2 project design, contract award-facilities petrochemicals

Buildings Practice Facilities Plants/PetrochemicalsChapter 2

Project Design, Contract award & Miscellaneous

AbbreviationsSome useful abbreviations generally used on design documents for references:-

1 A/G - above ground, AFC-approved for construction, AFD-approved for design, 2 BFD- block flow diagram, 3 CCR-central control room, CCTV-closed circuit television system, CCWS-common

cooling water system, CDR-conceptual design report, COM-commissioning, CP-cathodic protection, CT-cooling tower, CW-cooling water,

4 DC-direct current, DCS-distributed control system, 5 Easement- all land provided by Client to be used by Contractor for purpose of

construction, EPIC- engineering, procurement, installation & commissioning, ESDV-emergency shutdown valve, EWS-engineering work station,

6 FAT-factory acceptance test, FOTS-fiber optics transmission system, FEED-front end engineering design, FMEA- failure mode & effects analysis, FO-fiber optics, FRP-fiber reinforced plastic (generic name including GRP, GRV & GRE piping), F&G-fire & gas system,

7 GAD-general arrangement drawing, GIS-gas insulated switchgear, GPS-geo positioning system, GRE-glass reinforced epoxy, GRP- glass reinforced polyester, GRV- glass reinforced vinyl Easter, GGBS-granulated glass blast furnace slag

8 HVAC-heat ventilation & air conditioning, HMI-human machine interface, HSSD-high sensitivity smoke detection,

9 ICA-instrument, control & automation, IDF- intermediate distribution frame, I/O-input /output, INTOOL- trade mark name of Intergraph software for instrumentation eng, IST-integrated system test, ITP-inspection & test plans, IO&M-initial operating & maintenance,

10 LAN-local area network, LBV-line break valves, LER- local equipment room, LLCC-local lot control centre, LEED-leadership in energy & environment design

11 MC-mechanical completion, MCC-motor control centre, MDF-main distribution frame, MOV-motor operated valve, MTO-material take off, MWS-marine warranty surveyor, MS-MICROSILICA

12 ONAF-oil natural air forced, ONON-oil natural air natural, 13 PABX-private automated telephone exchange, PA/GA-public address / general alarm,

PC-pre-commissioning, PCS-process & utility control system, PDCC-power distribution control centre, PDS- plesiochronous digital hierarchy, PDS-plant design system, PMS-power management system, PEMS- power energy management system, PFD-process flow diagram. PFS-process flow scheme, PH- pump house, PIS-plant information system, PLS-programmable logical controller, P & ID- process & instrumentation diagram, PSFS-process safety flow scheme, PSS-plant safety system, PSV-pressure safety valve, PTZ-plant tilt zoom, PCC-plain cement concrete, PFA-pulverised fuel ash

14 QA/QR/QC-quantity assurance/quality requirement/quality control, 15 NCS-National construction specification, 16 RAM-reliability, availability & maintainability, RB-receiving basin, RFC-ready for

commissioning, RFQ-requisition for quotation, RMU-ring main unit, ROW-right of way, RTTU-remote transmission terminal unit, RCC-reinforced cement concrete, rebar-reinforcing bar

17 SAFE- safety analysis function evaluation chart, SCADA-supervisory control & Data Acquisition/monitoring system, SDH-synchronous digital hierarchy, SPT sustained performance test, STM- synchronous time moduling,

18 TETRA-trunked radio, TPC-Third Party Certification agency, TPI-third party inspector, TTL-transistor transistor logic,

Page 1 of 17 2012 Int. P Eng Suraj Singh



19 UFD-utility flow diagram, UFS-utility flow scheme, UPS-uninterrupted power system, U/G-underground,

20 VDRL-vendor data requisition list, VSD-variable speed drive, VSDS-variable speed drive system

Involvement of multidisciplinary teams for required designs

1 Process engineers, chemical engineers, reservoir engineers, mechanical engineers, electrical engineers, electronics engineers, instrumentation engineers, IT engineers, civil & structural engineers, coordinating engineers, planning engineers, quantity engineers, surveying engineers, cost control engineers etc. shall be included to formulate an overall strategy of designing proposed plant processing system further supported by soil engineers, hydrographic engineers, geological engineers.

2 After having proposed basic design been desk conceptualized, further FEED detailed works shall be undertaken for documentation by all disciplinary teams for elaborate formations relating to various details to be used on proposed project.

3 EPIC- Engineering Procurement, Installation & Construction4 EPC- Engineering Procurement & Construction5 Contractor, Subcontractor, Supplier, Vendor6 Subcontractors as Engineering Consultants or project managers7 Front End Engineering Design requires complete technological knowhow about

relevant proposed facility design technology & construction requirements/details that are fed to Client for inception of whole scheme, which Client approves & based on FEED package, bid/tender documents should be prepared for required Engineering, Procurement & Installation contract/s award/s.

8 This class of bidding/tendering necessitates an, extremely competitive & competent bidders to be technically, commercially & in all respects, a completely well established, experienced, pragmatic sound organization.

9 Complete Front End Loading is to be established & provided to appointed/elected design scheme.

10 EPIC contracting requires complete understanding of processing technology, all included trains functions & life cycle of implementation of technology, design knowhow giving all detailed design calculations for best & warranted performance of proposed facility as well as, whole design & its performance in short as well as, in long run of facility service life, which should be commercially competitive.

