obligations provided hereunder.
Seller warrants that if any article, material, or work furnished fails to conform to the
purpose expressly specified or manifestly implied in this order or is otherwise found to be
defective (excluding wear and tear from normal use and not due to conditions more severe
than stated or implied in this order), then seller shall promptly correct or replace the
deficient article or material delivered to purchaser at the address prescribed on this order at
seller's sole expense.
The articles, materials, or work to be furnished are to be used in a facility being constructed
by purchaser for the Owner. It is understood and agreed that all of the rights and benefits
accruing hereunder, including without limitation, all warranties and guarantees shall accrue
in favor of both purchaser and the Owner and may be enforced by either of them.
All the vendors will be required to provide twelve months warranty after Provisional
Acceptance Certificate.
3.17 Material Control
Sound material management will be essential to the project success. The sheer volume of
purchases orders, the number and geographical diversity of vendors, the numerous steps
and activities in the procurement process and the critical schedules create a very complex
system to be managed.
Page 27 of 88
CONSTRUCTION
DEPARTMENT PROCEDURE
DOCUMENT NAME:
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Page 28 of 88
CONSTRUCTION
DEPARTMENT PROCEDURE
DOCUMENT NAME:
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4.
Construction
4.1 General
4.1.1 The Outline of the Project
1) The Title of the Project
Melut Basin Oil Project Upstream Facilities EPCC of Palouge Produced Water Phase I
2) The Owner:
Petrodar Operating Company Ltd (PDOC).
3) The Scope of Work of the Project
Produced water from produced water skim Tank T-2330A of Palouge FPF transfer to new
construct 4000m3 buffer tank by 16 water lines, then inject to proposed wells by 4sets of
1400KW Mud Pump and 2sets of 6.6KV Water Injection Pump.
That means one new Pump station need to be constructed.
And install 4 water draw off pump which flow rate 150 m 3/ /h .to replace old 2sets of draw
off pump which flow rate is 50m3 /h in old palouge FPF.
4) The Construction Location of the Project
PUMP station is outside south east to Palouge FPF
5) Main Facilities in the Project
16 water line 600m
4000 m3 buffer tank
4 sets of 1400KW diesel engine drive mud pump
2sets of 800HP 6.6KV water injection pump.
2 sets of 4000KVA 33/6.6KV transformer for water injection Pump.
One MCC& 6.6KV switchgear and soft start room.
4 draw off water pump.
6) Key dates of the Project:
Contract Effective date: Dec 12008
Mobilization to the site: Before February 20 , 2009
Sectional Mechanical complete date of two mud pump from by-pass line
: May 1 2009
Provisional Acceptance date: October 1 2009
7) Geographical Conditions
The site area belongs to a part of the Sudan Savanna belt, and the climate is tropical. There
are two-season patterns in one year, a wet and dry. The dry season is from November to
next year May and the wet from June to October.
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Maximum rainfall for 24 hours is 131.4mm during rainy season, the ground vegetation is
flourish and most of them are flooded by water. And the area is subject to considerable
wind often accompanied with drifting sand and considerable thunderstorms and lightning in
rainy season.
8) Transportation
a)
Highway
It is 1200km asphalt-paved road from Port Sudan to Rabak and 300km off-road from
Rabak to PALOGUE. The off-road is in poor condition and thus the transportation is
restricted to a 90km mountainous passage from Agaba to Port Sudan. The grading on this
passage is approximately 1000~3000/15km. Some portions of the road will require
temporary constructed by-pass road and some portions are impassable during the wet
season. Bridges and the Wad Madani bridges on the Blue Nile, approximately 1000km from
Port Sudan, load-limited and to pass the bridge require special design of trailers with proper
distribution of weight, reviewed and approved by consultant of the authority of Road &
Bridges Corp. Based on our observation the load on the road from Port Sudan to the
construction site is limited to 88 tons. The off-road portion of between Rabak to PALOGUE
will require some earth-movement and construction equipment to follow such convoy for
paving- filling of deep valley pulling. The road is generally in a good condition in dry
seasons (from December to May), therefore, we have to deliver large-sized equipment and
bulk materials to the site prior to the raining season. Some equipment and materials for
urgent use, such as food and other living requisites will be shipped by air. Utilizing the
highway is our first choice of the proposed transportation method.
b) Railway
It is approximately 1200km from Port Sudan through Khartoum to Rabak by railway. But
when the material arrives in Rabak, it needs to be delivered PALOGUE by truck. It has
been observed that this part of the road 300km is in a very bad condition making the
highway transportation extremely difficult during the wet season.
c) Airfreight
Miniature airliner or cargo aircraft can fly from Khartoum to PALOGUE ( if the
PALOGUE airport can be used) and it takes two (2) hours. Working staffs and some
materials for urgent use can be transported by air, but the cost is extremely high.
d) Local resources
1) Local labor
Basically there are almost none permanent residents in PALOGUE Oilfield due to the
Page 30 of 88
CONSTRUCTION
DEPARTMENT PROCEDURE
DOCUMENT NAME:
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inclement natural conditions in this area. Currently, the only people who live there are the
ones who deal with oil exploration, development and production. The labors needed in the
project will be employed from outside this area. CPECC will employ Sudanese local
qualified labors as many as possible. This means we will try our best to hire local skillful or
semi-skillful labors. In particular, we are planning to subcontract civil work to Sudanese
civil construction teams with vast local experience and strength.
2) Local Industrial Resources
PUMP station is near PALOGUE FPF . we no need to build local infrastructure .CPECC
Palouge camp can be used.
3) Local Material for Civil Work
There are sandstone resources that can be used for foundation layers near the oilfield and
PALOGUE region. Sand,
elsewhere far off PALOGUE. Silica sand suitable for sand blasting can be obtained from a
place approximately 80km to 140km from PALOGUE.
4.1.2 Features of the Project
The general features of the project are: large size equipment , short construction period,
inclement natural condition, poor construction condition at site.
1) Short Construction Period
The construction period, from the Contract effective date to sectional mechanical
completion, is within5 months , Total provisional acceptance date is 1 October 2009
covering 1 rainy season . but we shall try to finish most installation before rainy season.
This posses greater difficulty to the project arrangement. It is a fast-track construction
project.
2) Poor Natural Conditions
Water pump station is located in poor natural conditions. it is very dry and hot in dry
seasons and heavy rain in raining seasons accompanying thunder and strong wind. The
black cotton soil on surface is dilative and loose after rain, which is detrimental to
construction activities. The measures for waterproof, leakage protection and water drainage
system must be taken during construction period. Raining in the wet season may cause
delay progress of construction, which makes it difficult to do any outdoor activities.
We must pay more attention to the personal safety and health aspect. All necessary
prevention measures including prevention against hazards related to such as mosquitoes
and poisonous snake must be taken.
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CONSTRUCTION
DEPARTMENT PROCEDURE
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3) Difficult Transportation
There exists great difficulties to transport equipment and materials required from Port
Sudan to PALOGUE Construction Site due to conditions described above. CPECC plans to
deliver the majority of equipment and materials for this project to the Construction Site in
dry season. The weight of individual equipment to be transported will be limited not to
exceed 88 tons to fit the road conditions of Sudan.
4.2 Construction Arrangement and Preparatory Work
4.2.1Construction Mobilization and Preparation
In consideration of the tight construction schedule, and all the expected difficulties during
the wet and dry seasons. After this project is awarded to CPECC by PDOC, immediately
mobilization and preparation should be carried out by CPECC.
The proposed mobilization and preparatory work includes, but not limited to, the
following:
1) Project management office and its staffing for all the preparatory work.
2) A Project kick-off meeting will be held and attended by all management staffs. The
Project Manager will explain the importance of this Project to the petroleum industry
and economic development of the Republic of Sudan, a project outline, local
environment, climate, and transportation conditions of the project location will also be
introduced. Meanwhile the project manager should also state the CPECC general
execution plan of this project.
