TENDER No.
SCOPE OF WORK
SH-FCP-EPC-PREQUALCAFC-HUILE 2011-01
SHEET 1 OF 180
CENTRAL AREA FIELD COMPLEX PROJECT
ITT FOR EPC
PART D – SCOPE OF WORK
Rev.
Date
Page
Description
Prep‟d
Chk‟d
App‟d
0
09/03/12
180
Issued for ITT
PMT
A.N.K
A. E
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
CAFC PROJECT
INVITATION TO TENDER
ENGINEERING, PROCUREMENT, CONSTRUCTION AND
COMMISSIONING
PART D – SCOPE OF WORK
Page 2 / 180
Part D - Scope of Work
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
CONTENTS
FOREWORD
9
EXPLANATION OF TERMS
10
ACRONIMS
12
INTRODUCTION
15
1. PROJECT OVERVIEW
16
1.1
CAFC DEVELOPMENT SUMMARY
16
1.2
CONCEPT
17
1.3
COMMON FACILITIES INSTALLED AT MLE
18
1.4
DEVELOPMENT LOCATION
19
2. GENERAL CONTRACTING AUTHORITY REQUIREMENTS
2.1
SUPPORT TO CONTRACTING AUTHORITY
3. GENERAL WORK DESCRIPTION
22
27
33
3.1
DESIGN CONCEPT AND DATA REVIEW
35
3.2
HSE
36
3.3
DESIGN INTERFACES
36
3.4
FUTURE FACILITIES
38
3.5
ALGERIAN REGULATORY BODIES
38
4. PROJECT MANAGEMENT
39
4.1
OVERVIEW
39
4.2
PROJECT EXECUTION PLAN
40
4.3
ORGANISATION
41
4.4
PROJECT PROCEDURES
42
4.5
QUALITY ASSURANCE
42
4.6
SOFTWARE
43
4.7
DOCUMENTATION
44
4.7.1
48
Data and Document Management
TOOL MIAP:
50
TOOL SPCPUMA:
50
TOOL EDAM:
50
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Tender No.
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4.7.2 CODING METHODOLOGY FOR CORRESPONDENCE
4.8
52
MANAGEMENT OF CHANGE
53
4.8.1
Management of Change Policy
54
4.8.2
Documents concerned by MOC
54
4.9
DAMAGE AVOIDANCE PROCEDURES
55
4.10
HSE PLAN AND MANAGEMENT
55
4.11
BRIDGING SYSTEM
56
4.12
PLANNING, SCHEDULING AND PROGRESS REPORTING
56
4.13
INTERFACE MEETINGS
58
5. SCOPE OF WORK AND DETAILED DESIGN/ENGINEERING
60
5.1
GENERAL
60
5.2
FACILITIES
64
5.2.1
Process Engineering
64
5.2.2
Mechanical/Equipment
70
5.2.3
Piping and Layouts
74
5.2.4
Pipelines
75
5.2.5
Operations and Maintenance
76
5.2.6
Instrument and Controls Systems
78
5.2.7
IT and Telecommunications Systems Design
82
5.2.8
Electrical and Power Systems Engineering
85
5.2.9
Corrosion Protection
87
5.2.10
Civil
88
5.2.11
HSE
94
5.2.12
Lifecycle Cost Assessment
97
6. HSE MINIMUM REQUIREMENTS
6.1
NATIONAL LEGISLATION, REGULATION, CONTRACTING AUTHORITY AND
INTERNATIONAL HSE CODES AND STANDARDS
99
99
6.2
DESIGN HSE PHILOSOPHY
100
6.3
HAZARD MANAGEMENT AND RISK MANAGEMENT
101
6.3.1 GENERAL PRINCIPLES
101
6.3.2 HAZARD IDENTIFICATION STUDY (HAZID)
102
6.3.3 HAZOP STUDIES
102
6.3.3.1
FEED HAZOP
102
6.3.3.2
EPC HAZOP
102
6.3.4 SIL ASSESSMENT AND VERIFICATION
103
6.3.5 FIRE AND EXPLOSION RISK ANALYSIS (FERA)
103
6.3.6 QUANTITATIVE RISK ANALYSIS (QRA)
104
6.3.7 DESIGN CASE SCENARIO
104
6.3.8 DESIGN AND SAFETY REVIEWS
104
6.3.9 ENVIRONMENTAL, SOCIAL AND HEALTH IMPACT ASSESSMENT (ESHIA)
105
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NOTE: ESHIA WILL BE PROVIDED TO THE CONTRACTOR AND CONTRACTOR SHALL BE
RESPONSIBLE TO CONDUCT ALL THE ACTIVITIES PART OF THE EPC ACCORDING
TO THE FINDING AND RELEVANT ACTION PLAN.
105
6.3.10 HUMAN FACTORS STUDY
105
6.3.11 SAFETY CRITICAL ELEMENTS (SCE‟S) IDENTIFICATION PROCESS AND MINIMUM
REQUIREMENTS
106
6.3.12 HSE ACTION TRACKING
106
6.4
INHERENT SAFETY
106
6.5
LAYOUT PHILOSOPHY
107
6.5.1 LAYOUT CRITERIA TO MINIMIZE RISKS
107
6.5.2 MINIMUM SAFETY DISTANCES
107
6.5.3 FIRE ZONE
108
6.5.4 ACCESS AND EVACUATION
108
6.5.4.1
ACCESS REQUIREMENTS
108
6.5.4.2
ROADS DESIGN
108
6.5.4.3
EVACUATION
109
6.6
PROCESS SAFETY CRITERIA
109
6.6.1 GENERAL
109
6.6.2 EQUIPMENT SAFETY REQUIREMENTS
110
6.6.3 EMERGENCY SHUTDOWN SYSTEMS
110
6.6.4 BLOW DOWN AND FLARE SYSTEMS
111
6.6.5 VENTING AND FLARING SYSTEMS
112
6.7
112
DRAIN SYSTEMS
6.7.1 CLOSED DRAIN SYSTEM
112
6.7.2 OPEN DRAIN SYSTEM
113
6.8
ELECTRICAL SYSTEM DESIGN
113
6.8.1 HAZARDOUS AREA CLASSIFICATION
113
6.8.1.1
EQUIPMENT SELECTION
114
6.8.1.2
VENTILATION AND PRESSURIZATION
114
6.8.2 EMERGENCY POWER SYSTEM
114
6.9
115
FIRE & GAS DETECTION SYSTEM
6.9.1 FIRE DETECTION
115
6.9.2 FLAMMABLE GAS DETECTION
116
6.9.3 MANUAL ALARM CALL POINT
116
6.10
117
ALARM SYSTEMS
6.10.1 ALARMS IN CONTROL ROOM
117
6.10.2 PA/GA AND FIELD ALARM SYSTEMS
117
6.10.3 ALARM VOTING FOR AUTOMATIC ACTIVATIONS
117
6.11
117
FIRE PROTECTION SYSTEMS
6.11.1 ACTIVE FIRE PROTECTION REQUIREMENTS
118
6.11.1.1
118
FIREWATER PROTECTION SYSTEM
6.11.2 PASSIVE FIRE PROTECTION REQUIREMENTS
118
6.12
119
BUILDINGS SAFETY CRITERIA
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6.12.1 BUILDINGS LOCATION
119
6.12.2 BUILDING SAFETY DESIGN REQUIREMENTS
119
6.12.3 HVAC REQUIREMENTS
119
6.13
STRUCTURAL DESIGN
120
6.14
PLANT CONSTRUCTION
120
6.15
PERSONNEL SAFETY AND OCCUPATIONAL HEALTH
121
6.15.1 PERSONNEL PROTECTION
121
6.15.2 SAFETY SHOWERS AND EYEBATHS
121
6.15.3 SAFETY SIGNS
122
6.15.3.1
122
MARKING AND ILLUMINATION OF ESCAPE ROUTES
6.15.4 MEDICAL FACILITIES
123
6.15.5 MACHINERY GUARDS
123
6.15.6 MANUAL HANDLING
123
6.15.7 ELECTRICAL SAFETY KIT
123
6.15.8 HOT AND COLD SURFACES/FLUIDS
123
6.15.9 HAZARDOUS MATERIALS STORAGE AND HANDLING
123
6.15.10
MATERIAL SAFETY DATASHEETS (MSDS)
123
6.15.11
RADIOACTIVE MATERIALS
124
6.15.12
TENORM
124
6.15.13
PROHIBITED SUBSTANCES
124
ENVIRONMENTAL STANDARDS
125
6.16
6.16.1 PROJECT ENVIRONMENT REQUIREMENTS
125
6.16.2 NOISE CONTROL
125
7. MATERIALS PROCUREMENT AND MANAGEMENT
127
7.1
GENERAL
127
7.2
SCOPE
127
7.3
PROCUREMENT ORGANISATION
127
7.4
PROCUREMENT METHODS AND PROCEDURES
128
7.5
APPROVED SUPPLIERS LIST
128
7.6
BID PACKAGES
130
7.7
SUPPLIER QUALITY MANAGEMENT
130
7.8
SUPPLIER INTERFACE MEETINGS
130
7.9
MATERIALS STATUS REPORTING
131
7.10
INSPECTION AND EXPEDITING
131
7.11
PROTECTION, PACKING, MARKING AND SHIPPING REQUIREMENTS
132
7.12
SUPPLIER DOCUMENTATION
132
7.13
CUSTOMS CLEARANCE
132
7.14
SPARES
133
7.14.1
General
133
7.14.2
Insurance Spares
133
7.14.3
Operating Spares
133
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7.14.4
Commissioning and Start-Up Spares
134
7.14.5
Cataloguing Spares
134
7.15
SPECIAL TOOLS
134
7.16
LOGISTICS
134
8. TECHNICAL INTEGRITY MANAGEMENT
135
8.1
MANAGEMENT SYSTEM
135
8.2
INTEGRITY PLAN
136
8.3
SYSTEM REQUIREMENTS
136
8.3.1
General
136
8.3.2
Specific Points to be addressed in the Technical Integrity Plan
137
8.3.3
Specific points to be addressed by the Contractor
138
8.3.4
General Notes to System Requirements
139
8.3.5
Risk Assessment and Management Programmes
140
8.3.6
Audits
141
8.3.7
Quality Control
142
9. CONSTRUCTION
146
9.1
GENERAL
146
9.2
CONSTRUCTION ENGINEERING AND TEMPORARY WORKS
147
9.3
SITE PREPARATION
148
9.4
SITE CONSTRUCTION FACILITIES
148
9.5
STORAGE OF EQUIPMENT AT SITE
150
9.5.1
General
150
9.5.2
Mechanical
150
9.5.3
Instrument/Electrical/Telecommunications
151
9.6
9.7
SITE CONSTRUCTION
151
9.6.1
General
151
9.6.2
Civil Works
152
9.6.3
Mechanical Equipment
154
9.6.4
Piping Systems
154
9.6.5
Gathering Systems
155
9.6.6
Structural
156
9.6.7
Instruments, Electrical and Telecommunications
156
9.6.8
HVAC Systems
158
9.6.9
Safety Equipment
158
9.6.10
Corrosion Protection and Painting
159
9.6.11
Welding Procedures/Welder Qualification
160
PRECOMMISSIONING ACTIVITIES UP TO MECHANICAL COMPLETION
10. COMMISSIONING AND START UP
10.1
160
163
COMMISSIONING OF UTILITIES AND PROCESS SYSTEMS WITH INERT FLUIDS163
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10.2
START UP
165
10.3
RESPONSIBILITIES
167
10.4
HEALTH, SAFETY AND ENVIRONMENT CONSIDERATIONS
167
10.5
PLANNING
169
10.6
PRE-COMMISSIONING, COMMISSIONING AND START-UP ACTIVITIES
170
10.7
GENERAL PROCEDURES
170
10.8
HANDOVER AND ACCEPTANCE PROCEDURES
171
10.9
PERFORMANCE TESTING
174
10.10 FAILURE OF FACILITIES TO PERFORM
174
10.11 TRAINING
174
10.12 VENDOR SUPPORT
175
10.13 DOCUMENTATION
176
10.14 ENGINEERING SUPPORT
176
11. SPECIAL NOTES REGARDING CAFC OIL PROJECT
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
FOREWORD
The written descriptions set forth in this Part D – “Scope of Work” of the ITT shall form part of
Annex II – “Extent and Limit of Supplies and Services” of the Contract and in addition
supplement the annexes of the Contract including the FEED. They are not intended to
describe in every detail all Work to be performed or for all things which are to be included and
reflected the Contract Price.
In case of any conflict identified by Contractor between this description of the Work and the
drawings, specifications and data contained in Annex I – “Technical” of the Contract including
the FEED Package or between the description of the Work and the codes and standards, it
shall be the Contractors responsibility to present the differences to the Contracting Authority
for resolution. The more stringent requirement shall prevail unless otherwise approved by the
Contracting Authority.
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
EXPLANATION OF TERMS
Live Commissioning
Means the dynamic running of systems to further check out the
functionality and integrity of complete systems, and continues on
from Pre-Commissioning. It is the last series of checks and tests
before running the process systems on hydrocarbons. It includes
the operation of the utilities systems where applicable to progress
the commissioning of process systems, all as more fully described
in Annex 2 (Scope of Work)
Contracting Authority
Shall mean SONATRACH and First Calgary Petroleums Ltd as
defined in the Form of Agreement, their successors and assigns.
Contractor
Shall mean the party or parties specified as Contractor in the
Form of Agreement appointed to perform the Work including its
successors and assigns.
Mechanical Completion
Shall mean that a system or sub system is installed and erected
and all aspects of checking, inspection and testing, prior to Pre Commissioning.
Plant Operating Efficiency
A measure of production performance, calculated according to the
principles to be defined by Contracting Authority. Refer to
document Tests and Performances Criteria
Pre-Commissioning
Means the series of inspections and tests, generally static, to
check the functionality of components and systems.
PreCommissioning commences after mechanical completion. It
includes energisation of systems to allow static tests to be carried
out, all as more fully described in Annex II – “Extent and Limit of
Supplies and Services” of the Contract
Operation
The quality or state of being functional or operational
Start-Up
Generally follows issue of Ready for Start Up Certificate and
commencement of the introduction of hydrocarbons into the
Permanent Works to continue to commission the process
systems.
Work
Shall mean all work that the Contractor is required to carry out in
accordance with the provisions of the Contract including all related
services, resources and equipment to be provided in accordance
with the Contract, all as fully defined Annex II – “Extent and Limit
of Supplies and Services” of the Contract
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Part D - Scope of Work
Works
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Shall mean the Permanent Works and Temporary Works :
Permanent Works: Shall mean the property of Contracting
Authority arising from the Works.
Temporary Works : Shall mean all temporary infrastructure,
structures or items that may be necessary to enable the
CONTRACTOR to access, fabricate, construct or install the
Permanent Works, whether on or off the worksite, but which are
not intended for incorporation into the Permanent Works .
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Part D - Scope of Work
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
ACRONIMS
AFC
Approved For Construction
AFD
Approved For Design
ARH
Autorité de Régulation Hydrocarbure
BdV
Base de Vie (Living Quarters)
CAFC
Central Area Field Complex
CCR
Central Control Room
CER
Central Equipment Room
CCTV
Closed Circuit Television
CDR
Contractor‟s Design Report
CMMS
Computerised Maintenance Management System
CP
Cathodic Protection
CPF
Central Processing Facility
CTC
Organisme National de Contrôle Technique de la Construction
CV
Curriculum Vitae
DC
Direct Current
DPEM
Direction du Patrimoine Energétique et Minier
DLE
Dry Low Emissions
EPC
Engineering, Procurement and Construction
ESHIA
Environment Safety Health Impact Assessment
F&G
Fire & Gas
FAT
Factory Acceptance Test
FEED
Front End Engineering Design prepared by CONTRACTOR
FEED Package
Results of FEED package prepared by Competitive FEED
HAZID
Hazard Identification
HAZOP
Hazard and Operability
HF
High Frequency
HSE
Health, Safety, Environment
HSEMS
HSE Management System
HV
High Voltage
HVAC
Heat, Ventilation and Air Conditioning
I/O
Input/Output
IBO
Industrial Base Operations
ICSS
Integrated Control and Safety System
ISO
International Standards Organisation
IT
Information Technology
ITP
Inspection and Test Plans
ITT
Invitation To Tender
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SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
LAN
Local Area Network
LER
Local Equipment Room
LPG
Liquefied Petroleum Gas
LV
Low Voltage
MAOP
Maximum Allowable Operating Pressure
MDR
Manufacturer Data Records
MLE
Menzel Ledjmet East
MLN
Menzel Ledjmet North
NCR
Non-conformance Report
NDE
Non-Destructive Examination
ONML
Office National de Métrologie Légale
P&ID
Piping & Instrument Diagram
PABX
Private Automatic Branch Exchange
PCS
Process Control System
PFD
Process Flow Diagrams
PHSER
Project Health, Safety and Environmental Review
PIM
Pre-Inspection Meeting
PMT
Contracting Authority Project Management Team
PSC
Production Sharing Contract (between Sonatrach, First Calgary Petroleums)
PSV
Pressure Safety Valve
PTT
Postes Télécommunications & Téléphones
QA
Quality Assurance
QC
Quality Control
RAM
Reliability, Availability and Maintainability
RCM
Reliability Centered Maintenance
ROW
Right of Way
RP
Recommended Practices
RTU
Remote Terminal Unit
SDO
Service Delivery Organisation
SIL
Safety Integrated Level
SIMOPS
Simultaneous Operations with Drilling, Construction etc.
SP
Special Piping
SPIR
Spare Parts List and Interchangeability Record
STU
Sewage Treatment Unit
UCP
Unit Control Panel
UFD
Utility Flow Diagrams
UHF
Ultra High Frequency
UPS
Uninterruptible Power Supply
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VHF
Very High Frequency
VPN
Virtual Private Network
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
INTRODUCTION
SONATRACH and First Calgary petroleum Ltd under Production Sharing Contract, intend to
develop Central Area Field Block 405b in the Berkine Bassin- Algeria. This is a desert location
(SAHARA), approximately 300km east-south-east from the town of Hassi Messaoud
The development consists of a field gathering system, central processing facilities and tie-Ins
between MLE and CAFC plants.
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
1. PROJECT OVERVIEW
A simplified schematic overview of the project is given in Figs 1.1 below. Fig 1.1 shows the
overall requirement of the CAFC project. Fig 1.2 shows the location of the CAFC project
within Algeria whilst Fig 1.3 gives more detail on the field development within Block 405b.
CAFC oil and gas processing facility will be built adjacent to the MLE CPF. Export lines are
sized to cater for both MLE and the Central Area Field Complex (CAFC).
F6-2 Lean and Rich Gas
F6-2 Gas
MLE
F6 Associated Gas
F6-1 Oil
Condensate
Phase 2: TAGI Gas
CAFC
F6-2 Oil
Plant
Gas
Phase 1: TAGI Gas
Injection
TAGI Oil
CAFC
Oil Treatment
MLE/CAFC
storage tanks
Fig 1.1 CAFC Project Simplified Overview
1.1 CAFC DEVELOPMENT SUMMARY
The CAFC development concept consists of a field gathering system and 41 oil wells to be
connected to CAFC plant, central processing facility and necessary support infrastructure.
-
The CAFC Oil wells (TAGI, F6-1 and F6-2 SWP) will be connected to the CAFC oil
slug catchers through gathering systems dedicated to TAGI reservoir and to F6 Oil.
The total number of wells is 51 divided in 41 oil producer (17 TAGI, 9 F6-2 and 15 F61), 4 water injectors (TAGI), 3 gas injectors (TAGI) and 3 water producers. The
associated gas from F6-1 and F6-2 should be sent to MLE plant for final treatment,
while TAGI associated gas has to be re-injected till the gas cap blow down, expected
in 10 years.
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The CPF shall process part of the associated gas relevant to the gas injection and the
Oil products. CAFC CPF will be provided with its own flares and off-spec oil tank.
The gas injection system is to re-inject gas into TAGI reservoir.
The water injection system is to re-inject the produced and Barremian water into TAGI
reservoir.
Infrastructure includes:
o Construction Camp
o Black top & Gypsum roads and access roads
1.2 CONCEPT
The general concept for development scheme consists on developing CAFC project
comprising following facilities:
Wells production / infields manifolds/ production and distribution
gathering system
Central Processing Oil Facility, associated utilities where
applicable and common installations
Gas injection & Water Injection
Infrastructures: road network and construction camp
The design and construction of CAFC project for common utilities installations will be
optimised in synergies with MLE plant.
A site topographical and geotechnical surveys should be carried out during the EPC activities
in order to acquire information regarding the physical characteristics of soil, assess the site
situation and planning civil works to be carried out.
Site preparation for CAFC facilities is executed by Contracting Authority and handed over to
the selected Contractor.
An Environmental, Social and Health Impact Assessment (ESHIA) study has been carried by
a third party contractor and submitted to local authorities. EPC Contractor shall comply with
the requirements of the MLE & CAFC ESHIA studies that will be provided.
The CAFC project is part of a two phase development scheme:
The initial phase shall consist of installing the CAFC wellsites and
Oil gathering system, and developing the CAFC CPF along with
its infrastructure.
nd
A inlet gas booster compression is foreseen for 2 phase, but not
included in the present SoW It is expected that the MLE booster
compressor required for MLE CPF after approximately year 5 will
also be used for CAFC
The second phase which is excluded from the Work is GAS
Blowdown phase.
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SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
1.3 COMMON FACILITIES INSTALLED AT MLE
The MLE NGL plant allowed space for future processing of the Central Area Facilities
Complex (CAFC) fields.
a.
Common Installation for Combined Facilities
Process
o Oil Storage for combined MLE and CAFC production is foreseen in MLE Plant.
o
o
Booster and Export Oil Pumps
MLE Project designed pumps for CAFC and MLE combined but installed
pumps for MLE Production ONLY. Remaining pumps to be installed
within CAFC project. CAFC RAM study to confirm CAFC plant
availability specification is met with the required pumps configuration.
Oil Fiscal Metering
- MLE Installed a larger fiscal meters for all products with required
turndown. No furthers fiscal meters are required for CAFC, only the new
technical meter as described in the FEED SoW.
Condensate Production coming from CAFC Gas Treatment could be connected to
MLE Liquid Processing
Off gas
The compressed off-gas for F6 gas only coming from the oil treatment section
will be dehydrated and re-injected along TAGI gas released from the slug
catcher. A connection to MLE plant is foreseen to be used in case of an
emergency.
Utilities
o
MLE Plant designed and installed sufficient size of the following utilities for CAFC
rates:
- Fuel gas
- Diesel fuel
- Utility Water
- potable water
- de-mineralized water
- F&G
- instrument air
- plant air
- inert gas
- firewater
- main power distribution
Instrumentation & Control/Tele
The control room to be used will be in the same building of MLE project. MLE
and CAFC projects shall be independent in terms of systems (DCS, SCADA,
ESD/F&G, etc.) to be used. However, it shall be necessary to exchange some
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information/data. This means that the CAFC equipment (DCS, SCADA,
ESD/F&G, etc.) shall be housed in the electrical building inside the CAFC area.
In order to allow communication among the different parts of the plant, PAGA,
PABX TETRA and security radio telecommunication systems have been
foreseen as integration/extension of MLE systems. Also, Fibre Optical Cables
(FOC) shall be foreseen to exchange data between CAFC plant and remote
sites, and between CAFC and MLE plants, as per FEED documentation and
MOM interface meeting between MLE & CAFC PMT during CAFC FEED.
1.4 DEVELOPMENT LOCATION
The CAFC field lies within the Ledjmet Block 405b in the Berkine Basin of Algeria
approximately 1200 km by road from the Algerian ports. It is also approximately 220 km
south-east of Hassi Messaoud which is an oil field activities center and regional base for
Sonatrach, FCP, contractors and suppliers. Location maps are shown in Fig 1.2 and 1.3
below.
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Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Fig 1.2 Location of CAFC
The next drawing shows the red dashed area in more detail.
Fig 1.3 Location of CAFC
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In the diagrams above and below, the Block 405b perimeter is highlighted in blue and the
difference in the area is due to the relinquishment of some of the block area back to
Sonatrach.
Fig 1.4 Location of CAFC wells
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Tender No.
Central Area Field Complex Project
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2. GENERAL CONTRACTING AUTHORITY REQUIREMENTS
As part of its obligations under the Contract, the Contractor shall provide to the Contracting
Authority the Permanent Works necessary to develop and exploit the CAFC field including,
but not limited to: from 41 oil production wells, 4 water injection wells, 3 gas injection wells, 3
water producing wells,, a Central Processing Facility (the “CPF”), and all necessary
infrastructure, as detailed in the document entitled “Process Basis of Design –” , and in the
FEED Technical Data. The primary components of the Permanent Works include, but are not
limited to, the following:
the Permanent Works shall as a minimum be capable of
achieving or exceeding all of the criteria stated in above in all
environmental and seismic conditions (and all combinations
thereof) up to and including the more onerous of the conditions
as specified in the document entitled “Process Basis of Design”
for all conditions and all modes of operation (and all combinations
thereof) for which the Permanent Works and/or any part thereof
are or may be intended to be used;
The Permanent Works shall be capable of operating on the most
onerous of soil conditions at the Location of the Permanent
Works, as independently determined and resulting from the
Geotechnical Survey to be performed by Contractor. Moreover
Contractor shall consider all conditions and all modes of
operation (and all combinations thereof) for which the Permanent
Works and/or any part thereof are or may be intended to be used;
the Permanent Works shall have a design operational life of a
minimum of twenty-five (25) years, for all conditions and all
modes of operation (and all combinations thereof) for which the
Permanent Works and/or any part thereof are or may be intended
to be used (except where the document entitled “Process Basis
of Design ” otherwise indicates);
the Work shall at all times comply with the Contracting Authority
HSE MS standards (Ref. Part C – Annex XI) and HSE Minimum
Requirements (See section 6) and shall incorporate all facilities
required for the Permanent Works to comply with such standards,
for all conditions and all modes of operation (and all combinations
thereof) in which the Permanent Works are or may be intended to
be used;
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the Permanent Works shall incorporate all facilities necessary to
perform the functions stated in above, whilst complying in all
respects with the Contracting Authority HSE MS standards (Ref.
Part C – Annex XI) and HSE Minimum Requirements (See
section 6) and with the product specifications, noise and
emissions requirements as detailed in the document entitled
“Process Basis of Design” for all conditions and all modes of
operation (and all combinations thereof) in which the Permanent
Works are or may be intended to be used;
the Permanent Works shall be designed, engineered, procured,
constructed and commissioned such that they are capable of
providing a minimum overall availability (defined as the average
system production over the expected production without any fault
and any preventive maintenance) of ninety seven per cent (97%)
(including the Contracting Authority‟s assumed three years
shutdown period), whilst complying in all respects with the
Contracting Authority HSE MS standards (Ref. Part C – Annex
XI) and HSE Minimum Requirements (See section 6) and with
the requirements as detailed in the document entitled “Process
Basis of Design” for all conditions and all modes of operation
(and all combinations thereof) in which the Permanent Works are
or may be intended to be used;
The Permanent Works shall be designed in accordance with Best
Industry Practice for ease of operation and maintenance, taking
into account the fact that they are located in a very remote area,
with difficult access and that they operate under harsh weather
conditions. Accordingly, all equipment comprising the Permanent
Works shall be robust, efficient, reliable in operation and capable
of being serviced on site. As far as practically possible,
equipment shall be standardised within the Permanent Works;
the Permanent Works shall be demonstrated as having
successfully completed all of the Process Performance Tests as
detailed in the Annex VII – “Performance Guarantees” whilst
complying in all respects with the Contracting Authority H HSE
MS standards (Ref. Part C – Annex XI) and HSE Minimum
Requirements (See section 6) and with the requirements as
specified in the document entitled “Process Basis of Design”;
the Permanent Works shall be capable of achieving the specified
turndown level and operating with the minimum production feed
flow rate, as specified in the document entitled “Process Basis of
Design” whilst complying in all respects with the Contracting
Authority HSE MS standards (Ref. Part C – Annex XI) and HSE
Minimum Requirements (See section 6) and with requirements as
detailed in the above referenced document;
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the Permanent Works shall incorporate all means of access
(including but not limited to means of access for personnel,
Materials, Installations and such other materials, construction
plant or other temporary works as may be required) and all
facilities required to, safely and efficiently, construct, commission,
operate, service, maintain and replace each part of the
Permanent Works, in such manner as to fully comply with the
Contracting Authority HSE MS standards (Ref. Part C – Annex
XI) and HSE Minimum Requirements (See section 6);
the Permanent Works shall permit easy access to all parts of the
Permanent Works that are required to be accessed for the safe
and efficient operation thereof, for all conditions and all modes of
operation (and all combinations thereof) in which the Permanent
Works are or may be intended to be used; and
the Permanent Works shall incorporate all support infrastructure
required for the Project, including, but not limited to, all buildings
and roads as specified in the document entitled “Process Basis of
Design”.
