First Web Edition 2006, Devoted to Engineering Community

Project Quality Plan

Corporate Quality assurance-Corporate Procurement-Corporate supports for all disciplines-Project site/field management & Co ordination-Project site/field Safety, health & environment-Project site/field Engineering-Project site/field Quality assurance-Project site/field Procurement-Project site/field supports for all disciplines

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Chapter 3

Engineering

Introduction

Company / Client believes from its vast experience that one of the key foundation blocks for successful, efficient and cost-effective end product FACILITY is the quality of detailed engineering and design. Therefore, Company / Client places a very high importance on the Contractor’s selection of an internationally recognised Detail Engineering and Design Sub-Contractor or “in-house” organisation with a proven track record of undertaking and successfully delivering similar projects in a single location under one roof. Accordingly, the Engineering and Design Subcontractor shall mobilise their team for the Project. Company / Client shall verify this at the time of review of CV’s and interviews of Key Personnel. This shall be one of the key bid evaluation criteria for the selection of the Contractor. The CVs shall be reviewed from an overall qualification viewpoint which means only academic qualification shall be not exclusively a basis but practical specific experience on interdisciplinary sphere to be considered for the acceptance of the proposed key personnel along with general capabilities such as communication skills, efficiency to carry out jobs in the field & in office environment & effective response the client personnel to prosecute the project coordination activities.
Contractor shall carry out site surveys to familiarise himself with the existing installations if any, pipelines, infrastructures, pipelines corridors and tie-ins locations. Site survey is also required to verify the proposed pipelines routes and confirm the tie-ins location and configuration etc. and to retrieve necessary information (data, drawings etc.) All survey records & database shall be verified by conducting full survey of the site to the requirement of the contractor’s scope of works. These actual surveys shall form the basis of the actual design to be approved by the engineer or the client. The survey provided with the FEED or the tender document shall be treated only for guidance.

It shall be Contractor’s responsibility to ensure that all relevant documentation and drawings available with Company / Client (at various locations) are retrieved in a timely manner, so as not to impede the progress of the detailed Design. All the records or as built drawings required for the purpose of coordination shall be required for practical interfaces & coordination criteria which should be requested to be issued by the relevant authority according to the planned requirements.

Contractor shall start from the engineering documentation supplied by Company / Client contained in the FEED Design Package and shall further develop the design to achieve the Contract objectives and requirement. However, Contractor acknowledges that the FEED Design Package does not define the Work in full detail. The contractor shall consider the FEED only as a guidance for client’s requirement & therefore, fully develop the project from conceptualisation to the completion accordingly, so that the project specifications are satisfactorily met at the end of the project execution.

Contractor shall carry out engineering as per Contract Specifications. However, incase of conflict or contradiction with Company / Client Corporate Standards and the latest edition / revision of the recognised international standards, codes and practices, Company / Client shall be consulted for taking the appropriate joint decision. Company / Client’s decision shall be binding and shall have no cost and / or schedule impact to Company / Client.

Contractor shall undertake the detail design of the FACILITY utilizing the typical details pertaining to the project.

The Company / Client Engineering Standards, which Company / Client is in possession, shall be made available to Contractor. However, Contractor shall have to arrange for the referenced Standards not available from Company / Client.

Engineering and design of all tie-ins and tie-outs to existing Phase installations shall be undertaken in such a manner that do not cause interruption of water supply or shutdown to the existing End-Users. Contractor shall work closely with Company / Client to achieve this task.
General Engineering Requirements

Contractor shall prepare all engineering documentation required for the Work, the documents listed and produce all or any other documents required for the successful completion of the Work. These documents should provide comprehensive engineering design information for all disciplines involved on the project such that all details are self explanatory requiring as minimum as possible further issues to produce works executive details in the form of shop & working drawings, though which may not be unavoidable from an working engineering viewpoint. The design should be explicitly clear in its basics theoretical calculative form giving adequate details to be well understood & coordinate properly all sequential activities for the team engineers to co-relate at various stages & at various offices. Clear details save the time & provide efficiency on the performance of execution.

Witness and report FAT (Factory Acceptance Tests) at Vendors Premises.

Prepare Final Documentation specified

Company / Client requires a 3-D CAD (PDS) model to be developed for the project. FEED 3D model may be utilized by EPIC Contractor for further development. The final 3-D CAD model shall include sufficient detail to allow plot plans and layout drawings to be produced from the model. The model shall include modeling of the following as a minimum

All Piping / pipeline

Pipe supports / saddles for piping larger or equal to DN50

Fresh Water Distribution System (Firewater storage and distribution)

Electrical and Instrumentation items including cable trays, ladders or ducts (300 mm width and larger)

All civil / structural works

Intake area upstream of Seawater Pumps.

All existing facilities (to the extent required) at locations such as tie-ins, crossover on existing piping / new pipelines, in existing culverts, etc.

All piping within package units such as Electro chlorination plant.

Vents, drains, manholes and vacuum breakers.
Contractor shall provide the entire model to Company / Client as part of final documentation. Contractor shall not employ any proprietary techniques or add-in programmes while developing the 3-D CAD model that may prevent Company / Client from fully maintaining the model after takeover.
Contractor shall provide a user manual to aid future update of 3-D CAD model by Company / Client.
Contractor shall provide view-only access to the 3-D CAD model for Company / Client’s nominated personnel whether they are located on Contractor’s premises [Office or site] or if they are accessing the system remotely during the course of detail engineering. A copy of (review model) updated regularly during Construction and engineering stages shall be available at Company / Client’s Offices at site. In addition, Contractor shall provide documentation, training and support for Company / Client’s nominated personnel so that their use of the system is unencumbered and effective.

Plastic Model

Contractor shall design, fabricate and assemble a plastic model for all facilities which include all pipeline / piping, all structures, buildings, etc. to be included on the Plant facility whatsoever, for making it operational. The models shall be produced to an acceptable size so that every part of the project is clearly identifiable by the user personnel. As far as possible, all essential design details shall be included for the exhibition purposes. These models should be fabricated in different modes like drawings that means bird’s eye view, sections within that & many different views for clarity.