3) The relevant staffs will be appointed to do the preparation work including but not
limited to the following:
Layout of work.
Control and management program plan for equipment manufacturing, fabrication and
transportation to the Site.
Familiar with Owners requirements of construction quality and all the Owners
specifications.
Necessary local training, on matters such as the situation of Republic of Sudan and
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its laws and Heath, Safety and Environment (HSE) to the staffs and workers.
Subcontractors shall be selected, especially the subcontracts for civil work and
transportation shall be finalized and executed in time.
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DEPARTMENT PROCEDURE
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Phase 3: 16 main water line welding. Factory air pipe and mud pump diesel pipe
construction. Duration: 1 Mar 2009- 30 Mar 2009
Critical work: NDT of main 16 pipe , pressure testing and pigging ,painting and
coating.
Phase 4: Two mud pump Sectional Completion by the end of APR 2009.
Critical work: 4 sets Mud pump installation under Guidance of vender.
Commissioning of two sets of mud pump
Connection of by-pass water line.
16 Main pipe shut down tie -in
Phase 5: 4000m3 tank installation , Duration : 5 APR 2009-28 June 2009
Critical work: CP installation of tank
NDT of welding
Water filling test
Blasting and painting
Phase 6 : 2 sets of 6.6KV water injection pump installation under Guidance of vender.
6.6Kv switchgear and MCC installation.
Duration : 1 Jul 2009 20 AGU 2009
Critical work: Transformer installation
6.6 Kv soft start installation
Substation housing installation
Phase 7: Final commissioning Duration : 25 AGU 2009 18 SEP 2009.
Critical work: transformer test
Injection Pump commissioning
By pass line transfer to tank
System put into use
shall be
CONSTRUCTION
DEPARTMENT PROCEDURE
DOCUMENT NAME:
PROJECT EXECUTION PLAN
Total finish shall be by the end of SEP. So the following points will be prioritized so
that the project can be accomplished in time.
Please refer to construction progress schedule for progress attached..
Please refer to Project Organization Chart attached.
Page 35 of 88
4.3.2
CATEGORIES OF PERSONNEL
2008
Dec
Jan
Feb
Mar
Apr
may
June
July
Agu
Sep
Construction managment
10
10
10
10
10
Construction Engineer
Construction Superintendents
Forman
Inspectors
Surveyors
drivers
10
10
Electrician
Electrical Welders
15
15
15
Gas welders
20
20
20
20
10
10
38
72
72
86
67
33
33
Piling operators
riggers
others
Subtotal
22
Page 36 of 88
Nov
Dec
4.3.3
Item No
Categories of Equipment
Size/Type
Unit
Qty
Own
Rental
1
Crane
25t
Each
Crane
15t
Each
Truck
15t
Each
Trailer
40t
Each
Bus
50seats
Each
Medium Bus
20 seats
Each
Pick up
TOYOYA
Each
JEEP
TOYOTA
Each
Walkie-talkie
each
20
10
winch
2t
each
11
Clevis
10t
each
20
12
Clevis
5t
each
20
13
Clevis
3t
Each
20
14
Wire rope
637+1 26
Meter
96
15
Wire rope
637+1 19.5
Meter
96
16
Chain block
5t
Each
17
Chain block
3t
Each
12
Page 37 of 126
To be Purchased
Item No
Categories of Equipment
Size/Type
Unit
Qty
Own
18
Chain block
2t
Each
12
19
Jack
20t
Each
20
Jack
10t
Each
21
10t
Piece
12
22
5t
Piece
20
23
3t
Piece
20
24
Civil machinery
25
Concrete mixer
400L
Each
26
Mortar mixer
200Z
Each
27
50
Piece
28
Each
29
6-10
Each
30
6-40
Each
31
6-40
Each
32
Each
Each
Each
Each
Each
Each
Each
33
Excavator
1m
34
Compactor
HW01
35
Dumping truck
36
Mortar dumper
37
Scraper
38
Bulldozer
16m
1t
D85
Page 38 of 88
Rental
To be Purchased
Item No
Categories of Equipment
Size/Type
Unit
Qty
Own
39
Loader
CAT950
3
20m
Each
Each
40
Water waggon
41
Piling machine
42
43
Lincon V400-s
Each
44
Miller DU-OP
Each
20
45
Each
20
46
GCD-150A
Each
47
ISY-350-1
Each
48
Electrode oven
500
Each
49
300
Each
50
51
Grinding machine
100
Each
60
52
Grinding machine
150
Each
60
53
400
Each
54
1/2"-3"
Each
55
13
Each
56
Impacting drill
Each
57
1/2"-4"
Each
58
Universal equipment
59
Generator set
46kw
Each
Page 39 of 88
Rental
To be Purchased
Item No
Categories of Equipment
Size/Type
Unit
Qty
Own
60
61
Generator set
Air compressor
20kw
3
Each
Each
Each
0-35MPa
Each
Each
62
Air compressor
63
64
Diving pump
65
250EG
Each
66
300EG
Each
67
CTS-22
Each
68
Each
69
Thickness measurer
Each
70
Hardometer
Each
71
Each
72
Each
73
Blasting equipment
Set
74
Each
75
Each
76
Each
77
Set
78
set
79
set
80
Theodolite
Each
AGDA
J-6
Page 40 of 88
Rental
To be Purchased
Item No
Categories of Equipment
Size/Type
Unit
Qty
Own
81
Levelling instrument
82
S-2
Each
Each
83
GPS
Each
84
HJ-4
Each
85
DUC-ST10
Each
86
TCM-312
Each
87
Moisture meter
YMWS-A2
Each
88
Anemometer
AVW-01
Each
89
FCX-C
Each
90
Weld measure
Each
91
F743B
Each
92
Digital multimeter
F930FG
Each
93
Piston manometer
0-25Mpa
Each
94
0-25Mpa
Set
95
ROSEMOUNT
Each
96
Megger (motorized)
500V/1000V
Each
97
Voltage meter
0.5,0-500V
Each
98
AC/DC amperemeter
0.5 0-1000mA
Each
99
AC/DC amperemeter
0.50-100uA
Each
100
Each
101
Torque wrench
Set
Page 41 of 88
Rental
To be Purchased
Item No
Categories of Equipment
Size/Type
Unit
Qty
Own
102
Heavy wrench
Set
103
Set
104
Set
105
Type-36
Set
106
MW9670
set
107
Light source
LP-5210
Set
108
GN-6025
set
109
Ericssion
set
110
Stripping pincer
Set
Page 42 of 88
Rental
To be Purchased
CONSTRUCTION DEPARTMENT
PROCEDURE
DOCUMENT NAME:
PROJECT EXECUTION PLAN
2)
Sudan has a large resource of manpower, among them many possess certain
skills and have worked for CPECC projects. It is CPECC's intention to continue
the engagement of local technicians and labors. We understand the procedure of
hiring local labor and are familiar with Sudanese labor law. In our future
projects in Sudan, all engagement of local labor will be handled through local
labor office and authority. All local employees whether having worked for
CPECC before or not will be required to contract with us through local labor
management office in order to prevent any disputes. All local employees will
be given a basic work training course organized by CPECC. In the meanwhile,
CPECC shall provide local employees with accommodation, necessary
insurance covering accidental risk. Labor protection appliances and medical
care will also be provided to local employees. After the execution of project,
termination of employment shall only be settled through local labor
management office.
3)
CPECC hereby solemnly commits to Employer that we will do our best to use
local labor, to increase the employment opportunities, and to provide necessary
working training for those local employees hired by CPECC. We will maintain
the good relationship established with local companies, and carry out our work
in strict accordance with Sudanese relevant law and regulations. In order to
avoid any kind of disputes between CPECC and local labors, CPECC will have
legal consultant during construction and warranty period. All the time, any
disputes (if any) happened will be settled immediately by CPECC pursuant to
stipulation in contract and CPECC will bear the responsibility itself without
impact on Employer. Employer shall bear no responsibility for any disputes
between CPECC and local labor/s.
