FABRICATION & SITE ERECTION

PROCEDURE
 CONTECT

Page

1. General 1
2. Material Indentification 1
3. Marking and Transfer of Stamp 1
4. Cutting Layout 2
5. Cutting and Edge Prepartion 2
6. Bending and Forming 2
7. Welding 4
8. Inspection and Test 6
9. Painting 6
10. Marking, Packing and Shipping 6
1. GENERAL

1.1 Scope
This Specification covers the general requipments for fabrication and site erection of the pressure
vessel, piping, tank, steel structure for __________________________ Project.

1.2 Reference
Vessel shall be complying with the requipments of the following codes, standards, and purchaser’s
spesification,

ASME SEC VIII, DIV. 1 : 1998 Edirion, With CODE CASE 2290
ASME SEC. II, IX : 1998 Edition.
ANSI Standard : 1993 Annual
API 560 and API 520
SSPC (steel Structure Painting Council) : Fourth Edition March 1985
Purchaser’s Specification.

2. Material Indentification

Material shall be checked that they are coincided with the designation. The identification of each
material shall be visually inspected with the mill test reports.

3. Marking and Transfer of Stamp

3.1 In case the original identification marking are unavaidably cut out or the material is divided into two
or more pieces tha marking shall be accurately transferred for the pressure parts of equipment prior
to the cutting.
3.2 The method for marking shall not insult in contamination ot the material, significant strain hardening
or sharp discontinity.
3.3 Stamping is permitted on ferrous materials 6 mm and over in thickness and on non-ferrous
materials 13 mm and over in thickness. The depth of the stamping should be approximately 0,5 mm
or less. A vibrating marking tool may be used for the ferrous material 6 mm and less in thickness
and for the nonferrous materials 13 mm and less in thickness. The tool shall be carbide tipped and
the depth of theidentification should be approximately 0.3 mm or less. The low stress stamp to be
used.
3.4 Marking for layout shall be performed on a basis of the fabrication drawing and cutting plan and
done exactly taking into consideration allowance for welding shrinkage and cutting loss with white
paint or steel needle,.
 3.5 For stainless steel for not use marking ink, crayons, or paints that contains chloride carbon or
harmful metal or metal salts such as zinc, lead or copper which may cause carriosive when the
parts is heated. Wax crayon or vegetable dye marks are acceptable.

4. Cutting Layout

4.1 Shell plates be layout in accordance with the fabrication drawing approved by purchaser.
4.2 Longitudinal and circumference welded seam shall not interferd eith nozzel openings,
reinforcement plates and saddle pads as far as possible.
4.3 Longitudinal welded seam on adjacent shall segment shall be separates by at least 5 times the wall
thickness of the thicker plate but at least 100 mm.
4.4 The other cases shall meet the requirements of para. 7.4.2 described in this fabrication procedure.

5. Cutting and Edge Preparation

5.1 All material shall be cut to shape and sized or prepared for welding by machining, grinding or termal
cutting.
5.2 Cutting of material shall be done on carbon steel by automatic gas cutting or maechanical cutting
such as machining and / or grinding and on the clad plate or stainless steel by plasma arc cutting.
5.3 Bevels of the flanges, nozzels flanges, butt weld connection, etc. Are finished with machining.
5.4 The shape and dimension of edges shall be checked for conformance with the relevant fabrication
drawing approved by purchaser.
5.5 After thermal cutting, all slag and detrimental discoloration of material has been molten shall be
removed by grinding prior to further fabrication.

6. Bending and Forming

6.1 Shell Rolling

6.1.1 Prior to rolling in order to avoid a flat zone in the weld area, the joining edges of
longitudinal joints of cylindrical shells first be shaped to proper curvature by preliminary
rolling from plate edges.
6.1.2 Shell section isi rolled to cylindrically with a bending roll machine.
6.2 Head Forming

6.2.1 Cold Forming means the forming operation that is performed at room temperature.
6.2.2 Hot forming means the forming operations that is performed to make to permanent
deformation after the plates has been heated to the grain refinement temperature
(carbon steel : 870 – 950° C).
6.2.3 A forming head shall generally be made from a single plate. Otherwise, all welds on parts
which are formed after welding shall be groud down flush prior to forming.
 In case of welding plate, RT is necessary before forming and MT after forming according
to ASME.
6.2.4 When temporary attachments are required during the forming work, they shall be welded
to the plate using the same welding procedure as for the main seams. After removing
these attachments, the surface shall be ground flush and examined by either magnetic
particle or liquid penetrant method.
6.2.5 Forming operation taken palce in 3 steps as follows ;

First Press

1. The first pressing is to provide and approximate crown radius to the plate
2. All first pressing operations are performed in a cold state.

Spinning

1. Cold Spinning
a. Carbon stell and low alloy steel including stainless steel may be performed
by cold spinning.
b. The knuckle radius should be performed as much as possible within a short
time.
c. Spinning work shall be applied to form kuckle radius by spinning machine.
d. Remarkable ripples on knuckle parts caused by rapid spinning shall not be
apermitted.
2. Hot Spinning.

a. Hot spinning work for carbon steel, the kuckle parts radius should be formed
in the normalizing temperature range (870 - 950° C) within as much as
possible a short time as 1 to 3 hours.
b. Hot spinning works shall be complated at the above lower critical
temperature and cooling shall be in still air.

Second Press (sizing)

After pressure forming and spinning work is finished should be checked by template. If
any deviations are found, resizing shall be done. However, sizing should be less than
specified tolerance. Thickness should be measured and confirm that it meet the required
thickness.

6.2.6 Shell and Head.

The inside radius of the chile and head shall be raound so that a template concentric.
Rigidly mounted disks having and outside diamter and space 300 mm a part, may be
passed completely through the shell without bending.

6.2.7 When the formed head ferrous materials are required heat treatment in accordance with
ASME sec. VII, Div. 1, UCS – 79, it shall be heat treated according to the requipments
specified in the para. UCS – 56 and Purchaser’s spec.
 6.3 Cone Rolling

6.3.1 Prior to rolling in order to avoid a flat zone in the weld area. The joining edges of
longitudinal joints cone shall first be shaped to the proper curvature by preliminary rolling
from plate edges.
6.3.2 Cone section is rolled to conically with and ending roll machine.
6.3.3
6.4 The tools to be used to roll titanium shall be used preclude any risk of contamination or inclusion of
ferritic steel.

7. Welding

7.1 Welding Process

Welding Process that are used followings :

 Shield metal arc welding (SMAW)

 Gas tungsten arc welding (GTAW)
 Submerged arc welding (SAW)

7.2 Preparation of welding

7.2.1 The surfaces of the parts to be welded shall be clean free from scale, rust, oil, grease,
harmful detect and deleterious foreign material for a distance of at least 13 mm for the
welding joint preparation for ferrous materials and at least 51 mm for nonferrous materials.
7.2.2 The welding shall be done by qualified welders.
7.2.3 The forming of the integral cald palte be performed carefully to prevent separation.
7.2.4 The clad surface shall be kept free from any scratches or demage during fabrication.
7.2.5 For the bevel of alloy clad plate, 8-16mm width of clad alloy shall be completely removed
along the bevel and rewelded by alloy material after finishing of base metal.
7.2.6 Weld overlay and welds joining clad plate shall be deposits in minimun or two passes. The
initial deposited with more gighly allowed welding consumable to take into account dilution
with the base material. The final pass shall have the same chemical composition as the
clad late.
7.2.7 Cut black shall be minium 4 mm from prepared edge for welding. The base metal welding
shall be groud prior to any subsequent bacnk cladding.
7.2.8 The usually, tack weld are applied to prepared edge for welding using the same welding
materials as main welding, and they shall be removed bt arc gouging or grinding so that
they are not marged into the actual weld. Weld bevel angle, gap and offset shall be
checked prior to welding.