11 EPIC contracting proposes its own qualified Subcontractors as well as, qualified vendors organization to be included as further/extended support.

12 Design Subcontractor shall also, be included as support in case, proposed EPIC organization is not adequately qualified as either, a competent designer or a consultancy group or not having, an in house design capability.

13 All documents based on aforesaid abbreviations are produced schematically while, preparing FEED documents for information purpose provided to bidder for communication about proposed intention of client project requirement.

14 FEED contractor of client should provide as much data, as possible to enable EPIC contractor understand various client requirements fully/comprehensively for EPIC implementation of contract & offer bid price accordingly.

15 It must again be stressed that FEED is endorsed by proposed EPIC contractor while, submitting bid as an evidence of acceptance of FEED & its incorporation on detailed designs, based on which all works shall be executed/prosecuted.

16 FEED document is considered significantly valuable since, it gives outline & details of complete design & philosophical requirements to be considered while, designing




all units, trains, structures & relevant equipment. 17 Generally, all relevant engineering theories are included. 18 All national & international codes intended to be complied with, are included. 19 Full information about project objective & purpose is indicated. 20 All intended elements or components to be included within & integrated in various

areas, such as off sites, process, administration & others are indicated. 21 Indicative use & design requirements from engineering & technical viewpoints are

included.22 FEED document should provide complete history of proposed project including site

location background in all respects, so that bidder is quiet clear about proposition to a maximum possible extent.

Project Tender Documents 1 Aforesaid teams of engineers shall prepare all required documents necessary for

facilitating an invitation of EPIC bids/tenders from short listed parties. 2 These documents must cover basic requirements & design philosophies pertaining to

all disciplines to enable bidder know each & every requirement precisely. 3 All disciplines shall be given full feedback in all respects in form of project drawings,

specifications, soil test reports, survey reports, marine survey report, bathymetric survey report, marine geological report, other conducted studies & observations, climatic conditions, various scheduled milestones, relevant quality standards to be adhered to, including all other essential parts of project contractual demands.

4 These documents should be crystal clear without involving any ambiguity. 5 As far as possible, details about all equipment to be permanently included on

proposed project should be described within various documents. 6 All national & international codes to be complied with should be enlisted explicitly.7 Project design parameters should be explicitly defined with allowed options. 8 Which national or international codes are relevant, should explicitly, be included for

compliance.9 Documents shall be provided in soft as well as, on hard copies. 10 All files included within hard copies must be supported by soft copies & all updates,

regularly, added for circulation to relevant parties or bidders.11 Production of such huge volume of design documents amounts to requirement of very

experienced teams of professionals/experts from all disciplines to meet design schedule requirement as well as, project construction requirement.

12 Project documents may include Budgetary provisions, FEED provisions, form of contract, special conditions or particular condition of contract, general conditions of contract, Designs, Drawings relating to all disciplines, Soil exploration reports, processing drawings, trains drawings or prospective, project specifications, general specifications, Bill of quantities if available etc.

13 Presentation of demanded project should also, be included in person by client representative by holding site visits many times with all bidders, so that no ambiguity is left from a clear understanding of requirements viewpoint.

14 Such meetings provide certain opportunities to various prospective bidding parties to raise various questions & obtain/receive necessary clarifications.

15 It is much better to raise silly questions sometimes, if given provisions are unclear rather avoiding them.

16 It is a fact that some misunderstanding/misinterpretation based incorrect assessment of bid cost for a project can cost millions of dollars as well as, contribute to loss of time & overall delay on project scheme delivery.




17 Maintenance Preparation Documents submission though applies at end of construction i.e. mechanical completion of project but, information are required to be issued at FEED stage for long term evaluation purpose as well as, value engineering consideration.

18 Contractor's obligations pertaining maintenance preparation, general engineering and procurement, which contractor shall take into account in its design of proposed facility its maintainability criteria, philosophy and requirements of spares to be defined in proposed FEED Design Package.

19 In particular, contractor shall make permanent provisions for accessibility (without dismantling of other equipment), dismantling/tooling, lay down and handling of heavy parts.

20 Make provisions for online monitoring of vital rotating machinery & certainly define critical ratings for equipment, sparing requirements for equipment, components and relevant parts.

21 Contractor shall prepare and submit necessary required maintenance documentation as generally, defined in various relevant exhibits, integrate its maintenance requirements in its vendor selection process and obtain, vendor’s documentation generally defined as such.

22 Requirements for vendors’ selection/Pre qualification regarding which, prior to issuing a call for tender for critical items, contractor shall check vendors' capabilities, such as ability to submit tenders conforming demanded quality requirements

23 Technical and financial long term competency & stability demands existence and suitability of Quality Requirement Assurance procedures within vendor's structure, covering relevant manufacturing process, relevant quality control process of raw materials, required assembly of components, required performance and conformity tests, required internal quality audits, capability to supply after sales service for maintenance, technical assistance, supply of parts, procedure for collection of product performance feedback etc.

Bid Evaluation1 Contractor shall take into account at bid evaluation stage, following defined criteria

for vendors selections and accordingly, advise vendors that their bids would be evaluated on such considered basis, so that prospective vendors must include pertinent price if, so effected by such considerations.