Page 43 of 88
CONSTRUCTION DEPARTMENT
PROCEDURE
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PROJECT EXECUTION PLAN
Scope
The civil works of the project shall include the followings: earth work, concrete work,
piling, assembly of building and structure, fencing etc.
4.5.2
Earth work
1) Scope of activities includes removal of garbage, topsoil, vegetation, etc. on site,
earth excavation, backfilling and final grading.
2) Removal of garbage, topsoil, vegetation, etc. on site.
a) CPECC shall submit the following documents to Owner for approval
Protective measures taken for public and private properties affected during
construction (If any).
Removal of any structures hindrances and obstructions on the surface or
underground (If any).
b)
CPECC shall complete the topographic survey of the area and define correct location and
elevation to ensure construction to be performed in accordance with the design drawings
prior to commence of work.
CONSTRUCTION DEPARTMENT
PROCEDURE
DOCUMENT NAME:
PROJECT EXECUTION PLAN
f) Over excavation, no matter caused by any reason, shall be back filled and
compacted according to specifications.
g) During excavations, CPECC shall take necessary measures to avoid cave-ins and
landslides to protect existing facilities.
h) Locations and elevations of pipe trenches and equipment foundations shall be
defined in accordance with dimensions and slopes shown on the design
drawings.
i) The width of pipe trench shall meet requirements for pipeline construction and
for compaction of back filled soil.
j) Measures shall be taken to avoid landslides or collapse of the ditch wall.
k) The trench bottom should be evenly compacted to bear the weight of pipelines.
All organic material shall be removed and over excavation shall be back filled
and compacted.
l) Each layer of fill shall be compacted in accordance with the design
requirements.
m) Within two meters away from underground pipelines and cables, manual
excavation shall replace mechanical excavation.
n) At road crossings, measures shall be taken to keep the road unobstructed as
required by Owner.
4) Backfill
a) CPECC should notify the Owner 3 days before filling and back filling.
b) Granule material of structural back filling should be clean, finely graded and
inorganic.
c) General engineered fill materials shall comprise clean, well-graded granular
soils or inorganic and low-plastic cohesive soils.
d) After the pipeline is laid and inspected by Owner, the trench shall be back filled
in due time. When the backfill reaches a height of 1/4 pipe diameter all
provisional supports and guards should be removed and the back filling should
continue.
e) To achieve the maximum density, the back fillings should be compacted in the
optimum water cut. Watering if it is too dry and airing if it is too wet.
f) For site fill and bund fill, the maximum dry density shall achieve 95%.
g) The final height of back filled soil shall be 150mm above the surrounding
surface.
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PROCEDURE
DOCUMENT NAME:
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h) Owner will supervise the whole filling compaction work. CPECC shall be
responsible for the density tests of each fill layer.
5) Final Grading on Site
Final grading includes excavation, back filling, compaction, disposal of material,
road pavement, etc.
For the area around wellhead, the surface shall be graded in a slope with 150mm
top layer of gravel to drain water out.
During the final grading, sufficient drainage shall be provided to drain water
from the site.
Drain ditches shall have the correct elevation, slope and size as specified on
design drawings.
After the completion of grading, CPECC shall clean up the site. All discarded
materials shall be disposed of as per the Owner's requirement.
All damages to existing structures, roads, etc. that occurred during the construction
period shall be restored to its original appearance as per Owner's requirement before
CPECC leaves the site.
4.5.3 Piling
1)
2)
3)
All piles in a common group shall be driven to the same tip elevation.
4)
Pile cap plates for steel piles shall be located exactly as shown on the drawings.
5)
Centre lines of plate and pile may not be in alignment due to horizontal
tolerance allowed for driving of the piles.
6)
Piles shall be driven with drop hammers, diesel, impact hammers or other
method approved by Owner. Contractor shall ensure that the equipment is in
good working order before starting the work.
7)
4.5.4
Fencing
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1)
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Scope of works includes Fencing of wellhead area and OGM areas with wire
meshes.
2)
3)
All the fencing work shall be performed by skilled and experienced fence
erectors in accordance with the construction drawings.
4)
Steel posts for fencing and concrete foundation shall be constructed as per
design drawing.
5)
Wire meshes for fencing shall be lapped and properly tensioned to avoid any
deformation.
General
PDOC provides line pipes with FBE coating. Joint coating shall be down on
site.
The survey team sets out the route and sets up stakes according to the drawings.
The survey team shall verify all existing elevations, bends and straight-line
sections. All existing utilities shall be marked and protected from damage. All
additional marks shall be laid out at this time. Any discrepancy of the
information from that in the drawings has to be recorded and submitted to the
Owner representative in writing for final decision.
4.6.3
Wire rope slings shall not be used under any circumstances for handling pipe.
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Slings to be utilized in handling the pipe shall be free from damage to pipe or
pipe coating.
The stringing of pipe along the route shall be done in a manner to minimize
joint overlap.
The interior of all pipes shall be carefully examined for the presence of foreign
matter before the pipes are lined up for welding. All such foreign matter shall
be removed. The open ends of pipes shall be securely closed in the end of each
day's work. The open ends shall not be reopened until work is resumed at that
point.
The beveled ends of pipes shall be cleaned by wire brushes or grinders before
welding, for a minimum distance of 25 mm (1 inch) from the prepared edge on
both the inside and outside of the pipe.
The external line-up clamps shall be firmly held in position until the root pass
is 100 percent complete and the pipe has been properly supported.
Prior to welding, the internal diameters of flange valves, tees, elbows, bends
etc, shall be measured to ensure that the internal bore will allow the passage of
a pig fitted with a gauging plate of 95% of the nominal bore, branch
connections shall not protrude inside the pipe.
4.6.4 Lowering in
Welding, NDT and coating & insulation records shall be inspected and accepted by
Owner before pipe is lowering in, and the ditch should be inspected to ensure no rocks,
hard objects, organic material etc which could damage the pipe coating & insulation is
present in the trench. After piping has been inspected and tested, the pipe can be
lowered in. Care should be taken during the lowering of pipe to prevent damage to the
coating &insulation. A hole shall be excavated around the joint to give welder freedom
of access to the weld. The welded joint shall be coated and insulated after welding and
the coating shall be tested and accepted.
4.6.5 Backfilling
1)
After lowering-in and inspection have been made, the following work shall be
completed and in conformity with requirements of the Contract prior to back
filling:
CONSTRUCTION DEPARTMENT
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4.6.6
Tie-in
1)
2)
According to .site visit and agree with production. Tie in point shall be at
operating section of existing 16 pipe on pipe rack.
3)
A elbow section shall be cut after shutdown, and one new16 T connection shall
be welded to replace elbow to achieve connect new 16 pipe to old pipe.
4)
The welded joints will be RT tested and visually checked. NDT and coating
records shall be inspected and accepted by Owner before pipe is put into use.
4.6.7
Pigging
After the pipeline installation has been completed, blinds at both ends of the
pipeline shall be removed and pigging equipment shall be installed. The
finished pipelines shall be free from foreign materials and objects. All valves
of the pipeline shall be in open position. Sizing pigs, brushes and scrapers shall
be air driven through all lines and the Owner shall be present.
Prior to cleaning the pipeline, pig launcher and receiver should be welded to the
beginning and end of the pipeline. Air inlet and outlet pipes for the launchers
shall be installed and connected to a compressor. The sizing pig and scraper
should be installed in the launcher, and the pig is launched by compressed air.
All rust, dust and other foreign material shall be blown out of the pig receiver.
When scrapers and foreign material arrives at the receiver, air pressure shall be
turned off and the receivers shall be depressurized before it is opened to
remove all equipment and clean out debris. The pipeline shall be pigged several
times until the piping interior is clean as specified and the QC engineer and
Owner are satisfied.