For EPIC or EPC, the design part is a major contribution to the successful execution of the contract. Design of the whole project components / constituents are demanded to be produced one by one meeting the timely requirement to the project plan. The designing team should understand explicitly the contract philosophy & the FEED documents prior to commencing the design work. Complete Project Design Systems should be produced based on the FEED & the best possible design alternatives for a minimum cost. The project target to be achieved should be clearly understood.

Initial drawings after complete checking & review of the design calculations should be properly recorded, approved & issued for Client review & approval.

Design drawings in general may be classified to the following categories

Plan showing process & non process area indicating trains, utilities, offsites, circulation, control as well administrative areas.

Plan showing existing facility if any, proposed location of sea intake as well as discharge into sea.
Plan showing out plan to facilitate construction of temporary structures for the use by the Contractor.

Plan showing located areas for warehousing, storage, equipment maintenance, access to site & all other necessary information the Contractor or bidder shall require to take into consideration the impact of cost on price.

Structural plans for buildings including elevations & sections

Bar bending schedules for all members of the structures building wise
Discipline wise plans for services such as electrical, HVAC, mechanical, drainage, sanitary, loss prevention, fire fighting, water supply, telecommunication, CCTV closed circuit television, security access, card readers, building management,
Roads layouts, maintenance roads layouts including types, & sections
Plant Piping layouts & pipe racks around including overhead crossings

Interconnection layouts

Structural plans for the steel buildings giving all design details

Landscaping giving all soft & hard landscape layouts

After having received the preliminary drawings approved by the Client, the design team should concentrate to produce all necessary drawings, which should then be submitted along with the building permit application to the relevant municipality if so required.

It is also suggested that what details are required should be planned in advance of commencing the detailing work in the form of a working schedule to keep a control on the quantity of detailing work.

Major items schedules respecting all disciplines should also be included within the detailed designs to guide the construction team for placing various Material Take Off MTO after due verification. After producing all necessary detailed documents, a guiding bill of quantity BOQ should be prepared for the whole project to assist the construction team to place various order after due verification of the quantities as well as the applicable specifications & codes.

No limit governs the quantification of the production of schedules for it depends on the discipline as well as the size of the project. There may be hundreds of such schedules for some project while some only a few. But quality schedules help the placement of the procurement orders.
Scheduling is no easy job. It requires complete know how of item under consideration. It also requires complete coordination within all relevant drawings & technical documents to reach final take off the quantities & the applicability of the specifications & drawings as well as specialist specifications produced by the manufacturers. Scheduler has to go through all these procedures immersing fully for all related items.
Submissions-

All aforesaid project documents which may include all design drawings, detailed drawings, schedules, project specifications designed by the specialist engineers should be registered properly according to the agreed system of documentation & thereafter be submitted under cover of a transmission sheet to the approving authority engineer for technical approval in the form of IFC Issue for Construction. It is not essential that the documents should be approved in first submission. Comments received back from the engineer should be incorporated on the revised documents & resubmitted keeping the process continued until the documents are approved for construction. After the approval for construction status, the document should be copied in required numbers as agreed within the documentation procedures duly sealed on the document & circulated to the concerned parties. Copies should also be transmitted to the engineer for site use.

All details as explained above cannot be practically produced within these documents. Depending upon various factors related to available material, details provided on the approved drawings & the trade practice & further minute technicalities involved for the production operations, it shall be essential to produce some more documents to be used by the shop floor engineer. These documents shall be worked out from the coordination among all such gathered information solving probable clashes & giving a final shape for production or execution on site. These documents should also be passed through the approval procedures & IFC document should be issued to site for construction. There shall be hundreds & may be thousands such documents necessary to be produced from time to time of site requirement. These can be entitled shop drawings.

Even after the availability of all approved documents, there shall be required some more drawings to be used by the supervisors on site as well as in the workshop. These drawings should support with further details of the sequence of works in the form of real fabrication & execution at shop floor or on site. These drawings should be well drawn clearly so that supervisors do not require further assistance to get the job done without further details. These drawings should also be approved but all drawings do not require approval. In some case based on the contract drawings & shop drawings further details are worked out which are consistent with approved drawings, may be used directly virtually off record.

Otherwise these drawings should also be approved by the engineer in which case proper documentation is necessary followed by the issuing procedures as explained earlier.
Technical Queries-

A technical query is raised when some discrepancy is discovered pertaining any design item not correlating or corresponding between architectural & structural or any other discipline drawing details. For the resolution of the correct detail, discrepancies are raised in the form of a technical questions format giving full details regarding the discrepancy & if possible, a solution be proposed or clarification sought or understanding for confirmation made. This document is originated by the relevant engineer, checked by the technical or engineering section & authorized by the site management for transmission to the engineer for response. Engineer scrutinizes the questions & writes back the answers for execution on site & recorded as red line mark up.

There may be engineering queries ETQ or site technical queries STQ or SC site clarification depending on the mode of the format adopted on the project.

ETQ is generally used by the Engineering team only whilst the STQ is used for the site execution purpose.

During carrying out works on site, dictated by the site conditions & to comply with the specifications & design criteria, it usually happens that suitable adjustments have to be made to the design details on the safer consideration. Such situation requires an agreement between the Contractor & the engineer on site, which should be recorded on the STQ for confirmation.

Other than aforesaid queries, there shall be many instances when alternative detailed proposal are to be worked out for site requirement to meet the design criteria & practicalities, proposals for such problems are made for the engineer’s approval. Full details in the form of sketches are prepared & put in the form of STQs or directly as sketches as working drawing as convenient. All virtual clashes on site due to unforeseen conditions may be resolved on site & recorded as technical resolution in the same manner.

At time of the contract execution as well as during the whole currency of the contract, the Contractor shall from time to time receive thousands of documents in the form of contract documents, post contract documents etc which should be appraised properly & competently. All such documents should be registered in such a way that traceability functions efficiently without wasting time of the engineers unnecessarily. The document controller should have on his tips on the database any required document located immediately. Arrangements should be such that documents for a particular element on the job should be proficiently filtered out for better control. Project in-charge should ensure that all required documents according to the register as well as fulfilling practical needs of the project for construction have been issued by the designers.

Issued / approved for construction documents pertaining all disciplines must be checked sequence wise as well as discipline wise to make sure that these contain well-coordinated information necessary for the 100 % construction of the relevant portion or element. Project engineer should immediately notify any missing information to be provided proficiently. Any clashes observed should be recorded any ETQ or RTQ raised for a possible resolution without any delay to the execution. The approval about the queries procedure should be perused personally in some urgent cases & the resolution communicated to the supervisor concerned for on site implementation prior to the mistaken work is carried out.