7.3 Preheating

7.3.1 Preheating shall be performed in accordance with the WPS preheat temperature, and
shall be kept uniformaly from the start to the end of welding.
7.3.2 Dissimilar welds between austenitic stainless and ferritic steels shall be welded by preheat
determined by the ferritic material.
7.3.3 The preheat shall apply to tack welding and temporary attachment welding.
 7.4 Connections

7.4.1 All the connections for nozzles manhole and handhold neck, which do not extend into the
vessel for internal connections shall be finished flush with the inside of the shell.
7.4.2 Openings for connections shall not through main vessel seams.
7.4.3 Pressure holding seams shall normally be full penetration double welded butt joint, single
welded butt joint which ensure full penetration may used where double welded butt joints
are impractical.
7.4.4 Seams in supporting skirts shall be made with full penetration butt welds. Connections
between skirts and vessel heads be made with a smooth flat faced weld, unless otherwise
specified. The width of the weld shall be at least equal to the skirt tickness and it’s height
shall be twice it’s width. This weld shall be magnetic particle examined.
7.4.5 Nozzel and manway in alloy welded and faced. The facing 5” and over shall be made weld
deposite or lining which is at least as thick as the cladding when properly machine of the
same as the cladding.

7.5 Welding and Removal of Temporary Attachments

7.5.1 Temporary attachments such as jig,bars,clamps, etc. Are used to hold the roundness of
edges to be welded. These welding shall be done by qualified welders using the same
quality rods as main welding and gualified welding procedure.
7.5.2 Temporary lugs shall be of the same material, when welded directly to the cladding
material, or shall be elded via pad plates of the same material as the cladding material
shall always be conducted by the same welding procedure as used for the cladding
material.
7.5.3 Arcf strikes on the pressure shell shall be avoided. When they occur, the surface shall be
ground smooth and examined by M.T or P.T only in case of stainless steel, and the
minimum design thickness shall not be violated.
7.5.4 Temporary weld shall be removed by thermal cutting and grinding. Surface ground shall
be subjected to magnetic particle examination for carbon steel and liquid penetrant
examination for stainlees steel.

7.6 Repairs Of Defects

7.6.1 Unacceptable defect such as cracks, porosity’s incomplete fusion and other gerects shall
be removed by gouging ang grinding.
7.6.2 After removing the defect, the part shall be examined by liquid penetrant examination. The
area to be repaired shall re-welded by qualified welder and using qualified method.

8. Inspection and Test

Inspection test shall be carried out in accordance it the specified drawings, the inspection and test
procedure approved by purchaser’s.

9. Painting
Painting shall be carried out in accordance with painting procedure and approved by purchaser
10. Marking, Packing and Shipping
Marking, Packing and Shipping Shall be performed with purchaser’s spesification.

QUALITY CONTROL PROCEDURE

Table of Contens

1. Managemet
2. Qulity Assurance and Control
3. Project Control
4. Engineering
5. Procedure and Material Control
6. Subcomtracting
7. Constructin
8. Mobilization & Demobilization
9. Commissioning
10. Field Safety and Health Programmed
1. QUALITY CONTROL PROCEDURE
In this section, we describe the way in which owner requirments for execution of the project will be
implemented. The management concept adopted by the bidder will bring together the resources of the
bidder and its subcontractors.

The main activities of project implementation are covered in this section. These are ;
 Management
 Quality Assurance and Control
 Project Controls
 Engineering
 Procurement and Material Control
 Subcontracting
 Construction
 Commisioning
 Field Safety and Health Programmed

Supporting procedures and standard documentation to illistrate the day to day running of the project will
be provided.

1.1 MANAGEMENT
 For successful project execution, the following should be established at the outset ;
 Work plan (defined objective)
 Execution plan
 Coordination Procedure
 Work Schedule
 Organization and Resource

The responsibility for successful execution of the project is delegated to the project manager
who will lead thye project management team. His basic responsibility is as follows :

 Complete the project within schedule and budget costs

 Ensure that the facilities are well organized and can be constructed, operated and
maintained in a safe, efficient and economical manner.
 Ensure that the facilites incorporate the requirments of client and the regulatory outhorities

1. Work Plan
Substantial initial definition of work scope will exist from both the proposal effort and the
client inquiry document. It will be necessary to ratify the basis on which project activity is to
commence and early duties of the project manager will be to :
 Define project scope and objectives.
 Establish work plans, scheduled, budgets, manning levels and project procedures.
 It is envisaged that a meeting will be held with client shortly following job award to confirm
the scope and objectives. Once these have been confirmed, the project manager will
arrange an internal “kick – off” meeting that will include department managers, senior
management and senior mambers of the task force. At this meeting, the project manager
will ensure that the contractor is aware of the project objectives, schedule, priorities and
other criteria requried to make the project success. In this and all similar meeting, it will be
stressed that the four vital factors required to achieve a full satisfactory jo are :

 Good Planning.
 Good Cooperation
 Superior Effort
 Timely Decisions

Where necessary, initial site visits will be arranged, ad a program for subsequent visits
determined.

2. Definitive Project Executive Plan

The main objectives in executing the work will be to :
 Set up, and maintain throughout the project, the appropriate communications and
transfer of information between client and the contractor.
 Organized and staff the project teams. Place major emphasis on the selection of a
balanced team with expert knowledge of the project’s requirements.
 Administer the contract to fulfill its terms and conditions.
 Ensure that the requirements of the client and contractor : governmental requlatory
agencies, certifying outhorities, insurance underwriters and other are complited with.
 Control the scope, cost, schedule and quality of the project work.
 Detailed aspects of the overall execution with the project manager and his staff and,
once approved, become the basis for the ongoing activity.

3. Coordination Procedures
The Project manager and his team will perform the ket function of ensuring effective
communications on the project to achieve unity of purpose and performance.
Coordination at roject management level will be carried out by project coordination
documents and regularly schedule coordination meeting.

Project Coordination procedures will identify and describe ;

 The Project’s principal managers, both client and contarctor, with their primary duties
ans responsibilities.
 The administrative, correspondence and general projecr procedures.
 The reporting systems and frequency, with identification of the task force members
responsible for supplying, gathering and compiling the information required for the
client and contractor reports.
 The procedure for obtaining client approvals as the work progresses, including the
identification of all document requiring client approval, the inssuance of same and the
time permitted by the schedule for such approvals.
 Any important factors, considerations or requirments of the contacts which are
relevant ti tight control of the project works.
 Successful completion of the contract will depend not only on the formal contacts and
procedures agreed between client and contractor, but importantly on the free exchage of
ideas and objectives between client and project team member

Day-to-day contact between project team members and their client counterparts will be
encouraged, freely and throught joint meetings, so that all parties can always participate in
the solutin of matters, provide there is no intent to alter or abdicate the resposibility of the
contractor to client for execution of contract works.

Internally, the project manager will hold ‘action now’ meeting on a weekly basis with his
management team. These will review the immediate time frame (past week/current week)
to produce a coordinated response to any term difficulties. A formalized progress meeting
will be held monthly with client in attendance.

4. Project Planning
Detailed schedule for the project will be completed as early date based on the master
project schedule. Upon receipt of the contract a project planning task force will be
established which will include the project manager and the project coordinators of
planning, quality assurance, construction. Members of the client team assigned to the
project may be asked as required to participate inthis effort.

This team will meet weekly or more often if necessary. Initially theywill :
 Confirm the master project schedule
 Set – up the quality assurance plan for the project
 Identify long – lead equipment and materials

5. Organization and Resource

The project management teams will be built-up from contract award as dictated by the
scope and schedule. In addition to the team members, the task force will be supported, as
required, by contarcto’s other departements including.
 Office service
 Personnel
 Information service
 Financial controls
 Communication printing service
 Legal and insurance

The project management team will implement the work on a matrix basis where by the
members recieve on-project supervision throught the immediate supervisors but also
obtain functtional guidance from the primary departments such as construction and
technical service.

Based on the confirmation of scope and objectives at the initial client meeting and the
tender provisions, the project manager will mobilize the key members of the task force
together with their initial support staff. These personnel will be fully briefed as regards
project work scope, execution plan and procedures. As the work expands, the task force
will be augmented by further personnel who will receive a similar unduction. All project
management team members will paticipate in the development of the definite project
 execution plan ehich will become the principle guideline reference for the execution of the
balance of the project.

6. Protection of Proprietary Information

Each employee of contractor is obligated by the terms of his or her employement to keep
secret, information made available to them in the execution of their woek which is
proprietary, A security identification badge system is operated in the contractor’s project
office. All employees are issude with badges which must be shown to gain admittance to
the office. Visitors are issude with temporary passes, with which they can enter the office
when sponsored and accompanied by a employee. Visitors attending at the invitation of in-
house clients are subject to the same regulation and clients are requsted to similalry
sponsor and accompany them.
Access to the task force areas is normally restriced to personnel associated eith the
project, which enhances the security and distributions of job document
Project files are kept within the task force area
Subcontractor’s completed project secrecy agreements are file in the relevant contract file.
All project document will normally be kept in file cabinets and document designated as
confidential will be strored in locked file with a limited access system. Distribution of alla
documents will be on a strictly ‘need to know’ basis.