2 Bid price and conformity to project specification.3 Cost of two years or as specified, in projected contract recommended operating spare

parts for all involved machines or equipment to be installed on project.4 Reliability of components (identification of components, non standardized or non

tested by vendor, under conditions similar to project conditions). 5 Various components should be fully reliable to meet their intended functional

requirement for their efficient performance operations.6 Standardization (identification of non standard components, justifications for

recommending such components, cost of spare parts needed for such components). 7 Full cost of spare parts contractually, required according to specifications shall be

included within bid correctly.8 Availability guarantees Ratio optimal conditions/optimal performances for which,

evidences to be obtained from proposed prospective vendors by visiting factory as well as, various references works carried out/inclusive on track record.

9 Proposed vendor shall provide with all technical brochures of intended product to EPIC contractor along with its bid, all documents giving all performance evidences.




10 Equipment/spare parts performance shall also, be witnessed by visiting manufacturing location of proposed spare parts.

11 Safety/Protection rating-Verification of performance evolution-Means for condition monitoring - Recommended frequency and duration of maintenance- interventions (total annual duration, maximum duration of a major intervention-Availability/ Reliability / MTBF / MTTR-Availability of after sales service (rating)-Availability of spare parts lists, Availability of documentation lists-Availability of documentation lists-Operational List of special tools maintainability-Modularity/Disassembly-Accessibility (rating)-Such ratings should be obtained from some of available independent agencies published documents, which should indicate that its observation & conducted relevant studies performed without any interference by proposed vendor.

12 Third party agencies usually publish correct effectiveness of these vendors product & services in parts or in totality at regular intervals or as required for some special assignment.

13 Handling (rating)- Similar record should be confirmed from available database of past successful projects on history of vendor’s track record & included with submission to contract engineer as an evidence to monitor proposed product efficiency.

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

15 Stability of Vendor, Quality Assurance, after sales structure- Proposals for maintenance contract (rating), guaranteed reliability Contract (rating), training programme (rating)-Vendor Maintenance Recommendations-Management and monitoring (rating)-First level maintenance (rating)-Diagnosis tables (rating)-Preventive and on condition operations (rating)-Method of intervention (rating)- Identification of conformity certificates-Requirements for component testing.

16 Various provisions of all aforesaid documents from prospective vendors’ records substantiate proposed vendor’s claim about its reliability & consequently, leads one step to customer satisfaction.

Vendor’s obligations to be enforced by Contractor1 Contractor shall generally carry out various procurement steps required to have

competent Vendors, who meet maintenance bid specifications requirements for intended supply of equipment and consistent documentation

2 Contractor shall prepare and include a Vendors' maintenance requirements specification in ‘call for tenders’ and ‘purchase orders’ in line with given Client guidance and submit for client’s approval.

3 Contractor shall obtain, check, approve and issue Vendor maintenance documentation (as Maintenance Dossier) and prepare their respective Mechanical Catalogue.

4 EPIC contractor shall comply with all given manufacturer’s instruction in respect of each & every equipment or each product & all evidences in this respect shall have to be provided as quality requirement assurance documentation to client engineer for approval & permanent recording.

5 Expected Vendors’ Maintenance Dossiers shall generally include, but not be limited to as following guidance is in essence only.Equipment data-Equipment descriptions-Equipment inventory-Technical data sheets (reference number, serial number, tag number, purchase order number)-Connection parameters (piping, electrical, instruments)-Software documentation both in electronic format and as a hard copy-Operating documentation-Operating procedures- On-line monitoring- On-line monitoring- First level maintenance by operators- Lubrication schedule.




6 All these documents & also, some other additionally required one, shall be approved by client engineer for implementation on its performance monitoring.

7 Maintenance documentation (per type of equipment)- Scheduled inspections or interventions-Preventive, on failure and an overhaul maintenance procedures, including description of personnel, tools, spare parts, drawings required - Trouble shooting charts- Lists of consumables- List of special tools- Spare parts lists (SPL), under format attached or equivalent- Drawing- General arrangement drawings- Section drawings- Schematic and wiring drawings- Control loop diagrams- Logic diagrams, cause and effect sheets

8 All these documents shall be properly numbered & recorded by EPIC document centre.

Technical Proposal1 It is unavoidable in this age of bidding/tendering particularly, on various Industrial

projects of international Quality Requirement Assurance nature, that all bids are submitted in two parts either together or separately, depending upon defined Client requirement.

2 Technical bid is always considered a lead submission package on commercial to fully & comprehensively, assure whether or not, involved project bidder got professional capability to execute & prosecute intended requirements of project smoothly & efficiently, keeping within limits of constraints such as time, quality & cost.

3 In case, submitted technical bid is rejected, there should be no further need for involved bidder to propose commercial part of project bid or if both bids are submitted together, incompetency on technical bid shall stop further consideration.

4 Technical bid is a voluminous document containing complete details of bidder’s intentions to carry out proposed project execution from its commencement to its completion stage, describing in details ways/procedures & methods, for each & every part of intended proposed project, defining how demanded requirements shall be handled & whether or not, bidder is adequately resourceful, technically capable & further scrutinizing all other aspects expected by client & engineer, bid is evaluated.