Scrapers shall be used for pipeline cleaning. If the scraper becomes stuck, the
pressure can be increased until movement occurs again. If the scraper becomes
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stuck and can not be dislodged by an increase in air pressure, second pig of
larger diameter can be used to induce movement.
When the scrapers are placed inside the launcher, they should be carefully
checked to ensure that clearance between the scrapers and the pipe wall are
within tolerance.
If there are small amounts of foreign material in the pipeline and the resistance
is low, the scraper speed must be controlled to avoid damage to the receiver.
4.6.8
Hydrostatic Test
1)
The pipeline can be separated into several segments for test according to water
availability, elevation etc. After separate tests are completed, the segments will
be joined. The final welded joints will be PT and RT tested and visually
checked. Strength test will not be done for these joints again.
2)
All welds repair and NDT have been completed, which can be considered as a
stop point.
Pigging has be completed and accepted by Owner.
Application form and safety provisions for testing have been approved.
Temporary provisions for testing are prepared ready.
Pressure gauges shall have been calibrated. Pressure gauges shall be installed at
an appropriate location of the pipe section to be tested and a thermometer shall
also be installed if necessary.
All the QC forms to be filled in according to the quality plan and procedure shall
be completed and approved by QC department and departments concerned.
3)
Pressure testing.
Test pressure shall be in conformity to the pipeline sheet and related
requirements.
A vent valve shall be installed at the highest position to vent out all the air in
the pipeline. When filling the pipe, a pig shall be put in pipe, and it will run
ahead of the water to drive air out so that air does not become trapped behind
the pig. When testing commences, the pressure shall be gradually increased up
to the 50% full test pressure and then stop and let stabilized for at least 1 hour.
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4.6.9
Road crossing
For this project, one FPF road shall be crossed . The pipeline construction will
be strictly in accordance with the requirements and specifications specified
under the bid documents.
Identifications for construction and lighting equipment shall be placed at the
road sections where the crossing operations is in progress after approval of
local traffic authority and owner and before commencement of work.
A steel plate or other materials to ensure re-opening of the road shall be placed
over the pipeline crossing ditch at the end of work.
A steel plate or other materials to ensure re-opening of the road shall be placed
over the pipeline crossing ditch at the end of work.
For pipeline crossing by ditching & backfilling method, the pipe ditch shall be
backfilled immediately after the crossing pipeline has been installed on the
bottom of the ditch. Each lift of backfilling shall be correctly compacted to the
levels of existing road base and surface prior to commencement of work.
The road surface shall be restored according to the original requirements of the
road.
The pipeline route will cross and tracks or roads at an angle as close as close as
90C to reduce the length of the crossing.
4.7
4.7.1
CONSTRUCTION DEPARTMENT
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PROJECT EXECUTION PLAN
j.
Accessories installation
k. Hydro test
l.
(3)
The surface of the sand layer shall be leveled and free of protrusions, sags and
cracks. The slope shall be in accordance with the drawings and the specifications.
The storage tank shall be checked with respect to the quality certificate of steel and
welding materials, if doubts exist, then chemical analysis and recheck are required.
Uncertified materials shall not be permitted.
(2)
The steel plate shall be checked with respect to material, surface condition, size and
quantity in accordance with the requirements. It is not permitted if the corrosion
allowance of the steel plate tolerance is above that of the steel plate thickness
allowance when repairing gouges.
CONSTRUCTION DEPARTMENT
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prefabricating.
(5) Valid measures shall be carried out to prevent the components from deformation,
damage or rust in the period of storage, transportation and field piling-up.
4.7.5 Bottom Plate Installation
(1) Prior to the bottom plate laying, it shall be sandblasted and coated against corrosion,
50mm edge of the plate edges shall not be coated.
(2) Edge plates shall be laid symmetrically both sides and the seams are to be welded
with base plates. The two moving plates shall be prepared as per actual sizes.
(3) The laying of central plate segments shall be carried out from the center to both
sides and generally long plates shall be laid prior to septarian plates. Three
overlapping plates shall be angle cut in accordance with the requirements of the
drawings.
(4)
The bottom welding shall be strictly carried out in accordance with the Welding
Procedure.
(5) The welds of the bottom plate shall be vacuum tested and free from leakage.
4.7.6 Roof Plate Installation
(1) The first ring of shell plates shall be installed on the bottom plates, then the top angle
installed and support legs or pontoons fabricated prior to the assembling of the roof
plates.
(2) The clearance between every adjacent weld of the roof plates shall be in accordance
with the drawings and the specifications.
(3) Support columns for tank roof shall keep straight and vertical allowance shall not
be more than 0.1% of column height.
(4) Roof plates shall be symmetrically assembled as per the drawn mean line. The
overlapping width of roof plates shall be in accordance with drawings and
specifications.
4.7.7 Shell Plate Installation
(1) The shell plate of the first ring shall be installed and welded to the roof plate, then be
lifted up with chain blocks and the other shell plates will be installed until the last
ring of shell plates.
(2) The enclosing plate shall be hoisted to its position according to the composition
diagram and then clamped. After the installation of the enclosing plates, the
clearance of the vertical joints and the verticality shall be adjusted and the levelness
of upper ring surveyed. The misalignments of girth welds shall be 20% less and that
of vertical welds shall be 10% less than the shell thickness of the upper plate.
(3) The welds shall be detected in accordance with the requirements. The clamps shall
be removed , and dents polished, and internal welds be ground with high velocity
abrasive machine or polishing machine.
(4) The assembled welding shall be in accordance with the follows:
a. The shell height deviation allowance shall be in accordance with the drawings and the
specifications.
b. The deviation allowance of the wall verticality shall be no more than 0.5% of shell
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height.
c. The clamps shall be removed from the wall and the dents and welding residues
repaired.
d. After the welding of the tank bottom, the local concave-convex deformation shall be
in accordance with the drawings..
4.7.8 Welding and Flaw Detection
The welding and flaw detection of the bottom plate, shell plate and roof plate shall
be carried out in accordance with the structural steel welding procedure
4.7.9 Accessories Installation
(1) The installation of the ladders, heaters and platforms shall be carried out as per
drawings and specifications.
(2)
The center position deviation of the pipe adapter of the tank opening shall be as per
requirements of drawings and specifications. Deviation of extension for pipe
adapter shall be in accordance with drawings and specifications. The curvature of
the opening patching plate shall be the uniform as that of the tank.
4.7.10 Hydro-Test
(1) All accessories and components welded with the tank shall be finished completely
and the welding seam relating to leakage test shall not be painted.
(2) Hydro test shall be slowly performed and be observed as respects of the foundation
settling, strength and tightness leakage status of the tank, tank bottom and the roof.
(3) The foundation settling test shall be carried out to assure the unevenly settling within
the deviation allowance until the stability is obtained. The bottom shall be qualified
against leakage. The wall and the roof shall be free of leakage and abnormal
deformation..
(4) The heater hydro-test shall be carried out in accordance with the specifications and
sustain the test pressure for a specified period.
4.7.11 Corrosion Protection And Insulation
(1) Corrosion protection shall be carried out in accordance with corrosion procedure.
(2) The equipment requiring insulation shall be carried out in accordance with insulation
procedure.
4.7.12 The temporary supports and other foreign materials of the tank shall be removed,
inspected and accepted by OWNER and closure record affixed.
4.8 6.6KV water injection pump and diesel engine Mud pump
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4.8.1 General
(1)
Foundations shall be completed and checked for correctness and levelness as per
drawings and specifications. Prior to installation, foundation shall be clean with
correct anchor bolt holes location, centerlines marked, elevations and levels
established for correctness. Shimming and wedging shall be carried out as per
drawings and specifications.
(2) As required, perform on-site installation of the various equipments as per approved
construction drawings and specifications, and instruction by a
manufacturer/vendor representative.