Inference of technical documents-

Inference of the technical documents is no easier an activity. Only a competent project engineer or an experienced discipline engineer should be entrusted the job to explore any missing information as well as to know whether or not the issued documents are giving adequate information for the purpose of full construction or yet, the technical queries are necessary to be raised. This activity requires total concentration to study the contents of the design & their coordination & mutual interfaces. It depends on the volume of the documents what duration is required for complete understanding of the technicalities involved on the design. Study & review should not be confined to design drawings only but detailed specifications should also be included so that complete project requirement is properly integrated for physical execution.

Meetings for the engineering discipline form extremely significant portion of the contract. Actually this activity commences at the tender negotiation time when technical proposal is submitted. Hundreds of clarification questions are raised by the Client on the contents of technicalities offered by the Contractor as well as those at pre bid stage as replied by the Client based on the Contractor queries. For a collection of important queries, meeting is conducted to resolve the issues in hand directly between the two parties.

During contract stage, when the design is submitted meetings are conducted for every discipline for a satisfactory response on the design questions, clarifications & software related issues or formal presentation of PDS project document system. During this stage, meetings shall be very long but impart efficiency for the decision-making & save time for the approvals.
During construction stage, regularly programmed meetings are conducted for the engineering difficulties or other matter related therewith which require urgent attention. These meetings more or less form part of the regular progress meetings until lot of queries have been accumulated necessitating separate meeting. Day to day meetings are conducted on site between the area engineers of two parties to resolve the matters subject to the approval of the field engineering manager of the Client.
Engineering meetings cannot be confined to the aforesaid instances but according to the job requirement, these have to be conducted at any level of supervision to expedite the site works progress.

These meetings also involve the contribution from the quality assurance & control engineering section on site for urgent decisions & acceptable to the construction department.

During the construction phases, activity wise construction method statements are required to be issued to the supervisors on site to adhere to the statements for the smooth carrying out of the activity concerned.

For the reference to the reader, a number of method statements have been appended only for knowledge exchange. These are based on the practical experience & are used on projects. Please use them for guidance only & create your own statements for particular requirement. But basics of the methods writing can be advised herein. Just think of what is the solution of particular construction operation.

Contemplate on what the involved minor activities are. What are the sequences & materials to be used for temporary as well as permanent inclusions what are the other requirement for the accomplishment of the operation from the inception of the activity to the final outcome. After having considered all these, make a sequence thinking that you are available on works & carrying out the activity. How the activity should be sequenced one after the other & write the statement lines & then recompile to a comprehensive statement.
There shall be a long list of method statement or procedures from different engineering disciplines.

For example site preparation, camp construction, temporary facilities establishments, earthworks, excavations, blinding concrete, formworks, reinforcement fabrication, reinforcement assembly or placement, concreting, finishes activities, complete HVAC system, electrical system, loss prevention system, specialist gas fire suppression system, aluminum works, cladding works, structural steel erection at low as well as high levels, road works, paving, piping both below & above ground, pre-commissioning, commissioning, performance, maintenance, quality testing & many more.

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Chapter 4

Construction & Controls-

Construction & controls are very interrelated sections for successful completion of any project. Design may be over safe or optimum but real construction involves actual expenses, contract time & reputation. It should be the motto of any organization to apply good controls on the project to keep on line with the programme or planning an actual part of controls. Control includes, progress, cost, time, budget, quality assurance & engineering & safety.

These are all integrated divisions, which should move in unison to achieve project target. A well-designed project could be jeopardized during construction phase from budget viewpoint should it not be given due controls application properly.
Schedules- Programming

Programming schedules indicating by GNAT bars or by CPM or PERT various graphical representations respecting the overall & detailed plans for the time, activities, milestones, manpower requirement, machinery requirement, cost flow & all other requirement & running reviews of all these during the whole currency of the project from real progress, lost time recoveries as well as look ahead projections. These documents are produced involving all sections working for the project & reports are inter considered by all departments.

The very first step to get into the stage of physical establishment for construction. The site is taken over & all transfer stations are established using available satellite records. Surveying department commences its works for the establishment objectives. Approvals are obtained from the authorities concerned & from the engineer or Client.

All arrangements for the accommodation for the personnel, sanitary facilities, water supply for drinking as well as for washing purpose, electrical & air conditioning, fire fighting, access to the camp, security, messing, sewage treatment plant, leisure areas, common rooms, sports courts, parking, swimming pool, local shops, etc as required by the contract & the temporary facilities that Contractor or the engineer deem necessary should be provided.

Mobilization also includes deployment of required manpower, machinery & the supervisory, construction, safety, planning & engineering as well as administration staff without any loss of time. This deployment shall accelerate the procedure on the commencement of job in the beginning & time may be gained to keep in line with the programmes.

Without materials no project can be completed in time. This is the only item that may delay the completion of the project due to possible non-delivery in time. Material constitutes more than 60 t0 70 % budget for the contract & every prudent Contractor should intend to make as much saving as is possible out from this element of expenditure simultaneously keeping in line with the quality assurance & control procedures.

Significant is this element in the absence of which nothing is feasible. Difficulty is to be faced when well-trained workforce is not available in time from the expected source. Contractor shall try to deploy manpower costing within the job budget. There shall be so many problems for deploying them & providing demanded facilities on the contract. Human resources department should be efficient to deal with this matter so that particular delay is avoided due to non-availability of the required planned manpower.

Equipment necessary for the inclusion on the project permanently requires considerable input from the Authorization, FEED stages to the performance stage. Technology decision for the project dictates the model & types of the equipment to be installed for the facility. Elaborate & descriptive detailing is extremely necessary during designing, approval & procurement stages. The equipment installed must satisfy the design requirement failing which the facility shall be jeopardized of performance giving any possible halt to the processing & the Client or the operation authority shall make the designer or EPIC Contractor liable to compensate all damages incurred to it by the faulty commissioned equipment.

Decision pertaining the model dictates the foundation designs. This need should also be kept in view while working on the designs to avoid delay on account of providing input to the civil design team.

