First Web Edition 2006, Devoted to Engineering Community

Abbreviations

FEED- Front End Engineering Design

Process engineers, chemical engineers, reservoir engineers, mechanical engineers, electrical engineers, IT engineers, civil engineers etc. shall be included to formulate an overall strategy of designing the plant system and supported by soil engineers, hydrographic engineers, geological engineers.

EPC- Engineering Procurement & Construction

Contractor, SubContractor, Supplier, Vendor

Sub Contractors as Engineering Consultants

The aforesaid teams of the engineers shall prepare all required documents necessary for the invitation of the EPIC tenders from the short listed parties. These documents must cover the basic requirement & design philosophy pertaining all disciplines to enable the bidder know each & every requirement precisely. All disciplines shall be given full feed back in all respects in the form of project drawings, specifications, soil test reports, survey reports, marine survey report, bathymetric survey report, marine geological report, other studies & observations, climatic conditions, various milestones, quality standards to be adhered to, all other essential parts of the project demands.

These documents should be crystal clear without any ambiguity. As far as possible, details about the equipment to be included on the project should be given within the documents. All national & international codes to be followed should be enlisted explicitly.

Project design parameters should be explicitly defined.

Documents shall be provided in soft as well as hard copies

Production of such huge volume of design documents amounts to requirement of very experienced teams of experts for all disciplines to meet the schedule requirement

This though applies at the end of construction i.e. mechanical completion of the project but information are required to be issued at the FEED stage for the evaluation purpose

Contractor's obligations pertaining maintenance preparation

Contractor shall take into account in the design of the FACILITY the maintainability Criteria, philosophy and spares to be defined in the FEED Design Package. In particular Contractor shall:

Make permanent provisions for accessibility (without dismantling of other equipment), dismantling/tooling, lay down and handling of heavy parts.

Make provisions for online monitoring of vital rotating machinery

Define criticality ratings for equipment, sparing requirements for equipment, components and parts

Contractor shall prepare and submit the required maintenance documentation as generally defined in the relevant Exhibits, integrate the maintenance requirements in the Vendor selection process, and obtain Vendor’s documentation generally defined as such.

Requirements for vendors’ selection

Pre-qualification

Prior to issuing any call for tender for critical items, Contractor shall check Vendors' capabilities such as:

Ability to submit tenders conforming conforming quality requirements

Technical and financial long term stability.

Existence and suitability of Quality Assurance procedures within Vendor's structure, covering the manufacturing process, the quality control process of raw materials, the assembly of components, the performance and conformity tests, the internal quality audits, capability to supply after sales service for maintenance, technical assistance, supply of parts, procedure for collection of product performance feed back etc.

Contractor shall take into account at the bid evaluation stage the following Criteria for Vendors selection and accordingly advise Vendors that their bids shall be evaluated on such basis so that the vendors must include any price if so effected by such considerations:

Bid price and conformity to project specification.

Cost of two years or as specified in the contract recommended operating spare parts for all the machines or equipment to be installed on the project.

Reliability of Components (identification of components non standardized or non tested by Vendor under conditions similar to project conditions). The components should be fully reliable to meet the intended functional requirement for the efficient performance operations.

Standardization (identification of non-standard components, justifications for recommending such components, cost of spare parts needed for such components). The cost of spare parts contractually required according to the specifications shall be included within the bid correctly.

Availability guarantees-Ratio optimal conditions / optimal performances- Evidences to be obtained from the prospective vendors by visiting to the factory as well as to the references works carried out on track record. The vendor shall provide with the technical brochures of the product to the contractor along with the bid all documents giving the performance evidences. The performance shall also be witnessed by visiting the location of the spare parts.

