First Web Edition 2006, Devoted to Engineering Community

Dynamic Analysis

Generally the same considerations for superstructure vibration also apply to foundation vibration.

The primary differences are that these foundations are often rigid blocks and that soil behavior must be considered. Rigid foundations supporting only one major machine can readily be analyzed using hand calculations and the concept of elastic half-space theory. For flexible foundations or foundations with many machines, a computer analysis should be utilized along with the concept of elastic half-space theory. The Designer shall prepare an instruction for foundation vibration analysis which contains current state-of-the-art approaches, soil information, machine information, dynamic analysis aids, published response criteria, example solutions, and a comprehensive list of references.

The dynamic amplitudes of any part of the foundation including any reciprocating compressor shall be less than 80 µm (80 x 10^-3 mm) single amplitude.

For the dynamic analysis, the exciting forces shall be taken as the maximum values that according to the Manufacturer of the equipment will occur during the lifetime of the equipment. When the exciting force is not given by the Manufacturer, it shall be determined from

Q(kN) = [Rotor Speed (rpm)/6000] x Rotor Weight (kN)

The dynamic calculations shall be based on a mechanical model wherein the weights and elasticity of both structure as well as foundation and the weight of the equipment to be represented in an appropriate way.

All natural frequencies below 2 times the operating frequency for reciprocating equipment and below 1.5 times the operating frequency for rotating equipment shall be calculated.

It shall be demonstrated that the amplitude of the natural frequencies between 0.35 and 1.5 times the operating frequency are within the allowable values even assuming that, due to differences between the actual structure and the assumed model, resonance does occur. In this case, a reasonable amount of damping should be estimated.

The natural frequency of the supporting structure shall not coincide with any resonant frequency of the equipment.

The static deformation for rotating equipment foundations shall be calculated and shown to be within the limits stated by the Manufacturer of the equipment. The calculations shall include but not be limited to the following causes of deformation.

Shrinkage and creep of concrete.

Temperature effects caused by radiation and convection of heat or cold generated by machinery, piping, and ducting.

Elastic deformation caused by changing vapor pressure in condensers.

Elastic deformation caused by soil settlement.

Non-Dynamic Analysis

Rotating equipment mass ratio = weight of concrete / weight of machine > 3

Reciprocating equipment mass ratio = weight of concrete / weight of machine > 6
Miscellaneous Design Data
Clearances and accessibility

Minimum clearances for Equipment, Structures, Platforms and Supports shall be in a accordance with the table in Specification for Design, Layout and Drawing

Coefficients of static friction for various material combinations are listed as follows:

Steel to steel Smooth, dry surfaced 0.3

Oxidizing steel 0.5

Steel to concrete or grout 0.5

Fluorogold, Teflon / PTFE and other similar materials as per Manufacturer's recommendations

Clean sound rock 0.7

Clean gravel, gravel-sand mixtures, coarse sand 0.55

Clean fine to medium sand, silty medium to coarse sand, silty or clay gravel 0.45

Clean fine sand, silty or clayey, fine to medium sand 0.35

Fine sandy silt, nonplastic silt 0.30

Very stiff and hard residual or pre-consolidated clay 0.40

Medium stiff and stiff clay and silty clay 0.30

Membrane sheet 0.20

Engineering Maintenance Manual

Design Basis

A brief description of the basis of design of all foundations, structures and buildings, including reference to the detailed calculations for each to enable them to be retrieved if necessary.
Inspection

Recommendations for the routine inspection of works to enable the early detection of potentially dangerous deterioration including guidelines regarding the symptoms to be looked for such as locations and types of cracking which could be found in reinforced concrete structures etc.

Routine forms for inspection are to be established.
Materials

A detailed listing of all materials used (both generic types and Manufacturers' details) in the works including concrete mix constituents, concrete surface coatings, steel grades, painting details etc. to enable the Company to obtain compatible materials for future maintenance.

Details of recommended repair procedures for common types of failure such as breakdown or mechanical damage to concrete surface coatings, cracking of small foundations plinths due to reinforcement corrosion etc.

Additional list of all finishing materials used in the project buildings including material catalogs and sources to enable the Company to obtain such material or equal for future maintenance.

Concrete asset management system (CAMS)

In view of the continuous deterioration of reinforced concrete structures in plants, a computerized database system shall be developed by the Company to carry out periodical inspections and monitor the evaluation of disorder, if any.

Data related to new structures / foundations is required to be entered by the Contractor in the system in accordance with the existing procedure.

An existing computerized monitoring system for tanks and critical foundations carrying large loads, rotating equipment foundations etc, shall be developed by the Company.

As a result of this ongoing program, new tanks and critical foundations shall be required to be monitored for future maintenance.

The Contractor is required to provide the following:

1. Permanent bench marks to allow for future check surveys.

2. List of tanks and critical foundations / structures proposed for monitoring.

3. Monitoring devices (non-corrosive material) embedded in the concrete foundations and fixed on the tanks as required.

4. Plot plans showing locations of the monitoring points and the permanent bench marks.

5. A computerized form filled with the first readings of the monitoring points surveyed at the completion of the Project.
Corrosion monitoring system for critical concrete structures

Some critical concrete structures due to operational requirements cannot be shut down for inspection. A new technology exists which allows for installation of metal sensors into concrete structures in order to monitor the corrosion risk at regular intervals. In this way protective measures can be taken before excessive damage occurs and without the need of a shutdown for inspection.

1. Below ground culverts

2. Outfall structures

3. Brine tanks

4. Below ground tanks such as sulfur pits

5. Reinforced concrete or pre-stressed pipes

Contractor is required to propose to Company the corrosion monitoring system to be used and to propose to Company the critical structures which should be equipped with the system. Contractor then is responsible to install the agreed system to structures.
Units Of Measurement

All dimensions, quantities and units of measurement shown on drawings or used in specifications and calculation sketches shall be given in metric units except pipe size which shall be given in the English units of inches. Refer to “Basic Engineering Design Data”.

Contractor shall design all buildings to adequate dimensions (lengths, widths and heights) to accommodate the necessary requirements inside. However the following minimum criteria shall be followed.

The corridors connecting the rooms within the buildings shall be wide enough to allow possible movement of equipment. The clear height of room from finished floor level to finished ceiling levels shall be minimum 3500mm. The space between equipment and walls shall be wide enough for a technician to walk around with tools, instruments, etc. (Refer to Company / Client Electrical Specification) and carry out the necessary inspection/maintenance works.

All concrete exposed to seawater or saline ground water shall be provided with additional protection as appropriate, including cathodic protection to the reinforcement, water proofing system, extra cover to the reinforcement, use of admixtures in the concrete and protective paint on the surface of the concrete. Corrosion Inhibitor shall be added to the structural concrete mix at the minimum rate of 10 lt / m3 for Pump Pits, Receiving Basins, discharge channel, outfall structure and to all structure foundations within water table or and below ± 0.0m NHD.

The list of required buildings and their conceptual drawings with finishing material schedule are provided. These building drawings are conceptual and have been developed based on preliminary building requirements and equipment sizing developed during the Front End Engineering Design. Contractor shall examine the drawings in detail and shall modify the drawings as necessary to accommodate final equipment selection and operational requirement.

Material Specifications

The selection of material is based on Project Specifications and any deviations shall be subject to Company / Client's approval.

Contractor shall import rock for outfall structure. The quarry shall be subject to Company / Client approval.

Concrete as Specified in project specification shall have fly ash, microsilica, corrosion inhibitor and the course aggregate shall be of Gabro type.

HVAC

Operation building HVAC System

The specification for DX Condensing Units / AHUSs shall be as per the Company/Client specification and other standards. Each AHU shall have a centrifugal fan chamber with back draft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s.

Twin duty / standby auto-change over fans shall be used for Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries.

All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers. The exhaust air outlet shall be fitted with weather louver.

Control building (extension) HVAC System.

The control building (extension) shall be air conditioned independently by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on control building (extension) roof.

The conversion of existing two rooms in to Laboratory in existing control room is foreseen during the FEED design. Contractor shall re-balance the complete Existing HVAC system for Ground Floor to accommodate the ventilation and cooling requirement of laboratories. For Construction of the Control Room Extension, the existing HVAC condensing units shall be either relocated and connected to Ground floor existing AHU’s or secured to allow the construction of First floor works without any disturbance to the function of ground floor HVAC system. Upon completion of first floor construction the new condensing units for existing ground floor along with first floor shall be installed on the first floor roof and connected to the respective AHU’s. Local Lot Control centres HVAC System. The Local Lot Control Centres Buildings shall be air conditioned independently by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on respective building roof.

Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s.

Twin duty / standby auto-change over fan shall be used for Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries.

All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers.

The exhaust air outlet shall be fitted with weather louver.

Workshop / Warehouse building HVAC System

All Offices and Electrical room in workshop / warehouse building shall be treated with wall mounted split units. Air-cooled condensing units shall be located on external walls. Vendors’ standard Indoor units shall be suitable for wall mounting.

Chemical / sensitive materials store (s) within warehouse shall be air conditioned independently by duty / standby Direct Expansion (DX) Package units to ensure 100% redundancy. Total 100 % treated fresh air shall be supplied by 100 % capacity duty / standby Package units. The duty / standby Package units shall be located outside workshop / warehouse building on ground.

The specification for Package Units / AHU’s shall be as per the Company / Client specification and other standards. Each Package unit shall have a centrifugal fan chamber with backdraft and volume control / shut off dampers. The Package unit supply air fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each. Adequately sized hinged access doors shall be provided to access each section of the Package unit. Electric heating coils and steam humidification sections shall be provided in the Package units air handling section.

Twin duty / standby auto-change over fans shall be used for Chemical / sensitive materials store (s) Pantry and Toilets room exhaust. Chemical / sensitive materials store (s) twin fans shall be eexd IIC, T6, non-sparking type.

Warehouse storage area for Mechanical items and Electrical Cables shall be ventilated by 100 % capacity duty / standby exhaust fans installed on roof and air intake through wall opening at low levels. Wall opening at low level shall be with sand trap louvers and G4 pre filters.

Workshop area shall be ventilated by 100 % capacity duty / standby exhaust fans installed on roof and air intake through wall opening at low levels. Wall opening at low level shall be with sand trap louvers and G4 pre filters.

Workshop building HVAC System

Offices area within workshop building including electrical room, electrical workshop, instrument workshop, tool room, spares parts room, HVAC room and corridor shall be air conditioned independently by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located outside workshop building on ground.

The specification for DX Condensing Units / AHU’s shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with backdraft and volume control / shut off dampers. The AHU fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each.

Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s.

Twin duty / standby auto-change over fan shall be used for Toilets, Pantry rooms and Locker rooms exhaust.

All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers.

The exhaust air outlet shall be fitted with weather louver.

Workshop area shall be ventilated by 100 % capacity duty / standby exhaust fans (i.e Four 50 % capacity fans) installed on roof and air intake through wall opening at low levels. Wall opening at low level shall be with sand trap louvers and G4 pre filters.

Gate house HVAC System

Gate House Building (s) offices shall be air conditioned with cassette type ceiling mounted split units. Air-cooled condensing units shall be located on external walls or on gate house roof. Vendors’ standard Indoor units shall be suitable for wall mounting.

Twin duty / standby auto-change over fans shall be used for Toilet exhaust.

220 kv switchgear and control buildings HVAC System

The 220 kv Switchgear and Control building shall be air conditioned by independent HVAC system for each building. Each building shall be air conditioned by duty / standby Direct Expansion (DX) split units to ensure 100% redundancy. Treated air shall be supplied by 100 % capacity duty / standby air handling units mixing fresh air and re-circulating air. Air Handling units shall be located in HVAC plant room. The duty / standby condensing units shall be located on respective building roof.

The specification for DX Condensing Units / AHU’s shall be as per the Company / Client specification and other standards. Each AHU shall have a centrifugal fan chamber with backdraft and volume control / shut off dampers. The fan shall be of 100 % capacity. The fan shall have a minimum of 2 belts each.

Adequately sized hinged access doors shall be provided to access each section of the AHU / CU. Electric heating coils and steam humidification sections shall be provided in the AHU’s.

Twin duty / standby auto-change over fans shall be used for Battery room exhaust. Battery room twin fans shall be eexd IIC, T6, non-sparking type. In the battery room loss of both fans shall inhibit boost charging of batteries.

All fresh air intakes shall have sand trap louvers / Prefilters and motorised shut off dampers.

The exhaust air outlet shall be fitted with weather louver.

For all Buildings

Contractor shall design, furnish, install and place in satisfactory operation a chemical waste sewer system with utilities for wash down of the Battery room. The Battery room chemical waste sewer shall be provided with floor drain and be piped to a local storage system for truck removal.

Plumbing facilities including number of equipment and fixtures, and their capacities shall be developed by Contractor in accordance with Project Specification.

Contractor shall allow for the design, supply and installation of eyewash, complete with plumbing and drainage works for all Battery rooms and electro-chlorination area.

The list of required buildings and their conceptual drawings with plumbing arrangement are provided. These plumbing drawings are conceptual and have been developed based on preliminary building requirements and sizing developed during the Front End Engineering Design. Contractor shall examine the drawings in detail and modify the drawings as necessary to accommodate final sanitary equipment selection and operational requirement.

In principle no road cutting is allowed in the State. However, cutting for road / utility crossings for cooling water pipe work, identified within the Scope of Work, is acceptable to Company / Client. For these crossings, Contractor to design, procure and construct approved road diversions, so as not to disrupt traffic at any time. Contractor shall reinstate roads / tracks / ground to its original specification / condition. For all other crossings, Contractor shall design and construct road crossings by way of horizontal drilling without cutting the main asphalted road and without disturbing the traffic.

All pipe crossings for existing roads and corridors shall be made through micro tunneling or cut & cover method depending on the availability of the micro tunneling equipment. Road design and construction shall be according to National Highway Design.

Road markings / road signs to be provided in both local language and English.

Crash barriers along culvert, bridges, change of road direction and along embankments such as ramps.

Overhead steel pipe to be painted with sign warning and clearance.

Marking road edges.

Flush kerb-stones shall be allowed for at change of road construction and change of road direction.

Considerations for final grading and surface drainage shall allow excess water to flow into open drainage and shall include the following:

The open ditch system should be connected to the storm water basin. The water can be re-routed to the sea.

Roads, other areas as necessary to be paved.

In case of heavy rainfall, all building and equipment areas should be accessible.

Road levels shall be higher than the adjacent graded level (as a minimum 500mm above FGL)

Detailed engineering should be developed by the Contractor for the following:

Construction lay down; including temporary facilities; warehouse area; construction camp; site offices for Company / Client and Contractor. Access road to Company/Client site offices shall be asphalted.

Parking, road marking, traffic signs & information in both local language and English

Handling Devices Structures.

Rising pipes should be installed on structural steel pipe racks. Road and utility crossing by indicated approximate sizes and elevation to NHD shall be prepared by Contractor. Minimum requirement of clearance between walls, bottom slab and sofit of top slab and pipe shall be 600mm. Also note that 5.5m minimum clearance is required between roads whether existing or / and new and bottom of structures supporting pipes in utility crossings.

For consumer utility crossing involving any combination shall be designed and built by Contractor. Contractor shall design all the pipe bridges and utility crossings required for Phase and construct only Phase bridges. Minimum clearance shall be as indicated on FEED drawings (6m).
Pipe Bridge Crossing Over Existing and New Discharge Channel

Contractor shall design and construct series of concrete support frames to support pipelines over the new and existing discharge channels. The corridor crossing occurs just up stream of the road bridge. Contractor to construct the foundation for the Pipe Bridges, each end user shall construct their own steel truss bridges for carrying pipes.