Procurement means to supply to the site all materials & equipment & the process commences from the requirement scheduling, vendor selection, quotation invitations, short listing quotations, specification matches, financial viability, approvability, warranties applications & then the final decisions based on the quotation that fits within the budget & items be the best for the optimum performance according to the requirement of the contract.

After having the mobilization been completed, time comes for the commencement of the permanent works for which the actual contract is meant for. It is definite that the civil construction takes the lead generally on all the projects. This requires the availability of all the approved for construction drawings circulated under control to the relevant supervisors/engineers for the purpose to correctly prosecute the works according to the contract requirement. Sooner the commencement, better the prospective to save the time and money.

It is very wide term on the Industrial contracts. Basically it is the main contract that requires well-established professional management but also covers various sub contracts as well as services contracts. Requirement of complete knowledge of the relevant laws, procedures & coordination correspondence are extremely significant for the performance of Contract management. It is not just one discipline, but from the beginning of the project & until post completion, Contract management shall be required to be applied & represented on site as well as in home office for the resolutions of many complexities. This term also covers a wide part of the documentations to be prepared for forming future arbitration basis as well as proceeding.

Project site manager or the construction manager or if project engineer be authorized for this responsibility, got very leading & significant obligation to dispose off on a daily & hourly basis. What is going on site is direct responsibility for accountability. Daily, weekly, monthly programmes as well as all discipline coordination is a must for the speeding of the operations. Then also comes the duty to arrange & coordinate the materials as well as the other resources to be utilized on the project. Attendance on the engineering, construction, safety & other meeting is a must. The outcome of the construction depends on the efforts of the construction team. Coordination with all team members as well as the team members of the engineer Client is a must. Co-ordinations with all sections of the site teams & home office teams as well as procurement are very significant. Authorizations of the letters & correspondences produced by the contract as well as other departments for the project is also one of the duties. Reporting all functions to the Client as well as to the home office & resolutions of all possible solutions is also one of the responsibilities. Authority has been invested with him to allow resources promotions & imparting training for the personnel of all categories as on job training. Job requires very dynamic & passionate person who commands all & gets respect from all sections & keeps good working relations with the Client as well as with home office.

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Chapter 5

The testing is carried out at various stages of given levels. It is conducted in the factory during processing as well as after the finishing of the production. It is then conducted on delivery, prior to the installation & commissioning & during performance & operation.

Verify quality & quantity visually according to documents

Demonstration of all system & diagnostic functions

Demonstration of technical parameters

Functional test for all components

Power consumption

Module, communication failure & recovery

Mechanical checks

Upon completion of system installation, align, adjust & balance the system for pre commissioning performance in order to ensure the conformance of the system to the requirements of the drawings & specifications. Deficiencies to be observed, corrected & if so required, replacement of the malfunctioning of the damaged items with new ones & re-testing until satisfactory performance conditions are achieved. Prepare forms for systematic recording of acceptance test results.

After pre commissioning is complete, provide a letter certifying the installation is complete & fully operable, including the names & titles of the witness to the preliminary tests.
Commissioning Test CT

It shall base on FAT & performed on site after the completion of installation & pre commissioning test. Where systems interface between each other, all necessary systems & interfaces shall be operational prior to starting the test.

Verify quality & quantity visually according to documents

Demonstration of all system & diagnostic functions

Demonstration of technical parameters

Functional test for all components

Power consumption

Module, communication failure & recovery

Mechanical checks
Site Acceptance test SAT

SAT shall be based on selected tests from the commissioning tests & witnessed by Client & Authority. SAT shall be performed at site after completion of commissioning tests.

To be performed of all sub systems or infrastructure used at physical, network & application level.

Specified equipment does not interfere with all other systems implemented & all operate without interference from each other in full operation or under fault conditions.

Long-term stability & reliability of the system under normal operating conditions as well as its ability of automatic diagnosis of defects & alarming any problem in a timely manner. It is done after IST for 30 days or longer

EPIC Contractor shall design for approval by authority

Design of sustained performance test

Reliability of central equipment

Field equipment reliability

External interface input or output failure

System sustainability as identified by frequency of false alarms
Operations & maintenance O & M

Every contract defines a particular duration of post practical or mechanical completion initial operation & maintenance to make sure & evidently prove efficient performance by the equipment / deliveries. During this period training is also imparted to the Client personnel according to the provisions / requirement of the contract so that these personnel get used efficiently for the proper control about operation of new technologies. During initial operation, the contractor shall operate the systems according to the functional requirement complying strictly to the equipment manufacturer’s instructions.

In case during the period of equipment performance as well as initial operation & maintenance, certain defects are discovered on the deliveries, these are identified, analysed & if so required, replaced or repaired as agreed with the Engineer or Client. The operation & maintenance period recommences until it is evident that no further defects exist on the deliveries.

On many specialists deliveries a clause is included that the product should be certified by a third party independently which shall be approved by the Client or the engineer prior to the commencement of its scope of the works. The third party shall, according to the provisions of the quality systems adopted or approved, inspect the deliverables in the factory as well as on site during procurement; pre-commissioning & commissioning & also during performance & maintenance. No payment shall be made to the Contractor until the third party certifies that the delivered product is according to the project specification requirement as well as meets all defined acceptable requirements.

Contractor is to appoint a Third Party Certification Agency (TPC). The list of approved TPC is to be provided within the FEED documents. The Third Party Certification (TPC) services shall be in accordance with DIN 50049, 3.1C and the certificate to be provided by Third Party Certification Agency shall include the following as a minimum:

Proof of identification of the material

Tests report duly signed by Inspector

Identification symbol of Agency or Inspector

Certificate number and date of issue

The different levels at which involvement of TPC are required shall include, but not be limited to, the following:
Material Traceability Level

Any material under the following categories (Traceability Levels) shall require specific certification or documentation as given below:

The TPC shall review the data books of manufacturers and witness all the tests in accordance with DIN 50049 3.1C or equivalent. These items shall be fully traceable. Level 1 includes Critical System, structures and components where failure could result in:

A significant hazard to personnel. A significant loss of production. A significant environmental hazard.

For example certification of Level I may include: ANSI/ASME B31.3, Generators, Switchgear, Transformer, Craneage and supports

The TPC shall ensure that the materials supplied to the Project can be traced back to Manufacturer’s Certificates (DIN 50049 3.1B or equivalent), which shall be compiled in a data book and delivered with the equipment package. It is to be ensured that the marked up drawings are supplied to Client for reference and traceability purposes. Level 2 certification is applicable to:

Critical system, structures, components where failure could result in:

A limited loss of production, A limited environmental hazard.