5 Technical bid should contain fully descriptive & completely integrated infrastructure of involved bidder in all respects about design & execution philosophies, execution plan, machinery & manpower proposal, alternative proposal if so necessary contemplated by bidder, full design criteria, materials proposed from its authentic source, acceptability of Third Party Certification, deviation from defined contract & its controls, complete safety programme details & risk analysis, Hazard study, safety records, safety plans proposed, evidence of past safety capability records, various well designed formats to be employed for using during whole duration of project cycle including post mechanical construction maintenance

6 It also, requires descriptive proposals from its Quality Assurance & quality control section providing all necessary formats & detailed methods of quality control maintenance including Inspection & test plans, check lists & all quality documentation procedures, execution or project construction method statements as well as, provisions respecting proposed independent materials testing laboratory.

7 All procedures pertaining company documentations shall be included involving internal documents matrix used & ensuring that documents traceability is smooth all times to come.

8 Engineering procedures including procurement shall also, be included within this proposal giving complete feedback on proposed designing system, software to be used, designer’s potential, complete requirement of job related materials, job temporary facilities to accommodate proposed manpower etc.




9 Since, required Technical Proposal is based on bid provided FEED documents by client/company or client/company appointed FEED contractor, whatever contents of required Technical Proposal be presented, should be based on necessary technical directives compliance included within bid FEED.

10 Bidder’s base firm proposal should not at all deviate from bid FEED requirements.11 Competent bidder is required to endorse submitted Technical bid stating that given

bid is completely, based upon provided FEED, meeting all requirements unconditionally/without any qualifications.

12 Its content of certification should be in accordance to client format provided.13 There may be an alternative proposal in addition to bidder’s firm proposal, which

may satisfy all requirements of FEED in addition to making/contributing cost & time saving to promoting client according to defined Value engineering consideration that owner/client could accept if all proposals comply with provisions included within FEED.

14 Technical proposal is very comprehensive presentation content wise giving all information of proposed contract execution involving all aspects, from design to its implementation performance & handover stage.

15 No room is allowed for any commercial reflection within Technical submission. 16 In fact, by making evaluation of this document’s contents, thorough consistency &

capacity of bidder is measured from all aspects.17 Many rounds of Technical submission including Technical meetings are conducted to

scrutinize submission of all included chapters. 18 These chapters should be simple in presentation style to allow full clear

communications from bidder to contract engineer/client, to facilitate an easy understanding pertaining to proposed project execution.

19 All sources of procurable materials, equipment & all other items/components to be used for all permanent inclusions on project, should be enlisted in a scheduled manner in line with all FEED requirements.

20 Proposed works schedule to meet bid defined milestones, should be explicitly described convincing everyone concerned stakeholder on client/company end that bidder approach is feasible to achieve indicated or defined targets in practical terms, so that commissioning of facility shall move smooth without causing any problems.

21 All workforce & staffing levels as well as, management to supervise & direct bid project, should be clearly defined including required CVs of all key levels personnel.

22 These levels should meet bid defined criteria according to given FEED as well as, bid expected professional competencies.

23 Design procedures should be clearly defined in a precise manner including giving all designations of Information Technology to be utilized for bid project.

24 In brief, all other proposals for bid proposed facilities for all temporary works as well as, for all permanent works, should be included explicitly.

25 It is quite a long format, but should be precise & clear point to point involving all significant considerations/points.

26 Bid client is never interested in a voluminous documentation for show off purpose, but a precise content giving all true & relevant information should always be welcome.

27 It should be remembered that all these proposal documents shall be required for bid actual demonstration proving required consistency as well as, competency & capacity reflected on bid proposal.

28 It is better not to propose something, which is not practiced by bidder, otherwise demonstration could detract bidder.

29 Many cases have been noticed, when after submission of proposal, comments are




received from client/company/engineer asking for/requiring many clarifications, which are difficult to reply positively & satisfactorily.

30 Better, be straight forward for bid submission. 31 Quality requirement assurance as well as, Execution statements constitute very

important & significant role for providing value to project technical bid, for which due time & devotion must be given by proposed bidder.

32 Relevant experts should be engaged for required detailed inclusions of all necessary information inclusion within bid documents for engineer/company/client consideration/review.

33 Untoward information should preferably be avoided. 34 Once, project bidder is short listed either by client/company/engineer or by project

establishment of project bid competency, call for its commercial presentation should be given to bidder, failing which there is no use in case, submitted bid fails to meet project FEED requirements.

Contract award1 Within this procedure, all short listed parties shall be invited to tender for

company/client EPIC bid, who in turn calculate cost of demanded facility on EPIC basis or EPC lump sum firm price basis for either whole or part of project job in defined fixed time based on compliance with all FEED documents provided.

2 Complete submission shall include Technical bid on one part & Commercial bid on other part.

3 Sufficiency of its Technical bid part shall decide whether or not, its Commercial bid part should be considered.

4 After having its Technical bid qualified by project bidder, qualified bidders shall be notified by engineer/company/client about opening time schedule of its commercial bids.

5 Then EPIC contract shall be awarded after complete scrutiny of all bid documents, availability of contract performance bonds & ascertaining fully its sufficiency of project quality as well as, capability pertinent project proposed Contractor.

6 A letter of award shall be issued by client representative/engineer instructing project successful bidder to immediately, commence project job giving one contract effective date of commencement.

7 A date shall be appointed by client/engineer for project contract execution between Client & successful bidder as well as, for initial/kick off meeting.

8 An agenda shall be drawn for kick off meeting defining sequence of deliberation/contract points to be discussed, while all officials & authorities from both parties would be certainly required to be present during this kick off meeting.