The required conceptual drawings Pipe Bridge are provided. These drawings are conceptual and have been developed based on preliminary requirements and sizing developed during the Front End Engineering Design. Contractor shall examine the drawings in detail and shall modify the drawings as necessary to accommodate final pipe sizes and routing.
Oil Spill Control Equipment

Contractor to design and construct Oil Spill Control Equipment based on the SOW (Scope of work) provided, however the SOW provided is based on the preliminary requirement of Company / Client, and the same to be modified based on the one constructed at Phase for Pump House

The Phase of the project shall derive power at 220kv from a new 220kv substation, as further detailed below.

Power Supply for Local Lot Control Centers located at the Consumer premises receive and distribute Power at 415V. At intermediate locations, power supplies for Local Lot Control Centers shall be derived from the existing 11kv network, by providing 11kv RMU units and 11kv / 433V Package substations and distributed at 415V. At Receiving basin and Outfall areas, the existing 11kv network shall be augmented by providing 11kv RMU units and 11kv / 433V Package substations and power supplies to llccs shall be distributed at 415V. The Contractor shall provide the following systems / facilities as a minimum.
220 kv System

Two 220kv / 34.5kv, 165/220 MVA transformers (located near the new 33kv switchgear building) shall be provided.

A 220kv Substation consisting of double bus switchgear shall be provided. Existing two circuits of 220kv cables shall be cut and terminated to the 220kv switchgear as incoming cables. New 220kv cables shall be provided from the 220kv switchgear to feed the two existing 220 / 33kv transformers. Also, new 220kv cables shall be provided for the two new 220 / 34.5kv transformers. The GIS shall have provision for additional two 220kv feeder bays to receive power from a future Electrical department substation.
33kv System

New 33kv double bus switchgear with Gas Insulated bus bars and vacuum circuit breakers shall be provided and located in 33kv Switchgear building. This shall include 33kv gas insulated bus ducts connecting the transformers to the 33kv switchgear.

Expansion of existing double bus Siemens make 33kv switchgear (gas insulated) located in existing 33kv Electrical Switchgear building-1 to cater to Phase loads located in Phase area.

One 33kv, 1250A rated tie feeder connecting existing 33 kv switchgear (feeder allotted from the expansion portion) to the new 33kv switchgear.

Two 33kv / 6.9kv Transformers (located near VSDS Substation for PH area.

Two 33kv / 6.9kv Transformers (located near Electro Chlorination building).

Replacement of two existing 33kv / 6.9kv Transformers with higher MVA capacity transformers (located near existing 33kv Electrical Switchgear building-2).

33kv XLPE Cables along with termination kits and associated items for feeding vsds transformers and various other loads.

Harmonic filters connected to new 33kv switchgear and to existing 33kv switchgear.
11kv System

11kv / 433V Package substations (consisting of RMU’s, 11kv / 433V transformers, LV Switchboard, etc.) For deriving Power supply for llccs in MOV corridor area, Receiving basin and Outfall area.

11kv XLPE Cables with their termination kits and associated items for modifications / additions in the 11KV network.
6.6kv System

New 6.6kv metal clad draw-out type switchgear with insulated (solid insulation) bus bars and vacuum circuit breakers shall be provided and located in VSDS Substation for PH building. This shall include 6.6 kv bus ducts connecting the transformers to the 6.6kv switchgear.

New 6.6kv metal clad draw-out type switchgear with insulated (solid insulation) bus bars and vacuum circuit breakers shall be provided and located in new Electro Chlorination building. This shall include 6.6 kv bus ducts connecting the transformers to the 6.6kv switchgear.

Expansion of existing 6.6kv switchgear (Schneider make) located in existing 33kv Electrical Switchgear building-2 to cater to Phase loads located in Phase area.

Four 6.6kv / 433V Transformers (located near VSDS Substation for PH building).

Two 6.6kv / 433V Transformers (located near 220kv GIS Building)

Two 6.6kv / 433V Transformers (located near new Electro-Chlorination building).

Two 6.6kv / 433V Transformers (located at operation building).

Two 6.6kv / 433V Transformers (located near VSDS Substation for PH building).

6.6kv XLPE Cables with their termination kits and associated items for feeding various loads.

New 415V Switchgear–MCC assembly located in VSDS Substation for PH building. This shall consist of an emergency section fed from an emergency diesel generator and shall also include 415V bus ducts connecting the transformers to the 415V switchgear.

New 415V Switchgear–MCC assembly located in VSDS Substation for PH building. This shall also include 415V bus ducts connecting the transformers to the 415V switchgear.

New 415V Switchgear–MCC located in new Electro Chlorination building. This shall consist of an emergency section for feeding emergency loads and shall include 415V bus ducts connecting the transformers to the 415V switchgear.

New 415V Switchgear–MCC located in vsds building for PH. This shall consist of an emergency section fed from an emergency diesel generator and shall include 415V bus ducts connecting the transformers to the 415V switchgear.

New 415V Switchgear–MCC assembly located in 220kv GIS Building. This shall consist of an emergency section for feeding emergency loads and shall include 415V bus ducts connecting the transformers to the 415V switchgear.

New 415V Switchgear–MCC assembly located in Operation Building. This shall consist of an emergency section for feeding emergency loads and shall include 415 bus ducts connecting transformers to 415 V switchgear.

Modifications to existing 415V Switchgear–MCC located in 33kv Electrical Switchgear building No-2 to add manual synchronizing for Load testing of the existing emergency generator.

New 415V Switchgear–MCC assembly located at existing Electro chlorination building to feed the loads of Power consumer. This shall consist of an emergency section feeding emergency loads.

Modifications to existing 415V Switchgear–MCC located in Electro chlorination building to provide power feeders to Power – MCC indicated above.

New 415V Power distribution centres for sub-distribution of 415V Power supply (Normal and emergency as applicable) at various load centres.

New 415V Switchgear–MCC located in each.

New 230V, 50Hz, UPS system shall be provided at the following locations:

UPS with battery banks for Phase equipment located in Phase-I area and located at extension portion of Control Building.

UPS with battery banks for Phase located in VSDS Substation for PH building.

UPS with battery banks for each LLCC building located in End-User premises, MOV Corridor, Receiving basin and Outfall area.

UPS with battery banks for 220kv GIS located in 220kv GIS building.

New 110V DC UPS system shall be provided at the following locations:

UPS with battery banks for Phase located in VSDS Substation for PH building.

UPS with battery banks for Phase located in 33kv switchgear building.

UPS with battery banks for Phase located in Electro Chlorination building.

UPS with battery banks for 220kv GIS located in 220kv GIS building.

The Contractor shall provide control, protection, interlocking and alarm systems for Phase-II equipment as detailed below:

Separate Relay panels, Control and annunciator panels shall be provided and located in 220kv GIS building.

Separate Relay, Control and annunciator panels shall be provided for new switchgear and located in new 33kv Electrical Switchgear building.

Separate Relay, Control and annunciator panels for extension of existing 33kv switchgear shall be provided and located in existing 33kv Electrical Switchgear building.

6.6kv System

Relays control and annunciation system shall be mounted on the 6.6kv switchgear LV Compartment for new and modified switchgear.

Relays, control and annunciation system shall be mounted on the 11kv rmus LV Compartment / 415V switchgear compartment as applicable.

Relays, control and annunciation system shall be mounted on the 415V switchgear LV Compartment as applicable.

The Contractor shall provide the following:

Separate SCMS system shall be provided for 220kv GIS. This shall include all necessary Control, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis.

One Human machine interface (HMI) with necessary software and graphical interface shall be provided for the 220kv GIS. This shall have necessary gateways for Electrical department, 33kv SCMS and Power Management system (PMS).

SCMS System FOR NEW 33kv System

Separate SCMS system shall be provided for the new 33kv GIS. This shall include all necessary Control, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis.

One Human machine interface (HMI) with necessary software and graphical interface shall be provided for the 33kv GIS. This shall have necessary gateways for Electrical department and PMS.

Transformer Monitoring System

Separate transformer monitoring system (equivalent to GE Faraday TMCS) shall be provided. This shall log all transformer signals from transformer monitoring devices.

PMS shall be provided for overall control and monitoring of the Phase electrical system

The PMS shall be linked to Gateways of the SCMS of 220kv and 33kv systems.

The PMS shall be linked to the data acquisition and control system of the new VSDS and all control, signals shall be enabled in the PMS.

The PMS shall be linked to the data acquisition and control system of the existing VSDS and all control, signals shall be enabled in the PMS.

The PMS shall be linked to the existing PMS and all control signals shall be enabled in the new PMS.

The PMS shall be linked to the Transformer monitoring system and all signals and data shall be available at the PMS.

For 6.6kv, all necessary Control, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis, shall be provided.

For 415V system, signals (status and analog signals), alarms and alarm processing, event recording, fault disturbance recording, fault history and analysis, shall be provided. Control shall be provided for Incomers, bus ties and feeders ties.

One (1) Human machine interface (HMI) with necessary software and graphical interface shall be provided for the PMS. This shall be located in the Control building. This shall have a gateway facility to DCS.

Tariff metering system shall be provided on the Incoming feeders of new 33kv switchgear.

The metering scheme shall be subject to approval by Electrical department.

Existing as well as new metering signals are to be transmitted to NCC

The Contractor shall provide lighting systems as detailed below:

Indoor lighting systems for all buildings in Phase. Building external lighting (Photo-cell controlled) shall also be provided.

Outdoor Areas Lighting systems (Photo-cell controlled) for the intake area of Phase.

Stilling basin. Additional lighting to be provided to enhance the lighting (Photo cell controlled) to 150 lux at the Outer edge of Stilling basin.

Security Lighting (Photo cell controlled) system shall be provided for the intake plant overall perimeter fence. This shall consist of pole-mounted floodlights. The poles shall be located inside the perimeter fence. The floodlights shall be with high pressure (HPSV) lamps. The lighting level at the fence shall be 150 lux.

The Contractor shall provide earthing system for all installations in Phase. This shall consist of insulated earthing cables and stainless steel earth rods.

Earthing studies and calculations shall be carried out to establish the parameters of the earthing system design.

Contractor shall perform the studies using CYME software to plot ground potential contours for 33kv and 220kv GIS installations to substantiate that the touch and step voltages are within tolerable limits. Both electronic and hard copies shall be submitted to Company / Client as a part of final documentation.

Lightning protection shall be provided for all the buildings and tanks associated with Phase. This shall also include the Control building extension.

The Contractor shall provide calculations to establish the design of the system.

Both electronic and hard copies shall be submitted to Company / Client a part of the final documentation.

Following studies covering the entire plant network shall be conducted. The studies shall be conducted in accordance to Company / Client specification and harmonic requirements.

The studies shall be contracted to a Company / Client approved study Consultant. All the studies shall be carried out on Windows based CYME package except Insulation co-ordination study, which shall be on PSCD EMTP software. The VSDS vendor documentation shall also the CYME software package for analysis and reporting.

Other Specialized software may be used for insulation co-ordination studies but this shall be subject to prior approval of Company / Client.

Load Flow studies shall be performed to validate the chosen equipment ratings (continuous). This shall include motor starting studies.

Short circuit studies shall be performed to validate the chosen equipment (short time) ratings.

The actual fault levels at the 220kv + PLANT substation shall be made available during detail design. Fault level details shall be co-ordinated with Company / Client during detail design.

Harmonic studies

As harmonic levels are in excess of the stipulation mentioned in the specifications, the Contractor shall install necessary filters to mitigate the harmonic levels to the specified limits. Following successful plant completion, Contractor shall perform extensive site verification tests to prove that limits imposed have not been exceeded.

Establish the relay settings for all protection relays. These shall include protection settings at all llccs.

The studies shall establish that the insulation levels of equipment are adequate for probable surges in the system with a safety margin. The studies shall also establish the location, number and rating of surge arresters/surge suppressors in the system.

Both electronic and hard copies shall be submitted to Company / Client as part of the final documentation.

Motor Starting

Substation Earthing

LV Power and Control Cables

XLPE insulated Copper Cables shall be provided as required to distribute LV Power, and for Control, protection and annunciation requirements.

The Contractor shall route the cables in concrete troughs, trays, conduits, raceways, under ground trenches, etc. As detailed in the cable layout drawings.

Emergency Diesel Generator

An emergency diesel engine driven generator with a minimum rating of 630kva shall be provided to cater to the loads of Phase emergency loads and located in VSDS Sub-station for PH. The Contractor shall size and verify the rating based on various loads connected to the emergency bus.

An emergency diesel engine driven generator with a minimum rating of 350kva shall be provided to cater to the loads of Phase-II emergency loads located in Phase area. This shall be located in VSDS Sub-station for PH. The Contractor shall size and verify the rating based on various loads connected to the emergency bus.

Bulk Materials

The Contractor shall provide as required Push button stations, receptacles (415V and 230V), local control panels, junction boxes, etc. As required for each system.

Scope at Remote PLANT Substation and NCC

The Contractor shall provide the necessary facilities at the remote end for tele-signalling.

The design, installation and commissioning of all 220kv equipment (including control and signalling to PLANT substation) shall require co-ordination/approval of Company / Client, PLANT and Electrical department.

Contractor shall take the responsibility / lead in obtaining approval for the interface facilities with PLANT and Electrical department. Company / Client shall facilitate the co-ordination and interface by a letter of introduction.

Contractor shall engineer, connect and configure the signals for monitoring and controlling the FACILITY pertaining to this Project only. Twenty percent (20%) of the spares shall be connected and configured as spares as detailed in the specification provided. Provision for expansion shall be made for connecting any additional signals (future).

Harmonic filters shall be provided based on the power system study requirements. This shall consist of :

One set to cater to the requirements of existing 33kv network and connected to the existing 33kv switchgear (in the modified portion). This shall be further split into two groups. Each group shall be connected to individual bus-section.

One set to cater to the requirements of new 33kv network and connected to the new 33kv switchgear. This shall be further split into two groups. Each group shall be connected to individual bus-section.

The filters shall require a minimum of manual intervention and shall be designed for minimum energy losses. The harmonic filter package shall be for the Phase (existing).

Tele-protection System and RTU

The existing tele-protection system (SWT-3000), in the existing 33 kv switchgear room, shall be expanded to be made dual redundant.

The existing tele-protection system in PLANT shall be expanded to be made dual redundant.

A new dual redundant tele-protection system shall be provided for the new incoming cables in the new 33 kv switchgear room and the new 220 kv switchgear room.

The existing RTU and existing C30 Controller located in existing 33kv switchgear room shall be expanded to cater for additional feeders.

The tele-protection systems at PLANT, existing 33kv, new 33 kv and the new 220kv are to be integrated into a network via redundant, dedicated optical fibre cables. The network shall be configured such that the functions of any one redundant tele-protection unit that has failed shall by automatically assumed by another tele-protection unit within the network.

Tele-signal Transfer

The existing communications system shall be extended and expanded in order to provide voice and data links from the new 220 kv substation to the NCC.

A new SDH node, PDH and PCM multiplex and supervisory system at the new 220 kv substation connected to PLANT via redundant optical fiber cables shall be provided.

Telephone and hotline telephone facility at the new 220 kv substation shall be provided.

The existing SDH and associated equipment at PLANT and NCC shall be expanded, including software upgrades, to cater for the new and expansion of the tele-signaling and telecommunication requirements or a new SDH equipment shall be provided.

Necessary software and hardware modifications, including map work, network display, etc., and additions shall be provided at NCC for the new substation.

Reactive Power compensation equipment shall be provided if necessary based on the power system study requirements.

The design shall be based on a design life of 30 years for all equipment.

Fibre Optic cables for all networked equipment.

In order to coordinate with others, Contractor shall provide the following:

Estimated annual load build-up for the Project based on available data on flow requirements and utilities. This estimate shall be in tabular as well as graphical format. The first submission shall be within four months of award date and tabulation shall be regularly revised every six months with the development of the Project.

Priority shall be given to finalising the load Schedules / load Data for all end-user llccs so that early coordination of LV power supplies can be undertaken with the respective end users.

Where new roads or maintenance tracks cross-buried cables, Contractor shall install duct banks to safeguard the buried assets. The design of duct banks shall be suitable for a 30-Ton axle load.