The material shall have a Certificate of Compliance (DIN 50049 3.1A or 3) Level 3 is applicable to material that is not in level 1 & 2.

Example of system / unit to be included in level 2, Any process system non-process wetted or non-pressure parts which are not in level 1 or 2.

Materials not in levels 1 & 2 e.g. hand rails, floor plate, cable tray.

Minor items e.g. sacrificial spool pieces of low value and non-hydrocarbon duty, etc, Produced water, Lube oil, Instrument air.
Packages

The traceability level for an equipment package can be found by using level 1. The component parts of an equipment package do not warrant the same level of traceability.

The certification type should always be considered consistent with the high criticality and type of equipment / material being designed, procured or fabricated. Consideration needs to be given to the applicable international codes and standards to which the particular equipment is being built.
Project records

All documents in whatever format produced, shall be controlled by master record copy in both hard as well as soft mode. These documents shall be duly numbered for the purpose of efficient traceability. Well established document centre of the Contractor as well as of the Engineer shall affect this requirement for all relevant incoming as well as outgoing documents. All records shall be well maintained & made accessible to the relevant authorities under the direct control of the document controller. All contractual documents, schematic drawings, design drawings, approved for construction documents, specifications, red line mark ups, deliveries, inspections, procedures & others, shall be kept in the centre for an easy reference / review for the authorized personnel. Only controlled copy shall be issued to the designated personnel for reference as well as official use.

These documents are meant for the construction purpose having due approval by the engineer & the Client. Without an availability of these documents, no work shall be allowed on site. The site personnel should ensure that the documents under use are approved for construction by making an enquiry from the document control centre. Document control shall immediately affix the superseded seal on the documents not to be used any further. These documents are also given various sequence of revision depending on the changes effected thereto. The document control shall regularly update the register of the documents showing these changes & revision references & circulate to the designated personnel.

Every operation on site should go smoothly when all details are available. There shall be instances due to the site requirement of actual conditions, which possibly might not have been included during the original design, that need immediate attention & effects to a certain extent the site for adjustments on the practical execution of the design after the approval by the engineer is granted. These changes on the site shall be recorded on the drawings or the specifications temporarily as red line markings/markups to be used as records for producing as built records. Every red line mark up shall be intimated to the engineer for the purpose of obtaining an approval for as built production. These shall be recorded in the document control as regular documents.

Every project requires documentation for the works done on site for the final handover dossiers. Those changes recorded as redline markups shall be properly studied by the discipline or the project engineers one by one to decided whether or not these changes should be reflected on the approved for construction documents. All redline mark ups shall be incorporated on to the as built title drawings before the submission to the engineer as project dossiers. Separate documents references shall be used for the se documents for an easy reference as well as traceability.

All equipment belonging to every discipline procured from any vendor shall be used on operation of the facility permanently under proper maintenance. The responsible facility operators should know explicitly how these machines or the equipment to be used. The respective vendors should provide all operation & maintenance manuals for the reference of the user describing fully to meet all normal as well as emergency requirement. The Contractor shall submit these manuals after processing formally as documents for approval by the engineer. These shall also form part of the handing over dossiers.

Before the mechanical completion as a part of the pre commissioning stage, joint inspections are carried out to enlist the minor defects as snags for all items one by one according to the approved checklists. These leads are given by the quality assurance & control department jointly with the construction & engineering. These notes of snags are recorded & a time frame agreed to incorporate the correction to items that are correctable. The items that need replacement because of defects shall have to be replaced immediately without any delay so as not to adversely affect the project handover. After conducting the correction to these snags, inspections are made & final list is prepared for minor defects that may not effect the commissioning or the performance of the facility which may be taken up to be repaired during maintenance stage to the agreement of the parties concerned.

It shall be easier to some extent for which prosecuted items may allow visual inspections for the purpose of full or part acceptance admissible within the quality assurance procedures. Item should then be closely inspected from inside & outside according to the procedures specified on the Inspection & test check list. Whatever observation made, should be recorded & final interpretation punched for further action which shall decide the level of acceptance & suggest the further remedial action applicable. These types of repairs should be immediately carried out to avoid unnecessary inclusion on the punch list.

Where technical defects have been noted on records pertaining items, amounting to severe nature, that case invites items to be replaced immediately to avoid any delay on the start up. In case defects amount to very minute nature which do not necessarily invite replacement action, touch up repair may be agreed with the engineer & after agreement, according to the procedures the repair be effected for re inspection & acceptance.

Where a non-conformance has been recorded to repair minor defects, should these defects be repairable, after agreement of the proposal with the engineer, the repair be conducted & approved by re examination.

Snags have been covered in aforesaid explanation but should be dealt with all according to site requirement & the item concerned. Some snags may require replacement of the item in full that should immediately be effected to avoiding any delay on the performance of the system.

During the inspection many categories of the snags for punch list shall be observed & pointed out. All these should be recorded & some important snags noted which amount to sloppy quality assurance for which investigation must be resorted immediately to establish the responsibility of neglect during supervision.

Final Project Dossiers shall be produced as per Engineering Standard compilation of Project Dossiers (Latest revision as on Effective Date Of Contract) and as described below:

General

All drawings and data shall be "as-built"

The Mechanical Catalogues shall include items such as given herein:

Lists for items for example - engineering documents, requisitions, general and particular specifications, Development Plan and Design Basis, Design criteria, Specifications and data sheets, PFDs (process flow diagrams), P&Ids (piping & instrumentation diagrams), line lists, Isometrics, ESD (electrical/electronic system diagrams), One line diagrams, Utilities summaries, Plot plans and layout drawings-Approved For Construction (AFC) drawings in all major disciplines (civil, structural, piping, electrical, instrumentation and others), Equipment lists, Load lists, Instrument lists-Major calculation notes for all disciplines, Instrument loop diagrams, Electrical short circuit and load flow diagrams, Electrical trouble shooting diagrams, Electrical relay co-ordination diagrams, Vendor drawings and documents for all equipment and materials, Un-priced purchase orders
Quality assurance record book

General

Contractor shall prepare Quality Assurance Record Books consisting of a compilation of quality assurance / quality control documentation representative of the material, manufacturer, fabrication, erection and test history of the equipment ordered and materials installed as appropriate.