The Permanent Works must comply with the following:
1.
2.
3.
4.
5.
6.
Algerian statutory requirements;
The Contract;
Contracting Authority documents;
Process Basis of Design;
All other Contracting Authority Technical Data;
FEED ITT Package documents (including reference list of applicable codes and
standards);
International codes, standards, best practice and guidelines.
7.
In the case of an inconsistency between the requirements of any of the aforementioned, then
priority shall be given in descending order. The more onerous requirements shall apply,
unless otherwise expressly determined by the Contracting Authority in writing.
Contracting Authority shall have the right at all times to modify its requirements in the interests
of improving the Safety, Health, Environment and welfare of personnel in the workplace. To
the extent that there is a conflict between the project HSE requirements and this document,
the more stringent requirement as determined by COMPANY shall prevail.
In the event that the Contractor wishes to seek from the Contracting Authority a concession or
waiver of any of the technical requirements of the Contract, the Contractor shall, to the extent
permitted by Article xx of the Contract, submit a Variation Order Request in accordance with
Article xx of the Contract.
(i)
The Contracting Authority shall have no liability to the Contractor for any adverse
impact on the Contract Price, Contract Schedule or Key Milestones for any
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Part D - Scope of Work
(ii)
(iii)
(iv)
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
request for a concession or waiver regardless of whether or not such request is
granted by the Contracting Authority, other than by way of a Variation Order in
accordance with Article xx of the Contract.
For the avoidance of doubt, the granting of any concession or waiver shall not in
any way relieve the Contractor of any of its obligations for Performance Testing
or any other provisions under the Contract.
The Approval of any Contractor‟s Technical Data and any project document
which contains any provision which is not in accordance with the Contract shall
not be considered an Approved concession or waiver unless Contractor has
complied fully with the above requirements for a Variation Order Request.
EPC contractor is wholly responsible at EPC stage for all the design related
variation arising during detailed engineering, procurement and construction.
The scope of work described herein provides a general overview of the activities to be
performed by the Contractor and is intended only to be sufficient for identification of each
major element of the Work. The descriptions herein are not intended to provide either a
comprehensive list of activities or detail of each such activity involved in the execution of the
Work and must be read in conjunction with all other documents forming the Contract. The
Contractor shall carry out all activities necessary to fulfil the Contractor‟s responsibility for the
complete performance of the Work in accordance with the Performance Criteria, the
Contracting Authority and the Competent Authorities, as appropriate.
The Contractor shall Design, Engineer, procure, supervise, manage, supply, transport,
construct and Commission the Permanent Works. Performance Testing (including the
Process Performance Tests) shall be undertaken by the Contractor to demonstrate to the
Contracting Authority‟s satisfaction that the Permanent Works meets the Performance
Criteria. The Contractor shall guarantee the Work and perform, complete, deliver and
guarantee all other work or works which the Contractor is, or may be, required to perform,
complete, deliver or guarantee under the Contract, all in conformity, in all respects, with the
provisions of the Contract, including, but not limited to, the Contracting Authority
Requirements and/or the requirements of the Contracting Authority‟s Representative, the
requirements of all Competent Authorities and all other requirements of whatever nature and
howsoever arising which the Contractor may have to comply with in respect of the Work
and/or any part thereof.
As the Work progresses, details of the Permanent Works may change, however the basic
configuration of the Permanent Works shall remain unchanged. Similarly, all existing
specifications, drawings, procedures, databases, manuals and other documents relating to
the Permanent Works shall be revised by the Contractor (subject to Approval), as appropriate,
and additional specifications, drawings, procedures, manuals and other documents as
specified in the Contract and/or as necessary for the proper execution of the Work shall be
prepared by the Contractor for Approval and/or for submission to the Competent Authorities.
The process of Design development approval as required by the Competent Authorities is an
integral part of the Work and shall not, in any circumstances whatsoever, be deemed to be, or
recognised as, a Variation.
In case of conflict between the provisions of the Contract and any of the requirements listed
above, the more onerous requirements shall apply, unless otherwise expressly determined by
the Contracting Authority in writing.
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In summary, the major elements of the Work shall include, but are not limited to:
(i)
management and services;
(ii)
detail design and engineering;
(iii)
Correct any inconsistency, lack, incompleteness; mistake arising during EPC
Phase from FEED documentation
(iv)
In the preliminary phase of the EPC, Contractor shall identify the external battery
limits and shall propose solutions for the integration between CAFC and MLE
facilities especially in term of HSE, operability and maintainability aspects
(v)
Support Contracting Authority in the interface management
(vi)
procurement, inspection, expediting, freight forwarding, customs clearance and
delivery of all Materials to the relevant Locations;
(vii)
arranging all approvals from the Competent Authorities, in particular the ARH
and CTC;
(viii)
maintaining Quality Assurance throughout the Work and demonstrating such to
the Contracting Authority‟s satisfaction at all times;
(ix)
construction to Mechanical Completion status;
(x)
preparation of all pre-commissioning and Commissioning procedures;
(xi)
Commissioning;
(xii)
Execution of the Performance Testing, in cooperation with Contracting Authority
(including the Process Performance Tests);
(xiii)
provision of on site engineering support to the Contracting Authority‟s operations
organisation for the Guarantee Period;
(xiv)
provision of the guarantees in accordance with the Contract;
(xv)
provision of HSE services and co-ordination thereof for the Work;
(xvi)
define and develop the project HSE requirements for all CAFC project facilities
with the aim to collate and document all the HSE design criteria and
philosophies, applicable regulations, codes and standards that are to be adhered
regarding detail design and engineering, procurement, construction
and
commissioning and start up of the CAFC project facilities
(xvii)
provision of status information regarding all relevant legislation at the
commencement of the Contract and ongoing monitoring, and advice to the
Contracting Authority, of any change in such legislation which affects, or may
affect, the Work;
(xviii)
preparation of the process operations manual (in French and English
languages);
(xix)
preparation of Final Status (“as-built”) documentation;
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(xx)
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
preparation, loading and commissioning of a computerised maintenance
management system (in the French and English languages); and
(xxi)
Compilation of all vendor operating and maintenance manuals and other
documentation (in the French and English languages).
(xxii)
Undertake a programme of training for Contracting Authority operational
personnel both on site and abroad in suppliers‟ works.
The Contracting Authority shall be responsible for the planning, engineering, materials
procurement and execution of:
(i)
the construction of all drilling pads for the hydrocarbon production wells, gas
injection, water injection and water extraction wells;
(ii)
the construction of all temporary access roads to such drilling pads; and
(iii)
The sub-surface completion of, and installation of wellheads (including the
supply and installation of the master safety valve, subsurface valve), for the
hydrocarbon production wells, gas injection, water injection / aquifer water wells.
The Contracting Authority undertakes to keep the Contractor informed of these activities in
order to allow the Contractor to maintain and update its overall Contract Schedule planning.
Contractor hereby agrees and warrants that it will utilise its best endeavours to ensure that
Contracting Authority drilling and completion programme is not affected by the performance of
this work.
2.1 SUPPORT TO CONTRACTING AUTHORITY
Provide the following office requirements for Contracting Authority Personnel in Contractor‟s
Engineering Design Office:
Contracting Authority PMT shall be co-located in Contractor‟s office for the duration of the
Contract. The team will be immediately mobilized after the signature of EPC award. Contractor
shall provide office facilities, furniture, parking and other associated services (e.g. telephone,
reproduction services, and stationery) for Contracting Authority personnel (30 people) in the
Engineering Design office.
The office space shall be equipped with smoke and fire detectors, burglar alarms connected to a
central security system or the local police station, fire-fighting equipment and escape-ways. The
office space shall satisfy Contracting Authority security requirements. Contracting Authority shall
determine access to the offices.
The offices shall all be equipped with necessary connections and power supply.
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The facilities are to include the following:
2 fully equipped and lockable Project Manager's office with conference table and
4X2 chairs and additional spider phones.
Minimum 2 fully equipped lockable one-man Engineering Manager's offices.
Fully equipped open office for 26people and with partition screenings for each
work place. Option for extension for 4 more people.
Project conference room for 20 people fully equipped with spider phone, PC, roofmounted overhead projector, board and flip-over.
1 secure document control room (approximate size 25 sq. m.) with lockable filing
cabinets
1 copy room equipped with:
o
o
o
One heavy duty colour copy machine with scanner, latest model “Xerox”
or equivalent, able to copy A3 size documents onto A3 size paper and
reduces A3 to A4 and other reduction facilities, normal A4 copies, single
and double sided copies, approximately sixty (60) copies per minute and
sorting/stapling facilities.
Laser telefax receiving and transmitting system located within the
provided office space and operated independently from Contractor‟s own
telefax facilities
Paper shredding machine
1 computer room environment to accommodate 3 servers and access to this
room to maintain servers
Access to a separate office with a 3D CAD viewing station
Access to a conference room equipped with all necessary equipment for external
videoconferences.
Office furniture equipment and services positioned in the area above office shall
include:
o 1 desk with lockable drawers
o 1 side table
o 2 x 3 shelf bookcases
o 1 lockable filing cabinet
o 1 high quality office chair
o 1 visitor‟s chair
o 1 table lamp
o 1 telephone
o 1 waste paper bin
o hat/coat hooks/stand
o 2 computer network connection (Ethernet) cabled to central computer
room
Provision of complimentary coffee, espresso machine, tea and cold drinking water
(carbonated and still)
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Kitchen facilities including refrigerator and microwave oven
Access to vending machines
Access to use of Contractor‟s canteen at home office during normal working
hours, at the same rate as charged to Contractor‟s personnel.
Stationery and office supplies, including computer consumables, except
Contracting Authority printed stationary and printed forms.
A telephone service operated from Contractor‟s switchboard at the home office
for Contracting Authority personnel.
Parking facilities for 30 cars in close proximity to Contracting Authority‟s office
location.
Services to these offices and their contents in respect as such items as heating,
air-conditioning, power, lighting, water, sanitation, cleaning, repair and
maintenance.
Provide and administer renting of cars (one for each manager and one each two
discipline engineer) and high quality and fully furnished living accommodation (for
30 people) as per Contracting Authority standard in the neighborhood (Rome or
Dubai) of the principal office location for Contracting Authority‟s personnel.
Location of living accommodation will be selected according to the following
criteria: safe area, quality, easy access to Contractor Engineering Offices.
The Contractor shall provide such support services as may be requested by the Contracting
Authority. Such services may include, but are not limited to:
additional offices and office facilities for the Contracting Authority;
obtaining and administrating Competent Authority and/or third party services in
accordance with Contracting Authority instructions;
Support services to arrange and administer travel reservations and obtain tickets,
visas, etc. for the Contracting Authority‟s Representative and/or other Contracting
Authority personnel.
additional secretarial, administrative and support services as the Contracting
Authority may require; and
Courier services for the urgent transportation of documents, packages and the
like.
1.
Other Locations
Where elements of the Work are to be performed at Locations the Contractor
shall ensure the provision of similar adequate, dedicated office space, facilities
and services for the Contracting Authority at such Locations, if so requested by
the Contracting Authority‟s Representative.
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The Contractor shall provide access to its canteen services (if any) at any
Location for use by the Contracting Authority‟s personnel and their visitors during
the periods such facilities are normally available to the Contractor‟s personnel.
2.
Provide during construction phase the following offices requirements for Contracting
Authority Personnel in Contractor‟s SITE offices as detailed above and for the
numbers of Personnel stated in Accommodation, Catering and Vehicle Attachment
hereto except hiring of Contractor‟s staff and provision of parking facilities.
3.
Accommodation and Messing for Contracting Authority Personnel at the Site Location
4.
The Contractor shall provide, mobilise, maintain, operate and demobilise fully
furnished and air-conditioned single occupancy accommodation and messing for up
to thirty (30) Contracting Authority personnel assigned to and/or visiting the Location
of the Permanent Works. Such Contracting Authority personnel shall also have full
access to all recreational facilities provided by the Contractor for its own personnel at
such Location.
5.
Provide the following secure IT and communications facilities for Contracting Authority
Personnel in Contractor‟s Engineering Design Office:
Provide dedicated project assistants according to the project workload.
For each member of the Contracting Authority‟s Personnel + 2 visitors (total 32
persons):
o
o
o
o
o
o
o
o
1 desktop PC
19” LCD monitor (second monitor to be added on a as needed basis)
Full internet and e mail access
Windows XP Professional operating system
Microsoft Office suite (Word, Excel, PowerPoint, Outlook)
Anti-virus and Anti-malware software
Contracting Authority's electronic data management system software
Other general and engineering software on a as needed basis (e.g.
Acrobat Reader, Acrobat Professional, WinZip, MS Project, MS Access,
Visio Professional, AutoCAD, Microstation)
Contracting Authority‟s electronic data management system shall be Contracting
Authority‟s electronic archive for administrative documentation and
correspondence and for all technical documentation distributed to Contracting
Authority for review/approval and preparation for final handover. The
configuration of the system shall be compatible with Contracting Authority's
electronic data management system (EDAM). Contractor personnel shall not
have access to Contracting Authority project team‟s electronic data management
repository. Selected Contracting Authority personnel shall have administrative
rights to the system hosted on Contractors IT network.
Contracting Authority shall be able to access Contracting Authority's electronic
data management repository from the Internet (external log in).
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A shared Contracting Authority‟s project mailbox (MS Outlook) to be provided.
Contracting Authority common IT facilities:
o
o
o
o
o
o
o
Multifunction printer A3 format
Colour printer
Colour Scanner sixe A3
Local Area Network as per Contractor‟s standard
Direct internet line (min. 4 Mbit synchronous) for the connection of
Contracting Authority provided wireless network (for PMT and visitor‟s
laptops). Minimum WPA encryption
Backup and recovery administration as per Contractor standard,
minimum daily backup
Access to a 3D model viewing station in or close to the Contracting
Authority‟s offices
The PMT shall be able to access Contracting Authority home office networks from
the supplied IT facilities using terminal server technology (Citrix, iLink, IRAS,
VPN).
Contractor shall provide IT helpdesk and technical support to all communications
and hardware/software services provided, as per Contractor‟s standard.
Contractor shall provide any and all data, metadata, and information created by
Contracting Authority or by Contractor on behalf of Contracting Authority upon
Contracting Authorities request. Contractor shall provide such information in a
manner or on media as required by Contracting Authority.
NOTE: Contracting Authority may choose to bring and install their own IT facilities
for Contracting Authority‟s Personnel located on SITE offices. This shall include
communication router/switches, security services, wireless access point, desktop
and/or laptop PCs, print server, application server, file server, backup device,
multifunction printer and colour printer. Contracting Authority IT equipment shall
be connected to a network line to Contracting Authority home network using VPN
technology.
If Contracting Authority chooses this option Contractor is to provide:
Accommodation for a minimum 4 Mbit synchronous data communication line
(supplied by third party service provider). The line shall amongst other support
remote access/replication to Contracting Authority's electronic data management
system server in Contracting Authority offices in Algeria.
Space for a Router and Switch and any security devices Contracting Authority
deems appropriate in a secured Computer Room with restricted access
Space for print server, application server, file server and backup device in a
secured Computer Room with restricted access.
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A cabled fast Ethernet LAN within Contracting Authority‟s project team offices to
be connected between the Contracting Authority provided switch, servers,
printers, PC‟s, laptops and wireless access point.
19” LCD monitor, keyboard and mouse for 32 laptops.
Technical support for above items to a standard deemed appropriate by
Contracting Authority, and commensurate with Contracting Authority‟s IT
standards.
6.
Provide the IT and communications facilities for Contracting Authority Personnel in
Contractor‟s SITE offices as detailed above
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
3. GENERAL WORK DESCRIPTION
This work covers a single Contract for all engineering, detailed design, procurement,
construction, Mechanical Completion, Commissioning and Start-Up of the main facility,
gathering system associated roads and infrastructure. This Work forms the basis of a fixed
price “lump-sum” Contract.
The scope includes design, procurement and installation of the Oil Gathering system, Central
Processing
Facility,
Gas
&
Water
injection
Systems,
interface
tie-in
piping/instrumentation/electrical between CAFC and MLE, plant and roads, as described in
this document and the FEED package.
In addition, the Contractor‟s Scope of Work shall include all civil works for site preparation
beyond the preliminary site preparation performed by Contracting Authority and the provision
of the infrastructure to support the sites during the construction, Commissioning, Start-Up
handover and operational phases.
All Work shall be performed in accordance with the Contract including resources to supervise
and administer Subcontractors. The Contractor shall furnish all resources, consumables,
Materials and Equipment, construction plant, labour, tools and services required to manage,
engineer, design, document, procure, fabricate, transport, install, construct, test, inspect and
commission the facilities in accordance with the Contract and this Scope of Work and perform
all operations to complete the Work.
In outline, the Contractor shall provide all necessary materials, consumables, services,
equipment and labour to undertake, as a minimum, the following:
1.
All Project Management, Engineering, Detailed Design, Procurement, Construction,
Commissioning and Start-Up including those activities required to:
Design, procure and construct, commission and start-up the Central Processing
Facility, Oil Gathering system, Gas & water injection systems, interface tie-in
piping/instrumentation/electrical between CAFC and MLE plant and roads in
accordance with the Project codes, standards and specifications described in this
Scope of Work and the FEED Package.
Participate in scheduled Project Health Safety and Environmental Reviews,
(PHSER). One review shall be held during detailed design and one prior to
fabrication/construction, and one prior to Start-Up.
Manage intermediary and final Hazard Identification (HAZID), Hazard and
Operability (HAZOP) and SIL Assessment sessions involving Supplier and
Contracting Authority participation.
Manage, liaise and provide all necessary documentation to gain the necessary
approvals of all Algerian regulatory and certification authorities.
Interface with the Contracting Authority Project Management Team and the other
Contractors involved in the Project as required.
Prepare final documentation in accordance with project specifications.
2.
Provide office facilities and services to Contracting Authority Personnel for the
duration of the Project.
Procurement of all equipment, steelwork and bulk materials.
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3.
Execute all required civil works and associated infrastructure, including all temporary
works
4.
Provision of a comprehensive logistics infrastructure to ensure materials are received
in country, handled, customs cleared, transported to the sites for storage and
installation.
5.
Provision of all necessary covered and uncovered secure storage facilities for
Materials and Equipment at all parts of the procurement chain. Ensure all necessary
equipment preservation activities (including but not limited to vendor
recommendations) are carried out.
6.
Obtain all necessary Algerian Government and Statutory permits and approvals.
7.
The Construction of the complete Central Processing Facility, Oil Gathering system,
Gas & water injection systems, interface tie-in piping/instrumentation/electrical
between CAFC and MLE plant and roads together with various elements of the scope
either specifically detailed, or implied, that together define the Work.
8.
Supply of materials and completion of fabrication, testing and all construction and
installation activities for the Work.
9.
Provision and installation of all required facilities for the Central Processing Facility,
Oil Gathering system, Gas & water injection system, interface tie-in piping between
CAFC and MLE plant and roads. This includes but is not limited to equipment and
utility services, power distribution and emergency power generation, distributed
control system, instrumented safety systems, materials handling facilities,
telecommunications and equipment rooms.
10.
Provision and installation of all necessary load banks and controls necessary to
undertake site testing and Commissioning of the emergency generator. Provision of a
temporary generator, to enable commissioning. Contractor shall substantiate actual
power requirements and temporary power generator sizing.
11.
Mechanical Completion activities
12.
Pre-Commissioning, Commissioning activities and Start-Up activities
13.
Provision, fabrication, installation and subsequent removal of any temporary piping
required for testing and cleaning activities.
14.
Cleaning of critical piping systems and equipment by retro-jetting, chemical cleaning
or other appropriate methods. Critical systems shall be defined and agreed with
Contracting Authority and shall include but shall not be limited to compressor suction
pipework, compressor discharge pipework and recycle lines (including discharge
coolers), fuel and seal gas systems, columns, Oil & Gas Gathering System, etc.
System cleanliness shall be demonstrated. Methods to demonstrate cleanliness shall
be defined and agreed with Contraction Authority. Detailed design of these and other
critical systems shall be designed to facilitate these activities. Demonstration of
system cleanliness is a key requirement prior to ready for Start-Up and the
introduction of hydrocarbons.
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15.
Provision of any necessary Construction camps and all temporary site facilities and
support services, including site offices and accommodation for the Contracting
Authority personnel.
16.
Provision of all necessary transportation to convey the Contractor‟s workforce to and
from the construction sites.
17.
Provision of water treatment, storage and distribution system, adequate for supporting
the temporary construction camps and facilities throughout the course of the Work.
18.
Provision of a sewage collection, treatment and disposal, adequate for supporting the
temporary construction camps and facilities throughout the course of the Work, with
particular attention given to the HSE expectations.
19.
Provision of site First Aid facilities and related medical supply, qualified personnel and
ambulances, consistent with the size, hazards and location of the workforce.
20.
Provision of site access and security compatible with program provided by the
Contracting Authority.
21.
Provision of Suitable Site accommodation and all necessary facilities for Contracting
Authority Personnel
22.
Removal of all temporary services and reinstatement upon completion of the Works.
23.
Provision of all Materials and Equipment.
24.
Provision of all Hydrotesting services including, installation and subsequent removal
of all materials required for the disposal of hydrotest water.
25.
Provision of all materials and services required for the Fibre Optic cable links within
this Scope of Work.
26.
Any additional construction plant and personnel which prove to be required for the
safe and proper performance of the Work or to satisfy the requirements of any
approving authority shall be supplied by the Contractor. The cost of all such additional
items shall be deemed to be included within the Contract price.
27.
Contracting Authority shall perform early site preparation, earth moving and sand
levelling, civil preparation including gypsum layer for CPF, and temporary construction
camp. Contractor shall endorse and use the as-is final state of the early site
preparation as the basis for execution of the Project. Any further site preparation
required for the requirements of the Project is Contractor‟s responsibility and are part
of the Work.
3.1 DESIGN CONCEPT AND DATA REVIEW
Front End Engineering Design (FEED) on the CAFC Project has been carried out by the
FEED Contractors. Information available from the FEED is to be used as a basis for scoping
and programming the Work.
The Contractor shall review, verify, endorse and take responsibility for the accuracy of the
FEED documents included in FEED Package whilst preparing his tender and during the onset
of the Work.
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The Contractor shall also require to perform a SITE SURVEY to endorse FEED and take
responsibility for the accuracy of the FEED documents included in FEED Package whilst
preparing his tender and during the onset of the Work.
A list of project specifications has been included with the FEED package. All specifications
shall be reviewed and updated as necessary by the Contractor, to ensure that they comply
with the latest Algerian Law and the latest industry standards and best practices. Where it is
identified that a specification is not provided as part of the FEED package Contractor shall
produce and submit for Contracting Authority, the relevant document complying with the
requirements of Algerian Law, project philosophies and recognised industry standards.
Contractor shall incorporate safety and integrity critical lessons learnt from previous projects
and requirements from Contracting Authority. This shall include but shall not be limited to
lessons learnt from serious incidents and near misses
The Contractor shall take responsibility for any conflict, error or omissions in the
documentation after the award of the Contract.
The Contractor shall be responsible for the removal of all “HOLDS” on documentation as part
of the Detailed Design. Where a “HOLD” is indicated, the Contractor shall clarify with the
Contracting Authority prior to removal of the “HOLD”.
The following sections provide additional details describing the development of certain key
documents provided. The design development requirements described below are not
intended to represent all design developments associated with these documents.
3.2 HSE
The design shall be consistent with CONTRACTING AUTHORITY HSE minimum
requirements and Process Safety Philosophies and Reports as reported in Section 6 except
where otherwise indicated within this document or the FEED package. CONTRACTING
AUTHORITY HSE and Process Safety Philosophies and Reports shall be updated by the
Contractor at the appropriate time within the design process as described above. Some of
these documents have been updated during FEED.
CONTRACTOR shall further define and develop the project HSE requirements for all CAFC
project facilities with the aim to collate and documents all the HSE design criteria and
philosophies, applicable regulations, codes and standards that are to be adhered regarding
detail design and engineering, procurement, construction and commissioning and Start Up of
the CAFC project facilities.
3.3 DESIGN INTERFACES
CONTRACTOR shall be responsible for identification, engineering and assistance to
CONTRACTING AUTHORITY in managing of all interfaces (limited to PLANT TIE-IN)
with CONTRACTING AUTHORITY, and via CONTRACTING AUTHORITY with
CONTRACTING AUTHORITY‟s other contractors and third parties that may arise in
performance of the WORK.
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Design and installation interfaces include, but are not limited to those listed in the
following sub-sections.
1. TIE-IN interface MLE and CAFC
MLE PMT has provided the engineering and design documentation for the valved TIEIN‟s for utilities and process connections to enable CAFC CPF to operate. Generally
these TIE-IN‟s have NOT been run back along MLE pipe racks to battery limit
locations between the two plants although space has been allowed on the MLE pipe
racks.
CAFC FEED contractor has to include in his EPC Offer:
- Purchase of all necessary pipe, fittings and instrumentation
- Installation and routing of all piping, fittings, and instrumentation from within
CAFC plant to the MLE plant to the battery limit tie in locations.
- Testing, clean up and hook up of all TIE-IN‟s
Specific details of the required TIE-IN‟s have been agreed with MLE PMT during
CAFC FEED study. (details attached here MOMxxxxxxxxxxxx dated 23rd September)
ATTACHMENT A to F
Adobe Acrobat 7.0
Document
Adobe Acrobat 7.0
Document
Adobe Acrobat 7.0
Document
Adobe Acrobat 7.0
Document
Adobe Acrobat 7.0
Document
Adobe Acrobat 7.0
Document
January 2012 MLE PMT and CACF PMT agreed the TIE-IN‟s. MOM is attached here
for clarification.
ATTACHMENT I
D:\Algeria\interface\
Jan25_2012\MOM 27 01 12 signed copy.pdf
CONTRACTING AUTHORITY will furnish detail documentation of MLE/CAFC TIEIN‟s during EPC Clarification period.
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2. OIL BOOSTER & EXPORT Pump Installation
CAFC production requires the addition of two sets of oil booster and export pumps
installed alongside the existing MLE pumps within the MLE CPF. These additional
pumps will be identical to the existing ones and be procured from the same vendor.
CAFC FEED contractor has to include in his EPC offer:
- Purchase of 2 off oil booster and 2 off oil export pumps exactly the same as the
existing MLE pumps and from the same vendor.
- Note, pump foundations are included in MLE SOW
- Install, hook up, test and make ready for operation.
3.4 FUTURE FACILITIES
The future facilities at CAFC CPF include, but are not limited to:
Booster inlet compression (not foreseen in the present SoW as this will probably be
integrated with MLE booster compressor)
3.5 ALGERIAN REGULATORY BODIES
The Contractor shall ensure that all the inspection requirements of the Algerian regulatory
bodies are met. This shall include but not be limited to any necessary payments and
coordinating visits to design offices, construction sites and supplier locations. Algerian
regulatory bodies include but are not limited to ARH, DPEM, CTC, ARPT and ONML.