Contractor to note that the terminology ‘Piping’ or ‘Pipelines’ anywhere in this document refers to complete piping systems (both ‘on plot’ and ‘off-plot’) including Pumping Station piping, Manifolds, package piping, fire water piping, utility piping, cooling water supply and return headers, piping from / to end users battery limits, etc.

Contractor shall check, validate and endorse all FEED documents, drawings and data during detail engineering as a part of his scope of work.

Contractor shall bring to the notice of Company / Client in writing any contradictions / conflicts in the FEED documentation provided.

All detail engineering deliverables shall fully comply with the requirements of all relevant Company / Client standards / specifications and FEED documents.

Topographic and Geotechnical Survey for all cooling water corridors have been performed as part of FEED engineering and the survey report is included. Contractor shall perform additional survey as required for detailed engineering to confirm the pipeline routings, tie-ins, fouling/interface with other facilities, collection of data for detailed engineering, installation of piping, road and utility crossings and pipe supports.

Contractor shall perform detailed engineering for piping including but not limited to the following activities:

Basis of Design

The FEED Basis of Design for Piping shall be expanded as required for detailed engineering. Any change in the Basis of Design shall be specifically highlighted and shall be subject to Company / Client approval.

Specifications

All FEED specifications shall be developed to detailed engineering status. Any modifications from the FEED specification shall be specifically highlighted and shall be subject to Company / Client approval.

Additional specifications, as required during detail engineering, shall be prepared by the Contractor. These shall be stand alone, self contained and Project specific.

Drawings

Verify that pipe routings indicated in FEED documentation have not been compromised or fouling with by on going works / projects.

Prepare Key Plans, which shall show the facilities subdivided into geographic construction areas and sectors and their corresponding documentation.

Develop piping general arrangement drawings for the entire facilities. All drawings shall be produced from 3D CAD model and in AUTOCAD electronic format and shall conform to Company / Client draughting standard requirements.

Plot Plans, Key & Area Plot plans. Overall Pipe Routing Plans. Fire Water / Fresh Water Routing & gads. Prepare a list and drawings on special supports. Prepare Piping Isometrics for all piping having the following information as a minimum: Complete line from start to end with all components with full dimensions. Complete Bill of Materials. Information on type and thickness of insulation. Information on Process conditions and parameters. Information on whether line is stress analysed, stress relieved, etc. Information on pipe supports. Pipe supports to be shown on the Isometric drawings only for DN 50 and above piping. Information on reference drawing

Studies,

Finite Element analysis for Critical Components, supports, and manifold Tees, reducers etc. Using COSMO, ABAQUS or ANSYS Soft wares.

Prepare a 3D PDS model for the entire facilities. Piping of all sizes shall be modeled. The 3D model shall further include modeling of pipe supports for DN 50 and above piping, electrical and instrumentation items / cable trays, civil and structural information, all equipment, etc. Intelligent model to be submitted to Company / Client, updated to include as-built status of installed facilities. This shall be used by Company / Client for further engineering during ultimate phase or future phase

Vendor Data Review. Review, check and comment on all applicable Vendor calculations, drawings and data and incorporate requirements in design and engineering. Construction. Prepare all documentation for fabrication, erection, installation, inspection and testing of piping. Tie-ins, Prepare Piping Tie-in schedule and details as per P& I D’s and other Project documents. MTO and Requisitions. Perform and prepare Material Take-offs and summaries for piping and support materials including bulk material. Prepare material / purchase requisitions (RFQ’s) for all piping and support materials.

Prepare Technical Evaluation Summary reports for all piping items. GRP Piping. Coordinate between different GRP Vendors. As Built Documentation

Prepare and submit final “As-Built” documentation.
Piping / Pipeline Deliverables

Electronic copies in native format (generic) and hard copies shall be supplied in final documentation for all disciplines. Piping Basis of Design. Piping Material Specification (Piping Classes). Piping Wall Thickness calculations Reports. Technical Specifications for Pipes, Flanges, Fittings, Valves, Rubber Expansion Joints, Bolts & Nuts, gaskets, etc. Process / Piping specialties specifications and data sheets. Valve Data sheets. Valve Schedule. Specification for flexibility/stress analysis. Specification for Pipe Supports.

Specification for Fabrication, Erection, Installation, Inspection and Testing of Piping. Specification for Hydrostatic Pressure Testing of Piping. MTO for piping and support materials. Requisitions for all piping bulk items, valves, specialities, etc. Technical Bid Evaluation Reports. Mechanical Handling study report. Surge Analysis report for the Fire Water (Fresh Water) System GRE Piping. (Plot Plans / gads / Pipe Routings) Key Plans. Plot Plans (Overall & Unit). Piping General Arrangement Drawings (key Plan & Plans & Sections / details). Piping Isometrics (AFC). Tie-in schedule and details. Critical Line List for Piping Stress analysis. Piping Stress Analysis calculation reports. Standard Pipe Support drawings. Special Pipe Support Drawings. Support Schedule. 3D – PDS Model (Generic and Intelligent). Overall Pipe Routings

Reports / Calculations notes etc. As listed. As-built drawings (for all above referenced drawings / documents)

Design, Fabrication and Installation of FRP Piping. Detailed design and supply for FRP (GRE / GRP / GRV) Piping are of specialist nature and hence shall be subcontracted to the Specialist GRP and FRP pipe manufacturer respectively.

Detailed Design shall include, but not limited to the following: All thickness calculations for pipes and piping components. Update and issue of design and installation drawings. Flow / Surge calculations for the system as may be appropriate. Static and Dynamic stress calculations and analysis. Design of jointing system based on the design. Design and location of supports, anchors, and design data for anchor blocks. Review of all proposed field design changes, which may affect FRP pipework or support throughout construction. Supply of FRP Piping and spool fabrication. Supply of piping components such as pipes, fittings, flanges, etc. For FRP piping system.

Supply of pipe supports such as saddles etc. Supply of fabricated spools.

Further, the FRP vendor shall furnish Installation, inspection and testing procedures for FRP piping and shall supervise the site installation activities in order to ensure single point responsibility of design, supply and installation.
Instrumentation & Controls

Contractor shall be responsible for but not limited to the following:

Contractor shall be fully responsible for the design and provision of instrumentation, and associated control systems for the Project. Responsibility extends to all required detailed design, material supply, engineering, factory inspection and testing, packaging, logistics, calibration at site, installation, hook-up and field verification. All systems shall be supplied, configured and tested in accordance with the relevant Project Specifications.

Refer Instrumentation & Control Basis of Design, General Instrumentation Specification, Specification for package Instrument Installation Contractor shall make a detailed site visit to study and familiarize the existing Instrumentation & Control system already implemented for Phase

Site visit report shall be submitted to Company / Client.

The Instrumentation and Control system to be implemented for Phase shall only be considered for the Project. Phase related items would be a separate project in future.

Instrument scope shall include, but not be limited to the items listed below:

Contractor shall develop a Master database of Instruments in ‘intools’. This database shall cover the details of all the tagged instruments and their signals as per the Company / Client Drafting & Numbering system. The basis for this list shall be P&ID. This database shall be dynamic until the ‘As built’ stage of the project. All the features of the intools e.g. Index module, Data sheet module, Calculations, wiring, Instrument Loop diagrams, hook-ups etc. Shall be utilized.

As a minimum, one license of ‘INTOOLS’ shall be made available for Company / Client use during project stage and the same license, complete database with associated information shall be handed over to Company / Client at the end of the project.
Instrument specifications & Data sheets

Contractor shall generate a stand-alone specification and / or data sheet for every Instrument and Control system. These documents shall be regularly updated until the “As built” stage.

The Specification shall cover minimum requirements such as the selection of type, Material, requirements pertaining to Manufacturing, QA / QC, Inspection, Painting, Storage, Handling, Transportation and Maintenance & Operations etc. The data sheets shall cover complete details of individual instruments.
Installation drawings and Documents

Contractor shall develop detailed instrumentation installation related drawings to facilitate the easy construction of the Instrument & Control System. These drawings shall include but not limited to the instrument equipment layout in building, location layouts, cable block diagrams, cable routing layouts, cable schedule, Hook-up Diagrams, Bill of Materials, MCT schedules, Air supply distribution, Termination diagrams, Loop diagrams etc.

Contractor shall develop a detailed Specification for the Installation of Instrumentation & Control System.

Input to various disciplines / participation in various studies

Instrumentation shall provide inputs to the various disciplines associated with the Project. Proper co-ordination among all the Project team members is expected. Instrumentation shall participate in various studies (e.g. Hazop, Constructability review etc.) During course of the detail engineering.

Procurement

Contractor shall prepare detailed Scope of supply (which includes Documentation requirement etc.), Material Requisitions for each type of Instrument and Control system. The enquiries shall be floated to the Company / Client approved Suppliers only. A detailed Technical evaluation shall be carried out and the Technical Bid Analysis shall be submitted to Company / Client. All the relevant documents shall be updated to reflect the make, model number of the individual instrument and submitted along with the technical section of the Purchase Order.

Vendor Drawing approval

Contractor shall carry out detailed review and approval of all the Vendor drawings and documents. Vendor Data Books shall be submitted in format explained in the relevant Project specification.

Inspection and testing shall be conducted as defined in the relevant Project specification.

Distributed Control System (DCS)

The Control system for Phase is EMERSON make Delta – V system. There are two options for Phase. Either this system can be extended to cater for the expansions including phase or an independent third party Distributed Control System integrated with the existing DCS through ‘OPC’ open system connectivity. It is intended that the Operator stations implemented for Phase shall be continued to be in use for Phase and all the future phases of the Project including Phase. Presently only one additional operator station is planned to be added.

Contractor shall finalize the hardware required for the Project and ensure smooth integration. It should be noted that the plant would continue to run during implementation of this Project. Contractor shall submit detailed Method statement for proper and uninterrupted transition of the new system.

A separate method statement shall be prepared for the pre-commissioning of the Control system. Depending on the final architecture and the routing of the Fiber Optic cable, a sequential start-up is expected.

Due care shall be taken to define and implement the communication links to various subsystems like HVAC, Machine Monitoring systems, VSDS, Switchgears, F&G Systems, End users’ systems, and various packages etc. The DCS shall have redundant F.O. network.

The Fire and Gas System to be used for Phase shall work on a F.O. redundant network of single mode fibres. Also the fire panel at each location shall communicate serially to the DCS over redundant link. The Master Fire panel shall be located in the CCR. Repeat signals shall be connected to the panels in PLANT Control at existing main gate house and Fire station within the PLANT .

The Phase seawater pumping & distribution project has a ‘Cerberus’ make Fire & Gas system having one operator station in CCR and one in PLANT control in existing main gate house. The system has hardwired contacts to the respective DCS subcontrollers. Also this system is communicating over multi-mode fibers and not on Single mode fibers. In order to integrate Phase systems, following two options are envisaged:

1. Communicate all the Phase alarms and signals to the existing F&G Operator stations located in CCR and PLANT control at main Gate House.

2. Replace the Phase system completely and bring Phase and Phase systems on to a single platform.

In this option, for the F&G panels in Phase building, either existing telecommunication F.O. network (single mode) shall be used or new connections shall be made to the F&G panels at nearest building that is being built in Phase of the project.

Every unmanned Building shall have HSSD System. The manned building shall have smoke detection and other associated detection system specified in the relevant Project specification. The Fire & Gas detection and alarm systems for each building shall have a F&G panel. All such F&G panels shall be connected to a new Master F&G control panel to be located in the existing Control room, the PLANT Control located at the Main Gate House (known in Phase as Fire / Incident Control Room) and Fire Station, which shall communicate with the Operator station.

Two new Gatehouses are planned in the Project, which shall also have alarm panels as defined in the relevant specification.

The Fire and Gas system shall provide a fast, comprehensive and automatic means of detecting, alarming and indicating the presence of fire and combustible gas hazards. The system shall also be connected to activate deluge of 220 kv / 33 kv transformers on detection of fire. The system shall close the inlet dampers in the control room and other buildings when toxic gas is detected. Refer Specification for F&G System and F&G System block diagram Instrumentation on Package Equipment.

Contractor shall develop Control strategy for individual packages where instrumentation and Control system shall be involved. All the interfaces between the various systems shall be properly defined.

Refer Specification for Package Equipment Instrumentation.

Flowmeters

Contractor shall implement water Metering System at discharge main header and each consumer’s intake.

Dual beam multi-path ultrasonic flow meters shall be used in line and shall have accuracy equal to or less than 0.5%. The ultra-sonic meters shall be clamp-on type. The mounting arrangement shall be such that there shall not be any loss of signals.

Analyzers

Analysers installed in Analyser House / shelter shall be utilised for environmental monitoring at the intake, outfall and at every consumer.

Control and On-Off Valves

All the Control and On-Off valves for the Project shall have Motorized actuators (with the exception of any pneumatic valves having independent Instrument Air system for Electro chlorination package). The actuators shall be intelligent type and shall communicate on single pair cable forming a network. A master station shall be located in the CCR / LLCC for certain number of movs based on Manufacturer’s recommendation. The output signal from DCS to the Control valves (fvs and ccvs) shall be hardwired. The Combined Check Valves (ccvs) shall have electro-hydraulic actuators. Each CCV shall have an independent hydraulic system and control panel.

Contractor shall develop the network and implement for the Project.

Other Field Instrumentation

Contractor shall ensure that all the field instruments are procured from the Suppliers listed in Company / Client supplier’s list. Also all the Instruments shall completely comply with all the Project documents.

There is a special requirement to measure the seawater temperature one meter below the surface at outfall. The temperature points shall be distributed in a semi-circular fashion at a distance of 100 meter from the discharge point. A sensor attached to a floating buoy is a preferred arrangement. Contractor may suggest any other alternatives for consideration by Company / Client. The cables for these temperature sensors shall be sleeved with a pipe and precast concrete blocks. Alternatively, remote wireless sensors and transmitters can be considered. Access shall be provided for sensors inspection / replacement.

Contractor shall design a laboratory, design, supply, install, test and commission the laboratory instruments as per the specification for Laboratory Instrumentation Doc. and Laboratory Layout Drg. The laboratory layout shows only indicative minimum requirements and Contractor shall suggest any requirement of additional equipment, space, etc.

Instrument air required for the laboratory shall be tapped and arranged from the existing Instrument Air compressor located near Electro chlorination package of Phase

F. O. Network

It is intended that a complete redundant Fiber Optic Network shall be utilised for the following:

DCS;-F&G;-MOV;-Telecommunication;

The F.O. Cables shall run on either side of the Cooling Water Pipelines. The cable shall be supported over the cable trays laid over the Pipe sleepers on the above ground portion. The cables shall be buried where the Pipeline is also buried.

In case, all the pipes are not laid in the defined Pipeline corridor and second route of the F.O. cable is not available due to this, Contractor shall be allowed to commission the system on non-redundant F.O. network temporarily as a special case. However Company / Client approval shall be taken in advance and shall be properly reflected in all the documents. Once the second route is available, the ‘redundancy’ shall be implemented.
Instrumentation Deliverables

All documents and drawings shall be continuously updated until “as-built” revisions.