1.2 QUALITY ASSURANCE AND CONTROL

Project quality assurance engineers, reporting directly to their respective task force manager will be
responsible for all quality activities associated with their part of the project. These activities which
will be many and various will have two prime objectives summarized as ;
 The establishment of a Quality System for their part of the project in compliance with the
contract and contractor’s quality assurance manual attached hereto witch was authorized by
ISO 9001.
 The verification of compliance (or otherwise) with the Quality System by all personnel assigned
to the project.

The project quality assurance engineers will specify the parameters necessary to secure the prime
quality objectives of the project. These are ;

 To specify the components of the quality sistem by production of the project quality plan
 To establish a schedule of quality system audits for the project
 To make sure that the documentary evidence of the quality system (the quality program) is
established and complete.
 To monitor compliance by project personnel (both home office and construction site) with the
project quality system by preparing, conducting and closing out oudits of specified activies in
accordance with the Audit Schedule.
 To shee that project personnel for their part of the project are fully aware of the quality system
and understand all quality requirements applicable to them.
 To respond to reviews of the project quality system by the company’s quality assurance
departement via the project manager.
 To advise company’s quality assurance managers and their respective project managers of
project progress/status by issuance of regular departemental reports.
  To locense directly with the construction site quality control groups, this will be under the
jurisdiction of the field engineering manager and report all partinent matters regarding quality to
the construction manager on a regular basis
 To license with client management representatives on quality related matters on a regular
basis.

More detailed information on quality assurance and control will be provide in the contract document
before contracting stage to be adopted are given in Quality Control Program.

1.3 PROJECT CONTROL

For effective control of the project, the contractor intends so use established project control
techniques and procedure developed for use on major projects. These techniques and procedure
include cost estimating, cost control and planning and schedulling control, and construction phases
of the project. They are administered by project personnels having specific experience and skills in
computerized controls.
In order provide efficient control of the planning for the project, the project planning coordinator will
be responsible for stablishing the planning basis for the project.

Immediately after the project is awarded his prime reponsibilities will be ;

 Project master schedule identifying major milestones and interfaces.
 Control and reporting detailed procedures based on integrated computerized systems,
common to all execution centers.

In carrying out this task, the planning coordinator will work closely with the planner in the individual
task force teams. During the project execution, the planning coordinator’s main responsibility will be

 To monitor actual project execution versus project objective

 To measure actual progress versus schedule progress.

In more detail the principal methods used to plan and control the progress of the job are as follows:

 Identify the scope of the project

 Procedure a master schedule for the project. This level 1 schedule is a single sheet bar chart
which would be manual prodiced. Normally this would be limited at about 100 activities and
would include all the key activities of engineering, procrument, fabrication, construction, pre-
commisioning and commisioning.
 Produce a 30 day kick-off schedule to direct and control the initial activities on the project to
minimize front end delay and focus the attention of the project teams. This schedule would be
updated weekly and used for project control until the detailed planning controls are
implemented.
 Prepare level II area schedule. These schedule would initially be procedure using the
ARTEMIS system by consolidating the level 3 network activities.
 Establish progress curves for engineering and costruction proegress to monitor actual progress
against the required progress to meet project objectives.
 Develop detail level 3 sub-networks where required to meet the objective shown as critical on
the master schedule. These detailed sub-networks would be procedure fo all activities reqired
controlling the satisfactory progress of the project and would be analyzed by the system.
 Prepared detailed level 3 schedule foe each are which would be used to track and control
erection contractor performance and progress. The detailed schedule would be prepared and
 updated by each erection contractor, based on the the milestone set for each contract, and
reviewed and verified by the contractor.
 Prepared weekly progress reports for the weekly meetings. The reports would show
achievements, activities to be achieved during the following week and critical activities. The
report would be used as and agenda for the weekly meeting
 Issue a monthly progress report which would incorporate progress made by all groups during
the period. Particular attention would be paid to any critical activities and problem areas
together with recommended action would be included.

The project planning group would be a dedicated project team reporting to the planning coordinator.
It is envisaged that the ARTEMIS system would be used extensively for planning and scheduling
activities on the project.

The contractor has considerable experience using the system on major project throughout the world
and has developed control which are specifically designed foe controlling project ot this size and
complexity.

More detailed information on project planning will be proposed document at he bidding stage.

1.4 ENGINEERING
1. Introduction
This engineering part of the implementation plan describes the organization of the engineering
teams and the main functions and approach to the work in each of the engineering disciplines.

The project engineering will be executed in two phase.

 Basic design phase to produce the engineering package based on the project
spesification to be furnished by the client.
 Implementation phase to procedure the detailed plant design necessary to carry out
procrument, plant erection and tasting.

The engineering teams will produce the drawings, data sheets, spesifications, etc. Covering all
technical aspects of the job, including the execution of studies, analyses and detailed design
which are necessary to allow the contractor to place purchase orders for the supplay of
equipment ans materials, amd to award such subcontracts as are planned for fabrication,
installation, construction and pre-commissioning of facilities.

The ebgineers will supplay client with the necessary manuals and documentation required to
operate and maintain the facilities. The starting points for the engineering effort of the
contractor will be inquiry documents Basic Design Package procedure by Client.

The Engineering Teams Will also provide the following :

 Project design manual input including drawing and data to define engineering basis,
and preliminary material quantities.
 Construction contracts input, including the contract scope of work and services and
technical definition.
 Requisitions, including quantities, specifications and inspection requirments, for the
purchase of all equipment and materials.
 During the basic design and the detailed engineering phase, the engineering teams with the
agreement of the contractor will arrange that all engineering drawings and data winch need
approval are submitted for review by client prior to issud for procrument and construction.

2. BASIS DESIGN PHASE

Basic design work for the project will begin with process package suplied with client’s inquiry
document including design spesifications, and from this basis project (job) spesifications for the
following will be produced.

The engineering design drawings and documents will be reviewed by client and upon approval
by client will take “ approved for design” status before inclusion in the project spesifications.

All equipment and material spesifications will be produced during basic design. The
spesifications will be reviewed by client and upon approval by client will take “approved for
construction” status.

3. DETAILED ENGINEERING

The following sections describe in detail the organization and execution plan in the engineering
disciplines. They are presented in the following order ;

 Projects
 Process
 Systems
 Loss prevention and safety
 Plants layout and piping
 Mechanical
 Materials and Quality Services
 Electrical
 Instrumentation Civil
 Building

Project Engineering

The engineering teams will include very experienced, senior project engineers primarily
comprising mechanical and chemical engineers. Project engineers are responsible for the
management of all the engineering aspects of the project, and provide direct support to their
project engineering manager. Each project engineer is assigned a section, or area, of the
project under the general supervision of the project engineering manager or his deputy.

Mobilization

Upon commencement of the project, each engineering team will organized a kick-off meeting
with all the project engineers and lead discipline engineerd to familiarize the personnel with the
scope, aims and schedule of the project.
Work Sequence

For their repective involvement, each area project engineer and each of the task force
managers and theirs deputies will oversee the execution of the detailed design phase including
prepartion of material reqisitions.

One of the first tasks during the detailede design phase will be development of project
procedures to vover all aspects of the design, construction support and commissioning phase
of the project. These procedure will based on standard procedures, modified as necessary to
suit the project requirments. Some of these procedure will have been developed during the
basic design phase.

During the detailed desing phase, the area project engineering will monitor and steer the
progress of theirs areas-and arrange for corrective action should deviations to shedule.occur in
addition they will monitor and co-ordinate each design dicipline to ensure that one is not being
delayed by another and will resolve local priorities.

As the project moves into the constructions support phase, a small team of
project/process/system engineers will remain in the home office , together with various
discipline engineers, to support the fabrication and construction work going on.

Work Methods

The area project engineers will monitor the progress in their areas against the project schedule
to detect early deviations to schedule and to arrange for corrective action, e.g additional staff,
computing facilities or other measure. A bi-weekly engineering progress meeting will be held to
outline the progress achieved, problems ecountered, and solution intended.