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4. PROJECT MANAGEMENT
4.1 OVERVIEW
The Contractor shall provide sufficient resources to effectively plan and safely manage the
Work, including establishment and operation of Quality and Integrity Assurance requirements
and Control measures and material procurement, expediting, inspection and control
procedures and the securing of all necessary permits and approvals.
The Contractor shall provide active management, direction and supervision of the Work,
including, but not limited to, the following:
(i)
ensuring that the Work complies with the Contracting Authority HSE MS
standards (Ref. Part C – Annex XI) and HSE Minimum Requirements (See
section 6) and with all national laws, codes and international standards and that
the Contractor's procedures are followed rigorously;
(ii)
organising the Work;
(iii)
reviewing and controlling project performance to ensure that the Work meets all
requirements of the Contract;
(iv)
preparing and providing to the Contracting Authority the project control reports
described in the Contracting Authority‟s Administration Instructions;
(v)
obtaining all approvals and satisfying all other requirements of the Competent
Authorities in relation to the Work;
(vi)
co-ordinating and supervising all contacts with the Contracting Authority and the
Competent Authorities in relation to the Work;
(vii)
keeping the Contracting Authority's Representative informed on all key activities
in the Work in a timely manner and promptly highlighting any areas of concern;
and
(viii)
Avoiding and resolving all the disputes between its subcontractors.
The Contractor shall provide all project services necessary to manage the Work in
accordance with the requirements of the Contract, with emphasis on efficient methods of
working and meeting the Contract Schedule, including, but not limited to:
(i)
organisation of the project services;
(ii)
review and execution of effective controls to ensure that the Work is executed in
accordance with the Contract;
(iii)
project management and provision of project control functions, planning,
scheduling, cost control and document control as required to fulfil the
Contractor's obligations under the Contract;
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(iv)
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
co-ordination and provision of all project personnel, office services, translation
services, accounting and secretarial functions necessary for the execution of the
Work;
(v)
co-ordination of the Work and supervision of all contacts with the Contracting
Authority and the Subcontractors;
(vi)
mobilisation of manpower for the Work;
(vii)
interface between the Contractor‟s project management and field construction
operations;
(viii)
preparation of detailed work schedules and execution plans;
(ix)
monitoring of progress and comparison of actual performance with the detailed
work schedules and reporting of deviations to the management of the Contractor
and the Contracting Authority; and
(x)
Production of progress reports as specified in the Contracting Authority‟s
Administration Instructions.
4.2 PROJECT EXECUTION PLAN
The Contractor shall submit with their offer a preliminary Project Execution Plan for
Contracting Authority review and evaluation, and within six weeks after award of the Contract,
a definitive Project Execution Plan based upon the Contractor‟s offer as amended by Tender
Clarifications, which shall be submitted to the Contracting Authority for Review. This shall set
out the entire Work plan for the Project covering all topics including but not limited to:
Organisation
Management
Design engineering
Construction Engineering including follow-on engineering and
MLE Interface Tie in execution
Procurement and Logistics
Technical Integrity Management
Construction Facilities
Risk Management Plans and Procedures
Materials Transportation and Management
Personnel Transportation
Planning and Cost Control
Subcontract Management
Prefabrication
Construction
Camps and Facilities
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CMMS Population
Mechanical Completion
Commissioning
As-Built Drawings
Certification
Start-Up and subsequent Performance Testing
Health, Safety, Environment and Quality (HSEQ)
Industrial Relations
Managing/interfacing community relations
Change management
Technical Query Procedures
Final Documentation & operating manuals
The Plan shall identify all of the Key Resources proposed for use in the execution of the
Project.
As the Project progresses through to completion, formal review and update of the Project
Execution Plan shall be carried out to reflect the change in focus of the Project.
The Contractor shall appoint a Project Director or Senior Project Manager who shall take
ownership of the plan and who shall be responsible to the Board of Directors of the Contractor
for successful delivery of the Project to the Contracting Authority. He shall ensure that all of
the resources required meeting the overall Project Schedule and the individual Project
Milestones are available and meet the specified acceptance criteria. He shall be the prime
contact between the Contracting Authority and the Contractor and shall be accountable to the
Contracting Authority for the achievement of the delivery of the Project to the standards
contained in the Contract.
The Contractor shall nominate a Project Sponsor from within the Contractor‟s Board of
Directors in order to ensure that Project goals are met.
4.3 ORGANISATION
The Contractor shall provide, in the Annex XV – “Contractor Personnel” of the Contract, an
integrated Project Organisation, which shall be mobilised as a single Project Task Force. The
Base Case shall be for the Project Task Force to be mobilised in a single Engineering,
Procurement and Construction Management office location, with a fully networked Information
Technology system linking all Key Personnel. At the appropriate time in the schedule, the
Contractor shall mobilise a team to site (Contractor has to communicate in due time to
Contracting Authority the number of persons composing this team).
As a minimum, the following Key Personnel shall be nominated by Contractor, and submitted
to Contracting Authority for approval:
Project Manager
Engineering Manager
Senior Project Engineer
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Discipline Technical Leads
Project Control Manager
Quality Assurance Manager
Quality Control Manager
Community Relations Manager
Lead Discipline Managers
Construction Manager
Commissioning Manager
Materials Manager
Welding and NDT Engineer
HSE Manager (Detailed Engineering and Construction phase)
Lead Safety Engineer
Site HSE Engineers & Superintendent
Operation and Maintenance Manager
Project Information Manager
Document Control Manager
Procurement Manager
Third Party Inspection Coordinator
Security Manager
Logistics Manager
Contractor shall give to Contracting Authority organization chart both for Engineering Phase and for
Construction phase.
4.4 PROJECT PROCEDURES
The Contractor shall prepare a Project Management Procedures Manual no more than 1
month after effective date of the Contract. These procedures shall clearly set out the method
by which the Project shall be controlled and shall include a comprehensive Work Breakdown
Structure. These procedures will be reviewed and approved by Company; however, Company
procedures will always have precedence.
4.5 QUALITY ASSURANCE
The Contractor shall implement a documented Quality System (the “Contractor‟s Quality
System”) in accordance with the requirements of ISO 9001:2008, to maintain Quality
Assurance. The design and development of computer software shall be controlled in
accordance with ISO9001:2008.
The Contractor‟s Quality System shall be suitable for all the Work, shall be detailed within the
Contractor‟s Quality Assurance procedures for each Location and shall be made project
specific by application of the Contractor‟s Quality Plan(s) for the Project as outlined in Annex
XIII – “Quality Plan”. The Contractor shall demonstrate the execution and maintenance of
Quality Assurance to the Contracting Authority‟s satisfaction through all phases of the Work.
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The Contractor shall implement all aspects of the work in accordance with the procedures in
the Contractor‟s Quality Plan. The plan will be an integral part of the Project and will come into
effect at signature of the Contract.
4.6 SOFTWARE
The Contractor shall use the following software for the execution of the Contract:
HAZOP software - PHA or LIHOU
Instrumentation Database
- INtools
Electrical engineering
- ETAP
Process engineering
- Hysys
- PRO II
- Unisim
- Pipesim
- OLGA
- FLARENET
- FLAREsim
Piping (CAD)
- PDMS (3D)
- AutoCAD or MicroStation (2D)
- CAESAR II
Pipeline:
- Archgis
- Autocad
- Microstation
Steelwork - STAAD.Pro
HSE
- Recognized Software‟s for Consequence Analyses
- Software‟s for Quantitative Risk Analysis
CMMS
- EAM
Planning
- Primavera 3.1/ Microsoft Project
Document Data Management: - EDAM
Material Management
- MIAP (to be defined during KoM or
dedicated meetings organized by Contractor).
Piping Specifications
- SPCPUMA (to be defined during
KoM or dedicated meetings organized by Contractor).
General
including
- Microsoft Office applications (2003 or above)
- Word, Excel, PowerPoint, Access, Visio
Professional. Files generated by Microsoft
applications shall be backwards compatible to
version 2003.
- Adobe Acrobat Professional, Reader
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Where required by the Contracting Authority, Contractor shall submit input and output files in
source format and .pdf format for review by the Contracting Authority.
4.7 DOCUMENTATION
The Contractor shall prepare all documents including Drawings, Specifications, calculations
etc. required to perform the Work. This shall include all documents described or listed in this
Scope of Work, all documents listed in the project specifications and any other documents
that the Contracting Authority or the Contractor deem necessary to fully define, build and
operate the Permanent Works.
Existing Contracting Authority documentation that is affected by the new design shall not be
renumbered, but the existing drawings shall be updated with new information.
In agreement with Contracting Authority procedures, Contractor shall prepare a Master
Document Register (MDR), which shall include all Contractor supplied formal and detail
design documentation. The Table of Contents for the MDR shall be submitted to the
Contracting Authority for review within 30 days after award of Contract.
The Contractor shall develop and maintain the MDR of all documents, showing planned,
forecast actual dates, current percentage complete and status for each document, which shall
be subject to audit by the Contracting Authority at any time. The document register shall
include all documents to be produced and/or updated by Contractor and all Supplier
Documents
The document register in place at the end of FEED attached in Annex I – “Technical” of the
Contract shall be confirmed and validated by the Contractor to include all design deliverables
within thirty (30) days of Contract award. All procurement deliverables shall be included
within sixty (60) days of Contract award and all construction/Commissioning deliverables
shall be included within one hundred and eighty (180) days of Contract award.
As Contractor updates the document register, each document shall be identified after
approval from Contracting Authority as requiring either review, approval or only for
information.
The dates that specify when Contractor shall submit documents to the Contracting Authority
shall be delivered from Contract Control Schedule. The Contract Control Schedule shall be
prepared by Contractor and reviewed and approved by Contracting Authority. All deliverables
shall be submitted with approved planned dates. Any change must be submitted to
Contracting Authority for approval.
For each document the Contractor shall give a weight and submit the changes to the
Contractor Authority. Any weight change in deliverables must be submitted to Contracting
Authority for approval.
From this Register of the Contractor's planned documents, the Contracting Authority shall
identify those which shall be submitted to the Contracting Authority for Review/Information.
Annex V – “Documents to be submitted to the Contracting Authority” of the Contract identifies
the minimum level of document review required by Contracting Authority.
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All documents shall be available to the Contracting Authority in locations to include:
Contracting Authority Home Offices, Contractor‟s Project Office and the field construction
SITE. All documents shall be developed such that they can be provided to the client in
electronic format.
Contractor shall prepare and maintain an index of all Supplier manuals. This shall be
maintained in an electronic format for eventual hand over to the Contracting Authority.
Contractor shall maintain all Drawings and documents relevant to Start-Up up to and including
final "As Built" status. The "As Built" documents shall be incorporated into the final
Contractor‟s Design Report for handover by the Contractor and acceptance by the
Contracting Authority.
Contractor shall produce Operating and Maintenance Manuals for all equipment, including all
equipment data books, operating instructions, emergency procedures, maintenance
instructions and recommended spares lists for each item, as provided by Suppliers. The
Operating and Maintenance Manuals (or procedures) shall be prepared in English and
translated into French. Both the Operating and Maintenance Manuals are to be completed by
Contractor at least 8 months prior to Start-Up.
The contents of the typical operating, maintenance and safety manual shall be followed at a
minimum:
Process description, with Plot Plan, PFDs, Material Balances;
Utilities description;
Distributed Control System;
Overview Drawings, such as Electrical One Line Diagrams, Area
Classification Diagrams, Material Selection Diagram, Hazardous
Area Diagram;
General Safety Instructions;
Operating Instructions;
Outline for Individual Equipment, including:
Brief description of Major Equipment;
Operating Instructions;
Operating Limitations;
Safety Items and Operational Hazards;
Recommendations for Maintenance and Repairs;
Recommended spare parts list
Support Systems, including:
Corrosion Protection System;
Communications System;
Safety Systems.
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Central Area Field Complex Project
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Contracting Authority require detailed “valve-by-valve” Operating Procedures in order to verify
clear, complete procedures and to certify competency of operator‟s knowledge and interaction
between control and process systems. The Operating Procedures for the Facilities shall be
prepared by Contractor. Contracting Authority shall provide technical support and
recommendations during the review process. The Operating Procedures shall require review
and approval by Contracting Authority and shall include, as a minimum, the following:
System descriptions
Technology descriptions
How the system shall be started, operated and shut down,
covering normal, abnormal, and emergency situations
Design limitations
Operational set points
Drawings (P&ID‟s, Cause and Effects, etc)
Any special operating procedures
Timeline and programme to include manpower requirements
List of commissioning, test, start up and recommended spare
parts procured
List of Commissioning Lubricants, consumables and bulk
materials
List of Chemicals
List of all Equipment with general information
List of Operations and Maintenance Training Requirements
Contractor shall review the content of the Maintenance Manuals and ensure that all technical
requirements are included. The finalised Maintenance Manuals shall be provided for approval
to the Contracting Authority 8 months prior to Start-Up
The following activities shall be also considered:
Review all Vendors Operating and Maintenance manuals for completeness;
Obtain from Vendors any clarification, explanation and additional information
necessary to satisfy the commissioning and operation requirements.
Documentation, including “As-built” documentation and Engineering Information shall be
supplied by the Contractor in accordance with Annex V – “Documents to be submitted to the
Contracting Authority” of the Contract..
The Contracting Authority reserves the right to review all Contract deliverables. However, it is
the intention that the Contracting Authority shall only review certain key documents. The key
documents are detailed in the review matrix to be defined and inserted in Annex V –
“Documents to be submitted to the Contracting Authority” of the Contract.
Review of documents by Contracting Authority does not relieve Contractor of the
responsibility to provide complete, safe and operable facilities in full accordance with
Contracting Authority supplied documents and Scope of Work. A program for document
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review shall be submitted to Contracting Authority by Contractor within 30 days of Contract
award. It is Contractor's responsibility to ensure that Contracting Authority‟s Representatives
are notified in good time of the issue of key documents for review and to expedite review to
avoid delay to the Work.
Contracting Authority shall require an Information Management Plan to be submitted for
review by Contracting Authority within 8 weeks of contract award. The Information
Management Plan shall:
Identify all database/software sources and the layout and
structure of data within any database on a discipline-by-discipline
basis. Advise software name and version.
Provide a schematic illustration of information systems and flow
of data between them. Identify direct application-to-application
links, file-to-file transfers and manual transfers.
List main document types to be produced by Contractor with
reference to production software.
Describe how 3D CAD models shall be organized, managed and
interfaced with other system tools.
Describe how 3D CAD models shall be developed and used
throughout the various project phases.
Allocate responsibilities to all parties involved.
Define how information shall be collected, processed, stored and
exchanged.
Identify Document control procedures, including document
distribution, review and approval of engineering and supplier
documentation, client review and approval,
Identify documentation quality plan and procedures.
Progress reporting for design documentation,
documentation and engineering data.
supplier
Provide schedules and identify deliveries against the project
milestones. Special attention shall be given to identify milestones
for pre-handover to Contracting Authority for operations and
maintenance planning activities.
Detail measures to ensure information integrity and singe source
philosophy.
Detail the implementation of a Master Tag register and how to
ensure this remains the tag master throughout all phases of the
project.
Define how to ensure the electronic version of the document is
regarded as the original (both engineering and supplier
documentation).
Define how data transfer to Contracting Authority systems on a
basis to be mutually defined.
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Define how information shall be distributed on the Sites.
Define how to
documentation.
ensure
correct
updating
and
as-built
As-built procedures.
Detail the process by which formal handover shall be achieved.
Handling of French translations of documents.
The plan shall be coordinated with the Contract Master Schedule.
Contractor shall give Contracting Authority access to a 3D model viewing station in
Contractors offices and on Site and should be accessible externally by the Contracting
Authority. The view model shall be updated by Contractor at regular intervals.
Contractor shall hand over the complete 3D design model developed during detail
engineering. This shall include all catalogues and specifications used and a description of the
hierarchical structure of the model.
Service descriptions used for tags shall be unambiguous, indicate both equipment function
and location, and be in line with the tag description practise established in the Computerised
Maintenance Management System.
Contracting Authority requires total access to all design and supplier documentation for
maintenance planning, training and other preparations for operations activities.
Information shall be transferred from Contractor‟s systems to Contracting Authority databases
at agreed milestones. A test transfer of electronic information shall be carried out as early in
the project as possible to verify the data transfer procedures. This shall include all relevant
types of digital formats.
Transfer of documentation and information into Contracting Authority data management
system is the responsibility of Contractor. This includes data quality, completeness,
consistency, data format and compliance with existing codes and attributes.
Contracting Authority shall on a regular basis carry out verifications to ensure that information
complies with requirements.
4.7.1
Data and Document Management
The design activities shall be developed according to the requirements of technical
specification defined in the tender documentation and according to the following Contracting
Authority Standards:
Contract requirements for technical document management and facility technical data
delivery
The following paragraph provides a detailed list of
Contract requirements concerning
technical document management and facility technical data delivery for Company database.
Each requirement shall be accomplished according to a listed set of Company specifications
The requirements include:
Technical organization for document and material management
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Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Minimum technical data required for typical basic design documents
Detailed full life document planning and progress report
Document approval management
Implementation of CAD Programs
Computerized delivery of technical data to Company Database
Delivery of model and spare part data for integration with maintenance
Paint & Coating Activities
Technical organization for document and material management
06215.DOC.GEN.SDS
20189.COO.GEN.SDS
blocks
20198.COO.GEN.SDS
Facility functional Units
Technical document identification and title
Item Numbering
Minimum technical data required for typical basic design documents
20259.DOC.GEN.SDS
06221.DOC.ELE.PRG
06227.DOC.GEN.PRG
06222. DOC.PRC.PRG
06223. DOC.MEC.PRG
06224. DOC.MEC.PRG
06225. DOC.STA.PRG
06681.DOC.ELE.PRG
06682.DOC.ELE.PRG
P&ID Piping and instrumentation Diagram
OLD One line Diagram
Facilities Plot plans
Equipment List
Line List
Hand Valve and Line Accessories List
Loops and instrument List
Electric load list
Electric cable list and electric cable report
Detailed full life document planning and progress report
27605.VAR.GEN.SDS Technical Documentation required during the Project
Development Phase
Document approval management
27608.DOC.GEN.SDS Management of approval of technical documents
Piping Class Management
CONTRACTOR will apply COMPANY standard methodology and software (
SPCPuma ) to manage and generate the facility piping class and relative piping
Referance Database ( RDB ) to import in a 3D CAD Model , according to
document:
The COMPANY will provide to the CONTRACTOR the appropriate access to
COMPANY Piping Class Database
Implementation of CAD Programs
20204.CAE.GEN.PRG Procedure for preparation of 2D CAD Drawings
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Part D - Scope of Work
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
20205.CAE.GEN.PRG General procedure for preparation of 3D CAD models
and deliverables production
20206.CAE.GEN.PRG Standard rules for preparation of 3D CAD models and
deliverables production by using Intergraph PDS3D
27901.CAE.GEN.PRG Standard rules for preparation of 3D CAD Models and
deliverables production by using AVEVA Vantage PDMS
20248.CAE.GEN.SDS Survey of existing facilities through laser scanning to
obtain the as-built 3D CAD Model and associated data and document
27906.CAE.GEN.PRG Standard rules for preparation of 3D CAD models and
deliverables production by using Intergraph SMARTPLANT 3D
Computerized delivery of technical data IN Company Database
06214.DOC.GEN.SDS Instructions to Contractors for information submission to
DBIMP
20203.DOC.GEN.SDS Handover of plant component data and key documents
for DBIMP
The COMPANY will provide to the CONTRACTOR the appropriate access to COMPANY data
Loading web site or, in alternative, the excel template.
Delivery of model and spare part data for integration with maintenance
20202.DOC.GEN.PRG Model and spare parts data required from Vendors
Paint & Coatings Activities
20000 VAR.PAI.FUN. Rev.3 - Protective coatings, galvanising and metallising for
internal and external surfaces of offshore and onshore structures and related
components
20550 PIP.COR.FUN. Rev.0 – External coatings for corrosion protection of steel
Pipes and components
20551 PIP.COR.FUN. Rev.0 – Internal coatings for corrosion protection of steel
Pipes and components
20552 VAR.PAI.FUN. Rev.0 – Maintenance of coated surfaces
Guide to implementation of OOC / ENI E&P computer programs for CAE (computer
Aided engineering)
Guide to implementation of OOC / ENI E&P proprietary computer programs for CAE
(Computer Aided engineering) or other recommended programs.
Tool MIAP:
ITEM BR 001 Rev A01
Tool SPCPUMA:
ITEM BR.002 Rev A01
Overview of Miap information system (item coding, bulk
material coding, model and spare part coding) (to be defined
during KoM or dedicated meetings organized by Contractor)
Overview of SPCPUMA Functionalities (computerization of
Piping specs, creation of piping spec catalogues (to be defined
during KoM or dedicated meetings organized by Contractor)
Tool EDAM:
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EDAM
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Engineering Document Approval Management
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Part D - Scope of Work
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
4.7.2 Coding Methodology for Correspondence
The information exchange and the engineering documents transmission will be performed in
accordance with the following criteria.
All the official information shall be transmitted in written. In principle any form of written
communication is accepted (e-mail, fax and letter).
The official information exchange between Company and Contractor shall take place through
the respective authorized representatives.
The main exchange of technical information shall be through e-mail or informatics platform.
For all the meetings between Company and contractor a minute of meeting shall be edited.
The conversations between Company and contractor not reported in writing will have no
effect.
Communications regarding different matters or relative to different discipline will be accepted
provided that the main points are recalled in the object of the communication so as to allow
their traceability.
In general the following indications shall be included in the correspondence in order to be
used:
- References to previous correspondence;
- Reply or expected actions;
- Timing for the actions or expected replies.
In order to facilitate the management of the technical correspondence among the parties
involved in the project the below reported identification shall be used:
FFFFFFSS_NNN_OOO_DDD_X_NNNNNN
Where:
FFFFFF
Facility Code
SS
Sub-facility Code
NNN
Correspondence Type
OOO
Originator (business name code - three alphanumerical characters)
RRR
Receiver (business name code - three alphanumerical characters)
X
Discipline (see Ref.2)
NNNNN
Sequential number
Correspondence Type
LET Letter
FAX Fax
EMA E-mail
TRN Transmittal
MOM
Minutes of Meeting
EMREngineering Monthly Report
EWR
Engineering Weekly Report
VOR Variation Order (Technical) Request
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
WSTWork Statements
TQ Technical Query
Ex. 00220600_LET_ENI_TCM_G_00001
Note
The weekly and the monthly reports shall have instead of the sequential number the date in
following format:
YYYY_MM_DD
Ex. 00220600_EMR_ENI_TCM_G_2009_04_01
The identification of transmittal IN of contractor and of transmittal OUT of Company for the
management of the approval cycle is defined in 27608.DOC.GEN.SDS - Management and
approval of technical documentation
The Company can request the contractor in each moment the files of the documents on
information support (CD or DVD).
This support shall be identified as follows:
FFFFFFSS_CCC_NNN_Data
Where:
FFFFFF
SS
CCC
NNN
Data
Facility code
Sub-facility code
Business name Code of contractor
Sequential number of CD/DVD
Creation date of the CD in format:
YYYY.MM.DD
In the CD/DVD shall be inserted the index of the files contained (including code, title and
revision of the document). In the index to each file shall be applied a hyperlink which sends to
the relative document.
4.8 MANAGEMENT OF CHANGE
The Contractor shall submit their proposed Management of Change (MOC) procedure with
their tender for Contracting Authority review to be integrated in Annex XVI – “Contract
Administration Manual” of the Contract. Contractor shall implement a change control
procedures to ensure that changes in the design of the work are controlled, in accordance
with the Contracting Authority minimum requirements. These procedures will be reviewed and
approved by Company; however, Company procedures will always have precedence.
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4.8.1
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Management of Change Policy
All temporary and permanent changes to organization, personnel, systems, procedures,
equipment, products, materials or substances shall be evaluated and managed to ensure that
health, safety and environmental risks arising from these changes remain at an acceptable
level. Contractor shall comply with changes to laws and regulations and take account of new
scientific evidence relating to HSE effects.
4.8.2
Documents concerned by MOC
Management of Change procedure shall be applied to the following documents including but
not limited to:
Plot plans
PFDs and UFDs
P&ID‟s
Equipment Data Sheets
Equipment List
Line List
Material Safety Data Sheets
Emissions Tracking Matrix
Cause and Effect Chart
Electrical One Line Drawings
Electrical Area Classification
PSV Design Basis and Calculations
Instrument Index
Aspect / Impact Matrix
Operating Procedures
Maintenance Procedures
Training Documentation
Emergency Response Plans
Compliance Matrix
Environmental Management Program
Safeguarding Philosophy and Diagrams
DP/DT Drawings
Material Selection Drawings
CV Datasheets
RV Datasheets
Hazardous Area Classification Layouts and Reports
Safety Systems Design
Design Pressure and Temperature Diagrams
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Heat and Material Balance
4.9 DAMAGE AVOIDANCE PROCEDURES
The Contractor shall ensure that no damage is done to existing MLE facilities or adjacent
land, property and habitation during execution of the Work. Contractor shall provide fully
developed damage avoidance procedures no more than 1 month after effective date of the
Contract and shall follow the procedures. Procedures may require installation of temporary
protection for simultaneous operation with a live NGL plant.
Such procedures shall include damage avoidance to existing infrastructure, and local
community facilities and relationships.
To facilitate the preparation of these procedures, Contracting
Authority will provide required documents which are included in
Annex XI – “HSE Management System Requirements” of the
Contract.
4.10
HSE PLAN AND MANAGEMENT
The Contractor shall prepare an HSE Plan and Management System in accordance with the
requirements of Annex XI – “Health, Safety and Environmental” of the Contract
The Contractor shall develop and implement an Approved safety management plan to
maintain Best Industry Practice with respect to construction and Commissioning which shall
apply to both Contractor and Subcontractor personnel. This shall include a safety organisation
for each Location, supported by procedures and the Contractor‟s project management team.
This plan shall address all safety critical activities such as personal protective equipment,
scaffolding, rigging, trenching and excavations, vehicle movements, speed limits, etc.
The Contractor shall prepare and implement a management system (“HSE Management
System”) for all phases of the Work to ensure that the Contracting Authority's HSE standards
and other requirements are implemented in the Design. The Contractor shall submit its
proposed HSE Management System.
The HSE Plan and Management System shall be revised and updated as the Project
proceeds.
The Contractor‟s organisation and arrangements necessary for the implementation of his HSE
MS shall be developed into the Contractor‟s HSE Plan. The HSE Plan shall be prepared
specifically for the Work.
The HSE Plan shall be subject to Contracting Authority‟s review and shall be finalised and
completed within four (4) weeks of Contractor‟s “Instruction to proceed with the Work”.
Contracting Authority reserve the right to review any proposed amendments to the agreed
plan, which may be necessary as the Work progresses.
The Contractor‟s HSE Plan shall make specific reference as to the procedures, permits etc.
which shall be used to ensure that the safety of the operations are not compromised.
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
The Contractor shall establish an organisation plan and procedures to ensure that all HSE
aspects of the Work are thoroughly considered, planned, implemented and followed up during
all phases of the Work. The HSE programme, which is to broadly comply with the
requirements of Contracting Authority‟s HSE standards and policy, shall be updated as
necessary through the period of the contract.
The Contractor shall provide a dedicated HSE Manager who shall have overall accountability
for the implementation of the Contractor‟s Health, Safety, Environmental requirements and
Technical Integrity requirements, as detailed in Section 6 of this document and in the Annex
XI – “Health, Safety and Environmental” of the Contract . The HSE Manager shall be directly
responsible to the Project Manager.
The HSE Manager shall be supported by representatives of the Contractor‟s HSE
organisation.