9 Project successful bidder/prospective contractor shall affirmatively make available its representatives to execute formal contract documents on that appointed day, failing which project client enjoys legal right to claim bidder’s bank release tender bond amount to compensate to client/owner/company.

10 A date shall also, be fixed/appointed by Client instructing project contractor to submit required performance bonds, insurance policies about project works as well as, for proposed personnel accidents coverage & all other necessary legal documents regarding these contractual obligations according to provisions included & agreed on General Conditions of Contracts (GCC) as also, on contract particular conditions.

11 Details about all deductibles, amounts covered under all policies etc. shall be submitted according to agreed documentation procedures.

Execution Programming a contractual binding document




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

2 Programme schedule shall cover an overall outline in Gnat format with CPM support, include all contract milestones defined, discipline & element or component wise detailed activities, detailed manpower, detailed machineries, recovering delays methods, identification of problems with proposed resolutions, activities wise measurements of works percentage based on agreed method of man hours evaluation or time based activities as well as, cost wise breakdown applicable to (WBS) work activity breakdown structure.

3 Progress S curves indicating various phases shall be included showing man hours histograms, work planned progress, machines availability histograms, cash flow etc. whatsoever, required by client/engineer or considered necessary for a good record & reflection of project progress measurement or required to be applied for risk coverage to time, cost & quality controls.

4 Once Contractor’s programme is approved, it shall not be altered, but constitute as a base programme to monitor & control all project, whole progress, coordinate & if so required, time recovery shall be applied, should there be any delay to project planned progress.

5 In addition to an overall descriptive programme, monthly 90 days look ahead, monthly submit able programme shall also, be charted out regularly, to monitor achieved progress on detailed basis.

6 This programme shall be supported by a detailed method statement giving complete information about all phases of works & their relevant elements arranged in an order keeping in view indicated priorities on contract project to accomplish aforesaid approved programme effectively.

7 Major sequences of operations to be covered from project home office activities including corporate management affairs, designing, procurement, documentation, selection of subcontractor, engineering, procurement, deliveries controls, customs, material storing, quality assurance, cost control & taking down to site relevant activities in all respects.

8 This part shall be taken up & considered very seriously, as work progress movement rests on its actual level of performance.

9 All foregoing functions constitute supports to project front office performance. 10 In case, these functions are conducted inefficiently by back or support office, front

end progress achievement shall be adversely impacted.11 Organization charts shall be presented showing contract design office, contract head

office, site office, subcontractor’s offices & all others, directly or indirectly connected parties & giving full description respecting all such project parties or stake holders & about their corporate structures.

12 (CVs) curriculum vitae respecting Key Personnel to be involved on project complete execution of contract project shall be proposed for approval by engineer/client.

13 Without such contractual approval, no key personnel shall be allowed to work on project contract.

14 Every project defines its level of requirements pertaining to essential qualifications & expertise for all key personnel to be dedicated to it for all smooth deliveries of contract requirements.

15 Format for Execution Programme only for guidance only -Scope, Work breakdown structure, Contractor’s organization including details of its organization,




subcontractors organization, job positions & descriptions of key personnel down to supervisory level, contracting strategy-direct hire-direct control or management, home office activities, other contractors interface coordination, operations, mobilization-break down of manpower by trade including manpower histograms-major equipment utilization schedule,

16 Construction sequence- temporary facilities including utilities & camp accommodations, site preparations-underground piping-underground electrical & instrumentation, civil foundations & concrete work-structural steel-equipment erection, pipe fabrication-pipe erection, electrical-instrumentation control systems-telecommunication, painting-insulation-pipeline.

17 Sequence of construction for all activities may contain many chapters, while foregoing description is given only for a guideline purpose, since those technical matters are not in scope of this document.

18 Systems-Quality management systems, Material management system-customs formalities-port storage- transportation to site-warehousing-storage-material handling-general responsibilities of field materials personnel-material receiving & inspections requirements-maintenance procedures-protection & preservation procedures,

19 Systems-Health safely & environment-responsibility of safety personnel-HSE process & execution plan-HSE orientation-HSE site programs-construction environment control procedures/permitting-medical facilities,

20 Systems-Site security, heavy lift & transport, personal transport, manpower (direct & indirect), field non manuals, construction automation plan, document control, acceptance,

21 Systems-Mechanical completion incorporating pre-commissioning, Pre-commissioning & commissioning organization-job descriptions, close out, attachment

22 Systems-Site organization charts, field non manual staffing plan, subcontract plan-number, name & scope of each subcontract, Level 2 construction schedule, manpower loading-histogram by trade including both, direct & indirect.

23 Systems-Equipment utilization plan, temporary facilities & camp accommodation plan.

Stages of Execution-1 EPIC / EPC - Project Delivery Contractor2 Safety, Health & Environment- Safety plans-Training-Induction-Regular courses-

Special courses- Site Walks-Toolbox Talks-Risks Analysis-Corrective Programmes-Inspections-Awards-Audits

3 Quality Requirement Assurance QA / QC- Quality plans-Training-Induction-Regular courses-Special courses- Audits- laboratory- dossiers.

4 Engineering – Design detailed philosophy, Design, Detailing, Shop drawings- Working drawings-Schedules-Technical Queries, Site works queries, Proposals for technical resolutions, Documentation appraisals, Construction ability checks, inference of technical documents, Engineering meetings, Construction Method statements

5 Construction & Controls - Mobilization-materials-manpower- equipment-procurement-physical construction-contract management – construction project management.