The area project engineer are responsible for the quality and completeness of work of their
area and will review and sigm all major drawings, data sheets, spesifications and requistions
after confirming that the requisite inter- dicipline and in-discipline checks have been completed.

Process Engineering

While performing the basic desing, process engineers will have become fimiliar with the project
background and the objectives of the basic sesign work, resulting in an efficient start to the
detailed design. During the basic desing complete process package of flow diagrams,
spesifications and data sheets and process optimization and flow sheet development will be
completed to the extent possible without spesific vendor data. Process work in the detailed
engineering phase will thus be minimal and will require the following activities ;

 Updating the process package

 Project support

Updating the Process Package

When the detailed vendor becomes available, there will be small updates to the process
design to accommodate the mechanical design and layout requirements, to suit the
characteristics of the purchased equipment. All such process change will be reviewed and
approved by the responsible process engineer. The process flow diagrams, spesification and
data sheets will be detailed design phase of the project, ensuring that all members of the
project team are informed to these developments.

Project Support

Process engineer provide and operational input participate in detailed design activities. In
particular.

 Bid evaluations for process package and major process equipment items.
 Review of key vendor prints
 P & ID review meetings.
 When necessary
 Model review meetings
 Review of safety aspects, cause and effect charts and control instrument diagrams.

Providing supplementary stream property information such as critical pressures for control
valve sizing or surface tension for two-phase flow calculations.

Systems Engineering

Systems Engineers, comprising mechanical and chemical engineers, spesialize inthe

development of P & Ids and the spesification of related process equipment, data sheets,
drawing, models and other disciplines’ activities.

Work Sequence

Systems Engineers will receive the P & Ids developed during the basic design and will develop
them to provide the final design. Multi-discipline review meetings will also be held to allow all
relevant groups, insluding construction and startup, to comment on the P & Ids, without adding
unnecessary embellishments. The P & IDs will show the interface at vendor supplied items.
Vendors will procedure their own P & IDs within their supplay boundaries.

The system engineers will develop the equipment lists, line designation table, in-line system
components and safety data related to the P & IDs.

The system engineers will also review and co-ordinate the materials selection, equipment
spare, piping material spesificstions, platform and plant layouts, electrical load data, and will
contribute to the theirs parts of the design manual.

After preparing the P & IDs, the system Engineers will assist in the preparation of an
emergency shutdown philosophy, the hazard area drawings and the chemical hazard report.

Loss Prevention and Safety Engineering

Loss prevention engineers assigned, are responsible for making sure that applocable safety
and loss prevention codes as well as clients special requirements as expressed in the safety
philosophy are supplied in a systematic and effective manner by safety audits during the
engineering design phase.

Loss prevention engineers take responsibility for the specification and overall design of fixed
fire and gas systems. Life safety system and fire fighting equipments.
The loss prevention Engineers also assist with the provision if decomentation to support safety
case and certification submissions as required by the applicable legislation.

Work Plan

The starting points of this work are the completion of the overall safety philosophy which has
been developed as part of the Basic Design.

From the overall philosophy, contractor propose to develop saparated detailed safety
documents for each section of the project facilities.

They will include hazards and prevention data including plants layouts and arrangements,
hazard source and evaluation, are classificatons, detedtion and alarm.

Systems for specific events e.g. fire, gas release, emergency shutdown, ESD systems, toxic
gas release, fire protection systems both active and passive, fire fighting equipment, means of
escape, life saving appliance, drainage systems, ventilation, communication, systems,
navigational aids, regulations for effluent discharge, emergency power supplay, sick bay and
first aid requirements.

Plant Layout and Piping

Detailed plants layout and piping design will follow the work done during the basic design

From the basic model for process units, layout and plot plans, reviewed by client during basic
design, a 3 dimensional CAD model will be developed which will incorporate the detailed
design information developed by all the design disciplines. After clash deterection this model
would represent equipment, structures,piping and all relevant plant features, and the following
deliverables could be extracted from the computer model ;

 Material
 Piping general arrangements and section drawings
 Piping isometrics

Piping isometric drawings will be procedure by computer. No isometric will be produced for
pipe-rack straight run lines. Lines entering a pipe-rack will be isometric drafter up to the natural
weld before straight track run. Branch lines to headers in track will be isometric drafter up to
the header branch weld or the branch weld of a header tee if used.

Material lists take-off for is drafted lines will be produced by using computer. A first bulk take-
off will be made for any small thickness will be produced and issude as a piping specification.

Piping stress calculations will be made using initial piping studies and overall piping
schematics stress isometrics for critical systems.

Pipe support will be to standard designs wheneverr practicable ; special pipe supports will be
kept to a minimun. Pipe supports will be supplied and fabricated onsite. Spring supports, will
be specified by home office designers. Final tie-in location will be fixed at site.

Piping spesifications and material clasification spesifications will be produced.

Assistance by the piping engineers will be given as required for small bore piping route
selection, material take-off, and material requisitions, includes ;

 Pipe
 Valves
 Fittings and Flanges
 Insulation Flanges
 Bends
 Internal coatings and Linings (if required)

Mechanical Engineering

Their work will include ;

 Prepartion of Specifications.
 Sizing and Selection of equipment.
 Analysis of vendor proposals.
 Design Audits
 Performance test assistance, if required
 Construction assistance, if required
 Start up assistance
 Maintenance and spares analysis
 Design studies input
 Noise Control.

Execution of the Work

The mechanical engineers will produce spesification, equipment data sheets and material
requisitions fir each item of equipment consudered. The equipment will be sorted into types
and size and grouped into similar types and convenient quantities for optimun purchase.

Rotating equipment engineers will closely with the control instrument engineers to ensure an
optimum match between process needs and machinery constraints.

The mechanical engineers will also work closely with the control instrument engineers to
ensure proper integration of machinery control with the plants control, and where required, will
participate in dynamic simulation modeling to verify stability of operation thermodynamic
performance, and driver dynamics.

To aid streamlining of future maintenance, standards will be agreed with client for common
items equipment such as main motor drivers, couplings and pump seals.

An engineer will be assigned to supervise noise control. Equipment producing noise will be
carefully selected in order to minimize the use of acoustic enclosures. Estimates will be
obtained for the noise spectrum emitted each item. The total noise levels in work areas, control
rooms, offices and other occupied or sensitive locations will be established.
Insulation and Painting

A protective coating specialist will be available for consultation and advice on subjects such as
insulation, fireproofing and painting. He will prepare bills of quantities for the insulation,
fireproofing and painting as guidelines for the relevant subcontracts. He will be responsible to
advise contractor’s project management, and client on special application and requiirements.

Materials and Quality Service

Materials and Quality Service (M & QS) discipline engineers have metallurgical expertise in the
following areas ;

 Materials selection/corrosion engineeering

 Materials spesificatons
 Fabrication/Welding technology – Vendor and field construction
 Corrosion protection – cathode, coatings
 Corrosion monitoring
 Non – destructive testing

M & QS will prepare Meterials selection Guides based upon final process flow diagrams.
Materials selection will be based upon project spesification materials requirements and
published corrosion data and will adopt the philosophy of economy subject to sound
engineering. Review will be made of materials and welding spesifications issued for project use
by other engineers.

At the procurement stage, M & QS will review vendor welding procedure for compliance with
specified requirement.

Electrical Engineering

The electrical engineers will prepare a preliminary electrical load demand study to dtermine
generation /local power requirements.

The overall electrical system one line diagram, together with the individual voltage one line
diagrams, will then be prepared as a design basis. All necessary short circuit and motor
starting calculations will be performed.

Next the overall electrical design specification and major electrical equipment speseifications
will be produced in the order of priority determined by the project master schedule. Using these
electrical equipment spesifications, the electrical engineers will prepare material requisitions for
the major electrical equipment.

Based on the agreed plot plans, the necessary hazardous area clasification drawing and
schedule will be produced for the selection of electrical equipment and as a design aid in
location of electrical equipment items.

Guide installation drawing and cable summary tabulations will be prepared to enable the
installation contractor to performs his work.
Electrical engineers will co-ordinate closely with the civil (undergroud service) engineers to
cover the requirementsfor cable trenching. The civil engineers will be responsible for
coordinatinang cable trenches along with other underground service and faoundatios.

Electrical engineers will co-ordinate closely with the civil (underground service) engineers to
cover the requirements for cable trenching. The civil engineers will be responsible for
coordinating cable trenches along with other underground services and foundations.