Safety / Protection rating-Verification of performance evolution-Means for condition monitoring - Recommended frequency and duration of maintenance- interventions (total annual duration, maximum duration of a major intervention-Availability / Reliability / MTBF / MTTR-Availability of after sales service (rating)-Availability of spare parts lists Availability of documentation lists-Availability of documentation lists-Operational List of special tools maintainability-Modularity / Disassembly-Accessibility (rating)-The ratings should be obtained from some of the independent agencies published documents which should indicate that the observation & the relevant studies performed without any interference by the vendor. These third party agencies usually publish the effectiveness of these vendors product & services in parts or in totality at regular intervals or as required for some special assignment.

Handling (rating)- Similar record should be confirmed from the data base of the successful projects on the vendor’s track record & included with the submission to the engineer as an evidence to monitor the product efficiency.

Maintenance Guarantees-This guarantee is required for the contractual maintenance duration for all the machines, equipment etc.

Stability of Vendor, Quality Assurance, after sales structure- Proposals for maintenance contract (rating), guaranteed reliability Contract (rating), training programme (rating)-Vendor Maintenance Recommendations-Management and monitoring (rating)-First level maintenance (rating)-Diagnosis tables (rating)-Preventive and on-condition operations (rating)-Method of intervention (rating)- Identification of conformity certificates-Requirements for component testing. The provision of the aforesaid documents from the vendors records substantiate the vendor’s claim about the reliability & leads one-step to customer satisfaction.

Vendor’s obligations to be enforced by Contractor

Contractor shall obtain, check, approve and issue Vendor maintenance documentation (the Maintenance Dossier) and prepare the Mechanical Catalogue. The contractor shall comply with all the manufacturer’s instruction in respect of the equipment or the product & evidence in this respect to be provided as quality documentation to the engineer for approval & recording.

The Vendors’ Maintenance Dossiers shall generally include but not be limited to as the guidance is in essence.

Equipment data-Equipment descriptions-Equipment inventory-Technical data sheets (reference number, serial number, tag number, purchase order number)-Connection parameters (piping, electrical, instruments)-Software documentation both in electronic format and as a hard copy-Operating documentation-Operating procedures- On-line monitoring- On-line monitoring- First level maintenance by operators- Lubrication schedule.

All these documents & also any other additionally required one shall be approved by the engineer for implementation on the performance monitoring.

Maintenance documentation (per type of equipment)- Scheduled inspections or interventions-Preventive, on-failure and overhaul maintenance procedures, including description of personnel, tools, spare parts, drawings required - Trouble shooting charts- Lists of consumables- List of special tools- Spare parts lists (SPL), under format attached or equivalent- Drawing- General arrangement drawings- Section drawings- Schematic and wiring drawings- Control loop diagrams- Logic diagrams, cause and effect sheets. All these documents shall be properly numbered & recorded by the document centre.

It is unavoidable in this age of tendering particularly on the Industrial projects of international Quality Assurance nature, that the bids are submitted in two parts together or separately depending upon the Client requirement. Technical bid is always a lead submission package that is invited to fully assure whether or not, the bidder is capable to execute & prosecute the project smoothly. In case the technical bid is rejected, there shall be no need for the bidder propose commercial part of the bid.

Within this procedure, the short listed parties shall be invited to tender for the EPIC bid who in turn calculate the demanded facility EPIC or EPC lump sum firm price for the whole or part of the job in defined fixed time based on the FEED documents, provided which submission shall be Technical in one part & Commercial on the other. Sufficiency of the Technical bid shall decide whether or not, the commercial bid should be considered.

A date shall also be fixed by the Client instructing the Contractor to submit the performance bonds, insurance policies about the works as well as for the employees accidents coverage as well as all other document about these according to the General Conditions of the Contracts (GCC).

Contractor shall immediately prepare a detailed execution plan based on the brief level 1 plan that was included within the Technical Proposal at bid stage for the complete contract works from level 1 to level 5 or as the case may be, in the primavera or MS project software format as agreed with the engineer or defined in the contract.