6 Testing - Pre Commissioning, commissioning, performance & maintenance,7 Operations & maintenance8 Third Party Certifications




9 Project records - Issued for Construction documents-Red Lines Mark ups-As built- Operation & maintenance Manuals

10 Punch List / Snags - Visual defects-Technical defects- minor non-conformance-snags- rectification- remedial measures-investigations

11 Mechanical Completion- Pre commissioning & commissioning-site acceptance test- performance - plant performance

12 Final Completion - maintenance & successful performance13 Hand Over- Recording learning lessons-suggestions-about subcontractors- about

Client engineers-Close Out-discharge14 Warranty liability - relevant defects guarantees for required periods.

-------------------------------------Industrial Safety BriefsSafety, Health & Environment-

1 First & foremost is considered safety for every project. 2 Slogan SAFETY FIRST is very common among all safety promoting projects. 3 Without safety provisions intact, no work is allowed. 4 Safety is a must responsibility of everyone. 5 Every person working on every project must use personnel protective equipment PPE

& all necessary special precautions must be adhered to whenever, directed by dedicated safety official responsible for project.

6 All activities must be conducted in a safe manner to its best possible minimum cost incurred on safety to achieve zero accident performance.

7 In case, no proper arrangements are made to keep safety intact, project execution of pertinent activity should be suspended.

8 On important works, safety team must be present to support project construction team for helping conduct smooth safety management on all activities.

9 Site engineers should abide by relevant instruction & direction given by deployed safety personnel.

10 Proper care must be adhered to during deep excavation works as well as, on ground & overhead works.

11 Safety ensures- Know safety no pain, No safety know pain.Safety plans

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

Training 1 Various classes of onsite training are considered necessary to be imparted to all site

personnel for onsite implementation. 2 No site admittance should be allowed to any personnel whether or not, full time

working on site, without formal safety induction.Induction

1 Immediate on joining, all personnel should be given safety induction course duly recorded on proper register for imparted training.

2 This course must include all precautionary instructions required to be complied with on working site generally, to be prosecuted onsite.

3 Provision should be defined for punishment for those personnel working in safety violations.

Housekeeping1 Training should be given to all personnel to keep all working & other areas tidy




during & at end of working day. 2 All tools should be properly kept on site. 3 No material should lie here & there unattended, but it should be properly stored. 4 Working environment should be made good/comfortable & also, felt comfortable by

all concerned personnel.Supervising safety

1 Every supervisor should be trained for full understanding of managing safe supervision over all site operations.

2 How to handle defined below & above ground works & how to handle all overhead works.

3 How to make all workers understand all procedures of safe handling respective operations, so as no operation should effect workers health badly or adversely, causing no overstress impact physically.

Heat stroke1 On construction sites particularly, in hot & arid regions, adverse effects of heatstroke

are imminent to workers. 2 They should be taught all methods respecting how to prevent such incidents by

gradually inducting every worker to hot working conditions & over timings adjustments due to fact that often, heat stroke can lead to death of personnel.

Fire watch 1 Every workers should be clearly taught ways to surveillance on possible fire incident

chances & if occurs, how to handle to extinguish such fire break /spread.Toolbox talks

1 In general, prior to begin certain activity, toolbox talk should be given to concerned group working on given activity involving particular or all callings.

2 How minor or major injury may occur during carelessly using/handling involved tools & how to act if, personnel is injured.

3 Details of involved activity, procedures how to safely handling tools & what precautions are necessary to adhere to, should all be made clear & ensured that every personnel understands such handling procedures correctly.

Toolbox TalksSkilled workers

1 Every skilled worker, semi skilled or unskilled should know about proper use of tools & maintenance of these.

2 They should be explained about all types of dangers if, various tools are not properly used during work

Liquid consumption & food1 Every worker should consume water or available drinks after a period of work

interval frequently, to protect one from imminent adverse effect by dehydration & should be allowed frequent intermittent rest pauses during hot weather conditions as well as, during carrying out of very critical activities.

Dust prevention1 Dust accumulation causes environment degradation affecting badly working activities

on site. 2 During such occurrence of inclement weather conditions, ample means of water

should be available to spread on site, so that dust does not lift or suspend into air.Sanitary

1 Adequate arrangements must be made on site for all workers & staff to use sanitary facilities throughout whole currency of relevant project to maintain its working area in healthy & hygienic conditions.




Regular courses1 In groups, workers should be given feedback on every site safety as well as, gas

inhale prevention, during fire, how & where personnel have to assemble, how loss prevention fire alarm works etc.?

2 How to construct temporary platforms at high levels to be used for various purposes, to meet every site instant requirement?

Special courses1 How to take precaution to avoid electric shocks or some other hazard?2 Incentive should be given to all leading workers, who keep up proper safety as well

as, check & advise coworkers & colleagues to take due measures. 3 Accessibility to site horizontally as well as, vertically should be explicitly explained

to everyone. 4 Positioning of all ladders in excavated trenches, which location shall not be more than

8 m. 5 Provision of all platforms guardrail of suitable height. 6 For example, use of wooden or Aluminum ladder in excavation areas or to various

higher working areas. 7 Platform construction, its supports, its toe boards etc. 8 Fire extinguishers use descriptions. 9 First aids use descriptions. 10 How to access emergency phones for hospitals?