Discussion will be held with piping engineers to idetntify cable tray/rack space reservations for
the routing of above ground electrical and instrument cabling.

The motor/power user summary and electrical load summary will be reviewed at regular
intervals and uptaded as necessary.

As soon as major equipment sizes are available, substation building sizes will be established
and located on the plot plans.

All vendor drawings are fully reviewed for compliance with equipment specification and general
requirements laid down in the materials requisitions.

A comprehensive electrical power system study will be carried out and a detailed protective
relay study, including time/current discrimination curve will be produced.

Heating, Ventilation and Air Conditioning

All the areas to be air conditioned or ventilated will be identified and designed to ensure
adequate environmental conditions for the protection/safety of equipment and the comfort of
personnel. The design will include ;

 Lay out drawings

 HVAC design philosophy specification and environmental schedule
 Spesifications for HVCA systems operartions
 Flow schematics and controls for the systems
 Schematic duct pre-sizing and route diagrams
 Scope of work for HVAC contact

Equipment the HVAC system design and construction will conform to all current codes,
requlations, and client standards.

Instrumentation and Control

The control systems work will be performed by a dedicated group of instrument engineers and
designers supervised by a lead instrument and controls engineer. This lead engineer will be
fully responsible for the total instrument and controls contect on his assigned part of the
project.

The instrumentation engineering and design will be execudet utilizing computerized instrument
schedules, hook-up selection, and materials listing to procedure consistent drawings and
documentation.

The control systems engineers in liaison with the process and project systems engineers will
finalize the P & IDs with the required controls and instrumentation for safe and efficient
operation. Instrument assemblies will be computerized in order to ensure consistency with
P & IDs.

In Line with Client Spesifications deteiled spesifications will be prepared for ;

 Field instrumentation
 Control/relief valves
 Supervisory control and data Acquisition systems (SCADA)
 Distributed control systems (DCS)
 F & S and shutdown/interlock systems
 General package unit spesification
 Installation/calibartion spesicifications for the field commissioning work

Control systems engineers will specify and design instrumentation systems and procedure
instrument data sheets, liquid co-ordination drawings and prepare calculations to determine
instrument air and electrical power consumption, control valve sizes, relief valve sizes, office
plate and in-line flow-meter sizes, for items not include in vender or subcontract packages.

The distributed control system (DCS) and SCADA communication specialist will prepare
specifications and will outline the system configurations for the complete system including the
central computer. Requirements for data trasmission, automatic controll, emergency shutdown
ESD, remote monitoring, Communications, Equipment standby philosophy and automatic
switching will be adressed. This work will be carried out by experienced engineers in this area
of technology.

Use will be made of CAD for design drawings, including ;

The control system work will commence with defining the fuctions of the systems and continue
with the preparation of materials requisitions. The requisitions will be groupe by equipment
types as possible to correspond with P & ID issues and project schedule requrements.

 Maximum control room layouts and cable route diagrams

 Block cable diagrams
 Typical block confuguration diagrams
 Process instrument hook-ups
 Control panel schematic layouts
 Pneumatic instrument location drawing showing instrument air headers
 Interconnection diagrams
 Instrument cable schedule multi-core and telecommunication
 Fire and gas schematic layouts, for system sizing.

Vendor drawings will be reviewed for conformity to specification and relevant design details
added to data sheets.

Control system engineers will perform shop acceptance testing of the DCS, matering, SCADA,
PLC, fire and gas, as well as other sophisticated control equipment.

Civil Engineering

Site Investigations
Depending upon additional data and recommendation required from the basic design, the civil
engineers will prepare a scope of work and subcontract requisition for additional soils
investigations and topographic surveys. This will be made the first priority.

Site Improvements

As the information becomes available from the civil discipline and engineering groups, site
preparation, paving and underground drawings will be prepared. This will coordinate the
locations of ;

 Foundations
 Drainage and Manholes
 Electrical trenches
 Roads and Paving
 Fencing
 Firewater Mains, etc

The civil engineers are responsible for the design of all gravity underground drainage
system ;pressurized lines are handled by the piping engineers. When designing the various
drainage systems, the civil engineers and desingners will give full consideration.

To the provisions that, during plant shutdown periods, each drain can be isolated without
jeopardizing the intergrity of other plants, the will also prepare intial material quantity list of
drainage pipe and fittings.

Foundations

Concrete design work will commence on the foundations for equipment, silos for which setting
plans areeither predetermined or for which information is available from pre-selected vendors.
At the same time structural design will commence on the pipe-rack strucute and the shelter to
determine the loading required for foundation design. Design of foundations for rotationally
equipment will commence when valid data are supplied.

The civil engineering team will prepare civil design packages foe each discrete plot area in the
sequence stipulated for the construction schedule.

Concrete desing work will include ;

 Reinforced concrete foundtaion for tanks, compressors, pumps, pipe-rack, elevated

structures.
 Mass concrete below foundations, and around cable ducting.
 Subcontract scope for each construction area

Structures

The following type of structures will be fabricated from structural steel ;

 Pipe rack in Plant

 Shelters and sub-shades over equipment
 Tee post conveyor supports
 Access platfoms, stairs, leadders and hand-railling
  Duct covers and seating angles for electrical rooms

Desing drawings will show setting out dimensions, member sizes, column base plate details
and special connections. Te fabricator will procedure shop drawings and erection marking
drawings. Civil engineers will audit the shop drawings for quality but will not carry out detailed
checking other than for special details.

Generally concrete fireproofing to structures will be applied to the steel members at ground
level before they are erected.

Buildings

The architecture engineers will be reponsible for all aspects of building design including ;

 Architectural Layouts
 HVAC
 Building Service
 Structure Engineering

1.5 PROCUREMENT AND MATERIAL CONTROL

1. Procurement
The procrument of all equipment and bulk materials which are defined in the scope of works for
this project will be carried out by the Contractor.
Contractor will utilize the contractor’s project office inijakarta to carry out procrument on a
worldwide basis.
The contractor will utilize his own resources to carry out any expediting and inspection that
may necessary to provide that the materials are delivered in accordance with the project
schedule and the relevant spesefications. Area expediting will be effected such that any
complex or critical pieces of equipment are procured in accordance with the schedule.
The contractor will comply with all necessary requirement in arranging that materials are
imported into indonesia with the minimum of delay and will undertake the onward
transportation to the job site utulizationb of contractor owned transportation equipment.
The contractor will establish a procrument center in jakarta to purchase all local materials.

2. Field Material Control

Handling of Materials
Materials will be delivered to site by road. During the Mobilization period local contractors will
be used for pff-loading and storange.
The contractor has allowed in his construction equipment schedule for cranes, forklifts, trailers,
tractors, dampers, trucks for handling of materials is during unloading, stroge and transfer to
site.
In the development of the materials handling plan the contractor has taken into consideration
the possible use of local subcontractor’s equipment such as truck etc.

Storange
 A detail material storange plan will be developed upon award of the contract. This will include
various warehouse and lay-down areas for stronge purposes. The contractor intents to use
vacant plots adjacent to the work face for pirpose of warehousing and lay-down

Areas, where possible. These areas shall be agreed with client during the pre-construction
phase.
Contractor plans to establish a central warehouse office, warehouse and fenced storage area
at site. The warehouse will be equipped with suitable storage racks, lighting and ventilation to
store vulnerable materials and small piping items.
Instruments, auxiliary equipment and some electrical equipment will be stored in a separate, air
condition warehouse to maintain a controlled environment. Unless appearance of demage to shipping
boxes and/or crates is evident, the materials will be stored as received in the original packing.

The storage yard will be fenced in and placed under tight security an control. Sections of the storange
yard will be allocated for the receipt of prefabricated steel structure and for the dumping of scrap
materials. In so far as practical and consistent with appropriate work shedules, large mechanical and
electrical equipment items are transported and equipment.

Material Control

A key factor for maintaining progress of the work is control over material. Contractor recognizes that the
field staff cahrged with this responsibility is the main and final control point. Contractor inspects each
incoming shipment and compares it with the purchase documents.

The purchasing office is immediately made aware for any losses, demage or shortage stored adjacent
to their foundations or final locations or are immediately erected directly from the transporting and
replacement is immediately initiated to avoid delaying the work. Materials are warehouse or stored
under a strict accountability system and are secured againts pilferage. Good materials control at the
field level and careful dissemination to assure its use only where designated, essentially eliminates the
“shortage” problems common to many large construction project.