(3) Final insulation jacketing shall be completed so that there will not be an excessive
amount of scaffolding erected in the plant areas where operators will work
during start-up. The number of insulation crews still working in the area shall not
be excessive.
(4) At the time of Mechanical Completion all fire proofing and rough insulation shall be
completed, i.e. all equipment, piping, instruments, instrument leads, etc. requiring
insulation for heat conservation shall be covered so that start-up operations will
not be delayed due to excessive heat loss. Insulation required for personnel
protection shall also be completed. Only areas that would be required to be open
for tightness testing (flanges, valve stems, etc.) will not be covered prior to
Mechanical Completion. Exposed insulation is to be properly protected and
sealed.
4.8.2 Rotating Equipment Installation
(1)
Prior to installation, inspection for equipment acceptance to be carried out.
Equipment installation includes loading, hauling, unloading, inspection, lifting,
shimming, aligning, placing, and securing in its final position.
(2) Remove all temporary supports, bracing or other foreign objects that were installed
in the equipment or machinery to prevent damage during shipment, storage and
erection, and repair any damage sustained. This may need vendor assistance.
(3) Before positioning the equipment, it shall be checked against the drawings to verify
the pipe installation of flanges, nozzles, junction boxes, couplings and other items
that require external connection.
(4) CPECC to prepare lifting and rigging plan for all heavy lifts taking into consideration
location and other activities such as equipment insulation, structural platforms and
ladders, instrumentation, piping erection and other work which can possibly be
accomplished prior to final erection of equipment, saving scaffolding and basket
work.
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(5)
The foundation and anchor bolts preparation shall be completed and checked by
CPECCs QC inspector prior to installation of equipment.
(6)
Prepare foundation surface, install equipment, and level the equipment as per
approved drawings and specifications.
(7) Inspect and check the work during the construction stage, and perform such nonoperational tests as are necessary to assure the integrity of the installation in
accordance with the issued for construction drawings, specifications and vendor
instructions.
(8) Flush systems and perform initial charge of all lubricants. Dispose of all flushing oil
to an area approved by OWNER.
(9) Conduct all operational tightness tests.
(10)
Qualified craftsman with experience in installing rotating equipment will be
assigned at site during the erection, installation, commissioning and start-up
period with vendor assistance as required for all special equipment.
4.8.3 Pumps
(1)
Rotate pumps by hand to ascertain that they turn freely.
(2) Align pump with driver after coupling installation; ensure that the axial and radial
deviations, and axial clearances are within the approved tolerances.
(3)
Disconnect the coupling, check motor for rotation, run-in for two (2) hours
uncoupled and check bearings. Submerged pump/motor may be run-in coupled.
After motor No-load test, re-couple pump to motor.
(4)
Install proper lubricants (fuel, coolant) prior to commissioning after review with
OWNER.
(5)
If the pump is to be used for flushing, install temporary packing if permanent
packing or mechanical seal is not suitable for flushing.
(6) Install strainers in the suction piping to prevent foreign objects from entering the
pump during commissioning and initial operating period.
(7) Reinstall permanent packing or mechanical seal on any pumps used for flushing.
(8) Check that machinery guards are available and should be fitted as per drawings and
vendors recommendations.
(9) Check and run-in pumps, maintain them after Mechanical Completion.
(10) When necessary, clean strainers by operators after pumps have been in operation for
a reasonable period.
(11) Check the general compatibility of the pumps with respect to any cavitations
problem, discharge head, excessive vibrations, excessive noise, etc. which may hint
at abnormal operation of the pump.
(12) Obtain the assistance of manufacturers if required.
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4.9
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Vendor equipment drawings shall be reviewed together with the specification requirements
(3)
Before installation, all locations, elevations and orientations of the equipment foundations,
anchor bolts shall be checked and verified in accordance with approved drawings and
specifications.
(4)
(5)
(6) Ensure steel packs/shims of adequate number are provided and leveled to the required elevation
on each side of holding down bolt as per specifications and vendors recommendations.
(7)
Level the diesel engine sets with packs/shims supporting the base plate near the foundation
bolts and at any point of the base plate carrying a substantial weight load.
(8) It is very important that the siesel set base be set level to avoid any mechanical difficulties with
the pump drive sets.
(9) Check alignment in accordance with vendors recommendations. When the unit has been
leveled and aligned, the holding down bolts should be gently and evenly tightened.
(10)
Check rotation of driver and it is correct and rotating freely after the final tightening of
manufacturer .
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(15)
Perform all the tests as specified in the relevant data sheets and specifications.
Installation of tank bottom anode bed, this job must be down before tank
foundation completed.
a) Prior to anode installation, check the type and specification in accordance with
the construction drawings and ensure anode to be free from any damage.
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b) Ensure the installation depth and the space between the location of anode ground
bed and the protected pipes to be in accordance with the construction drawings.
c) The insulation resistance shall be measured prior to laying of anode cables.
Laying route and location of anode cable shall be in compliance with the
construction drawings.
d) The connection of anode cables shall be tight and its sealing shall be in
accordance with specification and manufacturers instruction manual.
e) The space between anode ground bed surface and non-piping structure (eg. cable
etc.) shall be as a minimum of 0.3m.
3) Installation of the junction box
Prior to installation of the junction box, check and ensure the specification and
type to comply with the construction drawings without mechanical damage.
Installation location and height of the junction box shall be in compliance with
the detailed construction drawings.
The laying route of cables shall be as per that shown in the construction
drawings.
4) Cable connection
The connection of cables in the junction boxes shall be reliable and tight with
correct and complete marks. And the inlet and outlet of cable shall be glanded
properly.
The connection location of negative cable with pipeline shall be as per that
shown in the construction drawings.
CONSTRUCTION DEPARTMENT
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energized/protected potential.
Measuring and recording total current output and settings at the CP stations.
The insulation joints shall be installed for pipeline in compliance with the
location as specified in construction drawings.
Prior to installation, check insulation washers, insulation bushing and such like
to ensure them to be free from cracks or defects.
Measure the joints insulation resistance with 500v M meter to ensure the
measured value shall be over 1 M.
Installation of transformers
When transformers are put in place, attention shall be paid to ensure their
orientation in accordance with drawings. When they are lifted, the sling
deviation from plumb line shall be less than 30, and collision and severe
vibration shall be avoided.
For a transformer with gas relay, it shall be installed in such a manner that its
top cover has an ascent of 1%-1.5% along the gas flow direction of the gas
relay.
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After transformers are put in place, their roller shall be locked with removable
brakes. Ensure the earthing of transformer and foundation to be perfect.
3)
Testing of transformers
Transformation ratio of each tap will be measured and compared with the data
in the nameplate, the difference is little and is in accordance with the
transformation ratio law.
Insulation resistance and absorption ratio of windings along with bushings shall
be measured and be in accordance with the requirements.
The switchgear shall be bolted after its alignment. An inspection shall be made
for horizontality, verticality of each cabinet and front face deviation and gap
between cabinets in accordance with relevant regulations.
Check breakers with track and distribution units with drawer for the alignment
of drawout mechanism to make sure they can move freely, units of same type
can be interchangeable.
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Panel body and interior devices shall be connected firmly with all structural
members, check the fuses, CT&PT, indicators and relay to ensure they are all in
compliance with design requirements.
The connection parts at the end of insulation brace shall be stable and firm. The
porcelain-busing surface shall be smooth, free from cracks or damages.
The contact shall contact well and firmly when the switch is on.
Lighting installation
1) The Installation of Light Fixtures:
Check the type and specification of light fixtures to ensure they are in
compliance with area classification regulations.
The switch height of light fixture installed in a same place shall be uniform. On
every layer of equipment platforms, the light fixtures shall be symmetrically
arranged and aligned.
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The light fixture and support shall be fixed firmly and stable. The light fixtures
shall be beautifully installed and in good order. The pole shall be straight,
stable and the welding points shall be treated with paint.