Following is a minimum list of Instrumentation documents to be generated by Contractor or enhance the FEED documents where applicable for the implementation of Phase
Site Visit report, -Instrumentation and Control Basis of Design.-Specification of Individual Instrument;-Data sheet of Every Instrument;-Material Requisitions;-Technical Bid Evaluation and Recommendation;-Vendor Data Manual;-System Specifications (DCS, F&G, etc);-Functional Design Specification / Control Narrative;-Loop diagrams showing terminal numbers and all elements of the loop.-Logic Description;-Flow chart derived from the Cause and Effect Matrix (developed under Process discipline) or the narratives for trip, shutdown or operation of equipment.-Instrumentation Index (Database);-I / O Lists;-System Architecture Diagrams;-Logic Diagrams and sequence charts;-Instrument Cable Block Diagrams;-Cable Routing Layouts;-Instrument Location Layouts;-F&G Detector Layout,-Laboratory Layout,-Instrument Junction Box wiring diagrams;-Instrument Hook-ups;-Installation MTO;-Instrument Cable Schedule;-MCT Layouts for CCR and llccs;-MCT Schedule,-Interface wiring diagrams;-Equipment Layouts in the Buildings;-Instrument Loop Diagrams;-MODBUS address mapping details;-Instrument Grounding Layout;-Calculation of Instrument Air Consumption, wherever applicable;-Power Requirement Calculations and distribution drawings; -I/O allocations, Controller allocations;-Sizing Calculations for Valves, Orifice Plates, Power supplies, Instrument Air consumption;-Noise Calculations;-Following documents shall be generated by individual suppliers. These shall be duly approved by Contractor and submitted to Company / Client.-Panel GA Drawings;-Panel Dimensional Drawings;-Panel Wiring Diagrams;-Calibration Procedure;-Calibration reports;-Operation Manual;-Maintenance Manual;-Spare Part Manual (The manual shall include the complete Bill of Materials. All the parts that have individual part numbers shall be listed in the manual);-FAT and SAT procedures and completed dossier where applicable, for systems and packages.-Contractor shall detail the FAT and SAT already included in the Instrument Specification documents.

Instrumentation softwares required

Contractor shall specify all the proposed software to be used for the Project. Following is the list of preferred software: Database – intools; Flow Orifice Sizing – instrucalc / intools; Control Valve / Safety Relief Valve Sizing – instucalc / conval / intools; Drawings – autocad.

The Contractor shall be responsible for the complete design and provision of telecommunication facilities for the project. The responsibility extends to all required detailed design, material supply, engineering, factory inspection and testing, packaging, logistics, installation, hook-up, Integration and field verification. All systems shall be supplied, configured and tested in accordance with all the relevant Project Documents.

The Contractor shall provide telecommunication facilities for the existing Central Control Room (CCR), other new buildings in the Intake Area and Local Lot Control Centres (llccs) being covered in Phase of the Project. Refer: Telecommunication Basis of Design, Document No., System Diagram - Overall Telecommunication System, Drawing No., Block Diagram – Overall Telecommunication System, Drawing No and Equipment List – Telecommunication System, Document No. The Contractor shall interface with existing telecommunication facilities in the existing buildings as stated in the relevant documents.

The Contractor is required to make himself fully aware of all relevant standards and regulations, such as the following, on which the design and installation of the Telecommunication System shall be based:

Tel Publications.

IEEE wire regulations for Electrical Installations, ITU International Telecommunication Union, C Electromagnetic Radiations Compatibility, Company / Client Standards, Project Documentation.
The Contractor shall note that the Company / Client Standard, SD-ITN-001, Cable Infrastructure Standards of the IT Department is vendor limited, in some cases, and therefore shall not be issued to vendors.
The Contractor shall ensure that the entire Telecommunication Works shall be carried out through a qualified Telecommunication Systems Integrator. The Contractor and Systems Integrator shall attend liaison, review and progress meetings, in National, on a monthly basis during the design phase and weekly site meetings during the construction phase. The monthly meetings during the design phase to be for a period of 3 days and shall include site visits. Company / Client, at it’s discretion, may choose to conduct certain monthly meetings via teleconference. The weekly meeting during the construction phase to be for a limited period, as required, and shall include a joint inspection of the work taking place at that time.
The Contractor shall study and revalidate the FEED both as a desktop exercise and via a number of site visits to be conducted during the initial stage of the Project to familiarize and study the Telecommunication System implemented, as well as the changes being implemented, within PLANT. The Contractor shall make four (4) site visits for a period of two (2) full days each visit.
The Contractor shall suggest any enhancements, with rational, to the FEED following the FEED verification, in the form of a report, for the approval of company / client. The Contractor shall submit, for the approval of Company / Client, Site Visit Reports for each site visit.

The Contractor shall provide load analysis on any of the existing power supplies that shall be directly utilised as a part of this project and provide a report with rational and recommendations, having considered all alternatives.

All systems shall be provided fully assembled, supplied, configured and tested in accordance with the relevant project specifications. Also, the Contractor shall be responsible for interfacing the new systems with existing telecommunication systems; any upgrade work required on the hardware / software of the existing system for this purpose shall be carried out by the Contractor.
The Contractor shall obtain prior approval from Company / Client of his detailed design before proceeding with any purchase of equipment and any installation work. The Contractor shall participate in a formal design review, in National, six (6) weeks prior to purchase of equipment and include appropriate Company / Client comments in the design.

The Contractor shall obtain Tel “Type” approval as required.

The Contractor shall ensure adequate co-ordination between the Telecommunications System Integrator and all other disciplines / activities on site takes place in order to ensure an efficient installation.

The Contractor shall make provision and ensure common infrastructure like the routing of the Fiber Optic cables shall include the llccs / Buildings planned to be implemented in the future phases e.g. By provisioning a coiled FOC length near Phase llccs.

(i) add a SDH/PDH node at the Fire Station # 3. This new node shall be connected to the network via 2 x 24 core Single Mode Fibre Optic cable routed to the existing LNG 2 LLCC which is the closest node to Fire Station # and to LLCC in order to form a logical ring i.e the Western Ring.

(LPB-1). A new SDH STM-4 node Alcatel 1660, shall be installed in PAB together with additional Cross Connect Alcatel 1515 CXC and PDH multiplexer 1511 BA This shall form another logical ring, the Port Ring.

The Contractor shall perform the following Scope of Work:

Interfacing to existing Telecommunication Systems at various levels including linking through fiber optic network and upgrading / re-configuring (re-programming) of the existing ALCATEL system for the additional facilities.
Supply of a compatible telecommunication system which shall interface, tie-in to the existing system / network and continue to have a closed loop configuration or multiple loop configuration for the existing STM-1 ring network and two new spur link locations, Fire Station # and MOV Corridor H.
Supply of hardware and the software upgrades, as required, for the existing SDH system in order that the new terminal equipment shall be interfaced with the existing equipment.
Supply of two (2) redundant Plesiochronous Digital Hierarchy (PDH) equipments with multiplexers and associated Network Management System (NMS).

Supply of Fibre Optic cable and accessories up to subscriber connectivity and software configuration and upgrade.

Expansion of, and reconfiguration of, an existing Public Address / General Alarm System including supply of all necessary hardware and software.

Connectivity to any other required utilities.
Providing technical input required to support other disciplines.

Providing documents and drawings, including “as-built” revisions.

Interface with, and obtain approvals from, Tel. This shall include the design for the Telephone System infrastructure as well as any “Type” approvals as necessary.
Provision of all data sheets for telecommunication systems, subsystems and equipment.
Evaluate and confirm the adequacy of all the existing systems to accommodate the new systems, sub systems and equipment.

Upgrade the PC based Telecommunication Supervisory System to include the new PDH nodes.

Upgrade the Network Management System to include the new telecommunication equipments.

Commission and Hand Over all systems, sub systems and equipment fully integrated.

The Contractor shall generate a stand-alone detailed specification and / or data sheet for each telecommunication system, sub system and equipment, These documents shall be regularly be updated until the “as built” stage.

The Availability of the system shall be 99.999 %

For details of the guideline specification, refer Specification for Fibre Optic Cable and Accessories, Doc. No., Main Cable Routing Drawing, Doc. No. and Fibre Optic Cable Allocation Drawing, Doc. No.

A duplicated (main and standby) Single Mode Fibre Optic Fire Retardant Armoured Cable Network with Accessories shall be laid in order to provide the transmission medium to facilitate Instrumentation, Telecommunication, Fire & Gas, Electrical and Security systems as indicated below:

2 x 36 core cables shall be laid in two (2) separate physical routes for embracing all llccs to be constructed to/from the CCR in CB in a loop configuration.

2 x 12 core cables shall be laid within the Intake Area to accommodate Instrumentation requirements e.g DCS at various buildings and Pump houses to/from the CCR in CB.

2 x 24 core cables shall be laid between substations in the Intake Area to accommodate Electrical requirements e.g Tele-protection and Tele-signal transferring.

4 x 6 core non-duplicated cables shall be laid to / from the Telecom Room in CB and the four (4) hubs situated within the Intake Area to cater for the CCTV system. The cables shall also be laid between the hub and it’s associated CCTV cameras.

Optical Patch Cords / Connectors and Fibre Patch Panels shall be supplied to support the above.

For details of the guideline specification, refer Specification for Optical Transmission System, Doc. No. and System Diagram - Optical Transmission System Doc..

A redundant PDH spur optical link is to be implemented between Fire Station and MOV Corridor H. Each of the FO transmitting stations shall be equipped with at least two (2) optical receivers and two (2) optical transmall necessary hardware and software modifications shall be made in the existing SDH STM-1 Western Ring in order to ensure that phase II telecommunications facilities are seamlessly connected.
The existing SDH equipment shall be upgraded to provide CCTV Camera(s) signal transport from the Intake Area, LNG 2 and RB to CCTV monitors at CCR CB and to monitors and system management and recording facilities at CR Plant situated at the Main Gate House (MGH).

An independent dual optical fibre single audio channel based telephone connection shall be provided to four (4) llccs from a PABX, to be implanted by others, in the Telecom Equipment Room at CB on audio multiplexer systems.

PCM Multiplexers shall be provided in order to provide the required telecommunication facilities associated with Corridor H and shall be equipped with common equipment DC-DC converter (from -48VDC), equipment controller board, alarm board, 25Hz generator with the following user interfaces:

2W FXO channels, -2W FXS channels,

The terminal equipment shall be of Alcatel make, type PCM 1511BA.

The existing equipment (duplicated Alcatel 1515 CXC connected in series) shall be reconfigured, as necessary, in order to complete the system requirements.

The existing Alcatel 1320/1353 CT/CX Network Management System (NMS) for control and monitoring of all PDH / SDH nodes shall be upgraded with hardware for the new sites and the latest version software and reconfigured as necessary to include the new PDH nodes and other routing channels to provide connectivity across the new llccs. In addition the software shall be made available on two existing desktop personal computers in CCR CB and PAB and additionally on two laptop personal computers, to be provided, for maintenance personnel at site(s).

For details of the guideline specification, refer Specifications for Telecommunication Supervisory System, Doc No

The existing Hitachi make Telecommunication Equipment Supervisory System which operates on a separate LAN and provides alarm monitoring of the entire Telecommunication System shall be upgraded with hardware for the new sites and the latest version software and reconfigured as necessary to include the new PDH nodes. Further a Laptop PC shall be provided, equipped with the appropriate software and hardware accessories for programming fault detection and engineering purposes.

The Remote Supervisory Unit(s) shall be modular consisting of one or more modules. Each module shall include 32 x volts less contact shall be poared from the 48V DC supply.

For details of the guideline specification, refer Specification for Public Address and General Alarm System, Doc. No. and PAGA Field Location Layout Drawing No.

The existing PA / GA equipment is NOVA 2001 and manufactured by GAI-TRONICS of Italy.

In order to ensure adequate acoustical coverage shall be available in the Intake Area an acoustical analysis shall be conducted including site investigation and measurement, together with desktop calculations. The analysis shall take into account existing and future ambient noise levels. The analysis shall be performed, utilising a procedure to be approved by Company / Client, within three (3) months of the Effective Date. The results of the analysis shall be used to optimize the quantities and locations which shall to be included in a report to included coverage drawings, with rational and recommendations, to be submitted for the approval of Company / Client. The report shall also contain recommendations with rational on the existing Phase coverage.

The coverage in the Intake Area shall be verified, by measurement, as conforming to the acoustic analysis as part of the commissioning procedure.
The existing system shall be extended and upgraded as necessary, both hardware and software, in order to provide coverage at the new llccs and buildings in the Intake Area. The system shall be re-configured and re-zoned for the new and existing sites to meet the operational needs of Company / Client. Further a Laptop PC shall be provided, equipped with the appropriate software and hardware accessories for programming fault detection and engineering purposes.

Hotline Telephone System

For details of the guideline specification, refer Specification for Hotline Telephone System Doc. No. and System Diagram - Hotline System Drawing No.

Hotline Telephones shall be installed between the CCR in the CB to two (2) new customer sites associated with llccs LNG-1 and LNG-2. Provision of the Hotline Telephone service shall include the telephones and the PCM FXO / FXS circuits. The existing Hotline Console at CCR shall be upgraded to accommodate the new handsets and indicators, refer Hotline Console Layout Drawing No.

In the event that the customers sites are not available at the time of commissioning then commissioning shall take place in the applicable LLCC.

For details of the guideline specification, refer Specification for Telephone System Doc. No..

A PABX, Ericsson model MD 110, exists at PAB and all telephone users at existing llccs and in the Intake Area operate as remote subscribers via FXS/FXO circuits on the SDH Optical Transmission System. In 2nd quarter 2006 a PABX shall be provided, by others, at CB therefore all new llccs shall operate as remote subscribers from the PABX at CB and all users in the Intake Area shall operate as direct subscribers. The PABX at CB shall have sufficient capacity and be equipped for all new subscribers in the Intake Area and remote subscribers at llccs

The active components of the Data Network shall be supplied by others and the LAN shall be commissioned by others.

All cables, structured cabling, idfs, junction boxes, interfaces, interconnections etc to effect a comprehensive infrastructure shall form part of this Scope of Work.
Telephones, Fax Machines and Audio Mux

For details of the guideline specification, refer Specification for Telephones and Fax Machines Doc. No..

All Fax Machines shall have RJ-45 connectors and be installed in locations tentatively defined on drawings and documents and shall be model L-360 or later version from Canon or equivalent.

All telecommunication equipment shall be connected to the telecom earth at existing stations and a separate telecom clean earth of less than one (1) ohm at each new location.

A fully redundant nominal - 48VDC battery / charger system with 8 hours autonomy shall be provided and used to supply all telecommunications related equipment at LLCC MOV Corridor H. The battery / charger system shall be designed in accordance with Data Sheet, DC UPS, Document No. in order to supply power to the telecommunication equipment and shall have 50% spare capacity.

Testing shall take place in order to demonstrate the specifications of the equipment, sub system and system have been achieved and as stated in the applicable system specifications.

Training shall be provided as stated in the applicable system specifications in Appendix and is to take place at site. The training shall be as per manufacturer’s standard syllabus and shall be conducted by the manufacturer.

Documentation shall be provided for the design, purchase, installation, “as built” and O&M phases and as stated in the applicable system specifications in Appendix.

The Contractor shall be responsible for the complete design and provision of the Security System for the project. The responsibility extends to all required detailed design, material supply, engineering, factory inspection and testing, packaging, logistics, installation, hook-up, Integration and field verification.

The Security System for the Plant Industrial City shall be highly confidential. The details shall not be reproduced or / and copied.

The Contractor shall provide a Security System for the Intake Area, along the Pipeline Corridor and at the Receiving Basin (RB). Refer Specification for Security Control System, Document No., Closed Circuit Television System Diagram, Drawing No., Card Access Control System Diagram, Drawing No., Field Location Layout Security System, Drawing No. and Equipment Layout Security System, Drawing No..

The Contractor is required to make himself fully aware of all relevant standards and regulations, including Company / Client standards, base his design and installation on those standards and regulations.

The Contractor shall ensure that the entire Security Works shall be carried out through a qualified Security & Telecommunications Systems Integrator. The Contractor and Systems Integrator shall attend liaison, review and progress meetings, in National, on a monthly basis during the design phase and weekly site meetings during the construction phase. The monthly meetings during the design phase to be for a period of 3 days and shall include site visits. Company / Client, at it’s discretion, may choose to conduct certain monthly meetings via teleconference. The weekly meeting during the construction phase to be for a limited period, as required, and shall include a joint inspection of the work taking place at that time. Company / Client shall agree to combine the Telecommunications meetings with those of Security in the event the same System Integrator is chosen.

The Contractor shall be aware that the existing CCTV System at Plant is in the process of being upgraded to a an IP Ethernet based network and this is due for completion. The coverage of the existing and upgraded system does not include the location areas that form part of this Scope of Work.