Contractor’s methods of material control have contributed greatly to our capability to complete projects
as scheduled. Therefore, the contractor’s construction field materials group, under the direction of the
field material supervisor shall be responsible for the receipt, inspection, care, custody and distribution of
the plant materials, equipment and construction supplies, purchased for the project.

Piping material will be controlled through a piping inventory and control system. The inventory system
will be integrated with piping scheduling.

The warehouse office will coordinate the individual operation and maintain the record keeping for
incoming and the distribution of out-going shipments, monitor the storange and maintenance, control the
issuance to erection contractors and assure the overall accountability of materials and equipment.

The field material supervisor and his staff responsible for seeing that all materials and equipment are
properly identified, coded, tangged and certified. Furthermore, they ascertain that preventative
maintenance programmers are followed to ensure that all requirements are met to maintain equipment
warranties and client’s requirements. Additional controls will be made by the quality inspectors
Procedure for Receiving, Storing and Issue Of Materials and Equipment

All material procedured by Contractor arriving, at the job - site shall be received by the materials control
department at the Contractor's warehouse and sent to the appropriate area for unloading.
As material is received and off - leaded at the job - site, the material controller shall have the material identified
and checked that the number of pieces, cases or bundles is in accordance with those described by the vendor's
advice notes. the date of receipt is also centered in the advice note. the advice notes are the passed to the
receiving section where the materials are checked in details againts the packing list and purchase order. A
"Material Receiving Report" (MRR) will then be issued. The information from the material receiving reports shall
be posted on the purchase order files. These files form a complete history of the purchase order and contain ;
 P.O requisition (engineering data and specification) and supplements.
 Telex commitments and/or letters of intent.
 Formal P.O and its supplements.
 Expediting and inspection reports.
 All correspondence relating to the order.
 Material Receiving Report.
 Over, Shortage and Damage Reports.
 Out Shipment Reports.

Stock Records Cards

Stock records cards are to be made out for every other item of material or equipment received and shall show all
the information obtainable from the purchase orders and details or receipt and issue by the MRR's and
warehouse issue slips. Stock record cards shall be raised for each item of material upon receipt of a purchase
order requisition.

Material that does not comply with the requirements of the purchase order in regards to dimension, schedule,
availability of certificate, material specifications, damaged in transit etc, found during inspection shall be stored
separately. Over, shortage and damage report will by prepared. Under no circumstances will the material be
issued for construction unless the deficiencies rectrified and disposition obtained from the engineering manager.

Positive Material Identification

Positive material identification (PMI) checks will be carried out during or immediately following the routine
warehouse incoming material checks of alloy material.

Material Receiving Reports

Detailed material receiving reports (MRR's) shall be issued for each purchase order delivery within twenty-four
hours of the material arriving on the job site. these MRR's shall serve as the basis for posting material receipts
on the purcahse order files.
Over, Shortage and Damage Reports
If there is any damage or discrepancy between the vendor's packing list and/or the purcahase orders and the
material received, an OS & D report shall be issued and distributed with the MRR in order that the project
procurement coordinator in the home office may take the necessary action.
The warehouse shall also notify the carried by telephone and confirm inwriting, notice of any loss or damage
which may have occured in transit.

Daily Material Receipts Register

After the material has been off-loaded and checked, a brief handwritten summary of all incoming shipments for
the previous day shall be issued to the construction superintendent.

Checking and Recording of Material Receipts

It is important that the initial status report showing the bulk take-off figures is sent to site immediately. The status
is also an excellent guide to the construction planning department for estimating work areas at the start of
construction and for monitoring the trend of the work areas through completion.

Scrap Material / Surplus Materials

A final list of surplus materials will be prepared upon completion of the project. This list will be submitted to
client's contruction team to decide which materials clients wants to retain or wants to dispose of.

In case client wants to retain materials, these materials will be properly identified which labels, indicating P.O
number and commodity number and shipped to client warehouse with a completed transfer form (Contrac term
permitting).
Scrap materials will be disposed of in accordance with terms of contract.
Field Procurement
Contractor shall make use of his Jakarta office for general procurement in Saudi Arabia. Minor items may be
purchase locally by the site. These will be minimum and in case of emergencies only.

Parts of procurements will be committed in the job - site for better conveniences during the project execution for
some materials and equipment, if required or profitable. The purchasing activities in the Jakarta office for this
project shall be executed consistent with teh following procurement goals same as in case of head office's
procurement utilizing contractors existing overseas branches located in various areas of the world, and the
branches will be allowed. interchange of procurement responsibilities by geographic area to take advantage of
changing worldwide market conditions.

 Quality, technical acceptability and compliance with applicable client's documents and specifications.
 Reliability service and schedule.
 Consideration of duplicate and / or similiar type of equipment to take advantage of spare parts.
 Minimum job - site cost.

Expediting of field purchase materials from the materials from the time of purchase order placement to the time
receipt of the materials/services required in the job-site, contractors Jakarta material department will be expedite
all purchase orders including all revisions/amendments, utilizing the expediting team which will be organized with
experienced and qualified personnel.

1.6 SUBCONTRACTING

1. General

The Contractor proposes to carry the construction using local and/or expatriate subcontractors. Upon
award of contract a detailed subcontract plan will be developed by the contractor for the execuation of
the works. The contractor shall develop a project subcontract administration procedure for management
the subcontracts on site.

2. Subcontract Plan
The subcontract plan is developed during the early stages of the project to identify the portion of the
project that will be accomplished by subcontracts and the basic policies under which the work will be
contracted. These policies must be compatible with statement of statement of contracting policy should
cover the following subjects which are briefly discussed in this section.
 Competitive Bidding.
 Type of Contracts - Lump Sum, Unit Price and Cost Plus.
 Bonding Requirements.
 Retention.
 Escalation.
 Liquidated Damages.

3. Development of Subcontract Plan

The responsibility for preparation of the subcontract plan rest with the construction manager in
consultation with engineering and procurement and with the approval of the project manager. The
subcontract administrator, who is a member of construction, will assist the construction manager as
required.

The detailed subcontract plan and schedule initiated by contruction in collaboration with other
departments, will establish ;

 Scope of each subcontract.

 Estimated subcontract values.
 Critical milestone dates.
 Subcontract pre-commitment meeting / award dates.
 Construction area start dates.
 Engineering release dates.
 Degree of engineering definition required.
 General list of materials, facilities and utilities to be supplied to the subcontractor by Contractor of
Client.
 Definition of pay items.
 Scaffolding (separate subcontract, or within contractors supply)
 Construction site facilities available to subcontractors.
 Site plan o facilities and utilities available to subcontractor.

These decisions will be made after carefully taking into consideration ;

 Client Involvement
 Location of Site
 Field (Subcontractors) resources and staffing, and their ability to "deliver" on schedule.
 Procurement / engineering and construction schedules.
 Lead time for delivery of specific items.
 Prime Contract considerations.
 Cost of Contracting versus direct hire.
 Technical involvement after contract award.
 Labor availability and labor relations.

The subcontract plan shall comprise of the following ;

 Contracting policy for competitive bidding, bonding requirements, payment to contractor,

escalation of costs, and non performance penalties.
 Bidding philosophy for determination of number and bidders, pre-qualification of bidders and
limitations to bidders within defined geographical area.
 Work to be contracted : The list of the work package to be contracted should provide the following
information ;
- The name of the contract package. This should identify the package by trade,
system or component of the project.
- Scope of work. A brief description of the work which should identify the
subcontract package.
- Material supplied by contractor.
 - Type of subcontract, Lump Sum (LS), Unit Price (UP), or Cost Plus (CP)
- Estimated value of Subcontract.
 Special costruction requirements and availability of construction facilities and services effecting the
contractor.
 Contracting schedule for issuance of bid packages, receiving of bids, contract awards, and
start/completion of contracted work.
4. Subcontract Administration
The administration of subcontracts on the field can be summarized with the description of duties,
responsibilities, function of subcontract administrators, reporting relationship and inspection of
subcontract. It includes assuring that all the provisions of the subcontract document are complied with by
both parties namely the contractor and subcontractors for commercial and technical aspect.
 Reporting Relationships
The field subcontracts administrator reports to the contruction manager.
Field engineers assigned to monitor subcontractors report functionally to the engineering manager,
and on a day-to-day basis, to the construction superintendent with overall responsibility for
subcontractor's performance.