The orientation in which the light fixture installed shall be adjusted to give
optimum lighting distribution; it can conform with the operating requirements.
Before streetlights are erected, the assembly of the fixture shall be first fitted on
the ground, and then, examine and test wiring connections and insulation
resistance. After the lights is powered and lit, lift the assembly fixture with a
The height of sockets installed in the same place shall be identical and the
orientation in which the light sockets installed shall satisfy the operating
requirements.
The connection of socket and cable shall be in compliance with the terminal
mark.
The cable inlet of socket installed in anti-explosion area shall be well glanded.
HV cable Termination
The fabrication for the terminals of power cables shall be undertaken by the
competent personnel who are familiar with the fabrication process as per the
detailed sketches supplied by the manufacturers.
The lead-sheathed cables shall be lead-sealed. The lead-sheathed and armoredlayer of all terminals of cables shall be well earthed.
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Before the cables are finally connected, the testing for conduction and
insulation resistance shall be made. The DC withstand voltage test shall be
made to the high-voltage cables as per the relevant stipulation.
All the cables shall have the labels attached on both ends of the cables which
mark the cable numbers, types, specifications, starting points and terminal
points from the cable lists. The labels shall not be attached on the connection
spots and controlling station of motors.
4.11
Instrument shall be installed, far away from magnetic fields and heat sources,
kept at vibration free places, and protected from corrosion.
Instrument supports shall be secure and safe and they shall be coated.
1)
Pressure instrument
For pressure tapping of pressure instrument, dynamic pressure affection shall
be avoided as possible.
2)
Temperature instrument
The sensors of thermometers shall be installed near the centerline of piping. For
piping smaller than DN80, expanded tubes shall be added pursuant to design
stipulation.
CONSTRUCTION DEPARTMENT
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Control valves
Control valves shall be installed vertically in the places where operation and
maintenance are easy, supports shall be installed if necessary.
The height of valve pedestal above floor shall be in accordance with the
requirement.
4)
Field control panels shall possess safe and secure protection earth bars.
4.12
Cable arrived at site shall be checked to make sure that their types,
specifications and quantities are in conformity with the design requirements, no
visual damages and defects exist and certificates are provided.
2)
A list for cable allocations shall be prepared according to the actual length of
cables delivered to site and the length for laying. The sequence for laying down
shall be arranged and decided according to site situation.
3)
4)
Prior to laying down, cables shall be inspected and tested for their continuity
and insulation property and records shall be made in time.
5)
The surface color of intrinsic cable is blue and they shall be laid down separate
from the non-intrinsic cables.
6)
Generally, cables will be laid down in a single action, Caution shall be taken to
protect cables from damage. Indelible identification marks shall be tied at the
each end of the cable. The arrangement of cables in trays (trenches) shall be
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neat. When cables are laid in vertical, suitable supports will be provided to
secure them.
7)
After completion of cable laying, a further inspection and test for their
continuity and insulation property shall be carried out. A record for cable laying
and for re-measurement of insulation resistance shall be completed. When
confirmed satisfactory the cable tray covers shall be installed as soon as
possible to protect cables from mechanical damage and fire.
8)
When cables are laid down in trenches, sand or soft soil will be filled and
compacted in accordance the drawing requirements.
9)
Electrical continuity shall be well maintained for the cable shields. One end of
the cable shield shall be earthed on the side of the control room. Unless
required otherwise in the design documents, the indoor cables shall be earthed
at the place defined in the design drawings.
Materials shall be handled with suitable slings, pipe hooks, leather belts and steel
plate clamps to prevent damage to the materials. If wire ropes are used, liners should
be placed between the rope and the material.
2)
If sections of steels or steel plate are handled, the distance between wire ropes
and the weight of the material shall be considered to prevent damage or deformation
of the materials.
3)
Caution shall be marked on the material packages, which are not to be compacted
or inverted, each package shall be handled as a unit.
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4) If damaged equipment are found during handling, the damaged equipment shall
be recorded, and the purchasing department shall be informed.
5)
The equipment and material shall be marked during handling and transportation,
the marks or tags shall not be removed, damaged or erased.
The QC department shall ensure all equipment and materials comply with the
technical specifications and the second clause herein and sign off the MRR if
satisfied. Items lacking certification shall be quarantined until all deficiencies
are satisfied.
5)
6)
7)
The engineer shall decide whether defective materials can be used and the use
of material not complying with the specification is subject to PDOC written
approval.
8)
All packed materials shall be repacked after inspecting if not used immediately.
9)
Material Control shall protect materials against damage during receipt, storage
and issue, corrosion and deterioration ensuring the Manufacturers necessary
Lifting, handling storage and preservation procedures are available and
followed.
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10) Welding Materials shall be stored and locked in a secured dedicated warehouse
and controlled by specific personnel using temperature and humidity control
equipment as necessary.
11)
Steel products shall be stored together on sleepers to prevent soil contact, but
segregated according to grade, size and clearly tagged.
12) The distance between supports shall prevent steel pipe plates and sections from
distorting. Stacking height restricted to prevent weight damage and toppling.
Wedges/stops shall be placed at stack ends to prevent collapsing and rolling.
Protective Materials shall be used for coated pipe.
13) Where possible major and heavy equipment must be shipped direct to the job
site to reduce handling.
14) Special tools must be stored separately, signed out for use, signed in on return
and maintained in good order.
15) Cable can be stored outside, on sleepers to prevent soil contact. Cable reels
shall be hooded to protect against sunlight.
4.14 Construction Quality Management
1) CPECC establishes a QA/QC department under project management office. The
QAQ/QC department is responsible for quality management, supervision and
inspection. There are some full-time QA engineers and QC inspectors in the
QA/QC department and construction teams. They will be in charge of the
quality management, supervision and inspection, carrying out the project
quality plan and the documents of ISO 9000 quality system strictly under the
owners supervision.
2) The project management office shall establish a quality assurance system
in accordance with ISO 9000 quality system, prepare procedure documents
for construction and for construction quality control prior to construction.
Construction and inspection activities shall be carried out in accordance
with the contract, the specifications and the procedure documents.
4.15 Construction Quality Control (QC)
1)
All QC operations are responsible for enforcing the quality system thus
ensuring engineering meets the required quality objectives.
2)
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Inspection Hold Points shall be determined for key and major operational
sequences. The QC Engineer will not permit work to proceed to the next step
until he/she has inspected the Hold Point and issued an Inspection Release
Note.
3)
4)
5)
A weekly Quality meeting will be held to discuss current issues and progress
and the overall quality inspection and monthly to discuss and evaluate the
operations of the quality assurance system and to analyze engineering quality
and effect a program of actions to resolve any outstanding issues.
6)
Feasible and practicable measures shall be taken in rainy and windy seasons to
provide good to guarantee the welding quality.
1)
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2)
3)
Measures to be taken
a)
The project Management Office will ensure QA/QC will to meet the full
requirements of the specifications international standards and ISO 9000
standard, quality management and quality assurance.
Prior to construction, all the staffs and management will be familiarized with
the necessary codes, specifications, standards and quality requirements and
construction drawings related to the project. They shall read and review the
construction drawings on as necessary on an inter-disciplinary squad-check
basis to familiarize themselves with the layouts and inter-connections of
different materials and equipment and draw up any special operational
procedures and stipulate any hold points.
As materials and equipment arrive, they shall be checked against the material
requisition specifications, drawings in terms of size and quantity and against
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An acceptance Note will then be issued. If they are rejected, the reasons will be
given on the rejection note, prohibiting their use, and outlining a course of
remedial action or they are replaced as necessary.
All raw materials, fittings, parts, components, equipment for project use must
be supplied with material certificates and shop certificates. For special
materials, attention shall be paid to identification, marking and marking for
cutting (ensuring records are made at the time and properly kept).
b)
CPECC will be fully responsible to the Owner for the timeliness and quality of
construction, project handover and subsequent ease during project operation.