All systems shall be provided fully assembled, supplied, configured and tested in accordance with the relevant project specifications. Also, the Contractor shall be responsible for interfacing the new systems with existing telecommunication systems; any upgrade work required on the hardware / software of the existing system for this purpose shall be carried out by the Contractor.
The Contractor shall obtain prior approval from Company / Client of his detailed design before proceeding with any purchase of equipment and any installation work. The Contractor shall participate in a formal design review, in National, six (6) weeks prior to purchase of equipment and include appropriate Company / Client comments in the design.

The Contractor shall ensure adequate co-ordination between the Security System Integrator and all other disciplines / activities on site takes place in order to ensure an efficient installation.

Provide a new CCTV system consisting of cameras, hubs/switches and monitors interfacing to an upgraded existing CCTV System.

Provide a Card Access Control System (CACS) at Gate House # and Gate House # to automate inbound / outbound vehicle & personnel movements.

Provide security fencing and lighting around the intake facility.

The Contractor shall generate a stand-alone detailed specification and / or data sheet for each of the security system, sub system and equipment. These documents shall be regularly updated until the “as built” stage.

The Contractor shall use the Specification for Security Control System, Document No. as an initial basis of the specifications to be developed. The specifications shall be submitted to Company / Client for approval.

The Availability of the system shall be 99.999 %

The CCTV System shall include PTZ (Pan / Tilt / Zoom) cameras at the Intake Area, Pipeline Corridor and Receiving Basin (RB) together with fixed cameras, with alarm capability, to accommodate the provision of motion detection facilities around the perimeter of the Intake Area. All cameras shall be IP.

Company / Client is in the process of evaluating whether to proceed with motion detection or not in the Intake Area and consequently Security Field Layout Drawing No. show layouts with and without motion detection.

There shall be a combination of fixed focus cameras and PTZ dome type cameras around the fence of the Intake Area to provide a system capable of motion detection. Only PTZ dome type cameras shall be utilised for a system with no motion detection. In both systems additional PTZ cameras for enhanced monitoring within the Intake Area shall be installed. Refer Equipment List – Telecommunication Equipment, Document No. for quantities.

The Contractor shall state in Appendix B the price reduction should motion detection not be implemented.

There shall be two (2) PTZ dome type cameras installed at each the Pipeline Corridor and RB.

Three (3) new monitors shall be installed in the CCR in the existing CB. Signals from all the cameras in the Intake area shall be available on these monitors. These signals shall also be monitored at the four (4) new monitors located in the PLANT CR at Main Gate House (MGH) via the existing upgraded CCTV network. System control shall be from the existing upgraded CCTV system.

The signals from the CCTV cameras at the Pipeline Corridor and the Receiving Basin (RB) shall be monitored / controlled by the existing upgraded CCTV system from PLANT CR at MGH.

The existing SDH Optical Transmission System shall be upgraded with Ethernet Modules to provide CCTV Camera(s) signal transport from the Intake area, LNG2 and Receiving Basin (RB) to CCTV monitors at CCR CB and CR PLANT at the Main Gate House and to the existing Network Video Recording System at PLANT CR at MGH which shall be upgraded to accommodate the additional data to be received.

The existing upgraded CCTV System Management shall be further upgraded, including software configuration, in order to connect and activate the peripherals e.g cameras and monitors, as required to ensure a seamless integration of the CCTV System at the Intake Area, Pipeline Corridor and RB.

The CACS shall be a stand-alone system installed in Gate Houses of the Intake area. Separate controllers shall be installed in each Gate House, integrated together in order to provide redundancy for each Gate House.

The Access Control system shall have following facilities:

Card Readers to enable in-bound and out-bound vehicle and personnel traffic.

Vehicle gates; Turnstile gates; Automatic opening and closure of vehicle gates and turnstiles,

Controlled access by pre-programmed access card(s) or by security personnel access control.

Recording of time and date of in-bound and out-bound movement.

The card readers shall be compatible to the existing CACS being used at the Main Gate.

A photocell controlled, security lighting system shall be provided for the Intake Area perimeter fence. This shall consist of pole mounted floodlights. The poles shall be located inside the perimeter fence. The flood lights with high pressure HPSV lamps shall be used for the same. The illumination level at the fence shall be 150 Lux with overlapping fields facing towards the fence so that failure of one lamp shall not create any dark area on the fence. Refer: Perimeter Security Lighting Layout, Document No.

Testing shall take place in order to demonstrate the specifications of the equipment, sub system and system have been achieved

Training shall be provided as stated in the applicable system Specification for Security Control and is to take place at site. The training shall be as per manufacturer’s standard syllabus and shall be conducted by the manufacturer.

Documentation shall be provided for the design, purchase, installation, “as built” and O&M phases and as stated in Specification for Security Control,

Contractor shall be responsible for but not limited to the following:

The Scope of Work includes the design, fabrication, procurement, installation testing and commissioning of the Fire Protection, Fire & Gas and Safety Systems described in the project specifications, Loss Control Philosophies and Drawings in the EPIC package, Appendix and Company / Client Corporate Philosophy for Fire and Safety Company / Client-PHL-S-001 and other related documents.

Firewater Systems

The existing firewater (seawater) system is to be extended to all end user plots at Plant Industrial City. Drawing

A new firewater (fresh water) system is to be provided at the intake area. The power transformers (220 / 33 kv) located at the intake area, both existing and new (to be installed) are to be provided with deluge protection. The existing collection pit shall therefore have to be enlarged.

Contractor shall verify the project Specifications and drawings for the following systems and develop as required and implement them.

Fire protection system including:

Fire water (Fresh Water) supply, storage. And Fire pumps (electric motor driven, diesel engine driven and jockey pumps).

Fire water distribution layouts (seawater & fresh water network systems) including the deluge system.

Fixed and portable, manual and mobile fire fighting equipment (including hydrants, hose reels, water spray nozzles and other specialised fire protection systems).

Fire protection of Analyser Houses

Fire and gas detection and alarm system

Fire and Gas cause & Effect Charts

Contractor shall verify the project specifications on Fire and Safety System and Fire Alarm and Gas Detection System and develop them as required and utilise HSSD (High Sensitivity Smoke Detection) system. The individual smoke detectors shall be ionisation type. Contractor shall obtain the necessary permits from Supreme Council and obtain import licence for these detectors Company / Client shall issue recommendation letter to concerned authorities if requested by Contractor

Interface these fire alarm systems with the DCS system to alarm at the Main Control Room, existing PLANT Fire / Incident Control Room at the Main Gatehouse and a Fire Station # .

All the buildings, Main Control Room, LLCC’s, Sub-stations, chlorination units etc. Shall have fire and smoke detection and alarm systems which shall be interfaced to the DCS at respective locations and eventually to CCR.

All the information from Phase system shall be available on the operator desk in the existing control room, existing gate house and in the new Fire Station #3. Presently all the existing data & displays of Phase are made available at PLANT Fire / Incident Control room at the main gatehouse through Telephone link.

Location of this PLANT Fire / Incident Control Room is within the Security building located at the main entrance of the Plant Industrial City.

Fixed and portable personnel safety equipment, including safety showers and face/eye wash stations are to be located at the electro chlorination plant and 33 kv Switchgear Building, while self contained eye wash stations are to be located at all battery rooms and analyser houses.

Safety studies and calculation reports performed during FEED, including Operational Safety Study, and FMEA / FTA Study shall be updated by the Contractor.
Contractor shall carry out, in consultation with Company / Client, a complete and detailed HAZOP Study during detailed engineering phase. A third party independent chairman shall be the team leader and the HAZOP shall be carried out as per Company / Client. HAZOP review shall also be carried out for Vendor Packages.

Contractor in a report issued to Company / Client for review and approval shall detail the findings and the actions of the study. Contractor shall incorporate, as part of the detailed engineering work any / all modifications in the network design as requested and required by Company / Client, to comply with any portion of the study actions.

Contractor shall update, design and provide the Fire Protection, Detection and Safety Systems as developed during FEED.

Contractor shall be responsible for developing and establishing the fire protection system, avoiding interference with underground facilities. Guidelines on the number and types of fire fighting equipment are given in the Company / Client Corporate Philosophy for Fire & Safety (Company / Client) and its references. Contractor shall verify, finalise and provide the number and types of fire protection, detection and safety items shown as a minimum.
Mechanical Equipment

Contractor shall be responsible for but not limited to the following.

The Scope of Work includes the review and update of FEED specification and data sheets (as required for detail engineering development), fabrication, installation, testing and commissioning of the equipment installed at:

Mechanical Cleaning Plant, Main Cooling Water Pump Packages (Novated items), Utility Services, Electro Chlorination Plant, Lifting Equipment (for maintenance service),

Equipments installed at plant facilities are listed in Equipment List of Project Phase. All activities of procurement shall be carried out during detail engineering including development of Material Requisition / VDRL dossier.

Contractor shall verify the FEED Specifications, data sheets and drawings and update / develop as required to implement them.

Contractor shall include in his work scope for development of equipment specification and procurement engineering documentation, as required, when not included (missing or detail engineering development) in Equipment List of Project Phase.
Main Cooling Water Pump Packages

Contractor shall take full responsibility of owning novated Main Cooling Seawater Pump Packages (including electrical motor and VSDS system items) for Phase in accordance with Contract and ensuring guaranteed pump performance.

The items included in above pumps package shall be as per Purchase Order dossier, further procurement engineering up to commissioning shall be the Contractor’s responsibility and scope shall include the following:

Expedite, review and approve Vendor’s data sheets and drawings.

Participate and witness all required Factory and / or site inspection and testing; ensure TPC is made available for the items of these packages.

Organizing / conducting pump physical model tests at Pump Vendor works to demonstrate pump selection / performance,

Organizing / conducting sump (pit) model tests at specified sub-Contractor works to demonstrate pump hydraulic performance with all required functional flexibility, considering intake screening equipment, to verify the intake sump and consequently the screening equipment, to finalize the intake sump (and consequently the pumps house dimensions). The sump model tests shall be carried out in the presence of Company / Client and Pump Vendor. Contractor shall take full responsibility to design and construct the sump pit in accordance with above results. Findings of Sump model test report conducted by sub-Contractor shall be endorsed and implemented by the Contractor. This may include provision for additional splitter, flow stabilizing device, a weir, etc. as recommended in sump model test report.

Carry out the String test at Vendor’s shop for the first two Main Cooling Water Pump Packages including pumps, drivers, vsdss and associated auxiliaries. For other identical pump models, required performance tests shall be carried out at pump vendor works using electrical test setup established for previous string test.

All necessary co-ordination with Vendors and/or Sub- Contractors for timely delivery of contracted scope.

Prepare all “as-built” data sheets and drawings.

Carry out pre-commissioning, commissioning and start-up of pumps.
Deionised Water for VSDS

The first fill of deionised water used for the VSDS cooling system shall be provided by Pump Packages supplier. Any further topping up requirements shall be accomplished by supply of deionised water by Contractor till Contract Completion.

Verify and confirm Chlorination package sizing and selection.

Prepare and update the package data sheets and specifications.

Prepare material requisition packages.

Carry out bid evaluation and vendor recommendation.

Expedite review and approve Vendor’s data sheets and drawings.

Participate and witness all required inspection and testing.

Prepare all “as-built” data sheets and drawings.

Carry out pre-commissioning, commissioning and start-up of the packages.

Co-ordination with Vendors and Subcontractors.

Contractor shall procure these items in accordance with project specifications / data sheet included in FEED dossier (and covered in Equipment List) after review, verification and detailed engineering and design.

Coarse screening shall be performed at Fixed Bar Screens installed at Screen Yard upstream of pumps houses. Common traversing trash rake (grab bucket cleaner) and debris collection system shall be installed as covered in applicable specifications / data sheets. Screen bar material shall be to accomplish detachment / retarding of marine shells clinging to bars.

Rotary Drum Screens are to be installed for finer (mesh opening 3 x 3 mm) screening before seawater (service fluid) is fed for further pumping and construction materials requirements are covered in applicable specifications / data sheets. Contractor shall provide the falling object protection for drum screens. Design approval of Company / Client shall be required.

Contractor shall procure these items in accordance with project specifications / data sheets included in FEED dossier (and covered in Equipment List) after review, verification and detailed engineering and design.

Utility services include Instrument Air Compressor – Dryer Packages, Portable Submersible Pumps (for emptying compartments of Pump Sump Pits, Receiving Basin) and pumps for draining of piping sections / manifolds.
Lifting Equipment

Pump Houses and Screen-Yard Cranes (Common crane and additional cranes):

In Phase of the project extending of existing 60T / 40T capacity EOT Crane at pump-house and 10T capacity Semi-Portal Crane at screen-yard is envisaged. Common crane study report included in FEED dossier provides details of modification to be implemented. Besides this, an additional crane requirement at above two locations is subject to RAM study recommendation. Contractor shall carryout RAM study and confirm requirement of additional Cranes at pump house and Screen Yard.
Contractor shall procure these items in accordance with project specifications / data sheets included in FEED dossier after review, verification and detailed engineering and design.
Manifold Area Cranes:

Phase II of project facilities envisages Craneage to handle ccvs and Isolation Valves installed at manifold area. This new facility requirement is addressed in Material Handling Study Report and FEED dossier Equipment List covers the required equipment to be installed for servicing of manifold area items.

Contractor shall procure and supply all material handling items covered in Equipment List as stated in Material Handling Study Report, which shall be updated during detailed engineering stage after review and verification.

Contractor shall prepare procurement-engineering dossier when required for procurement of off-the-shelf items such as manual chain-hoist with trolley on monorail beam etc. And supply the same.

Mobile equipment viz. Mobile Crane, Fork Lifts etc. To assist transportation and handling of materials are not covered in equipment list / material handling studies. Being construction / operation aids these mobile facilities are envisaged to be directly purchased by Company / Client, only guiding specification / data shall be provided by Contractor as per detail engineering developments.

Contractor shall be responsible for but not limited to the following:

General Requirements (Refer to Company / Client Corporate Philosophy for Fire & Safety Company / Client-Environment Protection Law National)

Contractor shall comply with all rules, guidelines, regulations, procedures, programmes and policies in the “Environmental Guidelines & Environmental Protection Criteria for Plant Industrial City during the execution of the WORK.

The “Environmental Guidelines & Environmental Protection Criteria for Plant Industrial City

The initial calculation shall be based on equipment meeting the sound level and sound power level limits of Company / Client Specification. The final calculation shall be based on the vendor quoted and tested equipment sound levels. These calculations shall be included in an initial and final report, which shall be submitted for Company / Client approval. These reports shall contain the following:

Equipment list. Equipment physical data such as size, speed, and power.

Equipment location. Estimated industrial community sound level at Company / Client determined locations. Estimated sound level contours including in-plant areas, at fence line, and at inner edge of perimeter infrastructure road in 2.5-decibel (dba) increments. Equipment sound power levels used in the model. Equipment sound levels at one meter. Noise control treatments proposed. Vendor sound level reports. Vendor’s shop test reports. The final report shall be called the "Noise Control Design Basis - Summary Report".

Contractor shall conduct a co-ordinated overall noise control program, including cost effectiveness comparisons. In addition, Contractor shall recommend such alternative or additional acoustical design features or treatment as needed to meet the requirements.
Contractor shall ensure that the sound pressure level of cooling water pumps shall not exceed the values specified in Contract by applying any attenuation devices.

Contractor shall be responsible for identifying any necessary reduction of equipment sound level limits specified in Company / Client specification, to ensure compliance with the FACILITY sound level provisions.

Contractor shall be responsible for but not limited to the following:

Contractor shall finalise the design documents incorporating design data including emission data obtained from the Vendor’s. Contractor shall be responsible for compliance with the local Environmental Control Regulation and Project Specifications provided in the Contract. In general, the FACILITY should be designed to meet the ambient air quality and water quality guidelines of the National regulations as specified in the Project Specifications.