Contractor shall organise the Quality Assurance Record Book by Unit and equipment category. There shall be several Quality Assurance Record Books each consisting of several volumes. The final Quality Assurance Record Book shall be issued together with the other documents to be included in the Final Documentation in required number of copies.

The Quality Assurance Records Book shall be bound in hard, durable, binders with the Job Title and Project Number embossed on the cover. The Table of Contents of each Volume is to appear in all volumes. Contents should be sectionalized and separated by properly labeled dividers. Volume thickness of each Volume shall not exceed eight (8) centimetres. Book pages are to be A4 size. Drawings should be reduced to A3 size and may be accordion-folded to A4 size.

The Quality Assurance Record Book shall include but not be limited to the following items:

Approved dossier index-Signed off copy of quality plan-Technical Certificates of compliance as well as non-conformance technical certificates for the record if any.
Where NACE compliance is a requirement, NACE certificates-Typical material certificates-Fully traceable material mill certificates-Weld procedures and qualifications-Weld repair procedures-Welders qualifications-NDE procedures- NDE reports for examination of welds including X-ray films

UT test sheets-NDE operative qualifications-Visual examination certificates-Dimensional check report-Heat treatment Procedure-Heat treatment Charts-

As built drawings-Vessel nameplate details-Weight and centre of gravity details-Hydro test certificates-Pneumatic test certificates-Balancing reports-Over speed test reports-String test reports-Hazardous area test reports / certificates-Functional tests, either mechanical, electrical, control system and others as required by national standard or Client specifications, whether witnessed or not (as applicable)-Crane SWL certificate-Electrical continuity / insulation resistance test-Instrument calibration certificates-General electrical / instrument/control/telecommunication-testing.
The Pre-commissioning and Commissioning dossiers shall also be included in the Quality Assurance Record Book.
Manuals and data book

Introduction

Contractor shall prepare the Operating, Maintenance and Other Manuals for the Client to use for operator training as well as for preparing the detailed operating procedures. Contractor shall organize the Operating, Maintenance, Safety, other manuals and Data Books by unit, System or Sub-System.

For that purpose, a number of manuals shall need to be produced to allow the commissioning team to produce detailed procedures and instruction for operating and maintaining the FACILITY. The manuals are listed here in order that the Contractor may identify any information of an appropriate nature, which should be compiled and handed over to Client.
Client shall specify procedure for the coding, format and final completion of documentation, drawing and certification to achieve a smooth hand-over from the Client project task force to the operating staff. It is important that all stages of the Work are properly recorded. The records and documents generated during the Work shall be included in Manuals by Unit, System or Sub-System to be handed over to Client during the transfer of responsibilities from construction to commissioning to operation.
Complete document packages for each Unit, System or Sub-System shall be available before transfer of responsibilities for Unit, System or Sub-System takes place. Computerized records shall be utilized where appropriate.

PFD’s, P& ID’s and single line diagrams prepared by Contractor shall be in a format for direct input in Client CAD (Computer Aided Design) system. Also all such documents from Vendors shall be computable to Client CAD format specified in TDMS specification. Manuals shall be written with regard to the overall construction and commissioning program, quality control, operations and maintenance so that they are available at the right time for their proper utilisation.

Each Operating, Maintenance, Safety, Other Manuals shall be available in preliminary form three months prior to ready for commissioning for the relevant system or unit and be issued in the final form together with the other documents to be included in the Final Documentation at the time of applying for Certificate of Completion. The required number of copies of the Operating, Maintenance, Safety and Other Manuals as well as the format is defined somewhere in the documents. Contractor shall submit the details of the format and contents of the Operating, Maintenance and Safety Manuals for Approval prior to starting preparation. The Manuals and Data Books shall be bound in hard, durable, binders, with the Job Title and Project Number embossed on the cover. The Table of Contents of each Volume is to appear in all volumes. Contents should be sectionalized and separated by properly labeled dividers. Volume thickness of each Volume shall not exceed eight (8) centimeters. Book pages are to be A4 size. Drawings should be reduced to A3 size and may be accordion-folded to A4 size, stated in the English language. The Project Manager / Engineer shall be consulted as to what arrangement shall be most suitable. Also, Contractor shall prepare electronic media format Data Books. All drawings and data shall be "as-built"

It shall describe the overall FACILITY and contain the basic data which determines the methods of protecting, operating and maintaining the FACILITY. It shall contain the operating parameters including safe working limits for all vessels and pipes. It shall contain plot plans, area classification plans, together with escape routes and other items to be approved by Client.

This manual shall show access and lay-down for maintenance of all items of equipment and be developed by the EPIC Contractor for further review and approval by Client.

This shall be the collection of detailed operating procedures relating to each FACILITY or system. Operating manual shall be categorized into Process Units, Utility Units, Auxiliary Facilities, Safety, Control systems, Pipelines, Communications. The manual shall describe the FACILITY in sufficient detail to the level of a competent operator including but not limited to the following:-

FACILITY description, Unit capacities and limitations, start-up and shutdown procedures, emergency shut down procedures, equipment list, PFD, P&ID, operating parameters, cause & effect charts. The draft operating procedure manuals shall be produced well in advance of Equipment and FACILITY commissioning.
Emergency Procedure Manual-

This shall contain all the actions that need be taken in the response to an emergency incident on the site or in its vicinity such as acid spillage, pipe bursting, fire, accidents, etc. It shall describe the organisational response required to deal satisfactorily with such incident, the required liaison with outside authorities & include any special procedures or instruction relating to process / utilities equipment with normal operating procedures.

These are record dossiers of all items of FACILITY and equipment to be supplied by the Contractor. The manual should include Equipment data sheets / vendor documentation, specification, spare part lists, drawings, repair procedures and QA procedures etc.

These shall provide sufficient information to the Client Maintenance Department and be produced in a form which shall facilitate the setting up of a Maintenance Management System. The final formal and content shall be decided by Client to reflect site policies. The manuals should contain the appropriate data to allow Client Maintenance to perform their function effectively as well as include vendor’s equipment description, detailed drawings, spare lists, references, re-ordering procedures, maintenance and vendor manuals.