The Handover shall be carried out in accordance with the stipulations in the
Table for quality Control of Operational Sequences of Project Construction to
insure against starting the next sequence from an unacceptable sequence.
Periodic and non-periodic inspections shall be organized by discipline
technicians and quality inspectors to improve construction quality and correct
quality nonconformities arising in construction.
For key spots and difficult points in project construction, key and specialized
operational sequences shall be established in accordance with CPECCS quality
manual and the hold-point inspections shall be made for key points in
accordance with the specified inspection manners and conditions against the
specified inspection tables by the dedicated inspectors.
c)
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Civil
2)
Welding
Make sure that materials and fittings are in good quality, pay attention to
acceptance preservation and marking.
During the period of construction, inspect the first completed weld, before
allowing welding to continue.
Records for all Welding activities shall be made for process control.
Ensure that any system to be pressure tested is totally completed and, that
installation is in accordance with P&ID, isometric drawings, and other relevant
data requirements.
3)
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4)
Equipment hoisting
All the hoisting activities shall be under the command of the site commander.
5)
Electricity
Electricians shall report to duty with certificates.
6)
Instrumentation.
Make sure that the calibration certificates of instruments and devices are valid.
Calibration room shall be provided with air conditioners to meet the ambient
requirements.
7)
Coating and painting shall not be done until surface preparation is acceptable.
The next procedure shall not be continued until OWNER regard the hold point
is acceptable.
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quality of staff, carry out the safety education and provide regular, especially
to drivers, operators in high overhead place and those who work in hazardous
zone. Promote the safety consciousness among staff. Conduct regular safety
examinations to avoid any possible accidents from occurring. The safeguard
department is examination and direction to safety construction on site.
Project managers are the first-person taking charge of the safety in production.
Chief engineers are in charge of the safety of technology. Safeguard
department is in charge of safety supervisions and examinations. Operators
comply with their own operating regulations and establish posts responsibility
system of safety in production.
Identify the function of each management department. Establish and complete
the management regulations to form a integral safety management system and
a complete safety management network.
Management Measures
1)
The staff attended the construction must receive HSE training education. The
certificate shall be obtained after passing of the test. Personnel engaged in
special types of work shall obtain the safety training about technology and go
to posts with safety operation certificates. All the construction staff shall be
familiar with HSE management regulations of PDOC upon their arrival at site.
2)
The construction teams must be told about the detail technology. The whole
staff shall obtain the education about health, safety and environment before
starting work.
3)
Carry out the safeguard regulations of the project strictly. Go to work in frocks
and wearing the safety helmets. The safety belts must be tied when operating
in overhead place. The examination to be made by specified safety personnel,
none of unqualified man is allowed to enter the construction site.
4)
Aiming at the safety technical measures taken in, during the construction of
facilities and pipelines and during execution of non-destructive examinations,
welding, hydraulic pressure tests, gas sealing tests, and electric and
instruments test, etc. the detail management measures about health, safety and
environment shall be established.
5)
Safety inspection is to eliminate the unsafe factors during the construction and
is to prevent the happening of accident. Specified safety officers examine the
site at all the time to find out dangerous elements and eliminate them in time.
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In case of finding unsafe elements, they have the right to stop work and take
action, and report to construction team(subcontractor) for rectification. The
construction teams shall perform self-examinations daily.
6)
7)
8)
9)
10) The team rooms, construction facilities, engineering equipment, materials and
semi finished articles on the site shall be laid out in accordance with the
requirements of construction organization design.
11) The welding clamp cables, rubber tubes for gas torches, riggings and other
tools used in construction shall be taken back and put in order or stored in
warehouse.
12) Enhance the power management. The temporary cables, switches, power
facilities shall be complete protected with good earthing connections. The
electrician on duty shall examine that every day. In case of finding problems,
he shall settle them at once.
13)
14) The insulation of electrical facilities shall be protected from becoming damp
and pollution. Dampen electrical equipment shall be dried.
15) The high voltage test and complicated system test must be examined by the
personnel who in charge of technology before starting. A no-load test shall be
carried out before the load test when testing switchgears, relevant handles
shall be taken down or locked and warning card shall be hung to prevent
wrong switching on.
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16) No person is permitted to stand under the crane booms during the lifting
operation. All the riggings shall be strictly checked before lifting. A dangerous
area shall be marked out when lifting bulk materials. The warning cards shall
be set up when X-ray detection or gas pressure test is carried out to prevent
unauthorized persons from entering the operation area.
17) The facilities of drainage, lightning protection and fire fighting shall conform
to HSE management regulations. Combustible, explosive, poisonous and
harmful articles shall be stored in special containers.
18) The sources of power, water and gas shall be cut off after day's work. Remains
and rubbish shall be cleaned away from the work area and disposed and buried
in accordance with the rules.
19) The construction site shall be managed pursuant to the general plan. The
temporary facilities, material yard and equipment shall be laid out as per lay
out drawings design. Site materials shall be kept in good order and the utility
facilities shall be set up in order. Remove the temporary facilities and clean
away the rubbish in time, and keep the area tidy and clean after the completion
of construction.
a) rubber tubes of gas torches shall be brought back in tool rooms and put in
good order after day's work.
b)
20) Emergency safety measures shall be taken for commissioning and warranty
period.
21) Fire-fighting facilities on site shall be examined and changed regularly. The
fire permit shall be got and fire fighting measures taken, if the fire is used near
the combustible and explosive. The junction boxes in hazardous area shall be
of explosion proof type. Smoking is prohibited in hazardous areas. Oxygen
cylinders and acetylene cylinders shall be protected against the isolation and
put them separately with a safety distance. Warning signs shall be set up in
dangerous area.
22) The switchboxes at site shall be protected by water-proof shelters, and electric
leakage protection shall provide. The electrical facilities shall be well earthed.
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Operation of "power on" or "power off" shall be carried out in accordance with
work ticket system, warning sign shall be set up. When cables are laid down
under the ground, conduits shall be used for road crossing.
23) Machines and tools shall be operated by specified personnel, they go to posts
with certificates and comply with relative safety operating regulations.
4.19 Construction Management
Handling of Site Changes and Query
1)
Drawing Revision at Site
During construction, as found a drawing unreasonable or a substitute material
necessary, CPECC Site representative will write to Owner Site representative, the
involved work can proceed only after obtaining the approval of Owner Site
representative. If Owner finds a design not in compliance with specification or not
satisfying operation requirement, for ensuring construction progress, Owner Site
representatives can write directly to CPECC Site Representative asking for
modification of this design. All above modifications shall be indicated with red
mark-up in the drawings, which, after verification by Owner Site representative, shall
be incorporated in as-built drawings.
2)
For the modification or any work raised by Owner beyond Contractors Scope of
Work specified in CONTRACT, they shall be treated in accordance with
CONTRACT Condition of Contract for Change Orders. If any discrepancy occur
between two parties, the work can be done first as per required by Owner, the
discrepancy may be resolved later on by consultation.
Construction Practices
1)
Construction Meeting
a) In order to ensure right progress of construction, CPECC will have a meeting
every night attended by achieves of all departments to check daily
achievement, problems or concerns appeared and resolution to be taken, and
the planning for the next day.
b)
For ensuring safety of construction at Site, a Tool Box Meeting shall be held
every morning at Site prior to commencement of work, briefing major jobs and
safety precautions, which normally lasts for a couple of minutes.
c)
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Owner Site representative every morning, mainly about the major achievement
and concerns, for the purpose of ensuring smooth progress of construction
through joint efforts made by two parties.
2)
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Most of living incidental will be purchased in Khartoum and local, partially from
China. CPECC will set up an office in Khartoum and Port Sudan for providing
logistic support such as the convenience of procedure of construction permit,
material custom clearance, arrival of construction personnel and provision of daily
living needs.