The Contractor‟s offer shall include an overview of the proposed HSE Plan and a nomination
for the HSE Manager‟s position together with the dedicated HSE staff for detailed engineering
and construction & SIMOPS phase.
The Contractor shall develop and implement a Contracting Authority Approved safety
management plan to maintain best industry practice with respect to construction and
commissioning both for the Contractor and Subcontractor personnel. This shall include a
safety organisation for each Location, supported by procedures and the Contractor‟s project
management team. This plan shall address all HSE critical activities such as personal
protective equipment, scaffolding, lifting and rigging, trenching and excavations, vehicle
movements, and land transportation, confined space activities, working at height, radioactivity,
SIMOPS activities, etc.
4.11
BRIDGING SYSTEM
A suitable bridging system to the Contracting Authority‟s safety management, travel and
security plans shall be developed by the Contractor and submitted to the Contracting
Authority for Approval. Similarly, all Subcontractors shall be covered by suitable bridging
documents to clearly identify safety interfaces and responsibilities and required actions in an
emergency situation.
4.12
PLANNING, SCHEDULING AND PROGRESS REPORTING
The Contractor shall prepare detailed schedules for all areas of the Work. The Contracting
Authority Work Breakdown Structure attached in the ITT and to be included in Annex II –
“Breakdown of Prices for Goods and Services” shall form the basis of the Contractor‟s
Planning, Scheduling, Cost and Progress Reporting System. A dedicated analysis should be
done for the early works, with different planning and S-curves. The Contractor shall prepare a
document where it is described how he shall interface with the Contracting Authority Work
Breakdown Structure together with information on the Contractor‟s Management System. The
Contractor shall also provide a Level 2 schedule, histograms, planning and control procedures
with his offer, to be approved by Contracting Authority.
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
The Schedules shall be prepared in a structured way showing individual elements. Each
element shall be able to be definitively progressed and be rolled up to multiple levels of
control.
The schedule shall issue for comments and approval to Contracting Authority. Any changes to
the deliverable planned schedule dates and item shall be submit to Contracting Authority for
approval; until such approval the original schedule shall be maintained.
The Contractor shall update task level schedules through a weekly reporting system designed
to verify that Work is proceeding according to plan. The Contractor shall produce look-ahead
summaries of activities planned and resources to be employed, covering the period up to one
month ahead at any time. Weekly reviews shall be held with the Contracting Authority‟s
Representatives to verify progress and ensure that data flow continues to support the
schedule.
The weekly and the monthly reports shall include:
1 - “Baseline Curve Scheduled” (= ”Original Baseline Curve” ) and relevant per cent progress
(“Scheduled Progress”);
2 - “Actual Curve” and relevant per cent progress (“Actual Overall Progress”);
The weekly and the monthly reports can include the possible “Baseline Curve Rescheduled”
and the relevant “Target Overall Progress” only if approved by Contracting Authority.
Problem areas shall be identified and remedial action put in place by the Contractor. The role
of the Contracting Authority‟s Representatives shall be to ensure that remedial actions are
adequate and are appropriately co-ordinated across the Project. It is the Contractor‟s
responsibility to co-ordinate those actions within the Project and to advise Contracting
Authority of any potential impact on interfaces with other groups.
The Contractor shall prepare summary link schedules for Procurement, Construction and
Commissioning showing all critical activities throughout the execution of the Project. In the
Monthly Report he shall identify all critical and marginally subcritical activities and report on
his strategy for ensuring that the Project Schedule shall be maintained.
The Contractor shall provide, maintain and be responsible for all management of Contractor‟s
personnel and resources, which are involved in this Contract covering all aspects of the Work.
Contractor‟s systems shall be data based and capable of providing quick “what if” analyses of
adverse trends and problem situations. Systems shall be capable of producing a
comprehensive range of reporting options to provide timely and concise decision-making
information. Schedules shall be developed and maintained using Primavera version 3.1
software or equivalent subject to Contracting Authority approval. Where required by the
Contracting Authority, the Contractor shall submit data files in .PRX (source file) and .PDF
formats for review by the Contracting Authority.
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Part D - Scope of Work
4.13
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
INTERFACE MEETINGS
The Contractor shall hold weekly engineering meetings with the Contracting Authority to
review the issues and various discipline activities and progress. Contractor shall minute
issues and report progress against each item at the beginning of meetings.
Furthermore the Contractor lead discipline engineers shall have weekly scheduled meetings
with their Contracting Authority‟s counterparts to discuss discipline related issues. These
meetings shall also be minuted by the Contractor.
The Contracting Authority lead discipline engineers and other Contracting Authority project
personnel shall be able to discuss comments on reviewed documents or any issues face to
face with the Contractor‟s counterparts and other Contractor personnel on an ad-hoc basis.
Major Package and sub-order technical issues shall also be addressed on a weekly basis at
the above meetings, on top and above of any procurement meetings/activities.
Moreover the Contractor shall hold Interface meetings with MLE PMT when required under
the control by the Contracting Authority, in order to coordinate and facilitate interface
activities.
4.14
MANAGEMENT OF EXTERNAL INTERFACES
The primary Parties involved at the interfaces with the WORK are as defined in this SOW.
The design interface main work responsibilities at such interfaces are defined in item 3.3
(DESIGN INTERFACE).
CONTRACTOR shall prepare the design, planning scheduling or other work required for
progressing the resolution of such interface matters.
Interfaces include those area where CONTRACTOR has to exchange information with other
parties for carrying out his own WORK, as well as physical interfaces at the limits of supply
between CONTRACTOR and other Parties. Any additional cost and/or time impact due to
such interfaces shall be recognised by CONTRACTING AUTHORITY to CONTRACTOR
through a CHANGE ORDER.
CONTRACTOR shall issue drawings and documents as requested by other Parties and be
responsible for review of all engineering WORK associated with the interface to ensure that
the final design is on accordance with his own engineering WORK. CONTRACTOR shall
therefore be required to attend regular interface meetings..
All official contact with the Parties involved at the interfaces with the WORK shall be
channelled through CONTRACTING AUTHORITY. CONTRACTING AUTHORITY may,
however, at its options allow CONTRACTOR to have direct contact with interface party or
impose such conditions on him.
CONTRACTOR shall:
Via CONTRACTING AUTHORITY, initiate and organize contact at the technical level
with the Parties involved.
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Keep CONTRACTING AUTHORITY advised with sufficient notice so that
CONTRACTING AUTHORITY representative may attend any meetings arranged to
discuss such matters.
Provide for travel to and attendance at meetings in other Parties offices and for staging
meetings in CONTRACTOR‟s offices.
Prepare minutes of meeting, arrange for signature by, and issue to, all Parties. In
addition, CONTRACTOR shall formally advise CONTRACTING AUTHORITY of any
interface problems, which may arise form such meetings.
Prepare, submit for APPROVAL and implement a detailed interface plan and coordination procedure to cover for external interface activities as defined above.
Where aspects of a commercial nature are involved, CONTRACTING AUTHORITY shall be the
first and sole point of contact.
Technical interface co-ordination meeting shall take place as soon as practical after
AGREEMENT DATE with the Parties involved at the interface. CONTRACTING AUTHORITY
shall initiate interface kick of meetings. Further meetings shall be held at regular intervals during
the course of work.
CONTRACTOR shall schedule his WORK, in respect of interface matter to coincide with the
schedules of the other PARTIES. CONTRACTOR‟s proposed schedule shall be subject to
APPROVAL.
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Part D - Scope of Work
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
5. SCOPE OF WORK AND DETAILED DESIGN/ENGINEERING
5.1 GENERAL
The Contractor shall review, verify, endorse and take responsibility for the accuracy of the
FEED documents included in FEED Package whilst preparing his tender and during the onset
of the Work.
Annex I – “Technical” of the Contract lists the documents resulting from FEED and
Contracting Authority, which form the basis of the scope of this Contract. This includes, but is
not limited to:
Process and Utility / Flow Diagrams
Process Simulation Files and Calculations
Process and Utility P & IDs
Process and Equipment Design Data
Heat and Material Balance
Specifications, Standards, Regulations And Recommended
Practices
Material Take-Offs
Design Philosophies
Site Layouts
Flowlines and Trunkline Alignment Sheet
Typical Pipeline Installation Drawings
Equipment Lists
Equipment Data Sheets
Single Line Diagrams
Electrical Load list
Electrical studies
Control System Statement of Requirements and System
Hierarchy Drawings
Block Flow Diagrams
FEED HAZID and HAZOP reports for follow-up during EPC
phase
Safety systems
HSE studies and risk analyses
At all times the Contractor must give particular attention to the very hot environment in which
the facility shall be built and operated and the desert environment with sand/dust presence.
It is understood that the Work may be conducted at multiple geographical locations. In
addition to the Contractor‟s home site, subsidiary locations may include Algeria, and possible
engineering satellite offices as agreed with the Contracting Authority. At all times control and
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
execution of the Work shall be at the Contractor‟s home site, and all relevant control and
engineering information available and accessible from there.
Contractor‟s engineering shall be efficiency optimisation oriented.
When and where it is necessary for the Contracting Authority to obtain information from
Personnel at these locations, usage of video-conference, electronic mail and group
telecommunications shall be made available by the Contractor for efficient conduct of the
Work.
The Contractor shall organise and undertake all activities, including but not limited to:
1.
Obtaining all permits necessary for the execution of the Project prior to activities in
Algeria.
This shall include briefing, discussing and reaching agreement with the appropriate
Algerian regulatory authorities.
2.
Detail design for all civil works including all site preparation, foundations, roads, and
drainage. This shall include all survey necessary for the execution of the Work and
site investigation.
3.
Detail design for all structural and architectural works.
4.
Detail design of process, utility, electrical, mechanical, pipelines, piping, ICSS, control
and protection instrumentation, safety, and telecommunications required to provide
complete, safe, reliable and operational facilities. This includes maintaining and
providing copies of all calculations and providing same to the Contracting Authority in
original electronic format.
This is to include arranging any necessary agreements/licences. This shall also
require setting up appropriate sub-agreements with the Contracting Authority to allow
full access to and usage of information necessary for the design, erection and
operation of all facilities. The Contractor shall be responsible for the overall system
design to ensure process design requirements are met.
5.
Prepare all necessary, Approved for Design (AFD) and Approved for Construction
(AFC) Drawings, P&IDs, Data Sheets, Specifications, tender requisitions, purchase
requisitions and equipment lists sufficient to fully describe all components for
procurement, fabrication, transportation, storage, installation, Commissioning, start-up
and operation.
6.
Prepare AS BUILT documentation at the end of the Work, within 90 days of the
agreed Mechanical Completion date for documentation detailed in Annex V –
“Documents to be submitted to the Contracting Authority” of the Contract..
7.
Amend and/or update the Project Specifications, Drawings, Data Sheets, equipment
Lists and Studies developed during execution to meet Project specific requirements
as well as to provide a clear, concise technical documentation package. Prepare any
additional Specifications required for the Work not included in the execution
documentation.
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
These Specifications shall cover the design,
Commissioning and operation of the equipment.
manufacture,
construction,
Where elements of the Work (e.g. civil details, architectural, piping design) are subcontracted, Contractor shall apply all procedures, codes, standards and specifications
such that this work is conducted to a standard equal to that of the Contractor and
documentation provided to the MLE Project is of an equal standard.
8.
Maintain a design change control system.
9.
Complete all necessary material take-offs.
10.
Produce fabrication Drawings, as required.
11.
The minimum codes, standards and specifications to which the Work shall be
executed are included in the Contract Package. This includes all Contracting Authority
codes, standards, specifications, philosophies, inspection requirements, etc. Where
the necessary information is not provided the Phase documents and actual design
become the basis for the development of the minimum standard to which the work is
to be completed.
12.
Produce field erection Drawings, including Drawings for temporary erection aids.
13.
Preparation and maintenance of Contractor‟s Design Report. This shall include
summary of final design, basis, calculations etc.
14.
The Contractor shall perform all required engineering and shall maintain a dedicated
qualified engineering design team required to complete the design, procurement and
all construction support engineering for the Work listed as it progresses through until
Operation.
15.
Provision of general logistic and administrative assistance, including but not limited to
obtaining permits, visas, accommodation, hotel rates, car rental, transportation for
Contracting Authority Personnel
16.
Prepare Tender and Purchase Requisitions.
17.
Prepare bid evaluation documentation for Supplier selection.
18.
Procure all Materials and Equipment in accordance with Contracting Authority
Approved Specifications, and Data Sheets.
19.
Conduct Supplier clarification meetings to assist in bid appraisals. Contracting
Authority shall be invited to participate in technical meetings.
20.
Attend selected Supplier kick-off meetings following purchase order award.
Contracting Authority shall be invited to participate in kick-off meetings.
21.
Attend selected Supplier factory inspections to ensure that delivery schedules are
met. Contracting Authority shall be invited to attend in factory inspections.
22.
Attend Supplier Factory Acceptance Testing of equipment. Contracting Authority shall
be invited to attend in Factory Acceptance Testing.
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Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
This shall include advising the Contracting Authority of Factory Acceptance Testing,
with at least fourteen (14) days notice, making available records of defects and
comments. The Contracting Authority reserves the right to attend these tests.
23.
Check, verify completeness, record and catalogue all material mill certificates,
equipment documentation and test reports.
24.
Prepare detailed installation procedures for equipment based upon Supplier
recommendations.
25.
Prepare detailed inter-connection cabling and wiring/termination Drawings for coordination of packaged equipment from various Suppliers.
26.
Implement Welding, quality control and non-destructive testing plans and procedures /
workpacks. This shall include special welding procedures and welder qualifications
for carbon steel, alloy steel and other work.
27.
Prepare system mark-ups and hydrotest diagrams for Mechanical Completion tests.
28.
Develop Inspection and Test Plans.
29.
Implement expediting, inspection and testing as required by the Inspection and Test
Plans.
30.
Populate the Computerised Maintenance Management System (CMMS) in the French
and English languages according with provided templates
31.
Prepare Commissioning documents and procedures.
32.
Prepare detailed Operating Manuals and Maintenance Manuals and manage, review
and approve Supplier Documentation Manuals.
33.
Support the Contractor‟s Construction Team in interpretation of design in the field and
co-ordinate to ensure that Technical Integrity is maintained throughout the Project.
34.
Expedite Suppliers and interface with other Contractors required for the execution of
the work by the Contractor.
35.
Manage Suppliers to obtain equipment sizes and weights to ensure timely definition of
detailed layouts of equipment, piping, cabling, tubing etc.
36.
Interface with Suppliers to ensure Technical Integrity is maintained in accordance with
the Specifications and Data Sheets throughout the Project.
37.
Prepare all documents required to be submitted for approval by Algerian agencies.
Such documents shall be prepared in English and French.
Make changes to design where these agencies can show that all acceptable
interpretation of Applicable Code, Standards and Specifications has not been made.
38.
Provision of miscellaneous presentational materials necessary to the Contracting
Authority in gaining acceptance of the Work in the presence of Shareholder and third
party organisations.
39.
Provide copies and licences for all software supplied with the Project including PLC,
CMS, etc.
The HSE scope of work shall include, but is not limited to:
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Preparation of overall HSE policy, plan and procedures for all
phases of work;
Participation in design reviews of providing expert leadership for
formal safety reviews of the facility design e.g. HAZOP, SIL,
HAZID, PHSER, etc;
Incorporation of the results of the formal safety reviews into the
design
Verification that the design and the prosecution of the work
complies with all laws, regulations and the HSE plan /
procedures;
Provision of expert advice personnel at the construction sites to
assist line managers in ensuring a good safety outcome;
Compiling, analysing and reporting on safety statistics and
metrics achieved e.g. LTIFR etc.
5.2 FACILITIES
5.2.1
Process Engineering
The facilities are described in the document “Process Basis of Design”. The Contractor shall
use this document, the information given below and in the Part C of the Contract (the more
onerous where there is a conflict) as the basis for updating the “Process Basis of Design” to
include the facilities associated with the Project This shall be completed within 6 weeks of
contract award and shall be subject to Contracting Authority approval.
The Heat & Material balances (in the form of HYSYS output) form the basis for the documents
contained within the FEED package. Each equipment item is sized based on whichever of the
cases is most onerous when applied to that item. This principle shall be followed by the
Contractor. Where there is a specific reason, the design basis data may be modified in order
to take account of specific considerations applicable to specific equipment items. Such cases
shall be indicated by the data sheets or other FEED documents. Note: If there are any
discrepancies between the FEED documents and the heat and material balance, the
information contained within the heat and material balance, as may have been modified
during FEED update, shall take precedence over any information obtained from FEED
documents.
The Contractor shall review, verify, endorse and take responsibility for the design of the
gathering (oil and water production) and distribution (gas and water injection) system (offplot),
lines sizing, flow assurance studies (static and transient conditions), material selection,
described by the design documents included within the ITT in order to ensure that ALL of
design cases can be met at the site conditions described within the design documents.
The Contractor shall review, verify, endorse and take responsibility for the design of all the
associated process facilities, lines, vessels, pumps, cables, control systems, utilities, safety
systems, flares, drainage systems, power generation, electrical systems, cooling systems,
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material selection etc., described by the design documents included within the ITT need to be
designed and sized in order to ensure that ALL of these design cases can be met at the site
conditions described within the design documents.
The Contractor shall verify the sizing of all process equipment: columns coolers, vessels,
pumps, etc. Equipment sizes shall be increased where necessary. Contracting Authority
approval is required to change the size of any piece of equipment.
As part of the Contractor‟s offer, he shall confirm the latest version of equipment list and shall
include summary rating information (loads, dimensions, power output, etc) for each equipment
item included within his bid.
5.2.1.1
Process Flow Diagrams and Utility Flow Diagrams
During Detailed Engineering, at Project Completion, or after significant process design
changes, the Contractor shall update and maintain the PFD‟s, UFD‟s and Heat and Mass
Balance calculations to ensure consistency with P&ID‟s.
Contractor shall provide Contracting Authority with the simulation calculations and the means
of reviewing them (2 computer licences and simulation models).
The Process and Utility diagrams shall be produced in both English and French
5.2.1.2
Piping and Instrument Diagrams
The Piping and Instrument Diagrams (P&ID‟s) were developed during FEED to meet Project
requirements based on existing proven designs in Algeria and are included in the FEED
Package.
The P&IDs have been subjected to a preliminary HAZOP during FEED. All HAZOP findings
and recommendations shall be incorporated at the FEED stage. Any outstanding issues shall
be closed by the Contractor subject to Contracting Authority approval.
Line sizing on the P&IDs has been carried out based on the principles of the line sizing
philosophy In the FEED package. The Contractor shall verify line sizes on this basis and if
necessary shall increase line internal diameters when layouts and pipe runs are sufficiently
well defined. The line sizing verification shall include CAFC tie-ins where applicable. Line
sizes shall only be changed with Contracting Authority approval. Where additional piping
specifications are required these shall be developed during detailed design subject to the
approval of the Contracting Authority.
Specifications have been applied to the P&IDs. The suitability of these shall be verified by the
Contractor using process review, HAZOP and suitable techniques. The robustness of the
piping specification shall be increased where appropriate e.g. an increase in the maximum
design temperatures and pressures, or a decrease in the minimum design temperatures and
pressures. The robustness of a piping specification shall only be modified with the Contracting
Authority approval.
The Contractor shall be responsible for updating all process and utility P&ID‟s, along with
notes and details on these drawings, to meet the needs of the Project as Detailed Design
information becomes available. This shall include data from equipment Suppliers and
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interfaces with “Supplier systems” when data from the successful Supplier is available and
interfaces at delivery points. These shall be developed and issued at AFC level and updated
as necessary as all final information becomes available.
The Contractor shall produce a register of LO/LC valves which shall list valve tag number,
system description, P&ID number, line number, valve location, position in normal operation
etc.
The P&IDs diagrams shall be produced in both English and French.
5.2.1.3
Equipment Data Sheets
Basic process data sheets / loadsheets have been developed for the majority of items of
equipment during FEED to a level available for obtaining budget prices for equipment. New
process and utility data sheets shall be produced and existing data sheets updated and
issued in a controlled manner for approval. Due consideration shall be given to the full range
of operating conditions in preparation of the data.
As the process and utility design develops, the data sheets shall be re-issued as necessary.
The Equipment List prepared during FEED shall be updated to include all additional
equipment and design changes and be issued for approval by Contracting Authority. The
equipment List shall include all attributes to be agreed with Contracting Authority. The
Equipment List shall be maintained and updated as the design proceeds.
5.2.1.4
Process Design Calculations
The Contractor shall prepare and submit to Contacting Authority a full set of process design
calculations including, but not limited to, the following:
Equipment sizing
Line sizing/hydraulics (flow assurance studies for off plot systems)
Flare system sizing
Flare and vent radiation/dispersion
Control valve sizing
Relief valve sizing
Blowdown valve/orifice plate sizing
Equipment emission levels
Relief valve/pressure safety valve sizing.
Material selection study
Utilities consumption
These calculations shall be indexed by process system and, as discussed
earlier, be stored by the Contractor with an electronic copy to the client.
Hand calculations shall be scanned and stored.
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Flare and Vent Systems
A Flare and Blowdown Report was produced during the FEED. The Contractor
shall develop this to produce a Flare, Vent and Blowdown Design Report
setting out the following:
Relief Loads Assessment
Blowdown Loads Assessment
Continuous Emission Assessment
Radiation calculations and conclusions
Dispersion calculations and conclusions
Flare Stack Sizing
Flare Tip Sizing
Header and tail pipe sizing
Blowdown Valve Sizing
Blowdown temperature assessment
Noise calculations
Evaluation of Acoustic Induced Vibration
Flare Drum and Flare Drum Pump Sizing
Relief Valve Sizing
Orifice Size sizing
Bursting Disk sizing
The Contractor shall review the work done during FEED and verify all technical, capacity,
process, mechanical, piping, structural, etc evaluations have been
adequately completed and incorporate actual Supplier data as appropriate.
This shall include but not be limited to:
Evaluation of relieving scenarios
Capacity evaluation
Comparison of design temperature requirements
Acoustic Vibrational Analysis
Pipe stress analysis
Flare drum nozzle loading evaluation
Flare structure
Guy rope evaluation
5.2.1.6
Register of Safety Related Devices
A register of safety related devices shall be prepared in the early stages of the Work.
The register shall be maintained and updated with all Supplier data throughout the course of
the Work. This shall include turbo machinery and process facilities. As part of the document a
register of all “HP/LP” interfaces and pressure let down points shall be made that shall
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quantitatively demonstrate that wherever a change in design pressure is made the lower
system pressure is protected.
5.2.1.7
Instrument Protection Systems
The Contractor shall carry out an analysis to determine the functional requirements and
Safety Integrity Levels for all Instrument Protection Systems to ensure that the appropriate
equipment and system architectures are selected. Contracting Authority‟s personnel shall
participate in this exercise. This exercise shall include Instrument Protection Systems
contained within equipment packages. Contractor is responsible for performing a SIL analysis
and to ensure that systems are designed according to the SIL requirements that result from
the analysis. Along with the SIL analysis, the Contractor shall produce a register with required
testing frequencies for trips.
5.2.1.8
Shutdown Hierarchy Drawings and Cause and Effects
The Contractor shall produce the Shutdown Hierarchy Drawings and Cause and Effects
Drawings to cover the following:
Process control logic
Utility control logic
ESD logic
These documents form a comprehensive schedule of all I/O to the Emergency Shutdown /
Plant Control System.
The Contractor shall incorporate into the Cause and Effects Drawings all relevant Supplier
data in order to ensure that there is a sound understanding of the control and shutdown logic
throughout the facilities.
The Contractor shall prepare the Drawings in such a way that it is clear where the logic is
being implemented, e.g. Unit Control Panels, PCS, ESD system, F&G system.
5.2.1.9
Line lists
The Contractor shall be responsible for producing a line list with all the design and operating
data required by Piping. Line Lists shall be updated and issued so that they are current with
the status of the P&ID‟s.
5.2.1.10
Material Safety Datasheets (MSDs)
The Contractor shall prepare MSDs for all chemicals and other hazardous materials used
within the facilities. This is to include but is not limited to corrosion inhibitors, molecular
sieves, mercury and H2S removal chemicals, methanol, anti-foams and amine chemicals.
These shall be in the French, Arabic and English Languages.
5.2.1.11
Instrument Data Sheets and Schedules
The Contractor shall prepare process Instrument Data Sheets for control valves, relief valves
and in-line instrument schedules for pressure, temperature, flow, level, quality and other inline instruments showing all relevant process data including alarm and trip setting. All alarm,
trip and control settings shall be shown on the P&ID‟s.
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Furthermore, the Contractor shall produce and alarm and trip register combined with an alarm
response manual which shall list all the facilities (supplier‟s included) trips and alarms, and
include setpoints, possible cause of alarm/trip and suggested Operator action. All alarms shall
be subjected to a criticality review.
5.2.1.12
Process Design Manual
The Contractor shall prepare a Process Design Manual that presents a summary of the
process design on a unit by unit / system by system basis. This shall be sectioned to include
but not limited to: design basis, system product specification, schedule of design setting
cases, any particular features or constraints arising from the design history / development,
and a simple description of the process, control and shutdown systems, materials selection
and key features for operations to consider.
5.2.1.13
Operating Procedures
The Contractor shall produce operating procedures for CAFC CPF. The Contractor shall
gather input and guidelines from Suppliers and ensure that these procedures cover start-up
scenarios, normal operation, shutdowns, abnormal operation, a description of system
components and their operation and maintenance.
5.2.1.14
Equipment and Bulk Numbering System
All equipment, piping, instruments and cables shall have a unique and well visible in the field
tag number. It is the Contractor‟s responsibility to ensure that all numbering complies with the
Project Numbering Specification.
These procedures will be reviewed and approved by Company; however, Company
procedures will always have precedence.
To be defined during KoM or in meetings after KoM that will called by Contractors.
The guideline will be equal the guideline used during FEED phase; so double tagging (MLE
philosophy, ENI E&P philosophy). Please note that the double tagging shall be implemented
in the Engineering Lists only (e.g. Equipment List, Line List, Loop and Instrument List, etc.).
No double tagging is required in drawings. About Eni Tagging see standard
20198.COO.GEN.SDS “Item Numbering”.
Contractor shall do a document that explains the philosophy to transcode TAG from MLE
philosophy to ENI E&P philosophy.
Tag numbers shall be indicated for all functional components on Contractor, Subcontractor
and Supplier design documents and drawings.
It shall be Contractor‟s responsibility to change any tag numbers issued during FEED which
do not meet the above requirements and update all documentation in line with the tag number
philosophy.
To control the status of all tag numbers issued, Contractor shall establish and maintain a
Master Tag register. The register shall ensure consistency between various sources of tag
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information and at all times during the project reflect current status of planned, installed, asbuilt, replaced and voided tags.
5.2.2
5.2.2.1
Mechanical/Equipment
Description of Scope of Work
The Contractor shall carry out detailed design of all mechanical (rotary and static) equipments
foreseen for CAFC Plant with reference to the equipment lists and layouts in accordance with
the Project Codes, standards and Philosophies and preliminary data sheets provided with the
FEED Package.
EPC Contractor shall be responsible for the specification, design, procurement, installation
and testing of all mechanical equipment such as:
5.2.2.2
o
Pressure Vessels
o
Columns
o
Tanks
o
Heat exchangers
o
Air Coolers
o
Compressors
o
Pumps
o
Packages
o
Heaters
o
Filters
o
Any other equipment
Detailed Engineering
The EPC Contractor shall as a minimum:
• Update and review the preliminary FEED mechanical documentation (data sheets and
specifications) and prepare any additional document required to enable that the tender
requisitions to be prepared in a time sufficient to allow Supplier‟s data to be incorporated into
the design. The updated documentation shall be issued for Contracting Authority‟s approval.