The construction manager and engineering manager together with contruction superintendent, field
engineer and field subcontract administrators who have been assigned to specific subcontracts
should meet at the beginning of the job to review duties, relationships and respective responsibilities
of supervision, engineering and administration to ensure complete understanding of the following ;

 Subcontract communication.
 Scheduling and coordination of the work.
 Quality and quantity inspection.
 Limits of authority.
 Report and preservation of record.
 Subcontract interpretation.
 Control of field changes, day works, work interruptions and back-charges.
 Control of free issue materials, tools and equipment outside the contract.
 Progress payment processing.
 Final inspection and acceptance.

Duties and Responsibilities

 Contruction Superintendent (when assigned)
- Coordinates the planning and execuation of all subcontract activities in his
assigned area.
 - Coordinates interfaces among different subcontractor forces.
Review, approves, consolidates and monitors schedules of assigned
subcontractors.
- Assures compliance with project procedures, work rules and safety standards.
- Expedites subcontractor performance.
- Monitor

 Area Field Engineer

- Assures compliance with plans and specifications.
- Interprets plans and specifications.
- Verifies quantities of work performed for progress report and periodic progress payment.
- Performs inspection and prepares inspection and acceptance reports.
- Verifies quantities, work operations and schedule extensions for change orders.
- Monitors Schedule for timely completion.
- Review work interruption and delay submittal for accuracy.
- Initiates data for change orders, extra work and back-charges.
- Reviews and comments on subcontractor force, equipment and progress report.
- Supervises the area superintendent with the supervision and coordination of all subcontractor
activities as directed.
- Assist the pre-scheduling of site representatives, monitor their activities and verify their timesheet.
- Assist in the preparation of subcontractor evaluations.

 The Field Subcontract Administrator

- Receives logs and prepares for construction manager, all correspondence and
transmittals to and from subcontractors.
- Schedules, and conducts subcontractor meetings, prepares agenda, records and
distributes all minutess of meetings.
- Interpret subcontract terms and conditions.
- Issue revision notice, solicits proposals and prepares change orders for
construction manager's approval.
- Receives and progresses application for progress payment in coordination with
field engineering (quantities) and finance and accounting (payments).
- Assures subcontractor receives timely information, instruction, revised plans and
schedules, revision notices, change orders and similiar communications.
- Assures subcontractor compliance with submittal of proper, accurate reports of personnel,
equipment and progss in accordance with established procedure.
- Tracks subcontractors progress in terms of man-hours, cash flow and quantities.
 - Assures subcontractor compliance with terms and conditions, insurance and bond
equirements (taxes, social security etc) prior to Final Payment.
- Issues letters of final acceptance and warranty initiation.
- Prepare subcontractors evaluations in coordination with field engineering and
cost engineering.
- Monitors and updates vendor representative schedule and calls representatives as
directed, administers service contracts.
- Documents, evaluates and makes recommendations for claims settlement.
- Maintains and preserves subcontract documents.
- Implements subcontract closeout procedure.

Subcontract Inspection
The subcontractor is responsible for inspection, test and assurance that prescribed standards for
materials an workmanship have been met.
Contractor's quality control inspection does not relieve that subcontractor of his obligations. The
contractor's inspection is intended to ensure subcontrator compliance.

1.7 CONSTRUCTION

1. Introduction
This plan outlines the construction section of the project execuation plan. It describe the basic
philosophy, construction organization to execute the work, manpower plans, temporary facilities,
construction equipment, mobilization and demobilization.

Basic Philosophy

Home Office
In order to ensure proper construction input the specific project, contractor will establish a home office
construction management team at the start of the project. During ts early this team will ;
 Input to develop the project's non-manual an manual power requirements to complete project
within time and cost parameters.
 Input to develop requirements for housing and camp support facilities.
 Input to the required construction support facilities for the site.
 Develop requirements for contruction equipment, tools and consumables.
 Develop subcontract plan, review subcontract packages, bid and make recommendations.
 Review and schedule heavy lifts.
 Inputs to engineering development to ensure construct ability of the facilities.
  Prepare and issue a construction pan of execuation.
 Input to development of theproject master schedule and estimate.
 Develop safety program.
 Establish requirements for pioneer and early mobilization facilities.
 Coordinate and input necessary control system requirement for implementation.
 Determine project requirements for logistic /material handling facilities, in coordination with the
procurement/logistic group.
 Input of development of construction job-site procedures.
 Review and coordinate procurement plan to ensure maximum vendor fabrication to reduce field
work.

Construction
The contruction scope of the project consist of structural steel, mechanical erection, electrical and
instrument works including site preparation and concrete foundation works.

Site mobilization shall commence in month 3 starting with setting up of camp, temporary buildings and
service such as water, power and telecommunications.
2. Site Organization

General
The site organization has to be developed to ensure that all construction management disciplines are
available for the successful execution of the project. The site organization will ensure ;
 Meet clients requirements
 Overall control at director's level
 Coordination between client and contractor
 Schedule and budget controls.
 Quality Assurance and quality control through adequte supervision, engineering and quality control
personnel
 Maintain good labor relations.

Organization Charts
This is a site based organization and shall be overall in charge of the project.

It shall be fully responsible for all the project relater activities at the job site. This organization shall be
responsible for giving direction and liaise at senior level with the Client organization. The construction
manager reports to the project manager. The areas of overall responsibilities are shown on the
organization chart.
 There site organization covers the following function in field
 Construction management
 Field engineering
 Quality control
 Documentation control
 Schedule and progress monitoring
 Cost control and estimating
 Field procurement
 Material control
 Material identification
 Subcontract administration
 Quantity surveying
 General administration
 Field administration
 Field accounts
 Labor control
 Pay roll
 Temporary facilities
 Construction equipment
 Site fabrication
 Site transport
 Supervision and monitoring of subcontractor work
The above function are essential for successful completion of the project.

3. Temporary Facilities

Upon award of contract, the contractor will agree with the client, the location of all temporary building such
as offices, warehouses, workshop etc. These location shall be as close to the work - face as possible for
easy access and control of the project.

The location of the camp shall also be agreed. After finalizing the above a detailed temporary facilities plan
will be developed prior to mobilization on site. This plan will address the following ;
 Access roads
 Camp facilities including recreation and support services for contractor's manual and non manual
employees
 Subcontractor's camp facilities
 Construction offices for
 - Client
- Central administration building
- Area office
- Site securities office
- Prayer room
 Mess huts for local manual labor
 Field shop
 Warehouse ;
- Central warehouse
- Plant area warehouse
 Shops ;
- Pipe fabrication shops
- Support fabrication shops
- Equipment maintenance shop
- Shot blasting and painting shop
- Insulation metal shop
- Laboratory for civil works
- Non destructive testing facilities
 Construction lay down areas
- Permanent equiment
- Structural steel
- Bulk piping storage
- Civil material
 Subcontractors site facilities and lay down areas
 Construction power supply
- Determine source
- K. V. A requirements
- Permanent and temporary generation including standby
- Temporary sub-stations
 Construction fuel
- Supply, storage and delivery
 Water Supply
- Determine source
- Production of raw and potable water
- Supply main system for potable and sewage water
 Drainage
 - Temporary drainage for camp and site
- Provision of site toilets.
 Telecommunication
- Telephone
- Telex or facsimile
 Emergency services
- Local services available including hospitals, doctors, dentist, ambulance, law
enforcement and fire - fighting facilities.
- Provision of field/camp clinic and first aid, ambulance.
- Develop of fire protection programmed including considerations for fire
engines, fire mains, fire extinguisher, emergency evacuation procedures, etc.
 Security
The contractor in conjunction with client security shall develop a plan for security of camp and
construction areas, where possible areas such as offices, lay-down areas, etc. shall be fenced off.
Security guards shall be provided during day time and at night.

4. Accident Investigation and Reporting

During mobilization period the local contractors shall supply all the construction equipment required.
During the construction phase the contractor intends to bring in his own major equipment. This
equipment will be suplemented for specialized or peak requirement through rental services.