Contractor shall verify or finalise the engineering evaluations to ensure that the environmental control systems as designed shall comply with the required regulations.

Contractor shall be responsible for the pre-design survey, design, detail engineering, supply of material, installation supervision, commissioning and start up of cathodic protection systems.

An impressed current cathodic protection technique shall be utilized / applied to provide the corrosion protection for seawater screen equipments, earthing system, concrete re-bars of facility foundations and pipe support foundations adjacent to the Intake Area. Sacrificial anode cathodic protection technique shall be utilized / applied for the protection of pipe support foundations in areas remote from Intake Are.
Cathodic Protection Systems shall cover the following:

Seawater screen equipments-Bar screens-Drum screens-Stop log guides-Stop logs-Facility Foundations-Pump house pit concrete re-bars-Receiving basin concrete re-bars-Outfall structure concrete re-bars including discharge channels-All building foundations-All structure pipe supports/ foundations within the water table or / and below + /- 0.0 m -Earthing Systems -Pump houses-Building area at Intake-Receiving basin-Manifold areas-LLCCs-Detail Design Specifics

Contractor shall engineer, connect and configure the signals for monitoring and controlling the FACILITY pertaining to this Project only. Twenty percent (20%) of the spares shall be connected and configured as spares as detailed in the specification provided under Appendix. Provision for expansion shall be made for connecting any additional signals (future). Contractor to co-ordinate with PLANT and Electrical authority through Company / Client.

Contractor shall submit to Company / Client Hydraulic Models of Phase along with licensed Software programme, spreadsheets & Manuals used for the analysis. Company / Client shall have access to the simulation models while the simulation work is being done by the Contractor.

Contractor shall undertake Hydraulic Model studies and submit results during the detail design stage. Contractor shall comply with the following when preparing the hydraulic model:

“Marine Works” in particular “Physical model requirement”

Ensure that minimum flow of seawater is 300000. m3/hr.

Allow to clean up the beach twice at start and at completion of works (at intake and outfall areas) for a distance of 500m extending both sides of intake and outfall areas, i.e. Total distance of 3000m.

Allow for cut and fill complete with compaction to 100% of Maximum Dry Density (MDD) as specified for the full widths and lengths of pipe corridors. Excavation may require blasting. Excavation in rock & varying materials and backfilling shall be carried out in Phase. All pipes shall be installed above finished grade on pipe supports / saddles (complete with inserts) as the design shall dictate.

Contractor shall develop and optimise pipe corridors to take all Phase pipes, mainly pipeline routing / layout.

Contractor shall carry out site grading of pipe corridors to allow the flow of rain, surface and spill water to the surface water drainage.

Allow for grading area completely around intake structure by cut / fill and compact to receive Phase structures.

Allow for the design and construction of surface water drainage to cater for rain and spill water. Water shall be collected by a network of concrete paved ditches and discharged into the sea. “V” or trapezoid concrete paved ditches shall be designed and constructed. Protection to ditches and warning signs shall be allowed for.

Design and install chain link fences around building and local Control room areas as a minimum. Covered car parking is required for the operation building and as shown on the drawing attached in Appendix

Contractor is to allow for the design and construction of 10% extra for each building, e.g. Building “X” has to be minimum 500m2 to accommodate all personnel and equipment in accordance with the best international standards. Therefore, Contractor shall have to design and construct building “X” to be 550 m2.

Allow for temporary access roads during construction such as diversion roads. Such roads shall be subject to Company / Client formal approval.

Allow for seismic loading, where appropriate, in accordance with the Uniform Building Code for Zone 1.

Allow for the design and installation of access over Cooling Water Piping. Number, type and location are subject to Company / Client formal approval.

Design and construct roads as access to substations, chlorination building, control building, pump house and other buildings as shown in the Plot Plan.

Allow for surveying and relocating sand dunes within the pipe corridors, intake and outfall areas.

All the local Control Rooms at the consumer lot interface as well as other electrical installations shall have separate battery rooms and space for telecommunication equipment.

At the Consumer Lots / Interfaces, existing consumers have generally agreed to provide the required LV power supplies up to the battery limit.

The Contractor shall carry out a complete study on ‘Material’ for the entire Phase project and produce a report for Company / Client’s approval during the early stages of the project. The work shall be carried out by a third party consultant or by the Contractor itself provided it has the in-house capability to the satisfaction of Company / Client.

The Contractor shall implement any approved recommendation or findings of studies carried out during FEED such as RAM, FMEA, Hydraulic Studies by HRW, SYSOP, SAFOP, OPTAN etc.

Design of elevated floor slabs of substations shall be as per Drg.

The PLANT 11kv network is not part of the CCWP Phase I installation, therefore all works involving tapping into the existing 11kv network of PLANT shall involve the following:

Collection of ‘As-Builts” drawings and CYME calculations if any, from PLANT and verify that they are suitable for the proposed modifications i.e. Perform load survey, check protection settings etc.

Verify that the new loads when added shall not affect operations. Calculations (using CYME) & report of load flow, protection settings, etc. Shall be submitted to Company / Client for review. Protection settings shall include 11kv source circuit breaker upto down stream LV circuits of LLCCS.

On completion of the proposed works, existing ‘As-Built’ drawings shall be updated to reflect the new works, as performed by Contractor. Also, soft copy of CYME calculations shall be handed over as part of final documentation

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Chapter 9

Contractor shall perform the procurement and expediting of all materials and equipment necessary for the performance of the WORK in a timely manner and in accordance with the Execution Programme.

For the purpose of this Contract, the terms “seller”, “Vendor”, “Supplier” and “Sub-Contractor” shall be interchangeable in meaning and context.

Contractor shall be responsible for the performance of the following activities.

Identification of material procurement requirements and preparation of a procedure for Company / Client approval.

Preparation of all materials take off.

Preparation of requisitions

Preparation of Purchase Orders

Purchasing and Expediting

All vendors selection / evaluation, taking due account of Company / Client list of approved Vendor

Consideration of minimum maintenance philosophy.

Adherence to any standardisation requirements from Company / Client.

Consideration of quality related to Contractor’s warranties and guarantees.

Provision of the best possible warranties and guarantees from vendors for Company / Client’s benefit

Inspection and testing of all procured materials by TPC.

Transportation of all materials to Site including packing to sea freight/air freight standard as required.

Storage, preservation and handling at Site.

Identification of spare parts requirements.

Preparation and issue to Company / Client of completed spare parts interchange ability record (SPIR) forms within 3 months of placement of Purchase Orders.

Procurement of pre-commissioning, commissioning and start-up spare parts.

Procurement of insurance spares (If specified to do so by Company / Client).

Procurement of 1-year operations spare parts (If required to do so by Company / Client).

Customs clearance including payment of customs duty and payment of legalisation fees.

Payment to Vendors

Efficient use of materials.

Vendor support and assistance during construction, pre-commissioning, commissioning, start-up and performance testing (as necessary).

Obtaining all necessary certification and “as built” drawings and data from vendors including Quality Assurance Record Manuals, Operations & Maintenance Manuals etc.

Issue closeout report highlighting vendor performance.

During the FEED Phase of the Project, equipment, packages and systems that have a longer delivery time are identified as under:

Main Cooling Seawater Pumps

Main Seawater GRP Piping

The main cooling seawater pump scope of supply includes pumps, variable speed motors, variable speed system, transformers etc.
Scope of supply for main seawater GRP piping includes GRP pipes, GRP fittings, GRP flanges, etc. GRP piping is split into 11 packages, which shall be supplied by multiple Vendors.
Complete purchase requisitions including specifications have been developed and issued to potential suppliers. Quotations when received shall be reviewed for technical compliance with the enquiry and requisitions.
Company / Client intends to award the purchase orders for the above critical long lead items prior to Contract award, in order to maintain the project schedule.
A copy of the Material Requisition package for both the above long lead items is enclosed with this tender document in Appendix. The Contractor shall consider that the items listed in the Material Requisition shall be ordered by Company / Client on Ex-Works packed and loaded on truck / trailer basis.
Upon award of Contract Company / Client shall assign the purchase orders to the Contractor through a novation agreement. The Contractor shall take over full responsibility for the successful design and supply of the long lead items to meet the project engineering design requirements and schedule. Contractor shall be the single point responsible party for the long lead items in all respects.
contractor shall endorse the purchase order requisitions and specifications.
Contractor shall review and verify the purchase order requisitions in all aspects and if necessary shall carry out all required additions or amendments to purchase order requisitions to cover up any omissions / errors / shortcomings/deficiencies as deemed necessary for the successful design, supply and commissioning of all long lead items with prior approval of Company / Client.
Purchasing

Contractor shall be responsible for the following purchasing activities as a minimum:

Prepare RFQ specifications and documents for all equipment and materials in accordance with the Project specifications. Ensure that the terms and conditions of purchase, requirement of Pre-Commissioning, Commissioning, One Year Operational Spare Parts, SPIR forms, Vendor site support services and Final Documentation have been reviewed by Company / Client and included properly in the enquiry document. Rfqs shall be subjected to Company / Client Approval.
RFQ shall specify the Quality Program of Vendor(s) which shall comply with the requirements of ISO 9000 series, 2001 edition and requirement of Company / Client QA/QC procedure
Conduct purchasing in accordance with Company / Client approved vendors, and Subcontractor List. Procurement of those items which are not listed in approved List shall be subject to Company / Client approval and shall be carried out on a world-wide competitive basis except when technical regulations or specifications require otherwise. Contractor shall abide by the National regulations regarding the countries of origin.
Review bids received from vendors and prepare technical and non-priced bid tabulations advising the selected vendor and the ranking of the others. Company / Client review and approval shall be sought prior to placement of purchase orders for all major / critical equipment/items. Review all equipment/ material selection and verify their suitability and operability for the service intended. Before placement of purchase orders, assess and ensure that the financial status, availability of Vendors’ recommended Pre-Commissioning, Commissioning, One Year Operational Spare Parts, including quantity and unit prices thereof, present work load and suitability of the vendors are satisfactory to meet project objectives. Technical bid tabulation and Vendor’s technical proposals / clarifications shall also be provided to Company / Client for approval if Vendor is technically acceptable.
Contractor shall submit to Company / Client lists and prices of 1 Year Operational Spare Parts with the technical and non-priced bid tabulation.
Prepare purchase orders, complete with all attachments (i.e. Purchase requisitions, specifications, drawings, shop inspection and testing requirements), spare parts requirements, Vendors’ and Suppliers’ assistance requirements. Provide copies of non-priced purchase orders or any revision thereto to Company / Client.
Purchase all project equipment and materials as per the specifications and in accordance with the requirements of Execution Programme.

Contractor shall ensure that Purchase Orders are placed with only reliable Vendors/Suppliers approved by Company / Client.

Contractor shall ensure that Critical Equipment such as Main Cooling Water Pumps, VSDS, Chlorination Plant, Mechanical Cleaning Equipment, Switchgears, Motor Operated Valves, Control Valves etc. Shall be of proven type equipment, not prototype.
Issue status reports on purchasing activities to Company / Client in accordance with Appendix D.
Review and approval of Vendor’s drawings and documents (core drawings / specification to be submitted to Company / Client prior to approval by Contractor).
All Vendor’s drawings and documentation shall be in accordance with Company / Client Engineering Standard for draughting
Contractor shall engage the services of Glass Reinforced Polyester (GRP) pipeline manufacturer / designer, as a single point responsible party, to carry out detail pipeline engineering, manufacturing, fabrication, jointing, installation, QA / QC, inspection and commissioning for the piping system supplied by the particular manufacturer.
All the activities related to novated items as per item 5.2 above.
Expediting

In accordance with execution program, Contractor shall perform expediting of equipment, materials, Vendor’s data, technical assistance, personnel and documentation from RFQ to delivery at Construction Site for Vendors’ items including the materials on suborders. Contractor shall maintain a system to monitor progress on all the purchase orders and prepare and issue a detailed schedule to Company / Client in accordance with Appendix. The system shall be able to identify those items of the equipment and materials which are critical or are potentially critical from Execution Programme point of view and require special attention to ensure timely delivery, along with an action plan to achieve it.

Contractor shall execute inspection activities for all equipment and materials in accordance with the following requirements:

Contractor shall be responsible for arranging and co-ordinating the use of TPC services where required for equipment and materials in the country of origin, for statutory, insurance, or any other reasons. Minimum requirement of TPC services is provided in Exhibit of Appendix Such requirement shall in no way relieve Contractor of his responsibilities under the Contract. The TPC shall function independently and report simultaneously to Company / Client and Contractor. The list of Company / Client approved TPC Subcontractors is provided in Exhibit of Appendix. Contractor shall prepare a Certification Matrix in accordance with the requirement of Exhibit of Appendix for Company / Client Review / approval.

Contractor shall be responsible for sanctioning the release of completed equipment and materials for shipment after satisfactory completion of final inspections and certification and shall execute forwarding activities for all equipment / material (including long lead equipment items).

contractor shall give preference to Plant Port while importing materials. Plant Port is a modern port and has necessary FACILITY like exclusive heavy load berth, cargo berths etc. To facilitate Project import materials.

Contractor shall provide its own craneage facilities for all loading and offloading operations at the heavy load and dry dock berths at Plant Port.
Contractor shall be charged by PLANT for the use of the port facilities at Ras Laffan. Details of these charges are given in Appendix.
Contractor shall comply with Plant Port Regulations given in Appendix.
Sea / Air shipment, Inland Transportation and Customs clearance

Contractor is fully responsible for arranging inland transportation, sea/air freight, legalising/authorisation of Certificate of origin and other shipping documents, voyage insurance, customs clearance including payment of customs duty, legalisation fees and transportation of all equipment / material to the Construction Site

All equipment and materials shall be carefully handled and stored in adesignated area at Construction Site.

While floating RFQ, Contractor shall instruct the Vendors to indicate the requirement of Spare Parts as shown below:

Initial Spare Parts – spare parts to safe guard the operation of equipment during the start up / running –in and first year of operation.

Spare Parts for Normal Operation – spares for day-to-day maintenance for the period of one year following the initial operation.
Contractor to ensure that while submitting their quotation, Vendors shall provide description of the Spare Part items, number of Units recommended, ex-work Unit Price including seaworthy packing. Company / Client shall not approve any purchase order to be placed unless accompanied by One Year Operational Spare Parts and Capital spares list and prices.
Pre-Commissioning, Commissioning and Initial Operation &Maintenance Spare Parts and others

Contractor shall procure and supply Pre-Commissioning, Commissioning and Initial Operation and Maintenance spare parts, chemicals and lubricants, special tools and handling gear for each equipment as necessary up to Completion.

One Year Operational Spare Parts as such do not form part of Contractor supplied items under the Lump Sum Contract Price. Company / Client may procure One Year Operational Spare Parts and Capital Spares through Contractor for which Contractor shall be reimbursed in accordance with the provisions of Appendix of the Contract. The Prices quoted by Vendors are to be kept firm throughout the duration of the Contract and no escalation in this regard shall be entertained by Company / Client.

SPIR procedure and a sample SPIR form are enclosed in Appendix. Contractor shall obtain through the successful Vendors a completed SPIR form duly filled in within three (3) months of placement of Purchase Orders. Following review of the SPIR, Company / Client may instruct Contractor to procure the One Year Operational Spare Parts.

Contractor shall ensure that it procures equipment and materials only from Company / Client approved Vendors (Ref Exhibit of Appendix not included).

For procurement of equipment and material for which no vendor list has been provided by Company / Client, Contractor shall propose suitable Vendors. Contractor shall establish that the Vendors / Suppliers proposed have previous experience of supplying similar type of equipment / materials to such projects. Contractor shall provide all relevant information for the vendor proposed for Company / Client to determine the suitability of vendor and its ability to comply with the pertinent requirements of the Contract.
Any deviation to the Company / Client approved vendor list shall be avoided.
When specifications call for a particular brand or type, any proposed substitutions shall be subject to prior approval by Company / Client.
Notwithstanding the foregoing, Contractor shall be fully responsible for the procurement, timely delivery and performance of the vendors’ equipment, materials and services.
Should Contractor propose the use of non-recommended vendors, it shall present the following information to Company / Client in the form of Pre-qualification document for review and approval prior to placing related Purchase Order(s):
Financial records demonstrating the commercial stability of the proposed vendor for the last three (3) years.