• Use the preliminary specifications developed during FEED as a basis for the development of
the final enquiry packages. The final specifications shall cover the scope of supply and all
technical requirements. The updated and detailed specifications shall be issued to Suppliers
as part of the various enquiry packages and the Suppliers shall be expected to fully comply
with these requirements. The final scope of work and any possible exception or deviation to
the specification shall be subject of agreement and approval by the Contracting Authority.
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• Prepare specifications, drawings and data sheets for any identified additional equipment.
• Revise specifications and data sheets to reflect the purchased equipment for purchase. Any
agreed exceptions shall be embodied as an appendix to the specification or data sheet.
• Manage communication with other disciplines and with Suppliers to ensure that all interfaces
for equipment are agreed and correctly engineered in accordance with Project requirements
and limits of supply
• Obtain from the Suppliers sufficient documentation and information to enable the Project
design to proceed and to confirm that the packages are manufactured, tested, preserved and
packed in accordance with the applied national, international and Contracting Authority‟s
codes
• Conduct all necessary technical clarifications of the bids and hold clarification meetings with
Suppliers in order to enable Supplier designs and the Contractor‟s design to be efficiently
integrated. Contracting Authority shall be invited by Contractor to attend these meetings.
• Conduct a Noise study and prepare a report including expected Noise Contour maps for
each site.
• Carry out Mechanical handling and accessibility study as part of the initial design, with
particular reference to the requirements of the compressor packages.
• Carry out an operability and maintainability study for all equipment.
• Perform an Erection / Construction study for all mechanical equipment, tie in with MLE CPF
and prepare a report.
• Update all Technical Drawings and Documents to reflect the developments to As Built status
associated with the Long Lead Items (LLI) as detailed in the Long Lead Items Purchase Order
documentation and in the Long Lead Items Supplier documentation
• Be responsible for the integration of the LLI machinery into the Project design, review
Supplier documentation and confirm compliance with Project specifications and standards,
witness testing, etc., Using Project specific data from the chosen Suppliers, confirm and
modify as required layouts drawings and foundation designs and other associated
documentation.
• Ensure compliance with the control, instrument and electrical specifications and philosophies
for machinery control systems.
• Ensure that the fire and gas detection and fire protection philosophy for machinery packages
is consistent with the overall Project philosophy.
• Ensure that the Suppliers understand and accept the Contract P&ID‟s and issue the
Suppliers P&ID‟s accordingly EPC Contractor shall include Supplier P&ID‟s in the Plant
P&ID‟s set.
For Pressure Vessels, Heat Exchangers and Tanks EPC Contractor shall:
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• Check and confirm Supplier information, calculation notes and mechanical drawings of
pressure vessels and tubular exchangers, showing thickness, weights and sizes, in sufficient
detail to satisfy structural and piping design requirements.
For compressors EPC Contractor shall:
• Liaise with the civil/structural discipline to confirm that the shelters over the compressor sets
are designed correctly to interface with the various Gas Turbine / Compressor parts that pass
through the shelter.
• Design maintenance crane arrangement under the compressor shelter.
• Liaise with the compressor Suppliers with respect to process piping to achieve the following
requirements:
- The process piping which connects together the various compression, process and process
cooler skids shall be designed, supplied and installed by the EPC Contractor.
- The design, including stress calculations, dynamic response, residual pulsations
(reciprocating compressors) and layout, shall be reviewed by the compressor Supplier and
confirmed to be suitable.
- The compressor Supplier shall have a representative on site during fit up and installation
and shall confirm that the piping places does not place unacceptable loads onto the
compressor and shall confirm during commissioning that the piping places no unacceptable
loads onto the compressor during operation.
In addition:
Equipment shall be selected on the basis of acceptable Supplier design and technical integrity
including life cycle costing. In all cases equipment shall be shown to be tried and tested in hot,
arid desert environment, or where this is not appropriate assurance process demonstrated by
the Contractor to the Contracting Authority.
Equipment shall be inspected and verified as technically acceptable, performance witness
tested where applicable, and delivered to the Contractor‟s construction site to meet the
installation schedule.
Where appropriate, the Contractor shall attend Supplier‟s works for inspection and witness
tests. The Contractor shall deliver final certified equipment dossiers for all equipment in the
form of a Mechanical Equipment Data Report.
Contracting Authority and Algerian Inspection Agencies shall be advised of all factory
acceptance tests / inspections at least two week before test.
The Contractor shall ensure that the documents outlined in the Supplier Data Requirements
list are in place and that the documentation is received in a timely manner to ensure input to
design documentation and construction, pre-Commissioning, Mechanical Completion, final
Commissioning procedures and Start-Up.
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The Contractor shall design and select Supplier equipment with a view to compatible sparing
and shall whilst maintaining Technical Integrity keep equipment uniform, compact, and simple
for operation, access and maintenance.
The Contractor shall ensure that the Supplier has completed all instrumentation electrical and
noise data sheets. Any omissions shall be addressed and are the responsibility of the
Contractor.
All equipment shall be adequately supported during transportation and storage, in accordance
with the Specifications. Sufficient access to inspect and maintain the equipment in
accordance with the Supplier‟s recommendations shall be provided on site for storage and
installation.
The Contractor shall ensure long-term storage preservation procedures are instigated as
recommended by the Supplier, and in accordance with the Specifications.
The Contractor shall make use of Criticality Assessment programmes to assess and specify
the inspection, quality control and test requirements for each item ordered and shall justify
those requirements for review by the Contracting Authority.
The Contractor shall prepare a Mechanical Handling Study and shall identify all devices, lifting
beams, cranes, anchors, and ensure that adequate access, laydown and storage areas and
padeyes are provided in the facilities to meet the Contracting Authority Constructability,
Installation, Operating and Maintenance criteria.
As a minimum, the Contractor shall develop and provide the following documentation:
Sizing, Mechanical Design Calculations notes & sketches
Detailed mechanical specifications, including the scope of supply.
Mechanical data sheets, equipment weights and envelopes.
These shall incorporate best practise and experience of the
Contractor including use of alloy materials, vessel internals,
coatings etc.
Noise Study and Report
Machine and Auxiliary Layout
Machine Characteristic Performance Curves
HVAC Design specifications.
Mechanical handling and access study, incorporating crane and
mechanical handling device selection and location.
Technical Bid tabulation evaluations.
Purchase and enquiry requisitions.
Supplier documentation
All equipment where maintenance activities are carried out in-situ shall be provided with
shelters, which enable a high degree of weather protection without hindering the maintenance
activities or access.
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5.2.3
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Tender No.
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Piping and Layouts
The Contractor shall develop a fully detailed design of equipment layouts and all pipework
and pipe supports for the Work. The design shall include, but not be limited to, the production
of the following documents:
Plot Plan
Equipment Layout Drawings
A Piping Key Plan
Piping Plan Drawings (to aid construction sequencing and
phasing)
Piping Section Drawings (to aid construction)
3
3D CAD model (shall include all lines /4” and larger)
Piping Isometrics
Fabrication isometrics including maintenance/hydrotest, high /
low flow point, drains / vents
Piping Material Take-Offs – Preliminary, Intermediate and Final
Piping Stress and Flexibility analysis criteria
Piping SP Items Lists
Piping SP Items Data Sheets
Piping Standard Drawings for all details (sample points, flow
orifice taps etc.)
Utility Stations
Pipe Support Standard Detail Drawings
Special Pipe Support Detail Drawings
Nozzle loading Data Sheets
Service Support Schedule
Service Support Material Take-Offs – Preliminary and Final
Piping Valve and Material Specification (Piping Classes)
Manual Valve data sheets
Insulation and Painting Specification
Fabrication and Testing Specification
Nozzle Loading Specification
3D Model Design Execution Procedure
Requisition packages for all piping equipment
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5.2.4
5.2.4.1
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
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Pipelines
Oil and Water gathering System
Contractor shall design, procure, transport, construct, hook-up live pipeline, test,
commissioning and start-up the Oil, Water Supply and Water Injection flow lines and truck
lines to and from CPF as detailed in various documents included with the FEED package (e.g.
P&IDs, SLDs, instrument drawings, etc) that shall form part Annex I – “Technical” of the
Contract. This includes all Intermediate Field Manifolds, anchor blocks and all ancillary works
(cathodic protection instrumentation, metering and telecommunication system, etc…)
5.2.4.2
Pipeline Engineering
In detail Contractor shall perform any complementary engineering works in order to satisfy the
requirements of the Project in accordance with the FEED documentation.
In particular EPC Contractor shall:
-perform topographical survey and staking out of pipeline routes
-perform soil investigation survey and produce geotechnical report
-perform soil resistivity survey and report
-issue typical pipeline installation drawings, as deemed necessary for the project
-issue of General route maps
-issue of Alignment sheets drawings, updated with all the design information‟s
-issue of Crossings detail drawings
-issue of materials takes off
-perform stress analysis of the pipelines, including upheaval buckling verification, and plant
approaches (off set or anchor blocks solution)
-issue of technical pipeline specifications
5.2.4.3
Tie-ins
Design Tie-ins are foreseen to integrate CAFC oil facilities with MLE NGL plant & utilities.
Contractor has to run TIE-IN piping between CAFC and MLE plants. These are consisting of
CAFC product rundown line, future export equipments and utility systems. All the basic
engineering to run the interface piping has been completed. It is also included with Bill of
materials.
Contractor will procure, install and commission piping and other electrical and instrumentation
tie-ins from the MLE to CAFC.
Contractor is responsible for the planning and preparation of the Works to ensure this work is
carried out safely in the most effective way, considering possible SIMOPS operation with a
live NGL plant. MLE EPC CONTRACTOR has identified the TIE-IN location and produced
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isometrics for piping with MTO. CONTRACTOR has to evaluate them and submit a plan for
possible TIE-IN.
5.2.5
5.2.5.1
Operations and Maintenance
Review
The Contractor shall organise, at an appropriate time in the design development, but prior to
full design “freeze”, an Operations and Maintenance review to consider, unit by unit,
Operational aspects of the design. This shall include but is not limited to site access/egress,
valve access, provision for maintenance and inspection, catalyst/packing charging,
unchanging etc. Use of the 3D integrated surface design model shall be used for this review
and shall supplant necessity for 2D drawings traditionally used for this purpose.
Findings from the review shall be addressed by the Contractor and where can be reasonably
judged necessary for the safe and efficient conduct of operation, implemented by the
Contractor.
5.2.5.2
Engineering
CONTRACTOR shall submit a maintenance proposal to cover CAFC Plant operation phase.
Maintenance Engineering shall be in compliance with ENI Standards about Reliability
Centered Maintenance (RCM) [22011.MAN.GEN.RWP]. The requirements are deeply
described in Annex XII “CAFC plant Operability and Maintainability requirements for EPC
Contractors”.
This chapter provides technical and functional general requirements to be observed by
CONTRACTOR in all the activities related to the preparation of the technical documents and
management during the overall supply. In order to assure the best conditions for maintenance
and in order to ensure the goals of the efficiency, reliability, availability and HSE security level
of the whole asset, CONTRACTOR shall:
Perform a complete RCM analysis
Prepare the maintenance and inspection plans and procedures for the whole
asset.
CONTRACTOR shall develop the described tasks in collaboration with COMPANY foreseeing
progress meetings at least once a month.
CONTRACTOR shall issue a preliminary O&M activities schedule with the EPC Bid submittal
and a detailed schedule within the first progress meeting.
5.2.5.3
RCM analysis
CONTRACTOR shall perform a RCM analysis in accordance to Company Standard
[22010.MAN.GEN.SDS
rev
01
“Guideline
for
RCM
Implementation”]
and
[22011.MAN.GEN.RWP rev 01 “RCM Handbook”]. RAM analysis will be the basis of the
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maintenance strategies selection as well as the Maintenance plans development. Reliability
data collection, as starting point for the RAM analysis, shall be compliant with Annex XII
“CAFC plant Operability and Maintainability requirements for EPC Contractors”. The list of
main activities that are required is the following:
Master Equipment List (MEL) for CMMS population
Reliability Data Collection
Bill of Materials (BOM) for CMMS population
Spare Parts Interchangeability Record (SPIR)
Lubricants, consumables and bulk materials lists
RAMS/RCM Analysis
Failure Mode and Effect Analysis (FMEA)
Maintainability analysis (MA)
Criticality analysis (CA)
Reliability centred maintenance (RCM)
Risk based inspection (RBI)
Availability analysis (AA)
Availability analysis shall take as reference the RAM study performed during the FEED phase,
developing all pending aspects pointed out by COMPANY as deeply described in par. 5.7.9.4
of Annex XII “CAFC plant Operability and Maintainability requirements for EPC Contractors”.
5.2.5.4
Maintenance Plans and Procedures
CONTRACTOR is responsible to collect from Sub-CONTRACTORS all the information and
documentation related to maintenance (Maintenance and inspection plans, maintenance
procedure etc…).
CONTRACTOR shall prepare a complete set of maintenance and inspection plans for the
Scope of supply, completed with all the information requested by COMPANY in document
TBA “CAFC plant Operability and Maintainability requirements for EPC Contractors”. The aim
is to keep the installation to the optimum preservation status and to guarantee the optimal
performance and HSE security level throughout lifetime (starting from pre-commissioning to
the decommissioning).
Any change or modification to the maintenance plan which may have a detrimental effect on
the system shall be subject to COMPANY Approval. COMPANY shall be notified prior to
including such modifications or changes in the plan.
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In addition CONTRACTOR shall prepare for the whole asset a full set of Maintenance and
inspection procedures, starting from the information collected from the SUB CONTRACTORS.
Maintenance and inspection procedures should as a minimum address the instructions to
perform the following activities:
Routine preventative maintenance
Repair or replacement of failed minor equipment
Repair of failed major equipment
Refurbishment after a period of field operation
Paint/surface coating field repair
Fault finding
Preservation\Maintenance of spare parts and sub-assemblies.
Maintenance and inspection plans and procedures have to be delivered at least 3 months
prior to pre-commissioning phase, in an electronic format and template approved by
COMPANY and ready to feed the chosen CMMS.
5.2.6
5.2.6.2
Instrument and Controls Systems
Description of Scope of Work
Scope of this Work is the design, procurement, installation and testing of:
- all the field instrumentation necessary to properly control CAFC plant;
-
The Integrated Control and Safety System (ICSS).
-
Instrumentation cables
The ICSS equipment shall be installed in the CER in the electrical substation building in CAFC premises
and in MLE CCR; these two rooms shall also cater for the space needed for future expansion of the
hardware (both cabinets and operator stations). The ICSS shall comprise, but not limited to:
- Distributed Control System (DCS) for the control of process and utilities, providing adequate
information for the operators; this will include also the information available from third party
systems control packages to be integrated in the DCS as described in the FEED documents in
Annex I – “Technical” of the Contract;
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Emergency Shutdown System (ESD) for the control of the plant in upset conditions, protecting
personnel, the environment, the plant and the equipment;
-
Fire and Gas System (F&G) to protect from fire and gas hazards, providing alarms and activating
protection systems;
-
Remote control of Wellheads and Intermediate Manifolds through the SCADA system;
-
Operator interfaces to the above mentioned systems, such as operator and engineering stations,
graphic pages, alarm management system, auxiliary panels etc., fully compliant with equipment
and philosophies provided;
-
Extension of the synoptic display of MLE plant in CCR.
Provision shall be made for all the abovementioned aspects for future expansion, in terms of space,
hardware and software capabilities.
Moreover, Contractor shall be responsible for the integration of all CAFC control systems with MLE ones,
both in terms of hardware connections and behaviour, assuring ease of operation of the two plants from
the same team of operators.
5.2.6.3
Detail Engineering
The Contractor shall design all instrumentation and control systems required in order to safely and
effectively control and monitor all facilities. During the Work the information shall all be available in the
Contractor‟s offices where Contracting Authority‟s PMT is located.
The Contractor shall develop all principal ICSS documents including, but not limited to, the following:
-
Cause and Effect Diagrams for ESD, F&G and control systems. These shall define logic
functions within the main control system, process safety shutdown, and fire and gas systems.
The cause and effects diagram developed during FEED shall be updated to reflect any
development in detailed design e.g. as a result of the detailed design HAZOP (Contractor‟s and
Supplier‟s) and input from all the Supplier data (i.e. Compressor C&E). Furthermore the
Contractor shall organise a formal review of the Cause and Effects with the Contracting Authority
once detailed design is confirmed and all data from the Suppliers is received.
-
Updated control system block diagrams;
-
Packaged equipment block diagrams;
-
Detailed process control descriptions and control narratives for every complex control loop;
-
Logic Diagrams/sequences for all equipment identified on P&IDs as well as electrical and
mechanical packages interfaces, showing all the inputs (instruments/F&G/various equipment)
with relevant tags, the functional logics to be implemented inside the automation systems (DSC,
ESD/F&G, SCADA/RTUs) with relevant sequence numbering, and the outputs
(instruments/F&G/various equipment, control room) with relevant tags
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Man-machine graphics interface displays. These displays, with hard copy printouts shall be
produced in conjunction with appropriate personnel appointed by the Contracting Authority who
shall be a specialist in the facility operations;
-
CCR and CER layouts and furniture specification;
-
Layouts of the cabinets for all control system components;
-
Functional design specification for all systems
The Contractor shall develop all principal documents relative to instrumentation including, but not limited
to, the following:
-
Supply specifications and Data Sheets (TDS, IDS, DDS) for all instrumentation and control
equipment, items and materials;
-
A complete Instrument list;
-
Input /Output List for each system;
-
Provide a database (that can be integrated in the I/O list) capturing all key information relating to
instrumentation and control systems. This database shall contain, as a minimum, the following
information for packaged and non packaged instrumentation:
o
Plant Reference
o
Unit ID
o
Loop ID
o
Unique Tag
o
Service Description
o
Instrument Type
o
P&ID No.
o
System Connected to DCS, ESD or FGS
o
Signal Type Analogue or Digital
o
Signed mode input or output
o
Protection EExd or EExi
o
Engineering units
o
Range
o
Alarm Set Points HH, H, L and LL
o
Hook-up document number
o
Loop Drawing document number
o
Manufacturer
o
Model
o
P.O. Number
-
Cable specification and list;
-
Routing drawings for multi cables and multi tubes showing main transits, junction boxes, and field
cabinets;
-
Loose instrument and junction boxes termination drawings;
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Junction box schedule and specification;
-
Instrumentation erection specification;
-
Sketches for instrument mounting (primary process connections, pneumatic/hydraulic secondary
connections, electrical secondary connections);
-
Instrument mounting details/hook-up;
-
Instrument bulk material take-off, broken down per category of equipment and materials;
-
Plot plans to locate the tagged field instrumentation (electrical / pneumatic / hydraulic /etc.)
-
Loop Diagrams;
-
Calculation sheets for flanges, orifices flow elements, control valves, safety valves, choke valves,
etc…
-
Cable and Cable Trays routing in the Instrument Equipment Room (building by building) and
Control Room;
-
Terminal Blocks drawings (instruments/junction boxes/F&G/marshalling cabinets/among
automation cabinets),
-
Instrument air usage calculation;
-
HVAC heat load calculations;
-
Power consumption (including UPS loads) calculations;
-
Operating manual for each system;
-
Maintenance manual for each system;
-
Bills of material;
-
Details of the serial interfaces (Protocol, Signal Map, etc ) chosen to allow the communication
between different packages & ICSS
Suppliers make and model number shall be clear in Supplier documentation for the tagged equipment
items.
The Contractor shall be responsible to prepare, for each different item, the complete technical
documentation package to allow:
-
ITT to cater the different items
-
Technical Evaluation of the offers received
-
Contract Award for Instrumentation Items (by preparing the revision released “for order” for the
technical documentation package)
All the forms to be used to prepare the various documents (TDS, IDS, DDS, etc) shall be submitted to
Company approval
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Part D - Scope of Work
5.2.7
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
IT and Telecommunications Systems Design
5.2.7.1
Description of Scope of Work
Permanent systems
Contractor shall be responsible for the specification, design, procurement, installation and testing
(including
end-to-end
testing)
of
permanent
telecommunication
systems
and
provision
of
telecommunication services; Contractor shall also be responsible of all the necessary actions towards
Third Parties, such as PTT; ARPT etc. to insure the compliance of the installed systems with local
regulations.
The telecommunication systems shall comprise, but not limited to, the following:
-
Optical fibre backbone system (SDH) for the connection with remote sites and relevant interfaces
to other systems;
-
Public Alert General Address system (PAGA);
-
Public Address Branching Exchange (PABX);
-
TETRA radio system;
-
CCTV and IDS at CPF and remote sites;
-
Extension of the WAN/LAN networks of MLE whenever required.
Due to the strong interdependence between CAFC and MLE, Contractor shall maximize the compatibility
between the telecommunication systems of the two plants, including, wherever possible, the use of
shared equipment. Contractor shall also be responsible of the integration of telecommunication systems
between the two plants, including testing of the interconnections.
Temporary systems
The Contractor shall be responsible for providing their own general business IT systems for use during
the term of the Contract.
This Work includes the specification, design, procurement, installation and testing of temporary
Telecommunication systems and services necessary to support EPC activities, and shall comprise of, but
not to be limited to, the following:
-
Telecommunications systems and services taken from the range required for permanent
operations, for use by the Contractor, Contracting Authority and other contractors as appropriate.
Telecommunications facilities provided for Liaison shall include voice and data needs at the MLE
locations, Hassi Messaoud and Algiers and elsewhere as required for the execution of the
project.
-
Office telephones (with international access and access to Contracting Authority telephone
networks), for Contracting Authority personnel at each construction site.
-
Installation of Vehicle Radios into Contracting Authority Vehicles used during the construction
phase of the Project.
-
Vehicle tracking facilities using GPS (Global Positioning Systems)
-
Hand -held GPS (Global Positioning Systems) receivers
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It is the responsibility of the Contractor to obtain all licences and consents required for the Work,
including Fibre Optic communications, radio, UHF etc.
This work is further defined in, but is not limited by scope detailed in the FEED Package.
5.2.7.2
Detailed engineering
The Contractor shall design all the telecommunication systems required in order to run the facilities in a
safe and efficient manner. During the Work the information shall all be available in the Contractor‟s
offices where Contracting Authority‟s PMT is located.
Telecommunication systems associated with security and emergency response shall need to be
operational prior to the start-up of construction activities.
Contractor shall update the following documentation according to the possible changes appeared during
detail engineering:
-
Telecommunication system block diagram;
-
Block diagrams for all subsystems;
-
Site survey/frequency reports.
The Contractor shall develop all Telecommunications calculations, specifications, data sheets and
inventories including, but not limited to, the following:
-
Specification for each telecommunication systems and equipment, including TDS, IDS and DDS;
-
Detailed design of the sub systems;
-
Equipment list, including:
o
Equipment list for all systems;
o
Material take offs;
o
Spare parts list;
o
Test and maintenance equipment list;
-
Equipment functional design specification of each system;
-
Telecommunications asset ;
-
TETRA Radio field coverage and interference calculations and design;
-
Calculation notes, including:
o
Optical loss budget, optical power budget, etc.
o
Link performance calculations
o
Equipment availability/reliability calculations
-
PAGA coverage calculations;
-
Cable specification and list for all telecommunication systems;
-
I/O list of all systems;
-
Operating manual for each system;
-
Maintenance manual for each system;
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Heat dissipation estimate for all the equipment;
-
Power consumption estimate for all the equipment;
-
Test documentation;
-
Radio licence technical submissions;
-
Radio licence applications in accordance with Algerian PTT requirements including but not
limited to ARPT;
-
Technical bid tabulation evaluation.
The Contractor shall develop detailed Telecommunications and main computer server Drawings which
shall contain all Supplier data. These shall include, but not be limited to, the following:
- Single line Drawings;
-
Schematic diagrams;
-
Room and Enclosure floor and cabinet layouts;
-
Cabinet layouts, including termination strips, equipment fascia details and cable trays;
-
General arrangements, including dimensions, fixing detail and utility requirement;
-
Power supply and earth single line diagrams;
-
Enclosure and cabinet wiring diagrams;
-
Junction box termination details;
-
Equipment termination details;
-
Equipment layout drawings;
-
Equipment wiring drawings;
-
List of radio frequencies;
-
Acceptance test methodology and test procedure;
-
Recommended spares lists for both installation and maintenance;
-
Register of spares for equipment;
-
Type approval and certifying authority approval dossier;
The Contractor shall be responsible to prepare, for each different item, the complete technical
documentation package to allow:
-
ITT to cater the different items
-
Technical Evaluation of the offers received
-
Contract Award for Instrumentation Items (by preparing the revision released “for order” for the
technical documentation package)
All the forms to be used to prepare the various documents (TDS, IDS, DDS, etc) shall be submitted to
Company approval
The Contractor is responsible for the preparation and management of all PTT (ARPT) license
applications necessary for the Work.
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The Contractor shall ensure that adequate spare capacity is included for the future scope of the Project
and that utilising this capacity can be achieved without disruption to the running system.
5.2.8
5.2.8.1
Electrical and Power Systems Engineering
Description of Scope of Work
Electrical power to CAFC shall be provided from the MLE substation through 60 kV GIS (Gas
Insulated Switchgear). The main power for MLE plant comes from MLN (Menzel Ledjment
North) substation (220/60 kV) by means of 60 kV overhead lines.
The Contractor shall review the calculations and studies carried out during FEED (e.g. Short
circuit, Load flow, etc.). These documents shall be reviewed and updated during detailed
design. The Contractor shall carry out protection relay co-ordination studies, including relay
setting schedules in order to guarantee the stability of the electrical distribution system of
CAFC vs MLE also during the start up of the larger electric motors without any impact of the
MLE plant to COMPANY satisfaction.
The overall Single Line Diagrams, already developed to a considerable degree of
completeness during FEED, shall be the basis for further detailed design to be performed by
the Contractor.
The sizing of the Emergency Generators, Switchboards and Transformers etc. has been
based on input from the Load Lists which in turn have been developed from the P&IDs,
vendor data and other project information. The Contractor shall confirm that the overall design
intent can be achieved. All equipment and cable sizing shall be verified. Any change in sizing,
loading or capacities requires approval from the Contracting Authority. Fault levels shall be
calculated to ensure that they are within acceptable levels.
The SLDs provided within the FEED package for the various Switchboards and Panels shall
be updated and developed as necessary during detailed design.
5.2.8.2
Detailed Engineering
The Contractor shall take responsibility for the design of all electrical systems including, but
not limited to, the following:
Electrical load list for normal grid supply and emergency
generators, UPS and DC Power.
Selection of power equipment (transformers, breakers, buses,
…) to meet the system load requirements
Cable schedule for all lighting, electrical control and power
cables. Earthing may be by earth schedule / location plan.
Electrical equipment lists.
Load management system.
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UPS and DC supply requirements.
Inter-connection cable schematic Drawings.
Register of all electrical equipment and devices for installation in
hazardous areas, including a copy of / or dossier of hazardous
certification for all such equipment.
Detailed single line diagrams for all areas, including HV/LV
distribution, Schedule of DC power and UPS loads.
Layout, wiring and schematic Drawings for main and other substations.
Layout, wiring and schematic Drawings for emergency power
generation.
Detailed layout Drawings showing the proposed distribution
boards, power generation and electrical distribution for all sites
including construction sites.
Electrical layouts for power, control, lighting, grounding and
auxiliary systems for each area.
Motor Control Centre, switchgear and power control equipment
layouts.
Update of hazardous area electrical classification drawings
prepared during FEED.
Detailed interconnect diagrams for electrical devices, control
panels, marshalling and junction boxes.
Lighting and small power distribution board schedules
(AC/DC/UPS). This includes details of the automatic changeover
of supply in the redundant UPS system and DC Power Units.
Typical electrical installation details required to perform all
electrical work including, but not limited to, power, control,
lighting, and earthing details.
HV and LV switchgear control schematics.
HV and LV switchgear arrangement Drawings.
HV/LV switchboard layouts including base frame and switchroom
cable duct details.