Temporary Construction Facilities Layout
The Contractor shall be responsible, at his own cost and expense, for the electricity
and water for construction as per the Contract.
In order to facilitate the construction, we have built simple warehouse reformed
from containers and office in the scheduled space near maintenance workshop. In
order to facilitate construction and avoid material re-handling, we will put most of
equipment and material on the site and the expensive and key equipment and
material in the camp warehouse. The tool houses, the planned number of which shall
be 4, and simple break rooms, the number of which shall be 4 and they will all be
equipped with air conditioning.
The radiographic test shall be arranged so far as possible to be performed at night
time and all necessary safety precautions shall be taken at RT performance site,
ensuring no person within the dangerous area. All RT related equipment shall be well
stored under supervision of assigned person.
To facilitate construction activities and to accelerate construction progress, an
approximate 6,000m2 fabrication yard and a 6,000m2 sand blasting, painting and
insulation fabrication yard will be built near the camp.
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5.
5.1
5.2
5.2.1
Commissioning
Overview
This section will describe the commissioning plan, schedule and procedure in
order to meet the requirements specified in CONTRACT.
Commission two 6.6KV water injection pumps and 4 1400KW mud pumps
.produced water from Palouge skim tank T-2330 ,transfer to 4000m 3 buffer tank,
then inject water to wells by water injection pumps and mud pumps.
Precommissioning
General Description of Pre-commissioning
1) CPECC shall completely check, clean and pre-commissioning all systems and
equipment before commissioning. Owner representative shall witness field tests.
a)16 main water hydrotesting and pigging.
b)
Testing on transforms.
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9) To complete and clear all major punchlist items that affect the safety, operability
and integrity of the Pumping Facilities.
5.2.2
5.2.3
5.3
bolts
and
nuts,
lubrication
of
all
moving
part
and
correct
Pigging record.
Mark up drawing.
Commissioning Organization
Commissioning team will be assembled during the detailed engineering phase
and will consist of commissioning manager, plan/scheduling engineer,
procedure/co-ordination engineers for management and process, instrument,
mechanical and electrical engineers for technical support.
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5.4
1) The commissioning responsibility is briefly described below, which will be detailed after the
establishment of the commissioning team.
a) Commissioning Department
Preparation and compilation of plan, schedule and procedure for all
commissioning activities.
Review of operation and maintenance manual.
Pre-start-up audit.
b) Procurement Department
Arrangement and expediting of vendors representatives to be present at job site
based on commissioning schedule.
Purchase and storage of commissioning spare parts and consumables.
c) HSE Department
Safety audit which shall be carried out before produced water feeding.
d) Construction Department
5.5
e) Other Department
5.6
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Preface.
Detailed design data, fluid flow rate for commissioning and start-up.
Commissioning Schedule
The personnel of commissioning department will be at the construction site
four weeks before mechanical completion and pre-commissioning to be
familiar with the Project. The commissioning schedule will detail all activities.
The schedule shall also indicate the engineering engineers and vendors
specialists who will participate in the commissioning.
Vendors specialists will be requested to support the commissioning.
The engineering technical service shall at least include process, mechanical,
electrical, instrument and telecommunication.
The vendors specialists would be invited to job site, if any default or
deficiencies are found and technical support is needed.
Commissioning Procedure Development
a) Inspection and Preparation Prior to Commissioning
1) All instruments have been calibrated for operation.
2) The instruments have been calibrated, ready for operation.
3) Examine all electrical connections and earthing connections for completion and
security.
4) Operators are familiar with operating manual and relevant vendors data.
5) All required personnel, equipment and tools and recording forms are ready for
operation.
6) Inspection and Preparation
Confirm all mechanical completion records have been signed off and there are
no a category punch items.
Ensure that prior to start up that the area is suitably barricaded off, suitable
firefighting equipment and the relevant permit to work are in place.
7) Piping
Ensure that all piping /pipeline is ready to receive water .
8) Confirm that drain system is available and that all drain valves are correctly lined
up for operation.
9) Vent Point
All vent point vents shall be provided with 3/4 vent valves and flexible hose
with drain containers. The vent shall be plugged after commissioning completed.
b) Commissioning Procedure
5.7
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As a general description of commissioning and startup for the project, the major
procedure is summarized as follows:
1) First stage two mud pump put into use from by pass 16 water line( round tank).
Open valves for by pass line and drain water to Mud pump.
2) Second stage , from buffer tank drain water to the water injection system close
valves which connected to by pass 16 water line . and open valves connect to
tank suction and outlet.
In the second stage , commissioning activities as below:
Commissioning and startup for electrical system to ensure that all electrical
systems are powered properly,
Commissioning and Startup for Instrumentation System to ensure correct
operating parameters.
Commissioning and Startup for 6.6kv water Injection soft starter System.
Commissioning and Startup for Cathodic Protection System.
5.8
Provisional Acceptance
a) Application of Provisional Acceptance
When CPECC has completed the installation, it satisfies the following criteria:
All commissioning activities have been completed and the system is ready
for service.
CPECC will initiate notification for provisional acceptance one month before the Provisional
Acceptance Date, as the whole system could not be put into service for process start-up
without provisional acceptance certificate signed by PDOC.
Commissioning procedures.
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All vendor data book and utility equipment site acceptance tests reports and
certificates of utility equipment.
The hand over document may be prepared portion by portion which will be
made applicable for provisional acceptance.
Performance Testing
CPECC shall prepare and compile Performance Test (PT) plan, which shall detail the
measuring equipment/instruments to be used, the method of sampling and sample
analysis. CPECC shall also have the following responsibilities:
Achievement of stable operation in accordance with the Design Basis and Scope
of Work.
Close liaison and co-ordination with PDOC operations.
5.9
5.11
Line of Communication
CPECC realizes that close liaison and communication with PDOC is very important.
CPECC will attend commission meetings with PDOC. PDOCs supervisory staff will
work side by side with CPECCs commissioning personnel. However CPECC shall
assume responsibility for commissioning until provisional acceptance by PDOC.
Owner Involvement
During commissioning phase, PDOC shall play a very important role and close
cooperation shall be kept. Expected PDOC involvement is described below.
Provision of experienced, qualified, trained and certified operation personnel
who shall be organized as an integral operation and maintenance team.
Assurance of operation team to be mobilized to site at least four weeks before
water filling to process system.
Provision of safety audit to authorize the project for commissioning and start-up.
Arrange for the vendors installation assistance and commissioning team.
5.12
Handover
5.12.1
Handover Discussion
A successful handover requires agreement with the constructor as to scope of work
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and responsibility. Because checklists for each tagged item indicate activities that are
the responsibility of the construction contractor and which are the responsibility of
the commissioning team, these checklists provide a very detailed delineation and
definition of handover. All checklists will be reviewed early on by construction
supervisory staff and the Office Commissioning Planning Organization for
concurrence on scope. Therefore, the checklist concept helps assure a smooth
transition at handover.
Another requirement of a successful and trouble-free handover is the sufficient
planning of the handover process and early agreement on this procedure by all parties
involved.
5.12.2
Handover Procedure
Initially CPECC Interim operation group and owners staff will begin to develop
deficiency lists by system well before Mechanical Completion. If these lists are
excessively long, then operation may elect not to accept a handover of a system.
Close to the system handover date communicated by Construction to Operation, a
joint Owner/CPECC P&ID walkdown will rigorously detail deficiencies that indicate
non-conformance with project specifications, deviations or omissions from P&ID
drawings, operability problems or safety concerns. These items will be given priority
and returned to construction for completion or rectification. Any design changes will
be negotiated through an agreed upon change order system. Handover of each system
with remaining items outstanding will be verified by CPECC Interim Operation
Group and commissioning activities can commence. Remaining items are worked off
by construction, design changes implemented and the systems and areas are turned
over. The Interim Operation Group can then demonstrate performance test by
package and system as per the startup schedule.
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