Records demonstrating that the vendor has appropriate and relevant industry experience and in particular experience for supplying similar item.

Records demonstrating that the vendor has services support for its products or services in National (preferred) or in the Middle East.

Records in the form of correspondence / confirmation from vendor demonstrating inability of the listed Company / Client approved vendors to supply the equipment / materials.

Once the pre-qualification documents have been reviewed, Company / Client may instruct Contractor to undertake registration of some Vendor’s / Supplier’s with Company / Client Materials Department before approval of Vendor / Supplier.

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Chapter 10

Construction

Introduction

Contractor shall carry out all construction work in accordance with procedures and methods prepared during detail engineering for all construction trades in accordance with the Project specifications.

The FACILITY for the Project shall be provided and constructed in a safe, timely and reliable manner. The latest construction techniques and equipment shall be used to provide an effective construction approach, to achieve the Scheduled Completion Date.

Contractor construction work shall include, but not limited to, the following:

Obtaining all approvals, and permits for the Work as per Company / Client regulations.

Establishing Construction Site safety rules and providing a Safety Manager, Officers and staff for the Work.

In order to ensure the proper performance of the Work in accordance with the Subcontract Schedule, from the commencement of the Work to its completion, Subcontractor shall fully adapt his organisation for each specific phase of the Work to fulfil all Subcontract requirements and accordingly shall mobilise, develop and maintain the overall functional organisation and corresponding resources, including when, where and as necessary by providing additional means.

All construction equipment, scaffolding, tools, protection, testing and control equipment, auxiliaries, consumables, etc., and personnel (including management and supervision), necessary for the performance of the Work in particular for handling, transportation, warehousing, prefabrication, erection, testing. These include, but are not limited to:

Provision of maintenance and running of construction equipment

Provision of safety equipment and tools for personnel and works

Provision of personnel small tools

Provision of mechanical equipment and material necessary for working in water free conditions, whatever the volume or flow

Provision, storage, distribution and disposal of consumables (oil, lubricants, gas, etc.) And auxiliary materials (planks, timbers, tarpaulins etc.)

Provision of scaffolding and protection material

Provision of materials and apparatus for the technological laboratory to test materials, welders and provision of materials and apparatus to test all completed works

Safety equipment
Providing accommodation, lodging and transportation for construction personnel from Contractor, Subcontractors and Vendors.

Preparing construction procedures for the Work, which shall be submitted for Company / Client approval. In addition Contractor shall ensure:

Preparation of the Inspection and Test Plan (ITP) in compliance with the above and the Contract conditions, to be submitted for approval to Company / Client

Execution and recording of all test and inspection for equipment / materials and Work

Verification / checking the conformity of the Work and provide records

Issuance of construction method statement as per Company / Client request (for critical works)

Contractor must be able to prove at all times that the quality of the Supply incorporated in the Work complies with the quality specified in the Contract.

Managing and co-ordinating and supervising the work of Subcontractors and Vendors to ensure Work is performed on schedule and in accordance with the quality and safety requirements.

Preparing detailed schedules for the Work in accordance with the Execution Programme, regular monitoring of this schedule and making appropriate adjustments to obtain most efficient usage, taking into account the interfaces with TEL, Electrical authorirty, MMAA and other parties involved.

Providing detailed manpower and construction facilities deployment charts.

Providing schedule and progress reporting in accordance with the requirements of the Contract:

Progress reports (daily, weekly, monthly, flash)

HSE report

Work schedules

Physical progress reports

Construction equipment status reports

Supplies status reports, unpriced copy of purchase orders, certificate of origin of all equipment and materials to be provided by the Contractor.

Monthly status of material taken over by Contractor

Updating of the list of work items drawings

Providing a quality assurance plan and developing quality control procedures.

Providing all Temporary Facilities required for the Work:

Erection, maintenance, dismantling and removal of all temporary Site facilities, including all complementary works, civil, electrical, etc. Inside the allocated areas. It includes, but is not limited to:

Contractor and Subcontractor’s site facilities such as office, workshop, warehouse, shelter, sanitary building, storage area, concrete or bituminous mix production plant, etc. Including all complementary works, civil, raw and potable water and sewer networks, power supply, etc. Inside the allocated areas,

Lighting of the works areas

Temporary works to prevent personnel from injuries and/or properties from damage

Scaffolding and safety equipment necessary for the Works. Such scaffolding and safety equipment must be left in place as long as necessary to allow inspection, tests and control

Contractor and Subcontractor office facilities

Company / Client office facilities

Contractor and Subcontractor warehouse

All site utilities for Contractor needs to include, but not limited to:

Power supply

Power supply cost (for Contractor use)

Water supply (Potable, Raw)

Potable water Supply cost (for Contractor use)

Potable or raw water supply cost (for construction works use except for piping hydro test)

Raw water supply cost (for piping or equipment hydro test)

Treatment of the raw water for hydro tests

Nitrogen supply for pre-commissioning works

Nitrogen supply for Works including cost (for Contractor use)

Air supply

Air supply costs (for Contractor use)

Disposal of all sewer and wastewater, rubbish and trash

Fuels and lubricants for the temporary facilities and construction equipment

Maintaining construction records in formats to be submitted for Company / Client approval.

Ensuring timely mobilisation of Vendors' representatives and/or any specialists, and their retention at Construction Site for the required duration.

Providing QA / QC and inspection services for the Work. This shall include, but not limited to civil, structural, welding, piping, mechanical, electrical, instrument and painting inspectors.

Contractor shall mobilise a Third Party Inspection Agency (TPI) to perform the following: NDT and interpretation-Civil Lab Testing-Load Tests

Any other required Personnel and QA / QC Inspectors shall be provided by Contractor. Contractor shall mobilise adequate level of Inspectors. QA / QC Procedures and Equipment shall be subject to Company / Client’s approval.

Maintaining and operating an adequate system of control of availability of drawings and specifications at their latest revision at all places where the Work is performed.

Maintaining and operating an adequate material control procedure at all places where the Work is performed.

Assisting Company / Client with technical safety reviews to confirm that the FACILITY can be operated, maintained, shutdown and started up in a satisfactory manner.

Managing field queries, field changes and revision of drawings.

Preparing a complete set of data sheets, specifications and as-built drawings. Preparing rigging studies as required.

Mobilize in a timely manner the construction management team to Construction Site in National. Contractor should in particular submit:

Detailed construction execution plan, taking into account the Site constraints

Mobilisation plan

Scaffolding plan, including resources, technical solution proposed material specification and scaffolding management (HSE) procedure

The nominative organisation charts down to but excluding Foremen level and corresponding CV's

The list of resources assigned to the Work:

Personnel per category and nationality and split between the different disciplines and significant activities within each discipline as required in the Particular Exhibits

Construction equipment (type and quantity)

Allocation of Site temporary facilities and storage areas to Contractor

The Site temporary facilities detailed layout drawing and description

The Site storage areas (raw materials, finished materials) detailed layout

Provide housekeeping personnel for the Work on the basis of one cleaner per 25 persons.

Reinstate existing roads, track, channels and secondary roads to original conditions and specification.

Arrange for protection of turtle eggs during construction.

Contractor shall do whatever is necessary to take care of rock, obstructions or/and unsuitable materials present within the Construction Site.

Contractor shall dismantle and remove X nos. Temporary Cofferdam and take ownership of sheet piles and deliver the pre-cast units to Plant Port as directed by Company / Client.

Contractor shall within 30 calendar days from Contract Effective Date supply and install its own dewatering system in the cofferdam constructed by other Contractor.

Contractor is aware that there are buried services (pipe, cable, and duct) within the battery limits, and that co-ordination with Company / Client / Plant (for as-built drawings) shall be required during detail design, and that hand excavation shall be required in certain areas during construction unless confirmed in writing by Company / Client.

Protection and preventive maintenance of the Material handed over to or supply by Contractor as per the state of art and the supplier’s recommendations.

Contractor shall be responsible for the following:

Respect of Site constraints (safety, units in operation, site layout, location and set-up of temporary Site facilities etc.)

Protection of all tracks and roads used by Contractor and subcontractor and located in the vicinity of the Site

Make good to the original condition at Contractor's cost of the parts damaged by Contractor or his representatives (Concrete, steel structures, piping, instruments, painting, etc.)

Installation, dismantling and removal of all temporary protection devices used by Contractor to protect personnel, structures, piping, facilities and equipment on the Site

Any precaution and measure to avoid damage caused by traffic, dust, noise and any other cause that may affect the personnel, buildings, equipment or goods located nearby

Contractor shall be responsible for the following:

Daily collecting and removal of any materials used within the works areas such as iron scrap, debris etc

Disposal of refuse and debris in the relevant authorised dumps

Housekeeping of the areas allocated to Contractor

Daily cleaning of Site and of all tracks and roads used by Contractor and located in the vicinity of the Site. This also includes spraying of water, if required, for stabilising the dust. Destruction of temporary paving and concrete works including removal, transportation to an authorised dump and levelling of the concerned areas

Returning the Site to a suitable condition at Completion of the Work

Contractor shall comply with Company / Client Work Permit Procedures and Regulations appended in Appendix and with Electrical Authority / Plant Work Procedures, when working at Plant and at NCC.

The following Company / Client Regulations shall also apply:

Electrical Safety Instructions

Plant Security guidelines

Consolidated Permit to Work system in PlantIndustrial City.

Company / Client Lifting Equipment regulations

Plant Mutual Aid programme

Regulations for disposal of Dredged Materials within Plant Industrial City

Health, Safety and Environment Plan in conformance with Company / Client requirements

Contractor shall accept the Construction Site work "as it is", and shall complete the excavation work as required, dispose of ground and rain water, provide the complete required infrastructure, including additional temporary fencing, security gates for the FACILITY, roads, ditching, sewers, and more generally, be ultimately responsible for finalization of any Construction Site preparation work required.

Contractor shall obtain permission from Plant for access to areas close to Construction Sites for offices, lay down, fabrication yard etc.

Contractor shall provide office facilities to Company / Client as specified in Appendix.
All utilities required in all areas during the execution of Work shall be the responsibility of Contractor.
Safety and Security

Contractor shall take sole responsibility for safety (including fire prevention) of the Work. The scope of safety shall include, but not limited to, the following:

The construction work includes but is not limited to the activities described here after. Those descriptions are not exhaustive and are given solely for Contractor guidance and shall be read and continued within the context of present scope of work document.

Above Ground Piping Work Prefabrication and Erection including material management, prefabrication and erection works including all tests and control and flushing operation.

Instrumentation Work including the installation, connection, testing of all material and equipment in units and in technical rooms / control rooms including loop testing from control systems such as DCS, PLC, to each local instrument.

Electrical Work including the installation, connection, testing of all material and equipment in units and in substations including testing and energisation.

Site Preparation and Road, Piling, Underground Piping, Civil works and Building Works including earthworks, road, site preparation including fencing works, drainage, pressurized underground piping erection, gravity pipe networks, all concrete works such as foundation, structure, paving building construction including detailed design and supply / erection of secondary works and HVAC systems and all related test and control.

Steel Structure Fabrication and Erection Works including detailed design, supply, fabrication, transportation, erection and all associated tests and controls.

Insulation Works of piping and equipment including supply and erection of all type of insulation and associated tests and controls.

Painting Works of piping, steel structure and equipment including supply and application on field (or on shop for piping elementary components) of paint on but not limited to steel structure, piping and equipment.

GRP Piping Prefabrication and erection including material management, prefabrication and erection work including all test and control and flushing operation.

Hoisting, mechanical assembly of all equipment and material including erection work, alignment, test and control.

Heating, ventilation and air conditioning including installation, connection testing of all material and equipment.

Storage facilities including detailed design, supply, fabrication, transportation, erection and all associated tests and control.
Fire water tank, erection of fabrication tank, site construction, assembly and all associated field tests.

Pipeline construction-pipeline routing

Introduction

Pipeline construction scope shall compose of all works in relation to Piping / Pipeline construction as outlined below and as defined by the FEED Specifications, drawings, documents.

Contractor shall be responsible for identifying all disciplines in the extent of work requested for piping / pipeline construction activities. Pipeline construction activities shall include, but not limited to the following activities.

Installation of GRP piping manifolds at Pump Houses.

Installation of all Pump House Piping for Pump Houses.

Installation of all utility Piping in Intake Area.

Installation of all Piping for packages including electro chlorination unit.

Installation of Piping (above ground / buried) for fresh water firewater system.

Installation of the extension of seawater, firewater system (above ground / buried) to cover all new plots / facilities.

Installation of cooling water supply pipelines (above ground / buried) from Pump House to end user battery limits.

Installation of cooling water return pipelines (above ground / buried) from end user battery limits to receiving basin.

Note that ‘Installation’ includes all pipe, joints, valves, fittings, flanges, spectacles, supports, anchors, manholes, inspection holes, vents, drains, sumps, pits, welding, jointing, non-destructive / destructive testing, inspection & repair, trenching, lowering, backfilling, crossings of pipelines / utilities / roads, ROW preparation, hydrostatic testing, any temporary supports, etc.

Contractor shall make due allowance in its schedule and management of its Construction activities for other ongoing Third Party activities at Construction Site and the surrounding area.

Contractor shall be responsible for contacting and obtaining necessary permissions from all relevant Governmental Authorities and Third Parties before construction works commence. Contractor shall obtain all necessary permits and consents in compliance with the requirements. Contractor shall verify the location of any existing installations and services to the satisfaction of Company / Client and applicable service owners. Contractor shall allow the Governmental Authorities and Third Party service owners all possible access to inspect and witness Works execution in the vicinity of their installation(s) and shall conduct such works in accordance with their requirements. Contractor shall meet all its obligations in this respect in a timely manner such that there is no delay in the Works.

Contractor shall utilize only approved certified testing laboratories for all destructive testing to be carried out on the Works under construction.

If Contractor wishes to provide testing facilities on Construction Site to carry out such destructive testing, the facilities shall be certified in accordance with relevant international standards and also approved.

Contractor shall note that Works include at least the receipt, transportation, handling and storage (in addition to all other construction activities) of all items included in the novated purchase orders by Company / Client to Contractor. Contractor shall comply with all Company / Client instructions with respect to these particular items and its delivery to Site.

The following drawings form part of Appendix of this document.

Plot Plan.

Pipeline Routing Plans including sections and details.

Survey Drawings for the cooling water and firewater route corridors.

Contractor shall be responsible for verification and confirmation of all FEED deliverables.

Contractor shall initially locate existing pipelines and other facilities and shall place barriers to prevent his personnel or equipment from working over and damaging existing pipelines and other utilities.

General

Installation of the piping systems generally indicated on the P&ID’s, preliminary plot plans and preliminary main routing plans included in the Contract.

All material handling, craneage and scaffolding

All prefabrication of piping systems

All erection of piping systems, including tie-ins and crossings

All prefabrication and installation of supports including material supply

All welding

All heat treatment, if applicable

All non destructive testing

All hydro testing, construction cleaning, draining and drying of piping systems.

All chemical cleaning, if applicable.

All reinstatement

All nitrogen or air testing

Performing all inspections and tests

Providing all weather protection measures when and as required

Bolt tensioning

Provide all pipe spools and pipe fittings necessary for hydro test

Provision and installation of locking devices, to lock open certain valves where necessary

All works necessary for implementation of the modifications at the various sites or, alternatively, in workshops or other designated locations.

Scope of installation works

Installation at a definite location of equipment for the project, the activities to include setting, first alignment and tightening and tensioning of equipment foundation bolts.

Installation of all Equipments / Packages / etc.

Provide support structure

Second alignment after final connection of piping

Provision and installation of services items such as temporary blinds, caps, grease, etc.