Layout Drawings showing all electrical equipment.
Site General Alarm and Public Address System.
Security Systems design and layouts.
Cable ladder/tray and cable trench layouts for electrical,
instrumentation, F & G and communications cables. This
requirement includes the cross sectional views of all such cable
ladders, tray and cable trenches detailing the cable installation.
Electrical drawing legend.
Standard installation Drawings.
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Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Powerline (including structures) and tie-ins between CAFC and
MLE
Technical Bid tabulation evaluations.
Purchase requisitions.
Any documents not listed above but which are deemed
necessary by the Contracting Authority to properly define, build
and operate a complete electrical system.
The Contractor shall determine the most appropriate area for all earthing installations for all
sites to endorse the design, and to demonstrate the performance function of the site
installation.
As a minimum, the Contractor shall perform the following design functions and calculations,
incorporating applicable Supplier information, or areas of the Work that are sub-contracted,
such as accommodation, packaged switchrooms etc.
Update the FEED electrical load list as the design develops, with
particular regard to supplier information.
Short circuit calculations for all switchboards and feeder cables,
covering possible combinations of generators connected to the
power system.
Protective relay co-ordination study with required settings.
Load Management System
Transient Stability Study
Sizing calculations for Emergency Generators, Transformers,
Battery Banks, Battery Chargers, UPS, Circuit breakers and
contactors.
Design of power requirements and interconnecting supplies to
complete the construction and Mechanical Completion phase
using a temporary generator (not the facility emergency
generator).
Voltage drop calculations for complete electrical system including
individual cables.
Lighting level calculations for normal and emergency lighting in
all areas.
Security system design and facilities layout
Site General alarm and Public Address System
5.2.9
Corrosion Protection
The Contractor shall develop the design of the corrosion protection systems including
coating/painting, cathodic protection system and chemical injection.
All steel, pipework and equipment shall be supplied with protective systems (coating and
painting) prepared and applied strictly in accordance with the standards and procedures set
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down in the FEED Package. Any damage to protective coatings/paintings, which arises
during fabrication, equipment installation and/or Commissioning shall be repaired by the
Contractor.
The Contractor shall develop the design of the cathodic protection system and the chemical
injection system, where foreseen, in accordance with the requirements of the FEED Package
and relevant company standards.
Any damage and/or malfunctioning arising during installation and/or commissioning of both
the systems shall be properly addressed and resolved by the Contractor.
5.2.10 Civil
5.2.10.1
5.2.10.1.1
Description of Scope of Work
Civil Works
The Work includes the design, materials procurement and execution of Civil Works and any
further Site Preparation Works in addition to those provided by Contracting Authority. These
works shall comprise, but are not to be limited to:
Site clearing, stripping and grading beyond preliminary civils
Site bulk earthworks beyond preliminary civils
Flowlines and Trunklines Installation
Road works
Underground cable and piping trenches
Telecommunication and Power cables installation over the whole
gathering system
Pipe sleepers and pipe racks
Concrete foundations
Foundations and retaining walls for Off spec oil Storage Tank
Concrete Paving
Bridge Culverts and Duct Banks
Control of water in way of foundations; provide ground protection
against ingress of rainwater; provide drainage suitable for
extreme runoff conditions and provide subsoil isolation of strata
under bearing pressure against ingress of groundwater
Electrical Earthing
Sewage Collection, Treatment and Disposal System for CPF,
Leach Fields
Evaporation Ponds
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Foundations and Anchors for Radio Antennae Self Supporting
Towers
Soil compacting
Piling
Fencing systems
Provision of Concrete Batching Plant
5.2.10.1.2
Temporary Installation
The Contractor shall plan, provide, mobilise, maintain, operate and, subsequently, demobilise
all Temporary Installations required in connection with the Work. The Contractor shall be
responsible for the provision of temporary facilities to support construction activities including
but not limited to the following:
(i)
Construction labour camp to be located at a designated location close to the
MLE CPF. The Contractor shall be responsible for provision of all facilities at this
location to suit his anticipated site labour force.
(ii)
Lay-down and construction warehousing to be located at a designated location
adjacent north part of the CPF. The Contractor shall be responsible for provision
of all facilities at this location to suit his anticipated site labour force and material
handling requirements.
(iii)
Construction offices to be located at a designated location agreed with the
Contracting Authority. The Contractor shall be responsible for provision of all
facilities at this location to suit his anticipated site labour force.
(iv)
On-site offices, changing rooms, store etc. as deemed necessary by the
Contractor for the execution of the Work on CPF site and at off-site locations to
support offsites work. Execute the project with No Accidents, No Harm to People
and No Damage to the Environment.
5.2.10.1.3
Structural Systems
The Work includes the design, procurement and construction of Structural Systems at the
sites. The structural systems shall comprise of, but are not to be limited to, the following:
Pipe Racks and sleepers
Equipment Support Structures
Gantry Crane Supports and Runway Beams
Cable Tray Supports and major Pipe Supports
Platforms, Ladders and Access Ways
Flare System Supports and Anchors (as required)
5.2.10.1.4
Power Supply to temporary facilities
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Central Area Field Complex Project
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Power for the temporary camp and offices shall be supplied by the Contractor. Contractor
shall design, install, fuel and maintain generation and distribution network to support these
facilities. This power supply shall be independent of any provided to assist Commissioning or
Start-up activities.
5.2.10.1.5
Water Supply
Contracting Authority shall provide access to raw water. Contractor shall check compatibility
of the water with requirements of the work mainly concrete .Contractor may execute additional
analysis to confirm quality of the water.
Contractor shall run temporary lines as required from wells to camps and office locations as
required for the construction works including but not limited to:
Cement batch plant
Flushing and hydrotests
Accommodation
The Contractor shall develop and provide to Contracting Authority water demand schedules
and updated every two months as follows:
Monthly average and daily peak requirements during the contract
period
Contractor shall supply a suitably sized water treatment plant at
each location.
5.2.10.1.6
Liquid Effluent Disposal
Contractor shall install temporary evaporation ponds complete with security fencing, at each
camp location and worksites as required. The ground shall be reinstated by Contractor at
demobilisation
Contractor shall design and provide sewage collection and treatment units (STUs) at each
camp location
Sewage Treatment Units and evaporation pond sizes are to be confirmed by Contractor for
the duty defined by peak personnel numbers and process requirements. The Contractor
Camp evaporation pond shall be sized for peak Contractor headcount plus hydrotest water
disposal, if appropriate.
All liquid effluents, with the exception of clean rain water run-off shall be disposed of in the
evaporation ponds. Re-injection of fluids is not acceptable. It is envisaged that clean rain
water run-off from plant areas, following the first 15 minutes of rain fall can be routed to a
suitable soak-away remote from the plant. This approach and the sizing basis for the
Evaporation ponds must comply with Contracting Authority‟s Waste Management Philosophy
and relevant local permitting regulations.
As hydrotest fluids can potentially contain hazardous chemicals, the Contractor shall provide
a plan for disposal of any hydrotest fluids for approval by Contracting Authority. Plan shall be
agreed with Contracting Authority before release or batching of any fluids.
5.2.10.1.7
Solid Waste Disposal
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Central Area Field Complex Project
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Contractor shall provide a temporary solid waste incineration facility for Contractor camps.
Incinerator shall comply with all local authority regulations and be of sufficient capacity.
Contractor shall incinerate solid waste before landfill to minimise volume. Waste unsuitable for
such treatment shall be recycled. Contractor shall submit a waste management plan during
the tendering phase to demonstrate how to address these issues.
Contractor and his subcontractors shall comply with ESHIA findings and recommendations.
Each site used by Contractor and subcontractors must be re-instated to its original state.
5.2.10.1.8
Site Access
The Contractor shall upgrade and add to the existing field roads as required to allow free
movement of bulk materials and equipment at site. Any damage caused during construction
shall be repaired by the Contractor prior to demobilisation. The construction sites shall not be
accessible except via a strict control system. The construction sites shall require new and
dedicated access roads. These roads shall be designed to standards provided within the
FEED package.
5.2.10.1.9
Roads
The Contractor shall construct concrete, piste and/or tarmac roads to meet the requirements
as described within the FEED package in Annex I – “Technical” of the Contract.
Road construction shall include design and construction of wadi crossings and pipe/services
as required. CONTRACTOR shall manage site construction traffic to minimise damage to the
desert surface with as few new vehicle tracks as possible.
5.2.10.2
Detailed Engineering
5.2.10.2.1
Civil Engineering
Contracting Authority shall perform early site preparation, earth moving and sand levelling,
civils preparation including gypsum layer for CPF. Contractor shall endorse and use the as-is
final state of the early site preparation as the basis for execution of the Project. Any further
site preparation required for the requirements of the Project as Contractor‟s responsibility and
are part of the Work.
The civils design shall be in accordance with the requirements of Civil and Structural Design
Criteria –in the FEED Package.
The Contractor shall take the responsibility for the design of all civil aspects of the Work,
including, but not limited to, the following:
Undertake all necessary survey work over all sites included in the
Work, prepare survey plans and establish permanent survey
markers on the sites.
Undertake all necessary geotechnical investigations over all sites
included in the Work using suitably qualified and experienced
geotechnical engineers and prepare a geotechnical report. The
geotechnical report shall include all necessary drilling, test pit
excavation and soil testing and shall include all required design
parameters for the structures proposed.
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Undertake an assessment of the catchment areas contributing to
storm-water flows from and across the sites.
Select suitable locations for all facilities considering storm-water
flows and local topography.
Preparation of design Drawings and construction Specifications
for all site roads, hardstands, laydown areas, stormwater and
firewater drainage systems and all site access roads.
Preparation of design Drawings, construction and equipment
Specifications for all sewage systems, including sewage mains,
treatment equipment and effluent systems.
Preparation of design Drawings and construction Specifications
for all underground services including service trenches, ducts and
associated works.
Preparation of design Drawings and construction Specifications
for landscaping of the sites.
Preparation of design Drawings and construction Specifications
for foundations for all equipment, storage tanks, structures and
buildings.
Undertake all survey, geotechnical and design work required for
the preparation of design Drawings and materials and
construction Specifications for the installation of any
construction/access roads.
Preparation of materials Specifications for the supply of all civil
materials.
Preparation of design Drawings and construction Specifications
for all perimeter fencing and other aspects to provide security for
the Facilities.
Preparation of bills of quantities for import and export materials.
Preparation of documentation and calculations for building
regulation / other approval by appropriate Algerian agencies.
Although data shall be made available to the Contractor for topographical and geotechnical
surveys already undertaken in the areas adjacent to the facilities, it shall be the Contractor‟s
responsibility to verify or otherwise all of the data contained in the reports and acquire
additional information through further surveys if required.. Contracting Authority take no
responsibility for any errors or omissions in these reports and for any changes that may have
taken place since the surveys were undertaken.
5.2.10.2.2
Structural Engineering
The Contractor shall carry out the detailed design of all structures required for the Work. The
structural design shall be in accordance with the requirements of Civil and Structural Design
Criteria –in the FEED Package. The detailed design shall include, but not be limited to the
following:
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Tender No.
Central Area Field Complex Project
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Operational, erection and accidental load analyses / design of all
steelwork and concrete works verifying acceptability of all
members, joints and foundations.
Analysis and calculations to support the Contractor‟s construction
configurations and assembly methods.
Design of lifting attachments, installation aids, temporary
supports, and temporary transportation steel.
Design and specification of access ladders, platforms, walkways
and associated handrails and guards.
A bill of quantities for all steelwork, concrete, reinforcement and
associated formwork produced in sufficient time to avoid delays
to construction arising from material shortages.
Clearly dimensioned steel design Drawings enabling efficient
development of cutting and fabrication Drawings and procedures.
Clearly dimensioned concrete design Drawings enabling efficient
placement of formwork, reinforcement and pouring of concrete.
Structural general arrangements and details for
development of detailed design by other disciplines.
use
in
Passive fire protection Drawings showing extent of same on
steelwork.
Design and specification of crane monorails, structural steel for
maintenance activities and major pipe supports.
The Contractor shall deliver a structural design report including all analyses and calculations
used to justify the design.
5.2.10.2.3
Building and Architectural Design
The Contractor shall carry out the detailed design, including architectural design, of all
buildings included in the Work. The buildings and architectural design shall be in accordance
with the documents provided in the FEED Package. The detailed design shall include, but not
be limited to the following:
Clearly dimensioned general arrangement building and
architectural Drawings enabling efficient development of all
associated discipline Drawings.
Incorporate designs and calculations by other disciplines, e.g.
HVAC, telecommunications, controls, structural, building
services, drainage and electrical.
Incorporate computer floor and transit frame design for the
Control Room and the Equipment Room.
A bill of quantities for all architectural materials, fittings and
furnishings produced in sufficient time to avoid delays to
construction arising from material shortages.
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Documentation for building services in accordance with the
relevant codes and standards as defined in the FEED Package
documentation.
Provide input into bid packages for CER.
Architectural design of all buildings shall be by suitably qualified architects. The design shall
take into account decor requirements, the site environmental conditions, local building
practices and hazards associated with the site such as noise, fire and blast. .
The Contractor shall deliver a building and architectural design report including all calculations
used to justify the design.
5.2.10.2.4
HVAC Systems Design
The Contractor shall design or sub-Contract the HVAC Systems for all buildings and rooms
requiring controlled environments in order to meet reliability and availability requirements
specified. The HVAC design shall be undertaken in accordance with the codes, standards
and requirements detailed in the FEED Package. All HVAC systems shall be designed based
on an ambient design temperature of 55 deg C.
The HVAC design shall use a combination of pressurised, non-pressurised and naturally
ventilated systems, with safety, equipment requirements and comfort of personnel foremost in
the design considerations. The design shall minimise space requirements and remain
consistent with good maintenance access and safety performance. The availability of the
systems shall be a prime objective in the design. Appropriate redundancy and spare holding /
commonality shall be achieved for this critical plant.
The Contractor shall produce all HVAC systems Ducting and Instrument Diagrams,
Specifications, Data Sheets, calculations and studies.
Where appropriate, the HVAC system design shall be integrated with that of the F&G System
and the Control & Monitoring System.
Air conditioning units shall be provided with due consideration of the following:
Where rooms are air conditioned by dedicated units, split units
shall be used for low noise output
The number of alternative equipment types and suppliers shall be
minimised for ease of maintenance
Condensers shall be adequately shaded to improve performance
and operations life
Units shall be suitable for continuous operation at the extreme
local design temperatures
5.2.11 HSE
Health, Safety and Environmental Systems and associated equipment shall be designed and
installed to protect personnel health and safety, facilities integrity and the environment. The
systems shall be in the spirit of and meet Contracting Authority HSE MS Requirements in
Annex XI – Health, Safety and Environment of the Contract and HSE Minimum Requirements
(See section 6).
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5.2.11.1
Description of Scope of Work
5.2.11.1.1
Safety Systems
This Work includes the design, procurement, installation and testing of Safety Systems at the
CAFC sites. The Work shall comprise, but not to be limited to, the following:
Fixed fire extinguishing systems.
Portable extinguishers for facilities areas and buildings.
Fire and gas detection systems.
Manual alarm call points throughout the plant.
Passive fire protection systems.
Safety signs throughout the sites.
Safety equipment throughout the sites..
The philosophies for the safety systems shall be consistent with the philosophies provided in
the FEED Package. The Contractor shall develop the detailed requirements for approval of
the Contracting Authority.
5.2.11.1.2
Environmental Systems
This Work includes the design, procurement, construction / installation and commissioning of
temporary Environmental Systems at the sites. The Work shall comprise, but not to be limited
to, the following:
Temporary landfill site, lined for hazardous waste.
Removal of construction waste to appropriate facilities meeting
Contracting Authority HSE Requirements, specifically within ISO
14001:2004 requirements.
Sewage and effluent treatment facilities at sites suitable for all
construction activities (including Subcontractors) (where located
with temporary camps).
Domestic water facilities at sites.
Incineration facilities at sites.
Crushing facilities at sites.
Waste collection vehicles and front loaders at sites.
Dust suppression vehicles at sites.
Environmental testing / measuring equipment at sites.
Waste storage bins at sites.
The philosophies for the waste management are given in the FEED Package in Annex I –
“Technical” of the Contract. However, the overall Waste Management Philosophy for Algeria
is being revised. The Contractor shall develop the detailed requirements for approval of the
Contracting Authority.
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The Contractor shall prepare, implement and monitor a Contracting Authority approved
environmental management plan for the construction and commissioning of the Work. This
plan shall also identify standards and procedures for water handling, waste management,
waste material disposal, solvent disposal, etc.
The Contractor shall maintain the locations in a clean and tidy condition at all times. For
control rooms, instrument rooms and other areas where electronic equipment is installed,
suitable working practices and temporary equipment shall be installed to maintain the
environment as dust free.
5.2.11.1.3
Health Facilities
The Contractor shall develop and implement a Health and Hygiene Management Plan in
accordance with the HSE Requirements in Annex XI – “Health, Safety and Environmental” of
the Contract. This plan, inclusive of all relevant procedures, shall be reviewed by the
Contracting Authority and finalized by the Contractor with all comments incorporated at least
four (4) weeks before site mobilisation.
This Work includes the supply of Medical and Health Facilities and shall comprise of, but not
to be limited to, the following:
Temporary Health Facilities (including ambulance) to provide
medical support during construction activities (including first aid
room) at each site.
First Aid Room at CPF and any construction site.
The fully equipped first aid centres shall be staffed with qualified
medical personnel, with facilities and procedures for handling and
evacuating large scale casualties.
All Health Facilities, including final inventories and layouts shall be agreed with the
Contracting Authority‟s Occupational Health personnel. The Temporary Health Facilities shall
be accessible to all Contractor and Subcontractor personnel, and in the case of emergency,
Contracting Authority‟s personnel.
5.2.11.2
Safety and Environmental Engineering
The Contractor shall carry out the detailed design of all Safety and Environmental systems
included in the Work.
The Contractor shall be responsible for ensuring that the design of Work meets the
Contracting Authority stated goals for Safety, Environment, Emergency Response and
Emergency systems, as well as the CAFC Project HSE Requirements in Annex XI – “Health,
Safety and Environment” of the Contract.
Compliance with the Environment Performance Standards and the Performance Standards
for Safety Critical Items is mandatory.
The Contractor shall develop and provide all of the principal safety related calculations and
documentation as defined in the Contract deliverable list, including but not limited to, the
following:
Fire Water P&ID‟s.
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Fire Protection System design (including calculations).
Fire Water Demand Calculation and Hydraulic analysis.
Hazardous Area Classification Layout and Schedule.
Active Fire Protection Layouts.
Passive Fire Protection Layouts.
Fire and Gas detection layouts.
Safety Signs and Safety Equipment Layouts.
Data Sheets for Fire Protection and Safety Systems.
Safety Equipment Schedules and Technical Specification..
Safety Sign Schedules and Technical Specification.
Fire Protection
Specification..
Equipment
Schedules
and
Technical
Fire and Gas Cause and Effects
Flare Radiation and Gas Dispersion Calculations.
QRA Study.
FERA and Blast Overpressure Studies.
Noise and Vibration Study.
Air Emission Study.
HSE Case.
The Contractor shall develop and provide all of the principal environmental related
documentation, including but not limited to, the following:
Equipment data sheets.
Equipment schedules.
5.2.12 Lifecycle Cost Assessment
Equipment and packages shall be selected upon the following basis:
Proven equipment on similar conditions & environment
Demonstrated reliability in a hot desert remote environment
Lowest lifecycle cost
Particular attention and demonstration of robustness to the extremely hot, arid environment
prone to sand storm/ingress shall be made. In general, the review of lifecycle costs shall be
based upon engineering judgement. However, the selection of the emergency power
generators, compression and large pumps shall be based upon a formal, documented
assessment of lifecycle costs. This shall take account of:
Fuel consumption
Maintenance periods – duration and frequency
Cost of maintenance
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Reliability
Maintainability of equipment
Capital cost
Cost of recommended spares
Operability (cost of manpower)
Availability and cost of Supplier support
In addition to life cycle cost, the environmental expectations of the Contracting Authority must
be considered in all equipment selection decisions. This is covered elsewhere.
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6. HSE MINIMUM REQUIREMENTS
This section defines the Health, Safety and Environment minimum requirements (hereinafter referred to
as "HSE minimum requirements”), that the CONTRACTOR is expected to meet and to implement as a
minimum acceptable standard during the execution of the contract activities.
The HSE minimum requirements and activities in CAFC Project are categorized into the following 4
categories:
(1) Engineering and Procurement;
(2) Construction;
(3) SIMOPS;
(4) Interim Operation (to Handover; including Commissioning).
These requirements cover all activities, regardless of location and status, undertaken as part of the work
provided under the Contract, whether provided directly or by a SUB-CONTRACTOR, Vendor and
Supplier (including, but not limited to, material and equipment of the CONTRACTOR or SUBCONTRACTOR).
6.1 NATIONAL LEGISLATION, REGULATION, CONTRACTING AUTHORITY AND INTERNATIONAL
HSE CODES AND STANDARDS
The aspects of the design which are related to HSE shall comply with all the applicable regulations,
industry standards and project code and standards. In case of conflict between the Company‟s
specifications and the reference Rules, Codes and Standard the following order of priority shall apply:
1.
2.
3.
4.
5.
6.
7.
Algerian statutory requirements;
The Contract;
CONTRACTING AUTHORITY documents;
Process Basis of Design;
All other CONTRACTING AUTHORITY Technical Data;
FEED ITT Package documents (including reference list of applicable codes and
standards);
International codes, standards, best practice and guidelines.
In the case of an inconsistency between the requirements of any of the aforementioned, then priority shall
be given in descending order. The more onerous requirements shall apply, unless otherwise expressly
determined by the CONTRACTING AUTHORITY in writing.
CONTRACTING AUTHORITY shall have the right at all times to modify its requirements in the interests
of improving the Safety, Health, Environment and welfare of personnel in the workplace. To the extent
that there is a conflict between the project HSE requirements and this document, the more stringent
requirement as determined by COMPANY shall prevail.
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6.2 DESIGN HSE PHILOSOPHY
The design HSE philosophy is established with the intent to provide a framework and basis for
the design of CAFC project facilities to ensure that all hazards with the potential to jeopardize the
integrity of the project facilities and personnel attending the facilities have been identified and
risks have been reduced to As Low As Reasonably Practicable (ALARP).
The definition of the HSE design criteria during the detail engineering to be applied for CAFC
project facilities design shall be part of the CONTRACTOR activities to manage the HSE-related
risks during the entire performance of the work.
CONTRACTOR shall further define and develop the projects HSE philosophies for all CAFC
project facilities with the aim to collate and documents all the HSE design criteria and
philosophies, applicable regulations, codes and standards that are to be adhered regarding
design of the CAFC project facilities.
CONTRACTOR shall comply with, and further develop and update as necessary the FEED
project HSE philosophies during the EPC in consultation with and approval of the
CONTRACTING AUTHORITY.
CONTRACTOR shall comply with, and further develop and update as necessary the FEED HSE
documentations during the EPC in consultation with and approval of the CONTRACTING
AUTHORITY. Moreover CONTRACTOR shall agree with the CONTRACTING AUTHORITY on
the HSE deliverables to be prepared by the CONTRACTOR during the EPC phase.
Throughout the design of the installation, emphasis shall be placed on:
Provision of safe working conditions for personnel working on the installation facilities (and
immediate environs);
Protection of the asset;
Minimise the potential for hazardous occurrences;
Minimise the risk and consequences of an accidental event;
Provide sufficient safety devices and redundancy to isolate and minimise uncontrolled releases of
flammable and toxic substances;
Provide appropriate fire protection systems to rapidly bring under control and extinguish any
reasonably foreseeable fire which could develop during normal operations;
Protection of the environment and compliance with regulatory requirements;
Minimal damage to the environment under non emergency conditions;
Minimal adverse impact to the local community;
Minimum damage to equipment and prevention of long downtime or production deferment which
could be jeopardized by the occurrence of hazards inherent to hydrocarbon processing or any
other risks linked to an onshore processing facilities and industrial activities.
Ensure adequate means of Emergency Response (ER), Escape, Evacuation and Rescue (EER)
in the event of an incident.
The design philosophy is thus based on:
a) Elimination and prevention of hazardous incidents, as far as is practicable:
The application of codes of practice and standards, and performing the design in accordance
with Algerian Regulations and CONTRACTING AUTHORITY HSE minimum requirements,
standards and guidelines;
CAFC project facilities shall be designed in accordance with CAFC project document „Codes &
Standards‟ to be approved by the CONTRACTING AUTHORITY during the EPC phase‟;
Compliance with a project HSE Philosophies appropriate to CAFC project facilities;
Development of design and installation HSE systems based on the minimum requirements
established in this document and as they will be defined in the project HSE philosophies and
relevant CAFC project specifications.
b) Mitigation of the effects should a hazardous incident occur:
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Minimize the potential or frequency of hazardous events;
Control or mitigate the consequences of the hazards, including impact to the environment;
Define the requirements regarding asset protection, and ensure they are duly taken into
consideration.
c) Emergency Response (ER), Escape, Evacuation and Rescue (EER) in the event of an incident.
Provision of adequate escape, evacuation and rescue facilities.
6.3 HAZARD MANAGEMENT AND RISK MANAGEMENT
A goal setting approach will be applied to the project for its whole lifecycle. This will link the
processes of Hazard Management with Risk Assessment and other safety engineering studies
and reviews. Together, during the project phase, these facilitate confident and informed
engineering decision making which is directed at reducing risks to tolerable levels as the design
matures and demonstrating they are as low as reasonably practicable and appropriate for that
stage of the development.
CONTRACTOR shall submit during the detail engineering a final HSE Plan for engineering
clearly indicating the Hazard Management and Risk Management Process, (e.g. ALARP/ HAZID/
SIL/ QRA/EERA/HSE Impact assessments/HSE Case) it will use to implement HSE in the EPC
phase.
All studies shall form part of the overall risk management plan, to be developed during EPC by
the CONTRACTOR and submitted to the CONTRACTING AUTHORITY for approval.
All the methodologies for the required HSE studies shall be approved by CONTRACTING
AUTHORITY at the early stage of the detailed engineering and in any case before the
commencement of the studies.
6.3.1
GENERAL PRINCIPLES
A fundamental element of CONTRACTING AUTHORITY HSE Policy is that management of risk
is a continuous process and the cornerstone of all of the Contracting Authority HSE Elements.
The CONTRACTOR shall regularly identify the hazards and assess the risks associated with all
his Work. The CONTRACTOR shall take appropriate action to manage the risks and hence
prevent or reduce the impact of potential accidents or incidents.
Risk assessments shall be carried out to compare the risks as identified and analyzed with the
criteria for maximum acceptable risks as stipulated by regulations or defined by CONTRACTING
AUTHORITY policy. The guiding principle shall be that the project shall be able to demonstrate
that risks have been reduced to As Low As Reasonably Practicable (ALARP).
At the design stage significant efforts shall be made to manage hazards by the application of
Inherent Safety principles rather than by moving directly to control and mitigation methods.
ALARP principles (and Cost Benefit Analyses when required) shall be used to judge the
adequacy at each stage of the risk management process.
Consideration of HSE aspects shall be incorporated into all stages of the project in order that
issues can be addressed as soon as they arise. The earlier an HSE issue is identified, the easier
it is to address the issue and find a cost effective, practical solution.
It is the responsibility of the CONTRACTOR to demonstrate that the risks associated with CAFC
project facilities design comply with the CONTRACTING AUTHORITY requirements. Formal
studies methods shall be used to identify major hazards and assess risks so that adequate
protection features are provided.
The main studies to be carried out during the EPC are described in the following paragraphs.
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HAZARD IDENTIFICATION STUDY (HAZID)
A preliminary risk assessment, Hazard Identification Study (HAZID) has been completed during
FEED. As a result of this study a Hazard Register has been compiled detailing the Major
Accident Hazards. The findings and recommendations of FEED HAZID, performed during FEED,
shall be implemented by CONTRACTOR into CAFC project facilities design and operation during
EPC phase.