Site Safety Walks1 Whenever necessary, site walk should be conducted by responsible safety engineer

with dedicated site in charge to pin point existing deficiency on installed safety measures & on site correction applied in compliance.

2 Preferably, safety walk meetings can be conducted once a week & observations during walk meeting minute written for circulation, action & records.

Risks Analysis1 Keeping in view all types of operations on site, what risks are imminent, should be

studied by project safety engineer/manager & study be conducted in cooperation with responsible construction people so that, expected causes of risks & their relevant solutions be explained to site team for implementation of safety measures on site as well as, properly demonstrated & documented.

Safety respecting heavy equipment1 Crane operation, shovel operation, concrete pump operation or some other equipment

operation requires a complete safe operation system. 2 How to operate these machines safely on site? 3 License of operators as well as, banks man or rigger’s instruction manual. 4 Third Party Certification for all cranes & hoisting equipment particularly. 5 Only licensed operator should be allowed to carry out hoisting or lifting operations.

Programmes1 Regular & frequently, safety programmes should be conducted on site from every

aspects or risk consideration to make all aware of conducting overall safety to avoid certain minor or major accidents.

2 Practical training should be conducted for all equipment operators to let them understand all effects of not conforming to defined safety practice operations.

3 Inspections-Safety engineer should inspect working areas frequently, to examine that all arrangements adopted on site for running operations, meet necessary criteria of adhering to safety rules & if, observed certain deficiency, responsible site engineer should be intimated for resorting to application of corrective measures.

Awards




1 To motivate all workers on site to take due safety measures during working hours & thereafter as well, compliance awarding system should be adopted for all workers, who work on with full safety on site & regard safety measures during working.

Audits1 Corporate safety team should check casually & as programmed, some safety records

physically on site & due observation circulated along with certain proposed corrective measures.

2 A healthy worker on site works many times better than a sick & unsafe worker. 3 It is better to spend reasonable amount on safety rather than spending on loss of work

causing inefficiency on site. 4 Every personnel on job is important & got a full right to go back home safe &

healthy.SAFOP

1 Safe Operation- It is first key to get success of doing project in all respects.SAFAN

1 Safety Analysis- Prior to an application of necessary safety, its complete analysis is a must to know & select one best safety method out of many considered procedures.

SYSOP1 System Security & Operability Analysis-It is very significant from safety engineering

viewpoint. 2 Until complete problems are listed, applicable procedures may not be known. 3 Systems generally, involve safety against fire, safety against gas explosion & safety

against an electric default. 4 Therefore, these requirements import applications of observing all precautionary

measures, selection of which depends on various detailed solutions as obtained from considered risk analysis & details of equipment operations.

OPTAN 1 Operator task Analysis-Control & field Operator-This part also, involves detailed

study as well as, precise applications. 2 Slackening should be allowed.3 Attempts should be made to take due measures to prevent accident in hot work as

well as, cold work areas & also, in restricted & confined entry areas. 4 Permit to Work PTW system must be applied to various activities in such areas of

every facility.

-------------------------------------Quality Assurance/Requirement, QA / QR / QC Briefs

Quality/Manual-Plans-Training-Induction- Regular courses- Special courses- Audits- laboratory- dossiers

1 Term Quality Assurance or Requirement, which includes quality description, quality compliance requirement, quality control, being significantly important from client/customer satisfaction viewpoint that must be clearly understood by all participants / stakeholders on proposed project.

2 Many stakeholders do have an unclear concept respecting these terms. 3 For information, QA is a principle term, applies to overall quality system

management means, Total quality management, while quality control applies to particular quality control procedure, for example laboratory testing of material, site checks, inspection & test plans & so many other technical procedural involvement during construction operations.




4 Follow up of defined whole procedures, as included within approved quality plan from project inception to its handover & discharge that is to be made successfully to client/customer with full satisfaction is termed Quality Assurance.

5 It is understood that compliance with agreed system procedures would certainly deliver quality product.

6 But, recently, one term entitling quality requirement has been on lead role that demands at every step of quality operations to evidence that whatever, has been included on project must be required on production evidently, without granting any concessions.

7 QA involves major policy & competency of client/company. 8 Based on successful completion of various projects conforming to QA, past track

records is confirmed competent standing / capacity of company on QA. 9 Company means not be an exclusively, its management, but all members of company

at all levels of corporate & home office, middle management, lower management, workers etc.

10 These include working involvement respecting all disciplinary & operational departments of company in both home offices, branch offices, field offices & in front end fields, market contribution, market collaboration & involves so many other aspects as well, which cannot be covered in brief explanation.

11 Foregoing explanations also, apply to contracting organization as well. 12 It is added that now, QA involves quality requirement for all its intended purposes

in construction organisation as well as, contracting organisation. 13 No activity should move without its involvement.

Quality plans 1 This term includes company quality manual & project quality plan.

Company quality manual 1 A primary document of company announcing company’s quality basic policies in

full. 2 It provides various details regarding corporate management, company’s organization,

directors’ responsibilities, management of its various departments, documentations system, procedures for policy decisions, policy decisions, incorporations & accounting, definitions regarding company’s goals, instructions, job descriptions of its middle & lower level officers, detailed operational descriptions, procurement & material handlings procedures, human resources management, accounting management, transportation, but not limited to these.