Provision of protection against mechanical damage and damage from weather conditions.

Performing initial fill of lube oil, grease, etc.

Contractor shall perform a site survey and ensure spooling of correct dimensions suitable for erection at site and determination of field welds. Contractor shall prefabricate piping in quality controlled conditions (offsite) to the maximum extent possible.

The scope of prefabrication work shall include but not be limited to :

Transport, receipt inspection, storage, conservation, handling and administration of all materials at Contractor’s prefabrication shop location.

All prefabrication, hydro test (including supply and disposal of test water) and NDT works and send it to painting yard for blasting and painting.

Transport (incl. Loading and off-loading) of prefabricated elements from the prefabrication shop to the worksites.

Tagging of all spools with isometric number and storage it in a safe designated area at erection site.

Erection of piping

Prepare workpacks and identify piping spools for erection.

Erect rack structure, supports etc and align

All erecting, testing and re-instating of the piping systems, including supporting (both temporary & permanent).

All bolt tensioning required according to pipe specifications.

Installation of temporary strainers and removal after flushing.

Arrange and provide all testing and drying facilities

Supply, installation and dismantling of temporary supports.

All other necessary activities such as marking, re-stamping, inspections, documenting, establishing procedures, obtaining approvals from Company / Client, etc.

Surface protection, priming, painting, touch up etc.

Fabrication, erection and installation of U-bolts, pipe clamps, and / or other restraining devices necessary for the Work.

Pipe protection

At each location where pipes cross roadways at an elevated level inside the plant areas, permanent bunting poles with warning signs shall be erected.

At all locations where pipes are located adjacent to plant roadways and at all locations where new facilities are being constructed or modified, permanent ‘armco’ type barrier protection shall be provided.

Installation of GRE / GRP piping

Construction Supervision

Coordination with all GRP vendors / suppliers at site

Arrange meetings with other Contractors (interface) to avoid fouling with existing facilities.
Access to existing facilities shall not be interrupted. Future corridors reserved for other facilities shall not be encroached. Temporary access to existing facilities/roads shall always be maintained.
On/off loading and storage

Installation of piping system

Insertion of all sealing rings, gaskets and locking devices

Make up of all laminated / bonded joints and coupled connections

Acceptance of anchor bolts

Acceptance of trenching backfill and compaction

Acceptance of each system as ready for hydro test

Hydro test of spools / joints and double bell couplers prior to system hydro test.

Guarantee of successful hydro test

The above acceptance shall be signed by the Site Representative of the GRE / GRP Manufacturer prior to Contractor proceeding with the subsequent stage of construction in each case.

Contractor shall carry out pipe trenching in accordance with the following:

Contractor shall perform all required trenching and excavation by machine or by hand, including rock hammer and blasting where required and provide all necessary shoring, sheeting, dewatering, protection, stabilization and maintenance of the trenches, including the supply and installation of temporary crossings over the excavation if required.
Contractor shall take all necessary precautions to protect any existing facilities encountered during the performance of his Work. Where excavation is required within three (3) meters of any gas, oil, water, sewer, electrical, telephone or power lines, Contractor shall give Company / Client ample notice (at least two weeks in advance) for each work permit and follow Company / Client standard practice. Contractor shall also arrange for permits from the various local authorities.
Contractor shall take special precautions when working parallel and within five meters of any existing pipes or below overhead lines. All Work in the existing facilities areas shall be carried out adhering to the Company / Client Work Permit Procedures.
Welding and Radiographic Inspection

Contractor shall carry out welding and radiography inspection in accordance with the following:

Contractor shall carry out pipe, road, track and existing pipelines crossings according to the following:

Contractor shall ensure that internals of pipeline are thoroughly cleaned and inspected prior to hydrostatic testing in accordance with approved project procedures.

Contractor shall perform hydrostatic pressure testing of all piping in accordance with approved project specifications and procedures.

Tie-Ins

General Requirements-

Preparation of a detailed tie-in index and schedule

Obtaining approval from Company / Client for all tie-in locations.

Marking of tie-in locations at site for Company / Client Approval.

Provisions of all spades, gaskets and bolts for the tie-in Works.

Removal of piping, if necessary

Prefabrication of tie-in piping

Connection of tie-in piping, including cutting and beveling.

Non-destructive testing (NDT) of the tie-in location prior to and on completion of the works.

Hydrotesting and drying of the relevant part of the existing and new piping system.

Repair of coating on the existing system.

Tie-Ins during Shutdowns

Contractor shall furnish all equipment, materials, personnel, supplies, and consumables necessary for performing all tie-ins. Contractor shall confirm the adequacy of these tie-ins.

Contractor shall plan and schedule tie-in activities to take place during planned plant shutdown periods or, where there is not possible, to minimise any plant shutdown required.

Contractor shall submit a procedure and method statement for each of the tie-in activities, for Company / Client review and approval, including but not limited to:

Procedure-Method Statement-Work execution plan-Material for permanent incorporation-Consumable requirement-Safety consideration-Hazard identification-Operational Impact

Contractor shall tag (physically mark on site) each tie-in location after it is confirmed.

Contractor shall produce an isometric drawing with complete material list for each tie-in. Contractor shall ensure all materials are available for the tie-in Work prior to submission of the request to commence the tie-in works.
Final Cleanup

The Project area and all other areas affected during construction shall be maintained clean and free of environmental pollutants. Daily cleaning of the Construction Site shall be performed.

At the completion of the Work, the construction areas shall be restored as close as possible to their original condition. This includes Construction Site, staging and storage areas, excavated material stockpiles, existing structures affected, as well as any other areas disturbed by Contractor during construction.
Cathodic Protection

Contractor shall install cathodic protection system where necessary as indicated in Cathodic Protection Specification and Scope of Work document and provide post installation testing, interference testing, and preparation of as-built drawings and final report.

Contractor shall plan, in conjunction with Company / Client, to achieve the Mechanical Completion in accordance with the Execution Programme in readiness for the Pre-commissioning activities. Mechanical completion activities are linked in Exhibit of Appendix .

Without in any way limiting or detracting from the effect of any other Clause hereof, Contractor shall conform to the Byelaws and Regulations concerning navigation and shall obey the orders of any authorized and competent officer or agent of the Government or the Port Authority in reference thereof.

Contractor shall consider HRW studies conclusions as given below.

The water levels at the pumping station entrance and the approach flow patterns considered in the analysis took account of the flow into Pumping Station. The minimum water level of ‑0.95m NHD corresponds to a head loss of only 0.07m in the channel. Approach flow patterns are direct and well-behaved.

The typical maximum approach flow velocities to the bar screens are considered to be within acceptable limits in relation to potential turbulence levels at the bar screens.

The available submergence and proposed elevation for the pump bay invert (-9.50m NHD) are considered satisfactory in relation to the required submergence conditions for minimisation of free-surface vortices.

The proposed overall layout and dimensions for the screen chambers is considered satisfactory for FEED. It would be recommended, however, that the required width of each screen chamber element should be subject to further review / detailed design during EPC - following identification of the actual screen vendor and actual screen dimensions.

The roof slab is expected to be clear of the water surface even for extreme water level/wave conditions (notwithstanding possible transient water levels in the Intake Channel that might result from pump start-up or trip scenarios).

Simulations have been undertaken for a variety of operational conditions in the planned Plant CCWS pumping station.

To confirm and extend the conclusions of the CFD model study, it is recommended that a physical model study be carried out during the EPC phase. This would enable final optimisation of the internal layout, and confirmation of satisfactory performance under the final design operating conditions. For Physical modelling scope of work Refer to Appendix- (Hydraulic Study Report)

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Chapter 11

Pre-commissioning shall generally include the following and should be defined and followed up by PC status Index:

Pre-commissioning preparation shall start at the engineering stage together with Commissioning and Start-Up preparation, and shall include the preparation of the documentation, mentioned hereafter, together with the preparation of the FACILITY breakdown in Systems and sub-­systems and the FACILITY start up sequence mentioned under the Work Unit description for commissioning.

Contractor responsibility of Pre-Commissioning consists of, but not limited to the following:

Prepare plans, procedures-Prepare safety audit-Provide PC spares-Provide PC tools, equipment-Co-ordinate activities of Vendor(s)-Maintain all documents, records-Carry out PC activities, e.g. Conformity check-Main activities of PC are: -Flushing/air blowing, -Hydrotesting, and-No-load motor runs-PC documents as follows:

Check list-Test sheet-Status index-Punch list-Dossier
Pre-Commissioning Check Lists

The conformity checks defined above shall be carried out in accordance with, and reported on Pre-Commissioning Check Lists.

Pre-Commissioning Check Lists shall define the Scope of Work that must be systematically performed on each selected item of equipment and shall also be used as a log to record the checks made. A typical sample of such Pre-Commissioning Check Lists is attached in Exhibit 03 to this Appendix A.

One Pre-Commissioning Check List shall be filled in for each sub-system and type of equipment or package.

The Pre-Commissioning tests shall be carried out in accordance with the relevant specifications and reported on Pre-Commissioning Test Sheets.

The Pre-Commissioning methods and procedures shall be defined and followed up in a reference document entitled Pre-Commissioning Status Index.

The Pre-Commissioning Status Index shall summarise for each sub­system the corresponding pre-commissioning checks and tests to be performed for each item of equipment or materials (i.e. Pressure gauges, electrical cables, pumps and the like).

Pre-Commissioning punch lists shall be established for each sub-system being Pre-Commissioned, for the purpose of recording all discrepancies, damaged or missing equipment, malfunctions, missing documents and any deviation from the design drawings and specifications.

Contractor shall compile documentation pertaining to the Pre-Commissioning activities in a dossier arranged by sub-system, which shall contain all information required to demonstrate that a sub-system has reached the Ready for Commissioning status.

Ready For Commissioning Certificates-Punch lists-Systems descriptions and marked up drawings-Specific procedures-Pre-Commissioning Status Index-Pre-Commissioning Check Lists-Pre-Commissioning Test Sheets-Marked up AFC drawings latest status-Vendors’' shop test reports-Vendors' documentation needed for commissioning.

This section deals primarily with Commissioning. However, in view of the required continuity of the completion activities, i.e. Pre-Commissioning, Commissioning and Start-Up, this section also deals with interfaces between such activities.

Commissioning shall generally include the following

Pipelines and Piping system: Operational Tests and leak tests

Instrumentation: Loop check, Logic check and Operational Tests of DCS / F&G systems.

Electrical: Operational Tests on all power system equipment, all motor runs, tests on lighting system, tests on earthing system, tests on cathodic protection system etc

Telecommunication: Functional tests.

Chemical loading / filling.

Actual run in and on line tests during a significant period of the main process equipment in closed loop wherever applicable, and of the utilities systems.

Checking, startup, operation and maintenance of the utility systems.

Equipment packages shall be subject to Commissioning operations at Construction Site, irrespective of the amount of testing that may have taken place at manufacturers' shops.

Contractor shall execute all activities required to Commission the FACILITY and shall ensure that before each functional system of the FACILITY is started that the common activities have been performed in accordance with the requirement of the Contract.

All operations shall be organised by sub-system and reported on that basis.

Contractor's responsibilities for Commissioning shall include but not limited to the following:

Providing a team of suitable experienced and qualified personnel for Commissioning as per approved plans, schedules and procedures.

Preparing interface and Commissioning coordination procedure

Preparing safety audits and maintaining record of all approved safety audit items

Providing necessary Commissioning spare parts and ensuring their availability at Construction Site at least three (3) months prior to Commissioning of each relevant facility

Coordinating activities of vendors and any Subcontractors participating in the work

Developing all required software items

Maintaining all documentation and records of Completion Activities on microcomputer

Maintaining records of all changes for updating the operating manual towards the end of Work

Providing fresh clean water suitable for testing

Providing mechanical, electrical and instrumentation test gear and small tools necessary to carry out calibration and testing.

Gathering and completing the Commissioning dossier of the complete systems

Wherever applicable and as approved at the Commissioning preparation stage, each sub-system shall be the subject of an Operational Test, provided the Basic Functions of the sub-system have been successfully functionally tested.

Operational Tests shall consist of bringing a given system into operation under conditions as close as possible to normal. Included shall be testing the automated devices, controls, normal and shutdown sequences in operation, with a view to revealing mechanical or electrical faults likely to occur during prolonged normal operation of equipment. Such faults may be due to watertight performance defects, vibrations, overheating, overloading and the like.
Wherever applicable, the Vendors' performance guarantees shall be verified during such Operational Tests.
Typical sub-systems to be subjected to an Operational Test are: fire water pumps, air compressors, DCS system, and process pumps in recycle mode (under air or nitrogen whenever possible).
Each Operational Test shall be conducted in accordance with a specific Operational Test procedure to be established and approved at the Commissioning preparation stage.
Following successful Operational Test for any System or Sub-System, Contractor shall issue for Company / Client approval Ready for Start-Up Certificate for such System or Sub-System. Upon Company / Client approval of all Systems and Sub-System in the FACILITY, Contractor shall Start-Up the FACILITY.
Vendor’s Assistance

Contractor shall provide all required Vendors’ support and assistance by mobilizing Vendors’ representative and specialists to Construction Site.

Vendor support and assistance shall be required as necessary for the following.
Rotary Equipment:

Main Cooling Water Pumps-Fire Fighting Pumps

Chlorination System-Fire Fighting System -Hoisting / Lifting Equipment-Pipeline Metering Packages-Drum Screens and Trash Rake Machines.

Instrument Air Compressor / Drier Package.-Stoplog guide ways installation
Process Items:

FRP Piping Systems-Cooling Water System Valves

HV switchgear-220kv Cables-LV Switchgear and MCC-Transformers

Variable speed drives and Motors-UPS / Battery system-Emergency Diesel Generator-Cathodic Protection-Substation Control and supervisory system.
Control and Instrumentation:

DCS systems-Pipeline / Piping-GRP Vendor Support / Supervision-F&G systems-Cooling Water Pumps control systems-Flow metering stations-Telecommunication systems-Process Stream Analyzers-Laboratory Instruments.

The Commissioning Dossiers shall include the following:

Ready for Commissioning Certificate-Punch lists-All Functional Test Sheets-All calibration sheets and records-Vendor factory tests reports.-Set points of relays, protective devices-Record of site modifications in drawings-Statutory authority reports / certificates-Marked-up drawings-System Description-Commissioning Procedures
Completion Activities

Start-Up all Facility

Upon completion of all remaining commissioning activities of the FACILITY, Contractor shall carry out the Start-Up of the entire FACILITY in accordance with procedures to be developed by Contractor and approved by Company / Client. The Start-up activities shall be planned in accordance with the Execution Programme and shall confirm the design intent of the Project in terms of all design parameters, specification and Cooling Water quality.

Upon completion of FACILITY Start-up, Contractor shall assure that the FACILITY is operating at steady and stable conditions, whilst maintaining flow rate to all consumers including IPP.

Contractor shall design, procure and install Temporary Facilities, which shall be subject to Company / Client approval. Such Temporary Facilities can be based on plain Carbon Steel.

Contractor shall have the consumer interface system connections to all consumers, inlet & outlet, Mechanically Completed and ready to be connected to each consumer.
The 72- hour Performance Test shall be carried out satisfactorily by Contractor on or before the date stated in Appendix H.
Initial Operation and Maintenance

Contractor shall mobilize all operating and maintenance personnel and Vendor representatives as required for the operation and maintenance of all the FACILITY on 24 hour basis. The Initial Operation and Maintenance shall start after the 72 hour Performance Test and up to and including the Completion Date. The Operation and Maintenance of the FACILITY shall be undertaken by Contractor in accordance with the operation manuals and Vendor’s Instructions.

Contractor shall complete all remaining Works under the Contract such as, Punch List Items clearance, Material reconciliation, Final Documentation, Training and any other Works as specified in the Contract.

Upon Completion the Facility shall be considered as Handed over to Company/Client in accordance with the Contract.

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Chapter 12

Process Buildings Package