In every aspect of his Work, the CONTRACTOR shall carry out a risk assessment exercise to
identify Major Accident Events (MAE). Once on-site activities have commenced and prior to
commencing any new activity or as any condition changes affecting the previous analysis, a new
risk assessment shall be conducted. All resultant findings or action items necessary to
manage/control risks shall be updated in the Hazard Register.
The Hazard Register shall be maintained by the CONTRACTOR through out the Contract
duration. Any new Major Hazards and/or action items identified by the CONTRACTOR shall be
brought to the attention of the CONTRACTING AUTHORITY and addressed through the tracking
system.
During the detailed engineering of the EPC phase, CONTRACTOR shall perform new HAZID
follow up and shall perform a new HAZID to identify new possible Hazards related to CAFC
project facilities design , CONTRACTOR shall take in consideration the existing MLE facilities.
CONTRACTOR shall perform a Construction & SIMOPS HAZID before the commencement of
the construction activities.
6.3.3
6.3.3.1
HAZOP STUDIES
FEED HAZOP
A preliminary Hazard and Operability Study has been carried out as part of FEED excluding of
the following systems:
Raw Water;
Water Treatment;
Drinking Water;
Service Water;
Drain Water.
The findings from this study shall be incorporated into the P&IDs where possible. The HAZOP
report is included in the FEED package and action sheets shall be available to CONTRACTOR
during the ITT. Any actions outstanding at contract award shall be the responsibility of the
CONTRACTOR.
CONTRACTOR shall demonstrate that all the FEED HAZOP findings and recommendations
have been implemented in the FEED documentation. Moreover all the actions related to the
systems not studied during the FEED HAZOP shall be the responsibility of the CONTRACTOR.
6.3.3.2
EPC HAZOP
HAZOP shall be performed for the complete set of equipment based on issued P&ID‟s and
Cause & Effect Diagrams. HAZOP Action Sheets shall be issued for previous approval by the
CONTRACTING AUTHORITY. A HAZOP follow-up schedule shall also be issued and kept up to
date when implementing the actions.
The principal Drawings available for review during the HAZOP shall include, but not be limited to,
Process Flow Diagrams, equipment Arrangement Drawings, Electrical Area Classification
Layouts, Area Protection Layout Drawings, Flare and Vent System Data, Control Valve and
equipment Data Sheets, Cause and Effect Charts, PCS Logic, ESD Logic and F&G Logic,
Safeguarding Diagrams, DP/DT Drawings, Line Lists, Material Selection Drawings.
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For the avoidance of doubt, CONTRACTOR shall be responsible to implement all HAZOP
findings and recommendations arising as a result of the final (HAZOP & SIL) to be per carried out
during EPC phase.
The HAZOP scope shall be for the whole of the CAFC facilities including tie-ins and shall include
all utilities and Supplier packages. Supplier package HAZOP sessions shall take place at the
appropriate time in the development of these packages. CONTRACTOR shall ensure that all
required personnel attend the HAZOP sessions.
A pre start-up HAZOP shall also be carried out and the CONTRACTING AUTHORITY shall
assist in the co-ordination effort required to bring Operations personnel to the HAZOP if
available.
The selection of the independent chairperson and HAZOP recording and reporting procedures
shall be subject to approval by the CONTRACTING AUTHORITY.
If changes to design are made post-HAZOP, then procedures followed by the responsible
CONTRACTOR shall determine whether further HAZOP of such systems shall be made. These
procedures shall include approval by CONTRACTING AUTHORITY.
CONTRACTOR shall use preferably use the PHA or LIHOU Technical Software Services as the
HAZOP Manager Software. Any other alternative shall be subject to CONTRACTING
AUTHORITY approval.
6.3.4
SIL ASSESSMENT AND VERIFICATION
A SIL Assessment and subsequent Verification shall be performed by the CONTRACTOR during
the EPC phase after the HAZOP. A hazard risk analysis (SIL Assessment and Verification) shall
be undertaken for each protective function, based on the criteria defined in IEC 61508 and IEC
61511.
Note: no SIL assessment was performed during the FEED phase, thus CONTRACTOR shall
consider the implementation of any possible impact derived by the EPC SIL assessment.
HAZID, HAZOP and SIL sessions shall be led by a third party approved by CONTRACTING
AUTHORITY. Related costs shall be included and detailed in the lump-sum offer.
6.3.5
FIRE AND EXPLOSION RISK ANALYSIS (FERA)
A Fire and Explosion Risk Analysis (FERA) has been performed during the FEED; CONTRACTOR shall
perform a detailed FERA when proper project documentation will be available during the detailed
engineering.
The FERA Methodology shall be submitted to the CONTRACTING AUTHORITY at the early stage of the
detailed engineering for its review and approval.
A Blast Overpressure Study shall also be developed.
Note: during the development of the FERA, CONTRACTOR shall pose particular attention of its results
with respect to the blow down system design and philosophy. In fact, the current blow down philosophy
foresees that the plant is divided in two macro-areas: slug catchers area and process area. In case of
emergency, first the macro-area in which is detected the event will be depressurised and subsequently
the second macro-area. Once identified potential reciprocal impacts between the areas, CONTRACTOR
shall identify proper protective measures, since it is not acceptable that an event from one macro-area
could impact the second macro-area.
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QUANTITATIVE RISK ANALYSIS (QRA)
A preliminary Quantitative Risk Analysis (QRA) has been carried out at the FEED phase; CONTRACTOR
shall perform a detailed QRA when proper project documentation will be available during the detailed
engineering.
The QRA Methodology shall be submitted to the CONTRACTING AUTHORITY at the early stage of the
detailed engineering for its review and approval.
Note: it is CONTRACTING AUTHORITY intention to perform an overall QRA considering both CAFC and
MLE together, in order to determine the overall risks associated with the combined facilities.
CONTRACTOR could be requested to develop the study and/or implement resulting actions.
6.3.7
DESIGN CASE SCENARIO
The accidental scenario, both in terms of hazard likelihood and severity of consequences for assets,
identified for a specific plant area and considering all possible operating conditions (e.g. Construction,
SIMOPS), shall be used as a reference for systems design (e.g. fire fighting, F&G, safety distances, etc.).
Once the Design Case Scenario has been selected and its risk assessed against Risk Acceptability
Matrix for Assets, all the remaining risks shall be considered as Residual Risks and shall be analysed
through a QRA process.
6.3.8
DESIGN AND SAFETY REVIEWS
CONTRACTOR shall manage various design reviews and safety studies at the CONTRACTOR‟S
offices during the course of the Work. CONTRACTOR shall demonstrate by means of one or
more design reviews, as may be deemed necessary, that the design is safe, reliable, and
efficient and in accordance with CONTRACTING AUTHORITY requirements.
CONTRACTOR shall provide all facilities and information necessary for the effective
implementation of the studies. Each of these design reviews shall require the active participation
of the CONTRACTOR‟S key personnel who are working on the design, in an interactive
discussion with CONTRACTING AUTHORITY. Such design review may also include third party
participation.
Design reviews and participation from outside the project shall be arranged at the discretion of
the CONTRACTING AUTHORITY, although the CONTRACTOR shall recommend when, in the
opinion of the CONTRACTOR such participation should be invited and shall include such
milestones in the Project Schedule.
The CONTRACTING AUTHORITY shall provide assistance to the CONTRACTOR concerning
these studies and shall actively participate. The CONTRACTOR shall provide a „Case for Safety‟
for each site covering the project scope of work. This shall contain a summary of the relevant risk
management studies and include the ALARP demonstration, content of the HSE Case report
shall be agreed with the CONTRACTING AUTHORITY.
CONTRACTING AUTHORITY shall ensure that a project HSE Case is a key deliverable of the
Project HSE plan and the CONTRACTOR will be required to develop and submit to the
CONTRACTING AUTHORITY for approval an HSE Case which demonstrates that all significant
HSE risks have been identified, assessed and will be controlled to a level as low as reasonably
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practicable (ALARP). The Project HSE Case shall be completed before construction execution
and updated during Construction and SIMOPS phase.
CONTRACTOR shall update the HSE Case during the WORKS to ensure that the HSE Case
remains valid for the duration of the WORKS. The scope of work and document structure of the
HSE Case report will be agreed with CONTRACTING AUTHORITY before the beginning of the
activity.
The HSE Case document is composed of four main parts:
Facilities description;
Safety management system description;
Risk analysis and safety assessment;
Emergency and remedial actions.
6.3.9
ENVIRONMENTAL, SOCIAL AND HEALTH IMPACT ASSESSMENT (ESHIA)
An Environmental, Social and Health Impact Assessment (ESHIA) has been conducted during the FEED
phase by CONTRACT AUTHORITY and, submitted to local authorities. EPC Contractor shall comply with
the requirements of the MLE & CAFC ESHIA studies that will be provided.
Furthermore CONTRACTOR shall update at the EPC phase the FEED project environment requirements
according to the finding and the recommendation of the ESHIA and the latest Algerian laws and ensure
that all the finding and recommendation of the ESHIA report are implemented at the EPC phase.
Note: ESHIA will be provided to the CONTRACTOR and CONTRACTOR shall be responsible to conduct
all the activities part of the EPC according to the finding and relevant Action Plan.
6.3.10 HUMAN FACTORS STUDY
CONTRACTOR shall carry out a Human Factors Study during detailed design. The Scope of Work of the
Human Factors Study shall include:
An assessment of alarm protocols and priorities, location, numbers, access and visibility of
alarms and controls during normal and emergency operations.
Ergonomics of the local equipment rooms and changes to the current Control Room, including
lighting, general layout and workstation layout during normal and emergency operations.
Access to and egress from equipment, etc.
The exact scope of the study shall be developed by the CONTRACTOR and shall be subject to the
CONTRACTING AUTHORITY review. The study shall be initiated sufficiently early to be incorporated
into aspects of change to the existing Control Room, design of local equipment rooms and procurement
of the Integrated Control System.
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6.3.11 SAFETY CRITICAL ELEMENTS (SCE’S) IDENTIFICATION PROCESS AND MINIMUM
REQUIREMENTS
All HSE Critical Systems shall be identified and their performance standards shall be set for the CAFC
project. Setting the performance standards ensures that for the identified systems, the design,
procurement and operation fully meets CONTRACTING AUTHORITY standards.
6.3.12 HSE ACTION TRACKING
It shall be the CONTRACTOR responsibility to implement a suitable action tracking system, subject to
Contracting Authority approval.
All actions arising from new studies, risk assessments and all other safety related matters shall be
compiled into action sheets and controlled by the CONTRACTOR. CONTRACTOR shall prepare a
monthly report which addresses the various issues raised and compiled during different project reviews,
detailing the number of action items closed in that month and the current status of the remainder of the
action items. CONTRACTOR shall be responsible for initiating and undertaking any additional safety
studies to justify the design. Where required, all such studies shall be subject to review by the
CONTRACTING AUTHORITY.
6.4 INHERENT SAFETY
The principles of inherent safety that shall be adopted are as follows:
Segregation/separation.(See also Layout Philosophy section);
Minimisation of inventories/storage, etc;
Quality proven equipment;
Design simplification.
The design shall take all measures to ensure the stored inventories whether gas or liquids are minimised.
The areas where this applies are:
Pressurised process gas systems;
Liquid hydrocarbon storage.
Minimisation of the leak sources shall be achieved by:
Minimising flanged connections;
Minimising instrumentation;
Using ring type joints where practical for gas service.
Maximize ventilation/ Minimize congestion
Correct spacing of equipment in accordance with the distances as described in following section the
ventilation within the hazardous areas of the plant shall be maximised. Each risk area of the plant should
be assessed for the adequacy of the spacing and ventilation.
Orientations
To minimise the consequences of explosion overpressure effects consideration in the design shall be
given to orientating large items of equipment to reduce blockage. Buildings should be orientated for
minimum exposure to overpressure as should large vessels. Further technical development shall be
developed by the CONTRACTOR during the EPC phase to support this objective.
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6.5 LAYOUT PHILOSOPHY
6.5.1
LAYOUT CRITERIA TO MINIMIZE RISKS
In addition to normal engineering and process considerations, the design of the layout shall consider
defined safety criteria in order to minimize risks for personnel and equipment from fire or flammable gas
releases and maximize the capacity to deal with all possible emergency situations.
In addition to the requirements outlined in the FEED documents, the following intrinsic safety principles
governing plant layout shall be taken into account when locating the new facilities for CAFC Project:
The overall arrangement orientation will be such that the prevailing wind will tend to disperse any
hazardous release away from the safe area i.e. process equipment, hydrocarbon storage, and
flare and vent areas shall be located downwind of the safe areas. In locating the flare the
potential for dispersing flammables to be ignited shall be avoided either by separation or
orientation;
Adequate separation shall be provided between hydrocarbon-handling areas (hazardous areas)
and emergency services, main safety equipment, escape routes, areas to be non-hazardous and
permanently manned buildings;
Vents (if any) shall be located so as to cause minimum interference or hazard to plant and
personnel;
For gas systems, vent (if any) and relief valves shall be collected and discharged in safe location,
should the volumes to be vented be capable to create a hazardous condition;
The plant layout shall meet safety requirements for Hazardous Area Classification for electrical
equipment (See also Electrical System Design Section);
Adequate separation between flammable hydrocarbons and ignition sources shall be provided
and Limiting confinement and congestion in process areas; Units that contain large quantities of
flammable fluids shall be located so the prevailing wind will blow any vapour from an accidental
spill away from the plant;
Process piping and equipment, which are potential sources of hydrocarbon leaks, should be
routed so as to minimize the likelihood of external impacts (e.g. from vehicles, maintenance
devices, etc.);
Crash barriers shall be provided where there is any possibility of vehicle impact with pipelines,
HV transmission lines, fire hydrants, etc. (e.g. at road crossings);
Equipment shall not be located above live equipment for future phases nor shall it require lifting
above/across live equipment;
All basic design principles for minimising dropped objects and collisions shall be applied to
layout;
Signals shall be provided for the access ways in the Plant area to highlight headway and width at
overhead pipeline crossing points, maximum load capacity and turning bend radius;
Emergency shutdown systems shall be provided and located in such a way that the risk of
involvement in a developing accident is minimized:
SDV‟s shall be fire-rated and located at minimum practicable distance from the vessels and
equipment served;
The inlet and outlet ESDV‟s of a plant shall be isolated or protected from the Design Case
Scenarios and survive at least the time required to safely evacuate the plant;
Fire fighting equipment such as firewater/foam concentrate tanks and firewater pumps shall be
located away from any units having high fire potential.
6.5.2
MINIMUM SAFETY DISTANCES
Distances between units and equipment within the plant shall be established according to safe
accessibility aspects for operation and maintenance. Utilities shall be used as a “buffer” between
restricted and unrestricted areas.
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As a minimum, all components or units that will be installed in plant areas shall be
arranged/located to observe the safety distances prescribed in the CONTRACTING AUTHORITY
standards and any other applicable standards identified during the EPC phase.
Separation distances for safe and hazardous areas shall never be less than required by the
results of hazard assessments (e.g. QRA, FERA, etc.)..
Note: CONTRACTOR shall pose particular attention to the position of slug catchers and flare KO drums
taking in consideration the equivalent Note reported in FERA section.
6.5.3
FIRE ZONE
The process plant shall be divided into logical, physically located fire zones, which can be
process isolated. Each zone must be easily identifiable with respect to physical and /or process
boundaries.
Fire zone definition carried out during the FEED stage shall be further reviewed and developed
during EPC phase. The grouping of units into fire zones shall be closely linked to the process
flow and arrangement.
Each fire zone largely incorporates complete process units, which upon an ESD level activation
with depressurization will not produce a depressurizing capacity that is greater than the
predefined capacity of the flare system. As the governing factor for grouping is the flare capacity,
this limits how far process units can be further grouped into larger fire zones. Furthermore,
grouping of units into fire zones also corresponds to assembly of units with a comparable level of
process risks.
6.5.4
6.5.4.1
ACCESS AND EVACUATION
ACCESS REQUIREMENTS
Access to the process / utility areas shall be available from all sides to allow for both fire fighting
and maintenance activities. Space should also be provided for lay down of equipment during
maintenance or replacement.
For personnel safety in emergency situations it is necessary to provide some primary disposals
to ensure an easy evacuation from hazardous areas.
6.5.4.2
ROADS DESIGN
Site roads shall be provided giving good access for emergency vehicles, with due account given
to their turning circles, and cranes, as necessary, to all site areas.
Site access roads shall be provided with barriers and access control facilities to prevent
unauthorized entry. All roads will be subject to appropriate speed restrictions.
Equipment shall be located such that these site roads do not pass through areas classified as
“hazardous”. Any road that of necessity is classified as hazardous shall be subjected to restricted
vehicular access and the area shall be indicated accordingly.
Roads shall provide access to all sides of the process areas and buildings for fire trucks, portable
foam equipment and equipment to supplement permanently installed fire monitors;
Major site roads shall be of minimum width 6m, and shall not be more than 400 m apart. Minor
site roads shall be of minimum width of 4m. Minor site roads shall not be in an area classified as
zone 0 or 1;
The layout shall also meet requirements for vehicle and personnel traffic, security, emergency
evacuation, fire fighting and access for maintenance and operation;
Traffic barriers shall be provided around critical equipment, where located close to roadways;
Access ways shall be provided for escape and fire-fighting purposes, linking plant areas with the
site roads.
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EVACUATION
At least two opposite escape routes shall be provided for plant area and buildings. Escape routes
shall be arranged to direct escaping personnel away from the hazard towards the nearest exit
from the building.
The configuration of the primary escape routes shall ensure adequate room for fire and rescue
teams to operate unhindered. Every escape route shall be readily accessible at all times,
unobstructed, well marked and provided with adequate emergency lighting and signs.
For internal areas (rooms) the maximum allowable travel length to an exit shall be 7 m. At least 2
exits shall be installed if length exceeds 7 m. Dead end corridors shall not exceed 5 m. For
outside areas, escape routes shall be located at the outer edges of hazardous units.
Main escape routes shall be at least 1.2 m wide and have clear headroom of 2.1 m.
Escape/access routes leading to main escape routes shall have a minimum width of 0.8 m.
Consideration shall be given to the evacuation of injured personnel on stretchers,
Where changes in elevation of escape routes occur, ramps or stairways shall be provided. Their
minimum clear width shall generally be the same as the escape route they serve.
All doors and gates on escape routes shall be easily opened from either side and shall not be
possible of being permanently locked, except by frangible elements. Doors that open out on to an
escape route shall not reduce the escape path width below the minimum requirement .All doors
shall be illuminated by an emergency lighting system and safety signs.
Fixed ladders specifically designed for escape purposes are only required for escape from
access platforms less than 5m in length or form towers, columns, etc. and as secondary escape
from an elevated process area that has a main escape stairway.
One (or more) Assembly Area shall be provided for an emergency evacuation of the plant
personnel. This area shall be located so when an emergency evacuation is required, the
operating personnel can go to the assembly area and be in a safe place; the assembly area shall
be safe in prevailing wind conditions.
The area shall be identified with a large sign and should have a sheltered telephone. Direction
arrow markers shall be strategically positioned along escape routes where it is necessary to
guide personnel to the assembly area.
An Escape, Evacuation and Rescue (EER) Plan shall be a deliverable of the EPC phase and to
be provided by the CONTRACTOR.
6.6 PROCESS SAFETY CRITERIA
6.6.1
GENERAL
The process has to be as much as possible simple, in order to ensure the ease of all process
operations. The PSD system shall automatically detect abnormal operating conditions within
systems or equipment and initiate actions so that uncontrolled release of hydrocarbons is
prevented.
“Fail Safe” equipment has to be provided in order to limit the effects of failures or leakages (e.g.
in principle, shutdown valves to isolate process sections shall fail in closed position, blow down
valves shall fail in open position, etc.). All actuated valves with safety functions (e.g. SDV‟s,
BDV‟s) shall be “single effect”. The BDV valve shall have an air accumulator to avoid spurious
opening due to air instrument failure.
Two levels of protection, operating on different functionally basis (i.e. fully independent) shall be
provided. Duplication of identical safety devices with different set points does not satisfy the
requirement of two levels of protection.
Main process sections/equipment shall be sectioned and depressurized in an emergency.
Process and facilities will be designed such that no single failure during operations can lead to
unacceptable hazardous situations. These principles will apply to operational errors as well as
equipment failures.
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Material selection shall be dictated in consideration of corrosion, erosion, equipment and
personnel contamination .The most stringent level of integrity among utilities and process shall
be adopted for the interconnection between the two.
6.6.2
EQUIPMENT SAFETY REQUIREMENTS
Vessels and other equipment should be suitable for their operation duty and all reasonably
expected forces such as tank contents, ground settlement, frost, wind, earthquake and other as
appropriate.
Maintenance activities on process equipment will be protected by ensuring positive isolation from
the process. Adequate facilities for ensuring this shall be provided according the project isolation
philosophy.
All vessels that require access by personnel during maintenance will be designed with facilities to
connect utility systems, to ensure positive isolation from connected pipe work and to allow
adequate purging and ventilation before access.
All major hydrocarbon vessels will incorporate relieving systems which will be vented to Flare
System. Relieving systems shall be designed and arranged according to API RP 520, and sized
to meet the depressurization requirements of ANSI/API Std. 521.
All pipes containing hydrocarbons shall be arranged in such a way as to minimize the risk of
mechanical damage, either as a result of vehicular movement or lifting operations (e.g.
associated PSV recertification activities).All equipment shall be provided with the relevant
certifications of conformity, according to the applicable codes and directives (e.g. PED, ATEX,
and Machinery Directive).
6.6.3
EMERGENCY SHUTDOWN SYSTEMS
The ESD System shall be designed to perform the timely and safe isolation and shutdown of
equipment, systems and operations following the detection of an abnormal or unsafe
condition/incident. The ESD system shall be integrated with the Fire & Gas Detection System
and will be activated by one or more of the following inputs:
Process trips;
Confirmed alarms from Fire & Gas detectors;
Power failure;
Push buttons located in Control Room.
The operation of the ESD System shall be totally independent from the Distributed Control System
(DCS).
The following criteria shall be applied:
The shutdown system, including sensors, actuators and associated connections and circuits,
shall operate independently from other process and alarm systems .The ESD System shall be
based on programmable microprocessors; sensors will be hardwired.
The ESD circuits and actuators shall fail to a safe position on loss of power.
The ESD System design shall consider interference from other electromagnetic sources, and
shall incorporate suitable protection.
It shall be possible to test critical items of the ESD System without stopping the normal process
operations.
ESD actuators and cables shall have resistance to the effects of fires and impacts. ESD handswitches located on the auxiliary panel will be clearly marked and shall be protected from
inadvertent use.
Care shall be taken in the design and structure of the ESD System to eliminate common-cause
failures .The ESD System shall have sufficient separation/protection to ensure that a failure in
any part of the system would not cause other part of the system inoperative.
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The inlet and outlet ESDV‟s of a plant, SDV‟s and BDV‟s shall be isolated or protected from the
Design Case Scenarios and survive at least the time required to safely evacuate the plant.
ESD valves shall not auto-reset. Individual local and remote (under a detailed operating
procedure) reset shall be provided for ESD valves, only permitted once the shutdown cause has
been locally checked and removed. BDV shall have the automatic reset (and not local) in order to
avoid to forget some BDV opened before to re-start the plant.
The ESD System shall be characterized by logic with a number of intervention levels whose priority shall
be defined in relation to the extent of the deviations and their possible effects on production continuity,
personnel and equipment safety. The CAFC shall have a dedicated ESD System shall be structured on
different hierarchical safety shutdown levels, The ESD System shall subdivide the plant into discrete
isolatable sections (fire zone) that can be singularly depressurized.
CONTRACTOR shall develop and update the ESD philosophy developed during the FEED which shall
guarantee plant area protection against the identified design case scenario to be defined during the EPC
phase and considering synergy with MLE plant.
6.6.4
BLOW DOWN AND FLARE SYSTEMS
The blow down system shall be designed to safely receive contain and burn plant hydrocarbon
discharges from any emergency and process depressurization. Depressurization (blow down)
systems are required to reduce the risks of loss of equipment integrity during a fire and/or to
reduce a local loss of containment arising from a leak which may otherwise lead to escalation
and the risk of catastrophic failures.
The blow down philosophy is to depressurise the plant, fire zone by fire zone (following the
results of QRA and Fire and Explosion Risk Analysis), in accordance with ANSI/API Std. 521.
The design of the blow down system shall be based on achieving a pressure of 7 barg or 50% of
design pressure, whichever is the lower, within 15 minutes from blow down initiation, in the
involved fire zone(s).Blow down valves (BDV) shall be specified with a fail safe (open) failure
mode and with air accumulator to avoid spurious opening in case of air instrument lack.
The following general requirements shall be taken into account:
The effect of cooling due to the gas expansion during depressurization shall be carefully
evaluated during both normal operation and emergency conditions .Flare stacks shall be
designed to withstand the loads imposed by all known environmental conditions (wind,
temperature, sand, etc.).
Tip selection will take into account the maximum allowed noise levels in manned areas. The tip
shall be suitable for the calculated flare size and capacity, in order to ensure flame stability and
flashback protection. Tip and flare upper section material selection shall take into account the
effects of possible flame impingement.
Flare tip will be equipped with an adequate number of pilots, with a reliable means of remote
ignition; each pilot shall be provided with a thermocouple type flame detector; Open pipe flare
tips shall be designed for a maximum Mach number of 0.5.
Sterile areas shall be sized such that under foreseeable wind conditions flammable
concentrations of gas do not occur at ground level under flame-out conditions and respecting the
requirements in term of thermal radiation. In addition, it shall be ensured that ground level
concentration of products of combustion of the flared gas do not exceed permissible limits for
both short term and long term exposure.
Continuous venting or flaring of flammable gas shall be avoided. However, if it is necessary to
provide atmospheric vents from equipment or packages in flammable gas service, they shall be
collected in a common vent stack discharging at safe location.
The design objectives will be to operate without continuous flaring (except where specific consent
is granted, e.g. for start-up operations or other specific purposes). The flare collection headers,
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KO drums, risers and flare tips will be sized to cope with the maximum emergency loads.
Adequate system shall be provided for the flare headers to prevent air ingress and burn back.
Emergency depressurization (EDP) scenarios shall be verified at the EPC phase considering the
final process configuration and operating/design conditions (fluids involved, EDP scenarios,
effects of cooling/fireproofing protections, etc.) and considering synergy with MLE plant.
6.6.5
VENTING AND FLARING SYSTEMS
The design shall not require continuous venting of gas other than the minimum necessary for
purging. Flaring under normal operation shall be avoided.
All facility venting shall be routed via dedicated blow down systems to a flare for safe disposal by
burning of surplus flammable vapours produced from the plant.
The flare and corresponding sterile area shall be located and designed with due attention to all
relevant flaring rates and wind conditions to ensure that the heat radiation will be within
acceptance limits in all areas of the installation and of the neighbours, with due regard to
exposure of operators, structures such as cranes and towers, electrical and mechanical
equipment and piping.
The flare flame or hot gases shall not represent a hazard due to increased surface temperature
in exposed areas. Particular attention should be paid to cranes, towers, structures and personnel
in exposed areas. Further the design of the cold vent systems shall cater for heat loads caused
by a possible ignition of the discharge. Flare radiation calculations shall include the effect of
direct sun light.
A means to prevent personnel entering the sterile area shall be provided.
A dispersion analysis shall be carried out at the EPC phase to establish ground level
concentration of pollutants in the event unburned gas is vented.