This manual shall be produced by Contractor for approval by Client. It shall give a brief description of systems and the associated subsystems. It is intended to be used for training purposes only for which, it shall form the basic of a detailed programme for the operation and maintenance activities of the facility, system and subsystem where appropriate.

Maintenance procedures are to be split per main equipment or main equipment category. General-Detailed description of the equipment and auxiliaries-Detailed instructions for use-Detailed trouble shooting Section and details of self-diagnostic routine-Detailed dismantling instructions-Itemized spare parts lists with reference drawings-Recommended list of consumable-Maintenance schedule

Data Books are intended to provide the information necessary for Client’s resident Technical Department or an outside Contractor or consultant to understand the processes involved, calculate performance capacities, efficiencies and design modifications.Data Book(s) shall in general conform to the following:

Basic Engineering Data: General Information. Utility Information, Meteorological Data, Summary report on Soil conditions, Site conditions, Operating and design parameters. Elevations and Coordinate References and government requirements. Drawing Index of all Client, Contractor and Vendor drawings This index shall include: (a) One column wherein all drawings included in the Data Book are clearly indicated and, b) one column wherein all drawings for which electronic format (CAD). Tape / diskette) supplied to the Client are clearly indicated. Also, those included in the Equipment Reference File should be so marked. Refer TDMS specification requirement . Contractor with Client approval, shall provide a database for recording of the index.
Equipment Schedule-

Of all equipment by item number, description and specification number. Group equipment by category, i.e. tower, exchangers, vessels, etc. Also Manufacturer's name.

Include Process flows (show oil and utility quantities for specified charge rates), P& IDs by Unit, Block flow diagrams, Process plot plan, Heat and material balances, Process calculations index and Battery limit line Tables for Process and Utility lines, Licensor’s documentation.

Including sources, treating facilities, cooling water, etc., distribution and balances for normal and maximum design conditions; fire water systems design pumps, hydrants, hose and hose reels, fixed spray systems, monitors, etc. systems plot plans, P&IDs, and water treating data sheets.

FACILITY and instrument: Include design basis (quantities, pressure, dew point). Also, systems plot plans, flow sheets and tie-ins when provided.

Include design basis for air quality dispersal rates; setting stack heights, and major equipment used in control. Also, flare stack height data related to smoking / non-smoking capabilities; maximum emission allowances for C02, S02, etc. as required by local and other governmental regulations.

Include in-plant and community design noise level limit criteria, specifications, where required the local and other governmental noise limit regulation for in-plant and community noise.

Including all distribution facilities, design basis abnormal load and peak demand tabulation of significant operating conditions. Systems plot plan (including substation locations), single-line diagrams of ‘generating and main distribution’ system. Design data for switchgear and motor controllers. System description and data on telesignalling system

Include system description, special requirements (radio, walkie-talkie, etc.) and equipment layouts.-

Include brief description, type of construction, plans, elevations and plot plans.

Special requirements as related to operating units and equipment.-

Pump information to include pump list data sheets. performance curves, outline and dimensional drawings (including driver), mechanical seal arrangement drawings and auxiliary (vents, drains, lube oil systems) piping drawings. All power System Studies to be submitted as a stand-alone dossier complete with drawings, data, CDs etc.

Centrifugal & Reciprocating Compressors and Drivers information to include data sheets, performance curves, general arrangement (outline) and cross-sectional drawings, steam gland and sealing diagrams (when required), lube and seal oil diagrams indicating instrumentation and control and outline drawings, specifications of lube oil and seal oil consoles. Special Equipment such as mixers, filters, etc. to include data sheets, drawings, piping arrangement, electrical.
Instrument information to include schedule, listing data by category (temperature. pressure flow, etc.); process information and pertinent mechanical description Maintenance Facilities information to include list (type, size) of permanently mounted shop tools, special portable tools and special inspection equipment; plan and arrangement drawings of simple buildings used for maintenance and bulk materials storage. Also, major platform arrangements, including access for operations and maintenance. Line list information shall be provided as per specification.

Back up of the control / DCS system configuration made for the plant or package shall be provided in CDs or DVDs in 4 (four) numbers.

Contractor shall develop and provide Final Documentation in accordance with TDMS specifications.

The supply of the software is not included in the Scope of Work of this Contract. Client shall install the SAP system software. Contractor shall compile the data in accordance with the SAP structure as per the Scope of Work. Contractor’s Scope of Work is to input / entry data into the SAP system in conformance with the Scope of Work and structure as indicated in the SAP document. The operation of SAP is included in the Scope of Work of Contractor. However, the Contractor shall provide hardware and Software interface between SAP System and the DCS. Between the SAP system consisting of SAP modules and the DCS equipment, an Open access module is required. The SAP Open Access module shall extend the functionality of SQL plus to provide direct access to SAP modules from the APIs of DCS equipment. The Open Access module shall be both a Client and server to SAP, so data exchange may be initiated by either SAP or any application program on DCS (like Setcim and Infoplus of Aspentech etc.).

Handing over the site refers to mechanical or physical handover to the client at practical completion. The works should have been completed in all respects so that these can be used for the intended purpose & production commences according to the plant designs & technology involved.

It should be the endeavour of a professional contractor to record all incidents during the contract execution which obstructed the progress on the contract & all instances evidencing the cooperation by the engineer & his staff. All problems faced or experienced by the contractor should also be recorded on documents giving base for incorporation solutions for future contracts. Contractor should also describe his mistakes or how otherwise the problems could have otherwise be tackled to minimize the loss of time & expenditures. Also a record should be made for the performance of the engineer or the client personnel & any required improvement. These documents are termed as close out report part. The client & the engineer should go through these records to amend its style of working on the future projects.

Suggestions-about the sub Contractors- These should also be recorded based on the regular records during the various progress stages.

About the Client engineers-These records should also be based on the regular comments noted on the progress achievement during the contract period giving necessary suggestions about enhancing the client or engineers efficiencies & dealings in the interest of the future projects.

Close Out-The close out reporting is very significant in essence as it is a final document speaking all history summary of the project which may be used to learn various lessons for future use by all parties involved & can form an operational research database for supervision analysis

Discharge-After obtaining the final completion & maintaining certification, discharge certification should be given by the client & the engineer relieving the contractor of the construction responsibilities provided the contractual warranties as well as liabilities remain in force as secured for the coverage of certain guaranteed items on the scope of work.