3 Company’s planned approach in business & defined approach or methodology to satisfy a prospective customer.

4 Manual is a permanent document amendable after by revision from time to time, after its original issue or publication depending on achieved advancement & progress of organization.

5 Virtually, it is like a written constitution of company telling or describing everything about its company management performance rolls.

6 All operations & project sections are included as completely descriptive giving elaborate information to all concerned persons.

7 Based on contents within this document, further documents for presentation & approval are prepared for future upcoming projects or tenders submission.

8 Relevant major policies included within this document shall guide constituent contents formation within various project quality plans to be operated on newer prospective projects.




9 This document main chapters include describing or summarizing company policy, company’s potential, company’s long term objectives in national as well as, in international market, company’s organization approach & basis, company’s various sections or divisions, corporate structure, constitution of its governing board & applicable regulation or bye laws, staffing level, job descriptions of corporate & senior staff, company’s strength comprehensively giving machinery as well as, manpower, company’s knowhow potential all, but not limited to these.

Contractor’s project quality manual1 For purpose of including within its technical package submission for tender/bid as

well as, for contract authentic documentation submission for approval purpose, a proposed document containing specific project details in conformance with company quality manual, giving elaborate explanations respecting various ways, methods & philosophies for executing relevant project from its award to its handover & final completion stage is entitled as contractor’s project quality manual.

2 It shall include all aspects relevant to quality applications meant for a specific project. 3 It shall cover all requirements relevant to a particular project. 4 It may be referred as an agreement of practically working on project site among all

constituent parties involved on a particular project contract.Project Quality Plan

1 This document is specifically constituted for conducting management control functions respecting relevant project & provides all information applicable to prospective job, which cannot be generalized otherwise.

2 Included contents respecting various issues within it depend on & respond to many specific requirements of project & may differ from one project to another one as well as, from one discipline to another one.

3 Contents within this document should be indexed like chapters headings indicated below for only guidance purpose, while real requirements index can be designed for certain specific project.

4 Description & magnitude of proposed project & company’s general policy towards this project- Brief details of prospective project & contract- Project design requirements- Project execution programme- Corporate office involvement- Joint venture involvement- Subcontractors involvement- Specialist vendor/s involvement- Corporate management & Co ordination- Corporate Safety, health & environment- Corporate Engineering & all others, if relevant to project.

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

6 Aforesaid chapters or parts to be included within this document should be designed in conformance to specific requirements meeting all contract criteria, company manual, international practices & standards, conventional practical standards & defined ultimate objective for customer satisfaction.

7 This document should be prepared by divisional quality manager/engineer in conjunction with corporate as well as, project manager/construction manager/project engineer, after studying all details & specifications relevant to its contract, General Conditions of contract.

8 Proposed draft should be approved by corporate management & then by Client.9 It should be distributed as controlled copy that cannot be altered. 10 Original master document should be recorded with designated tracing reference as

such, with document controller.




11 In case, some alteration is required, another approval should be obtained. 12 All relevant supervisory staff must know & understand to a maximum extent possible

about its contents, implications & interpretations regarding various provisions made within such documents to their respective discipline & explicitly explained to all how these implementation shall be effected on project execution.

13 This document should detail necessary proposed documentations to be made on site in relevance to specific project.

14 These records should provide guidelines to be generally, used to produce documents namely NCR or non conformance report, ITP or inspection & test plans, check lists etc.

15 Proposed schedule of method statements about construction & all other disciplines should also, be indicatively included.

16 Term ‘quality procedures’ is applied to all such documentations.17 All foregoing quality requirement philosophies do refer to a system of quality

management that does not guarantee in itself, result in quality product. 18 Quality product depends on value of adhering to degree of compliance of quality

testing procedure applicable to respective product. 19 Quality control is a subsystem under purview of quality requirement, while it is

expected to meet demanded or specified requirements should quality requirement procedures are fully complied with at every stage of quality system.

20 Quality system applies to all disciplines as well as, sub discipline on a wider prospective of Engineering Project Construction & Installation areas applicable on their FEED, designs philosophies, designs concept, designs detailing, biddings, constructions, completion & operations as well as, maintenance.

21 For achieving targets on all disciplines of projects, various procedures to govern quality system work efficiently under agreed principles, are formulated for general as well specific applications on respective discipline or a part of it.

22 All such sub disciplines required knowhow of working proposed systems, their relevant technologies, their engineering, their prosecutions & resulting consequences.

23 Projects main control points or major disciplines names as Time, Cost & Quality are significant & to an extent, these can be controlled to that extent, quality requirements are achieved.

24 Time is 1st factor on top priority & its length is decided keeping in view all foreseen risks & other factors that can pull time to an uncontrolled line.

25 Cost is affected adversely in case, time is not honoured. 26 Time based lost cost cannot be recovered. 27 Quality requires time for its application & as a consequence, it may not be achieved

when, sufficient time is not allowed for its accomplishment. 28 Fixing Time & Cost remaining unchanged & delaying required activities, quality

criteria shall certainly be adversely affected leading to achievement of substandard product.

29 Basic principles on projects understandingly, demand or expect that products should comply with a minimum of required or demanded quality standards, while value engineering expects product to have quality higher than expected.

30 Quality evaluation more than defined one is termed value engineered over demanded quality.

31 Every product is expected to be added with such value engineering amount, which may or may not be measurable in quality terms.