Scope, Work breakdown structure, Contractor’s organization including details of its organization, sub Contractors organization, job positions & descriptions of key personnel down up to supervisory level, Contracting strategy-direct hire-direct control or management, Home office activities, other Contractors Interface coordination, Operations, Mobilization-break down of manpower by trade including manpower histograms-major equipment utilization schedule,

Site security, Heavy lift & transport, Personal transport, Manpower (direct & indirect), Field non manuals, Construction automation plan, document control, acceptance,

Site organization charts, Field non manual staffing plan, Sub contract plan-number, name & scope of each subcontract, Level 2 construction schedule, manpower loading-histogram by trade including both directs & indirects,

Safety, Health & Environment- Safety plans-Training-Induction-Regular courses-Special courses- Site Walks-Tool Box Talks-Risks Analysis-Corrective Programmes-Inspections-Awards-Audits

Operations & maintenance

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First & foremost is the safety for any project. Slogan SAFETY FIRST is very common among the safety promoting projects. Without safety no work is allowed. Safety is the responsibility of every one. Every person working on the project must use personnel protective equipment PPE & all necessary special precautions must be taken whenever directed by the safety official responsible for the project. All activities must be conducted in a safe manner to the best possible minimum cost incurred on safety. In case no proper arrangements are made to keep safety intact, the execution of the activity should be suspended. On important works, safety team must be present & support the construction team for smooth safety management. Site engineers should abide by the instruction & direction given by the safety personnel. Proper care must be taken during deep excavation works as well as overhead works.

Discipline activity based safety plans should be prepared in conjunction with construction in-charge, approved & issued by the safety department for the guidance of the construction personnel.

Induction- Immediate on the joining, all personnel should be given safety induction course duly recorded on proper register for the training. The course must include all precautionary instructions required on the site generally to be prosecuted onsite.

House keeping- Training should be given to all personnel to keep the working & other areas tidy during & on the end of the day. Tools should be properly kept on site. Material should not lie here & there. Working environment should be felt comfortable by all concerned personnel.

Supervising safety

Every supervisor should be trained for the understanding of managing safe supervision over the site operations. How to handle the ground works & how to handle the overhead works. How to make the workers understand all procedures of safe handling the operations so as no operation should effect the workers’s health badly causing no overstress physically.
Heat stroke

On constriction sites particularly in hot & arid regions, the effects of heatstroke are imminent to workers. They should be taught the methods of how to prevent such incidents by gradually inducting the worker to the hot working conditions & over timings adjustments.

Every workers should be clearly taught the ways of possible fire incident & if occurs, how to handle to extinguish.

In general, prior to begin any activity, tool box talk should be given to the group working on the activity involving any or all calling. How minor or major injury may occur during carelessly using the tools & how to act if injured.

Every worker should consume water or available drinks after a period of work to protect one from the adverse effect of dehydration & should be allowed the intermittent rest pauses.

Adequate arrangements must be made on site for the workers & staff to use sanitary facilities throughout the currency of the project to maintain the working area healthy & hygienic.

In groups workers should be given feed back on the site safety as well as gas inhale prevention, during fire how & where to assemble, how the fire alarm works etc. How to construct for temporary platforms at high levels to be used for various purposes to meet the site instant requirement.

How to take precaution to avoid electric shocks or some other hazard.

Incentive should be given to the leading workers who keep proper safety as well as check & advise coworkers & colleagues to take due measures. Accessibility to site horizontally as well as vertically should be explicitly explained to every one. Positioning of the ladders in the trenches, which location shall not be more than 8 m. Provision of the platform guardrail of suitable height. For example use of wooden or Aluminum ladder in excavation areas or to the higher working areas. Platform construction, supports, toe board etc. Fire extinguishers use. First aids use. How to access emergency phones for hospitals.

Site Safety Walks-

Whenever necessary, site walk should be conducted by the safety engineer with the site in-charge to pin point the deficiency on safety & on site correction applied.

Every skilled worker, semi skilled or unskilled should know about proper use of the tools & maintenance of these. They should be explained about all types of dangers if the tools are not properly used during work