Contractor shall arrange for technical safety, operability and maintainability reviews which are required to be carried out by Company / Client at specific stages of Engineering, Procurement and Construction during the Project development to check for safety, reliability, operability and maintainability of the FACILITY.

Contractor shall make available all records and all aspects of the Work at all times and at all places where Work is performed for detailed auditing by Company / Client or any third party appointed by Company / Client. In particular, Contractor shall make available for reference and Company / Client use at all places where the Work is performed, a good quality copy of the latest issue of all applicable codes, norms, standards, drawings, specifications and qualified Contractor Personnel to assist Company / Client. Contractor shall also provide a suitable venue for such reviews. Additionally, Contractor shall carry out Hazards Analysis, Safety Analysis and Project Health, Safety and Environment Review (PHSER). Contractor shall also prepare Safety Audit and Inspection Manual to submit to Company / Client for approval.

Chapter 6

Contractor shall be responsible to arrange to acquire all the service logistics required at Plant Industrial City for the performance of the Works. The costs of such services shall be included in the Lump Sum Portion of the Contract Price.

Examples of the required services are:

Land rental for Accommodation / office camp and lay down area.

Gate pass of personnel and vehicles, equipment, plant

H2S, BA Certificate courses.

Fresh water etc

All these facilities shall be managed by the contractor sufficient in advance so as to meet the schedule requirement. It should be noted that the procedure for the lease of the planned land for the camping consumes considerable time by the municipality or the industrial city authorities as well as other authorities. Also, the application procedures for the security gate passes based on its own regulation take certain hours for the issues. All these points should be kept in notice to initiate the application quiet in advance to meet the schedule requirement.

Contractor shall choose from option 1 or 2 (below) for its accommodation camp.

Option 1 - Accommodation facilities Inside the Fence of Plant Area.

Contractor may utilize accommodation facilities provided by Plant inside the fence of Plant area. Charges and fees to be paid by Contractor to Plant for such accommodation if so preferred & available. Contractor notes that Plant accommodation facilities shall be subject to availability at the time of request and be provided to Contractor or other parties on the basis of first come first served.

In the event that the Plant accommodation facilities are not available, Contractor shall utilize an approved Plant designated area and construct, operate and maintain his own accommodation facilities.

Option 2 - Accommodation facilities Outside the Fence of Plant Area.

Notwithstanding the above, Contractor may elect to have his accommodation facilities outside the Plant area fence. In such case Contractor shall obtain necessary approval from local authorities as mentioned in the foregoing.
Other Construction Temporary Facilities

Contractor shall provide, maintain and operate a suitable lay-down area, fabrication area and office camps and obtain permit from Company / Client Plant and / or Government Agencies to build these temporary facilities at Plant Industrial City including permits for all utilities such as power, water, telecommunication, etc. In accordance with the latest Health, Environment and Safety standards for which Company / Client shall assist Contractor by issuing an introductory letter to the Authorities.

Contractor shall submit office Accommodation and lay-down area requirements for Company / Client approval after Contract award. Contractor shall utilise these Temporary Facilities for the purpose of the Project only.
The approved temporary office camp and lay down areas shall be at no cost to Contractor, provided that these space requirements are considered as reasonable and justified by Company / Client / Plant.
General

Contractor shall take over construction preparation for the Temporary Facilities after obtaining approval from local authorities, Plant and / or Company / Client. Contractor shall build, operate and maintain up to Completion the accommodation camp for Contractor Personnel and other related facilities. The camp design and construction is to conform to the design requirements to be developed by Contractor and approved by Company / Client during the engineering phase.

Contractor shall provide accommodation, catering and servicing (including safety, medical aid, housing, cleaning, recreational facilities, laundry) in the camp and generally cater to all personnel (no accommodation to be provided to Company / Client personnel) assigned to Construction Site. Contractor shall be responsible for operation, maintenance and housekeeping of the Accommodation Camps and other facilities.

Contractor Personnel are to be accommodated in camp facilities in accordance with the latest Health, Environment and Safety standards.

After Completion, Contractor shall close down and re-instate the Accommodation camp to its original state (as a minimum) and other facilities including all facilities provided to Company / Client.

Office Buildings and Other Facilities

Contractor shall build, operate and maintain throughout the duration of the Work all other required Construction Site facilities including but not limited to the following:
Office buildings for Contractor and Company / Client Personnel.

Reprography and communications (including phone, fax, radio, etc.)

Pipe fabrication shop.

Warehouses and lay-down area

Warehousing facilities shall include covered storage, air-conditioned storage and outdoor storage as appropriate. Piping must be protected with pipe caps.

Radiography examination room. Toilets, washing facilities, showers and change rooms. Testing laboratories, both civil, mechanical and E &I

Concrete batching facility. Roads, paths and car parking for construction requirements. Guard houses, entrance control and fencing. Craft work areas, Fuelling stations for equipment, trucks, buses, adequate storage and handling facilities, Rigging loft, First aid medical stations (minimum three (3) stations), Equipment maintenance facilities, Labour canteen facilities, Explosives storage if required, Lining storage area and work area.

Steel fabrication area, Civil prefabrication work areas, Grit blasting, painting shop, Utilities such as power, water, air etc. For the phases of Work up to Completion, any other facilities required for the Work,

Contractor shall prepare details and obtain relevant approval of the facilities proposed. The temporary construction facilities provided by Contractor for the Camp, Offices, lay down areas fabrication shops, etc. shall be subjected to the inspection of the State Environmental Supreme Council such as sewage disposal, earth renewal and disposal, dirt transportation disposal, spills, etc. In case, Contractor is not compliant with the minimum requirements, Contractor shall take all necessary remedial actions for proper compliance.
Utilities For Accommodation Camp, Office Buildings and Other facilities at Construction Site

Power- accommodation camp

Contractor shall arrange for power to be provided from Electrical Department through Plant or alternatively to arrange for his own power generation system,

Office buildings and other facilities –

The office buildings and other facilities are to be located close to the Facility to be constructed. Company / Client shall not allow Contractor to utilise existing Company / Client facilities / utilities and Contractor arrange for its own power generation system.

Contractor shall arrange for temporary power and lighting arrangement in all work areas at Construction Site.