Upon award of contract, the construction team working in the home office will develop a construction
equipment plan. This will address the following ;

 Construction equipment schedule

 Availability in Indonesia
 Items to be brought from outside source countries
 Nearest back up service center for equipment
 Site maintenance shop
 Site organization for control of maintenance of major equipment
 List of tools
 Cost studies

The construction equipment plan will be update and service on a regular basis by the construction
equipment manager to ensure that the needs of the are project are met. The contractor realizes that the
construction schedule is dependent on timely offsite availability of construction equipment and tools.
Delayed arrival of individual components can delay the construction schedule.
 Detailed mobilization schedule of construction equipment required for the proper execution of this
project is provided in the section 6 as per the scope of work to be defined in tender documents.

5. Fire Precautions

Crawler cranes with capacity of 120 tons 450 tons, hydraulic cranes of 100 ton have been allowed for in
the contruction equipment plan for heavy lift.

All equipment of 50 tons and more shall be unloade near the foundation.

100 ton trailers have been allowed for movement of heavy loads on site if any.

Heavy lifts are generally classified in the lifts are ;

a) In excess of 50 tons or
b) Exceed 80% of rated capacity of the crane or
c) The loaded has an unusual configuration

These lifts will be identified at an early stage in the project to ensure that suitable means of lifting them
have been catered for in the construction equipment plan allowance has been made for trailers and
access. In general rigging studies shall be carried out for all heavy lifts.

1.8 MOBILIZATION AND DEMOBILIZATION

Mobilization

A pioneer office shall be established at job-site for the front-end of the contruction mobilization effort. The
administration shall be carried out by the Jakarta office. Local subcontractors and equipment and labor shall
be used for this purpose . Transportation shall be locally rented until such time as the project is able to
function on its own.

During the early mobilization the contractor's construction team will work closely with client and input their
requirement into the provision.

Demobilization
A demobilization plan shall be drawn up to address all the issues including but not limited to ;
 Demobilization of expatriate and local staff, supervision and labor force.
 Removing of temporary facilities and buildings
 Disposal of surplus material
 Construction equipment
  Restoration of temporary facilities area
 Camp demobilization

Non-manual expatriate personnel will be released as soon as the demands of the construction effort will
allow assumption of their duties by national non-manuals. Their accomodations will be removed at the
stages.

Non-manual national employees will be released as their area of their area of the contruction effort is
compoleted.

Subcontracts will be closed and any claims resolved as expeditiously as possible after final acceptance of
their work. Subcontractors shall be responsible foe their own demobilization.

Construction equipment will be taken out of service as soon as practical, restored when necessary, and
returned to owners. Surplus materials, tools and consumble will be inventoried, service where necessary
and either turned over to client or sold as required or returned to contractor's home office.

Temporary facilities will be removed, and areas cleared up graded. All documentation, model etc. Shall be
handed over the client.

1.9. COMMISSIONING

The commissioning superintendent shall be assisted by be assisted by the commissioning engineers and
vendor's start up engineers, craft personnel from the subcontractors as required by commissioning team. A
document coordinator will be records into turn over packages for presentation to the client.
The commissioning superintendent, with the assistance of the engineer, will be responsible for the
production for detailed commissioning procedures and record documentation. These detailed procedures
will be based on the approved overall procedures prepared during the engineering design phase of the
project. Thesuperintendent will also be responsible for a detailed commissioning schedule, which will be in
accordance with the approved overall schedule and the construction schedule.

The commissioning superintendent will monitor construction progress and will highlight any delays likely to
affect the overall pre-commisioning schedule and plant startup dates. He will propose remedial action to
minimize schedule impact.

The pre-commissioning team will carry out a complete check of all equipment systems at the mechanical
completion stage to ensure that all necessary work and test have been completed and that the
mechanically complete, the pre-commissioning team will provide assistance to client to perform all the
 required pre-commissioning test and checks in accordance with the procedures. Commissioning
superintendent shall assist client in start up and commissioning activities.

Fatal accidents serious injuries, fires and dengerous occurrences will be reported immediately to the client.

1. Fire Precaution

Contractor’s safety officer will see that fire that fighting equipment is available to immediately control
and extinguish any small fires that occur at the job-site. For coverage in event of large fire, channels of
communication will be established whereby assistance is obtained throungh the local fire outhority.

Priority will be given to fire preventation activities such as regular cleaning and good house keeping;
adequate waste bins will be provided. Flameproof sheeting will be used when welding and burning is
performed in plant area.

Particular attention will be given to fuel and portable fire extinguishers and fixed hose reels. Smoking
will only be permitted in office and designated by client. Employess who fail to observe these rules will
be subject to instant dismissal.

2. First Aid, Health and Welfare

Site employees will receive medical care treatment at the contractor’s first aid center. A vehicle will be
available to transfer injured employees to local hospital when required.

Records will be maintained of all injuries including those requiring first aid. A weekly log will be provided.
A number of contractor supervisor will be trained in first aid and be able respond to emergencies.

Suitable and adequate toilet and washing facilities will be provided and maintained on site. Mess rooms
for manual workers shall be provided as required. Reqular inspections will be made to see that a high
standard of sanitation maintained. Records will be kept.

3. Site Security

Site security will be developed in accordance with the client’s requirements

The fanced plot will have controlled ingress and egress. Each subcontractor will be responsible for
security of his own tools and equipment. Contractor will be responsible for the security of all material
free-issued to the subcontractors whilst stored in the warehouse or lay-down areas.

4. Subcontractors Compliance

Contractor has considerable experience of managing subcontracto’s safety program and will make sure
that all subcontractors selected demonstrate competence in the management of health and safety
matters. They will be required to submit an acceptable safety program along with names and details of
personnel responsible for the effective implementation of their safety program
 The safety program shall contain detailed procedures for the prevention of accident. Fire prevention,
first aid and other safety matters which may arise.

Each subcontractor will appoint in writing a subitable qualified safety officer who will atted all safety
meetings. The appointed safety officer shall be given sufficient time, aothority and requirements. Safety
will be included as an item for all pre-contract kick-off meetings with subcontractors.

5. Commitment to Safety

Each subcontractor will be responsible for the implementation of his own safety program, which will be
in compliance with the approved policy. Contractor will regulary audit each subcontractor’s program for
effectivenes and thus assure coordination with other contractors.

The subcontractor’s weekly progress report shall contain of any recent significant safety activities and
problems that can be foreseen. Subcontractor’s not complaying with safety ruler and regulations will be
given a verbal warning. If points requiring attention are not dealt eith after a reasonable time, then a
non-comliance letter will be issued to the subcontractor concered.

Cobdition will be established in the general condition of subcontract to enforce compliance with the
safety program.

1.10. FIELD SAFETY AND HEALTH PROGRAM

1. Safety Action Plan

The job - site safety action plan which will be submitted to client for approval before the work
commences will contain full details of the safety program.

Emphasis will be given to inspection, management audits and safety training. Key safety milestone
dates and activities will be detailed.

2. Induction
All personnel including supervisors will make aware of the safety program regarding;
 Job - site safety policy.
 Construction accidents.
 Security procedures.
 Accident reporting.
 Employee responsibilities.
 Specific safe working practices.
  Protective clothing and equipment.
 Health, welfare and equipment.
 Special fire precautions.
 Emergency evacuation procedures.
 Occupational Safety and Health Administration (OSHA) Regulations.
3. Safety Inspections
Contractor and the subcontractors will make formal safety inspections of the work on a regular basis.
Infringements or poor safety practices found will be rectified promptly by the contractor concerned.

A program of inspections will be drawn up by the safety officer.

Contractors and subcontractors senior management will take part. Supervisors responsible for work in
the areas inspected shall also be included.

Supervisor will required to prepare and use simple checklist during these formal inspections.

4. Accident Investigation and Reporting

It is contractor's policy to investigate all accident resulting in injure and the reporting of "near misses".
The purpose of these investigations to;

 Make sure that important safety lessons are not lost.

 Increase safety awarness.
 Encourage improvements for the future.
 Enchant fact - findings.

All supervisors and foreman will take an active part in the investigations and prepare statements and
reports. Reports will also include detail of remedial action taken and recommendations to preventa
recurrence. The contruction manager will review and sign-off all report prepared.

Reporting under requirements of the reporting of injuries, diseases and dangerous

occurrences will be responsibility of the employee concerned. Contractor will see that accidents are
reported correctly and that copies of the prescribed forms are available in the project office for
verification. Reporting of injuries, disease and dangerous occurrences to the client's project
representative will be as described in the coordination procedures.