6.7 DRAIN SYSTEMS
Drainage systems shall be provided to convey drainages from plant areas and systems to treatment,
recovery or disposal facilities and according to CAFC drainage philosophy. Drainage systems shall be
designed to:
Safely dispose hydrocarbons during drain-down of process vessels and equipment;
Contain any spillage of flammable or pollutant liquids;
Minimize the spread and area exposure of spills and fires;
Collect direct spills to a safe location, where spills can be retained and either recovered or
disposed;
Prevent backflow and fire spread through the system;
Avoid any possible impact on the environment caused by accidental spills.
Drainages from hazardous areas shall be physically separated from drains serving non-hazardous areas.
This separation shall ensure that communication between hazardous and non-hazardous areas via the
drain system is prevented.
Two different kinds of drain systems shall be provided in the plant:
1. Closed (process) drain systems;
2. Open (atmospheric) drain systems.
6.7.1
CLOSED DRAIN SYSTEM
Process drains from vessels, equipment, instrumentation and piping shall be routed, via dedicated closed
drain headers, to a closed drain vessel. The closed drain vessel shall be sized to receive the maximum
liquid load, provided that the process items are singularly drained. Where possible, adequate pump
system shall be designed to reprocess fluids into the system.
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OPEN DRAIN SYSTEM
Open drain systems collect rain waters and oily waters coming from the washing of process
paved areas (oil is separated prior to the discharge of water, and separated oil is sent to the
closed drain system).
Kerbs or drip pans shall be provided under potential leak sources (e.g. vessels and pumps). All
process area and utilities area (i.e. chemicals) shall be paved and sloped to low points.
Transit of spill from one zone to another, including through drainage system shall be prevented.
The drainage system for the process areas, bounded areas or kerbed areas shall be designed
taking into account of the potential firewater / foam flows, which may be released in the event of
a fire case. Moreover, since the plant is located in desert area, the design and the operation of
the open drain system shall take into account problems related to sand accumulation.
6.8 ELECTRICAL SYSTEM DESIGN
The electrical system design shall be in accordance with established codes, sound engineering practices
and international standards. The electrical system shall be designed to provide the following:
Safety to personnel and equipment;
Reliability of service;
Minimize the risks;
Sufficient emergency power to safely shutdown in the event of an accident.
6.8.1
HAZARDOUS AREA CLASSIFICATION
The facilities shall be classified according to the degree of hazard present in the place of the
installation and the probability of flammable gas being released.
The classification shall be carried out in accordance with the procedures laid down in IEC 6007910 or API Recommended Practice 505. Areas will be classified as Zone 0, Zone 1, Zone 2 or will
be unclassified (i.e. non-hazardous), using the definitions given in these specifications.
Details for hazardous area classification will be provided in “Hazardous Area classification report
during the EPC phase.
The following areas shall be defined as non-hazardous either by location or, if enclosed, by positive
pressurization by an HVAC system:
Assembly areas;
Areas of emergency power and control ;
Control and electrical rooms;
Accommodation areas and offices;
Air intakes.
Hazardous Area Classification datasheets and drawings shall be prepared by CONTRACTOR, to ensure
the new facilities foreseen in the Project are adequately specified according to the degree of classification
of their area to include the following information:
Characterization of the hazardous fluids;
Identification of sources of release;
Ventilation inlets and outlets;
Air intakes and exhausts of internal combustion machinery;
Location of all equipment units;
Tank or process vents;
The classification and extent of all hazardous zones;
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Ventilation type.
6.8.1.1
EQUIPMENT SELECTION
Electrical equipment to be installed in hazardous area shall be suitable for use in the appropriate
classified area, and shall comply with the requirements of ATEX Directive and IEC 60079 and be ATEX
Certified by a recognised international authority (e.g. IEC, CENELEC, BASEEFA, CESI).
The minimum certification of electrical apparatus to be installed in an hazardous area shall cover gas
group IIA and temperature classification T3 (200°C). The minimum IP rating for outdoor electrical
equipment, considering the desert environment, shall be IP 55.
All mechanical equipment installed in hazardous area shall be of a type which will ensure that hot
surfaces are insulated, shall be non-sparking and adequately protected against the generation of
electrostatic charge.
All internal combustion engines that shall be installed in hazardous area shall be specified with suitable
protections, according to EN 1834-1:2000 requirements (e.g. protections for air intakes and flue gas
discharges if located in hazardous area, automatic trip of the engine in case of overspeed, etc.).
6.8.1.2
VENTILATION AND PRESSURIZATION
To minimize the classification of a hazardous area, adequate ventilation is necessary.
In unrestricted open areas a natural airflow across the area is sufficient. In enclosed or sheltered areas,
forced ventilations by means of suitable stirrer fans is likely to be required to achieve the minimum of 12
air changes per hour necessary to prevent the area being inadequately ventilated.
Where forced ventilation is required, the following basic principles apply:
Gas extractors shall be located as close to the source of hazardous area as possible;
Gas extraction rate shall be equal or higher than the gas leakage/emission rate;
Air flow patterns (e.g. location of fresh air inlet ducts and extractors) shall be designed in
order to minimize the extension of the hazardous volume.
6.8.2
EMERGENCY POWER SYSTEM
The emergency power shall be provided at CAFC Project separately/independently from each other. The
emergency configuration at CAFC will be defined/determined during the design phase of the plant.
Emergency electrical power supply is required at least for the following emergency systems (essential
loads):
Safety controls (including F&G and ESD systems);
Critical monitoring equipment;
Emergency lighting;
Firefighting system;
Ventilation/pressurization systems;
Alarm and communication systems;
UPS System.
An Uninterruptible Power Supply (UPS) system shall be provided, located in a dedicated safe area and
shall supply, at least, the following utilities:
CAFC project will use the Battery back-up. Battery back-up shall be provided, but not limited to the
following vital electric loads:
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Fire & Gas Detection system;
Emergency shutdown (ESD) system;
Distributed Control System (DCS) and control panels;
Public Address/General Alarm (PA/GA) system;
Internal and External Telecommunication systems.
Batteries shall be sized to ensure alimentation to the above systems for a period as required in Eni E&P
Standard n. 20208.VAR.ELE.SDS. ELECTRICAL POWER SYSTEM
6.9 FIRE & GAS DETECTION SYSTEM
The objective of the Fire & Gas Detection System is to detect gas leaks or fires at an early stage, in order
to promptly activate/initiate the relevant alarms and protection means. To achieve this, F&G detectors will
be provided in all areas with a significant fire or gas hazard; detectors will be selected and located to
maximize the speed and reliability of response. The functions of the F&G Detection System shall be:
To monitor all areas where fire can arise;
To monitor all areas where flammable/toxic vapours might be present in normal operation;
To monitor air locks and HVAC air intakes to buildings/enclosures for toxic and flammable
gas;
To provide a facility for raising an alarm;
To alert personnel on any fire, gas (toxic or flammable) emergency situation;
To activate the automatic fire fighting system and ESD system;
To close fire dampers of facilities where gas is detected;
To alert personnel in Control Room of any fault detected by self-test facilities;
To evaluate signals from F&G detection system, using voting techniques where necessary;
To monitor state and availability of the fire fighting systems.
F&G is mainly initiated automatically and/or manually via F&G detectors or devices/systems.
Toxic gas detectors could be required in case toxic gaseous or liquid chemicals are handled/processed in
the plant.
6.9.1
FIRE DETECTION
Fire detection systems shall be installed where it is considered that the development of a fire constitutes
a possible threat to the plant. The fire detection system shall be designed to:
Detect a fire as early as possible;
Initiate preventive/shutdown actions at an early stage in order to mitigate the consequences;
Alert personnel of the danger;
Activate the ESD System in the affected area;
Shut down and depressurize the systems in the affected area on confirmed fire detection;
Activate fire fighting/protection systems (as required).
The selection of the fire detectors for an area shall reflect the anticipated prime indication of a fire. Heat,
smoke and flame detectors shall be considered, depending on the expected type of fire to be detected
and the environment in which the detectors are located.
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The location of the fire detectors shall take into account the following issues:
Location of the foreseeable leak source;
Released gas dispersion/dilution and influence of the ventilation air flow patterns;
Anticipated flow of hot combustion gases;
Shielding by beams, equipment and piping;
Process system configuration;
Accessibility for maintenance and testing.
6.9.2
FLAMMABLE GAS DETECTION
Flammable gas detection shall be provided at locations where accidental releases or ignition of such gas
constitutes a possible threat to the plant or personnel. The flammable gas detection shall be designed to:
Detect earlier a release of flammable gas and warn personnel of impending danger;
Allow preventive actions to be taken at an early stage, in order to reduce leakage and isolate
ignition sources;
Activate ESD in the affected area;
Shut down and depressurize the systems in the affected area on confirmed gas detection.
The requirement for number and type of detectors to be provided shall be based on an evaluation of:
Materials processed in the detection area;
Gas evolution rate and buoyancy;
Process conditions (e.g. high pressure, low temperature) which could affect the dispersion of
the released gas;
The likelihood of successfully detecting the released material and the major accident
potential.
The local ambient conditions and strong sources of ignition need careful consideration in the
selection and positioning of gas detectors. Installation, testing and maintenance shall ensure
reliability in order to minimize spurious alarms. Flammable gas detectors shall be set at two
thresholds of detection for explosive mixtures, in order to facilitate a prompt action in case of
gas release.
A detailed definition of type, number and location of gas detectors shall be performed during the detail
engineering of the EPC phase.
6.9.3
MANUAL ALARM CALL POINT
In addition to automatic fire detection devices, local manual fire alarm call points (MACs) shall be
strategically located throughout the plant areas, so that personnel working on the plant can raise
the alarm if a hazardous situation is detected.
At least one MAC shall be provided in every unit or plant area; the maximum distance between
two MAC‟s shall not exceed 150 m. These stations shall be of a break-glass type, specifically
manufactured for this purpose. Once operated, the station shall remain in alarm position until
manual reset (i.e. glass replaced).
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ALARM SYSTEMS
6.10.1 ALARMS IN CONTROL ROOM
All the automatic detection systems installed in the different areas shall send, in case of emergency, a
separate alarm signal to the main F&G Alarm Panel in Control Room. MACs, when operated, shall send
a common alarm signal per area to the main F&G Alarm Panel in Control Room.
6.10.2 PA/GA AND FIELD ALARM SYSTEMS
The PA/GA System consists of loudspeakers which must be strategically located throughout the plant
area, in order to enable personnel to listen to vocal messages or alarms from any point of the plant. The
system is supported with flashing lights in areas where noise levels are elevated.
Emergency lights and sirens shall be located throughout the facilities to alert field personnel in case of
emergency. Standard visual and acoustic signals, automatically activated by F&G detection or MAC
activation, shall be as shown in the following table.
Gas Alarm
Cause
Gas detection (at upper detection threshold)
Acoustic Signal
AS3 (YELP), corresponding to a short siren sound
(600 1250Hz) repeated with a 0.25” cycle
Fire/General
Alarm
(1)
Visual Indication
Red flashing light in all plant areas
Cause
Confirmed fire detection or MAC activation
Acoustic Signal
AS4 (SLOW WOOP) corresponding to a bitonal rising
sound (500 1200Hz) repeated with a 4.1” cycle
Visual Indication
(1)
Red continuous light in all plant areas
(1)
NOTES : AS3 signal takes priority to AS4 and can silence it during simultaneous emergencies. Head of
Plant‟s messages take priority and usually silence other acoustic signals.
6.10.3 ALARM VOTING FOR AUTOMATIC ACTIVATIONS
All loops and detectors shall be arranged such that any arising hazard can be easily located. A
F&G Cause/Effect Matrix shall detail the alarms and executive actions taken on fire, gas, heat
detection or manual activation. Detection in one loop (except for fusible plugs) or in one detector
shall provide an alarm only.
Any firefighting or shutdown/depressurization actions required to automatically occur in the
hazardous process areas shall require a voting system of instruments. At least two detection
devices (as a minimum 2ooN voting logic) in the same voting group shall be provided to sense
the hazard before an automatic action occurs.
6.11
FIRE PROTECTION SYSTEMS
The plant fire protection is achieved through a combination of the following:
Active Fire Protection, by means of extinguishing or cooling agents (e.g. water, foam, inert gas)
either manually or automatically activated on fire detection.
Passive Fire Protection, by means of intrinsic safety principles (e.g. adequate spacing between
equipment, containment by bunds or kerbs, drainage) or barriers/coatings on structures, which
provides protection against heat transfer.
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Note: FEED requirements for active/passive fire protection have been developed in accordance with the
preliminary FERA and shall be updated according to the final FERA to be carried at the EPC phase.
6.11.1 ACTIVE FIRE PROTECTION REQUIREMENTS
The general philosophy for Active Fire Protection systems design is to identify critical facilities
and buildings requiring fixed fire protection systems and areas where mobile/portable fire fighting
systems need to be provided in order to permit to operating personnel to control small fires.
The fixed fire fighting system will be designed based on the assumption that only one fire at a
time may occur in the plant; the requirements for fire extinguishing and cooling facilities will be
then calculated for the worst possible fire scenario, according to standards requirements. Active
fire protection systems shall also be designed and located taking into account environmental
conditions (i.e. wind direction, atmospheric corrosion).
6.11.1.1
FIREWATER PROTECTION SYSTEM
The firewater protection system as defined at the FEED stage shall be reviewed and verified by
the CONTRACTOR to reflect the design development during the EPC and considering the
results and the recommendation of the FERA and the other HSE studies (e.g. QRA, ).
CONTRACTOR shall perform a design review of the fire fighting system at the end of the EPC
phase.
Note: for the design of the fire fighting system, CONTRACTOR shall take into account that the firewater
flow rate is fixed since provided by the MLE plant firewater system. In case this value is exceeded, proper
reduction measures shall be implemented.
6.11.2 PASSIVE FIRE PROTECTION REQUIREMENTS
Passive Fire Protection is required where intense fire exposure can cause the collapse of
equipment, the spread of burning liquids, and the loss of operability capabilities of critical
systems. The aim of passive fire protection is then to avoid the escalation of the emergency, due
to the collapse of heavy structures or equipment containing dangerous fluids (e.g. flammables).
In particular, the purposes of passive fire protection are as follows:
To prevent, within a specified time, the collapse of steel work supporting equipment containing
flammable materials via fireproofing. The release of such materials would increase the intensity
of a fire and the problems and hazards of search and rescue and fire fighting (i.e. to limit the
escalation of fire between adjacent fire areas).
To protect safety critical equipment for a period sufficient to fulfil its function.
As a minimum, fire resistant materials shall be provided as primary protection of:
Structures directly or indirectly supporting significant hydrocarbon inventories or emergency
systems. Structures supporting heavy loads which, where their failure would lead to a significant
hydrocarbon release, or catastrophic failure, loss or damage to a control centre or emergency
system;
Class 0 hydrocarbon storage vessels or other plant that could fail catastrophically or lead to
further significant releases.
The requirements for passive fire protection coatings on structural steel will be based on an
assessment of the implications for further loss of hydrocarbon containment following structural
failure, and the durations of fires relative to the time necessary for structural failure to occur.
FEED requirements shall be reviewed and detailed according to the results of the HSE studies to
be carried out by the CONTRACTOR during the EPC phase.
The extent of provision of structural passive fire protection shall take into account the hazard
distances presented by credible fire scenarios, considering also the benefits of depressurization
systems in reducing fire durations and hence heat doses to structures. Identification of fire
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potential equipment, structures to be fireproofed and degree of protection shall be in accordance
with API 2218 criteria and FERA results.
Note: fireproofing shall be by means of in tumescent epoxy based paint only.
6.12
BUILDINGS SAFETY CRITERIA
6.12.1 BUILDINGS LOCATION
Critical buildings (i.e. central/local control room, electrical substation, offices, etc.) should be
located as far as possible from highly congested process units containing large amounts of
flammable gases. Buildings should be located upwind from any potential hazard (e.g. fire,
flammable or toxic gas source).
If spacing criteria are not applicable/sufficient, a certain degree of protection shall be provided,
according to international standard requirements and/or defined on the basis of risk assessment
studies.
CONTRACTOR shall demonstrate that no additional impacts have been generated from CAFC
facilities on MLE CPF buildings.
6.12.2 BUILDING SAFETY DESIGN REQUIREMENTS
Buildings that are permanently manned by plant personnel and/or that must remain operational shall be
located/designed in such a way to protect personnel from the effects of accidental releases (i.e.
explosions, fires or toxic concentrations).In addition to buildings location criteria and safety spacing, in
order to limit the damage to these buildings in case of explosion and to guarantee a minimum protection
without special additional requirements, the following minimum design criteria shall be considered:
Buildings shall be supported by a steel or reinforced concrete frame; structural details should
allow a large plastic deformation before collapse .Roofs and ceilings shall be designed such that
they cannot easily collapse during an explosion; the structural integrity of the roof must not be
endangered by damage to the supporting walls;
Buildings should preferably be rectangular shaped and single storey with flat roof. The roof
should not be charged with heavy equipment .Windows should be avoided, or their surface
should be minimised and should be fitted with suitable glass .Doors, frames and fixings should
ensure the same structural resistance as the rest of the cladding;
In addition the following features shall be considered in building design, to allow a rapid and safe
evacuation in case of emergency:
Access to the building areas (e.g. doors) shall be located onto the side opposite from process
areas;
Emergency exit doors of buildings shall be equipped with anti-panic bars;
Minimum door dimensions shall be 2.1m height and 0.9 m width;
Doors from enclosed areas shall open outwards, in the direction of escape;
No locking facilities shall be provided for doors along escape routes.
6.12.3 HVAC REQUIREMENTS
All buildings shall be provided with an air conditioning system that shall ensure that the air quality
is kept within acceptable limit values and shall have adequate cooling/heating capacity.
All ventilation air intakes shall be located in non-hazardous areas and as far as possible away
from any contamination sources. They shall be placed at high level and provided with high
efficiency sand-trap louvers and bird screens.
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The openings should be located where the influence of the wind pressure is at a minimum.
Openings for air intake and air/gas exhaust should be located so that exhaust air/gas cannot
recirculate again through the air intake.
Acceptable internal conditions shall be achieved for air temperature/humidity, air velocities, and air quality
and noise level. The following data unless otherwise specified in the other project documentations should
apply for the design of the HVAC systems, according to ASHRAE guidelines:
Internal design conditions:
25°C with 50% RH
Tolerances:
±1°C; ±10% RH
Maximum working condition:
42°C with 100% RH
Minimum working condition:
10°C with 100% RH
Maximum final air velocity near person:
0.25m/sec
Maximum ambient sound pressure level:
50dB(A)
Internal overpressure:
25Pa
In addition to the above requirements the HVAC system shall be provided with flammable gas detectors
in the fresh air suction ducts. The HVAC system shall automatically close all fresh air intakes and exhaust
outlets and operate in recirculation mode or completely shutdown the system in case of flammable gas
detection at the air intakes.
6.13
STRUCTURAL DESIGN
Accidental loads shall be identified and taken into account in the structural design. The
probability, magnitude and potential consequences of identified loads shall be assessed and
analysed.
Loads caused by extreme weather, earthquake damage to structural elements (damaged
condition) or extreme temperatures shall be considered.
Explosion loads affecting structures and equipment shall be considered. Explosion loads shall
be established by use of recognized computer models.
6.14
PLANT CONSTRUCTION
Plant construction shall be taken into consideration during the design in order to minimize hazards to
personnel, environment and damage to equipment during construction.
A risk assessment associated with construction of the facility shall be carried out during the design phase
in order minimize hazards during construction. Construction and SIMOPS HAZID studies shall be carried
out by the CONTRACTOR at the EPC phase.
The design should consider but not limited to the following:
Injuries or damage caused by mechanical works such as cutting, welding, heavy lifts,
transporting equipment, use of impact tools, exposure to pits/trenches and working at heights.
The design should minimize site construction, e.g. vessels and columns should be delivered fully
dressed.
Exposure to hazardous chemicals or substances, e.g. pipe work preparation prior to painting,
nucleonic testing of welds .Mechanical and electrical isolation requirements during construction
and commissioning.
Leak testing and pressure testing of piping and vessels. Cleaning and purging requirements prior
to commissioning in order to remove any material that may create a hazard when hydrocarbon is
introduced, e.g. oxygen.
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PERSONNEL SAFETY AND OCCUPATIONAL HEALTH
To ensure plant operating personnel safety and health, various types of facilities and equipment for
personal protection shall be provided and strategically located throughout the plant areas and buildings.
6.15.1 PERSONNEL PROTECTION
Suitable personnel protective equipment (PPE) shall be provided for day-to-day operation and
non-routine activity. The following non-routine activity and hazards should be considered:
Vessel entry;
Handling toxic and radioactive material;
Protection from solar radiation;
Welding, cutting, grinding, etc;
Working at height.
Walkways across pipes and working platforms on vessels and equipment shall be provided with
non-slip surfaces. An adequate number of the following safety equipment, stored in a suitable
ambient, shall be as minimum provided for personnel working in the plant area:
Safety shoes;
Polycarbonate helmets;
Spectacles;
Portable breathing equipment (with spare bottles);
Thermo-reflective gloves;
Thermo-reflective and fireproof blankets;
Fireproof overalls;
First Aid box/cabinet.
6.15.2 SAFETY SHOWERS AND EYEBATHS
Safety showers shall be provided in all areas where direct contact with chemicals would be
damaging or harmful to people, especially in chemical hazardous areas. They shall be equipped
with eye wash fountains. They shall be readily accessible and immediately available in the event of
an emergency.
They shall not be obstructed or obscured from view in all directions. Where visual obstructions
cannot be avoided, means shall be provided to indicate their locations. They shall use potable
water only. After use the standpipe shall drain automatically.
In principle, the following areas/buildings should be equipped with both safety showers and eyebaths:
Methanol and other chemicals pump and injection areas;
Glycol storage, handling and boiler areas;
Laboratory;
Process utility area;
Strategic locations within process areas;
Workshops;
Battery rooms.
These emergency units shall be connected to potable water supplies, and designed to ensure the
water is at a safe temperature for use, considering the possible direct exposure to sun radiation.
They shall be fitted with suitable alarms to give indication of operation in control room. Portable eye
washes shall be provided also inside the battery room. Safety showers and eyebaths shall be
clearly indicated and easily accessible.
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6.15.3 SAFETY SIGNS
Warning and safety signs shall be provided to warn people of hazards and the need for protective
equipment throughout the facility. The signs shall be clear, easy to understand and consistent
throughout the facilities. Warning symbols shall follow CONTRACTING AUTHORITY and
internationally recognized standards. Wording will be in Arabic, English and French. They shall
indicate:
Prohibited activities (e.g. no smoking) ;
Warnings (e.g. hazardous chemicals);
Mandatory requirements (e.g. helmets must be worn);
Location of fire-fighting equipment;
Location of personnel safety equipment;
Locations of manual alarm call point.
Readily visible windsocks shall be provided inside the plant, as an aid to determine direction of any
gas cloud during a release and to assist in escape route planning.
6.15.3.1
MARKING AND ILLUMINATION OF ESCAPE ROUTES
Doors and hatches for emergency exits shall have illuminated signs carrying the words
“EMERGENCY EXIT” and “NOT TO BE OBSTRUCTED” in French, English and Arabic.
Escape routes shall be provided with adequate battery powered emergency lights signs or outside
with electro luminescent direction signs. Plans shall be positioned around each area, which shall:
Show the location of escape routes;
Show manually operated fire-fighting equipment;
Be easy to read;
Be robust in construction;
Provide instruction of actions to be undertaken in the event of an emergency or on
hearing the respective alarms.
Escape ways shall be provided with non-slip surface. Anywhere where oil or other spillage might
occur, Self-drained grating shall be provided. Escape routes shall be clearly identified. Plans shall
be displayed throughout the plant and shall:
Show the location of escape routes,
Show location of safety, fire-fighting and survival equipment;
Be easy to read;
Be robust in construction.
Safety and warning signs and operating instructions for safety equipment shall be provided throughout
the complete facilities in Arabic, English and French.
There are six basic categories of signs as follows:
Fire fighting: those giving information/instructions with regard to fire prevention and fire
fighting equipment;
Mandatory: those giving instructions or information that must be obeyed or observed;
Emergency: those giving information, which should be heeded to avoid possible dangerous
occurrences;
Warning: Those giving information, which should be heeded to avoid possible dangerous
occurrences;
Prohibition: those that prohibit a particular activity;
General: those that convey general information of a non-critical nature not covered by the
five categories above.
Road and traffic signage shall comply with Algerian Regulation.
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6.15.4 MEDICAL FACILITIES
A medical facility is foreseen at the Base de Vie (MLE) for the treatment and stabilisation of
personnel who may become injured or ill as a result of an accident or illness.
First aid boxes shall be installed in plant control room, operator shelters, buildings, workshops and
stores. First aid boxes suitable for electrical injuries also shall be provided in electrical substation.
6.15.5 MACHINERY GUARDS
All exposed moving parts on all machinery shall be suitable guarded to protect personnel from
injury.
Guards and safety devices provided shall be well maintained and kept in position whilst machinery
is running.
6.15.6 MANUAL HANDLING
Manual handling requirements shall be minimized or suitable facilities provided to prevent hazard/injury to
personnel. The areas for consideration shall include but not limited to the following:
Mechanical lifting facilities should be provided for weights that may injure personnel.
Minimize handling of hazardous substances; provide bulking handling facilities and suitable
personnel protection.
6.15.7 ELECTRICAL SAFETY KIT
Electrical safety kits shall be provided inside local and central control rooms and electrical substation.
6.15.8 HOT AND COLD SURFACES/FLUIDS
Appropriate design measures shall be taken to protect against injury from hot or cold equipment
that has an external surface temperature that may be hotter than +70°C or colder than –10°C, and
may in normal operations be touched by personnel.
The design measures may include the use of insulation or guard barriers. The design should not
rely on personnel wearing gloves or other PPE, except for items such as handrails, which may
exceed 70°C due to solar heating, and where the use of insulation would be impractical.
6.15.9 HAZARDOUS MATERIALS STORAGE AND HANDLING
A hazardous material inventory shall be maintained. This shall include all flammable materials,
corrosive or toxic substances and any radioactive materials which are to be stored permanently or
temporarily at the installations. Recommendations for the storage of the materials identified in the
hazardous material inventory shall be made, according to their nature.
Paints and flammable materials shall be stored as far as it is practicable from other hazardous
areas. Corrosive or toxic chemicals shall be stored in suitable containers, marked with warnings
and precautionary measures.
No asbestos to be employed in buildings, thermal insulation or gaskets
Ceramic fibre insulation should be avoided because of its relatively high pulmonary biopersistence.
This requires that workers wear BA sets when working the material in order to comply with the
occupational exposure limits. Adequate PPE shall be provided and worn by the operators during
hazardous materials handling operations.
6.15.10 MATERIAL SAFETY DATASHEETS (MSDS)
Material Safety Data Sheets shall be provided for all chemicals, detailing all safety information for
material handling and emergency response. MSDS shall be written in the spoken language of the
people involved in their handling (as a minimum Arabic, English and French).
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6.15.11 RADIOACTIVE MATERIALS
Special consideration shall be given to handling of radioactive material, and use of radioactive
material shall be minimized. Formal procedures shall be developed and used whenever radioactive
materials are brought into the field, or onto the site, e.g. for radiography of equipment or pipelines.
Radioactive materials or equipment shall be manipulated only by certified personnel and shall be
handled under strict procedures. These procedures shall be written in the spoken language of the
people involved in their handling (as a minimum, Arabic, French and English).
6.15.12 TENORM
The primary radio nuclides of concern in petroleum industry TENORM are radium-226 (Ra-226),
radium-228 (Ra-228) and their associated progeny. The waste streams most likely to be
contaminated by elevated radium concentrations include (i) produced water, which is formation
water that is brought to the surface along with the produced oil and gas; (ii) scale, which is a hard,
insoluble deposit that accumulates on the surfaces of equipment and solid debris that come in
contact with produced water; and (iii) sludge, which is a slightly granular, usually hydrocarbon-rich
deposit that accumulates in the bottom of some storage and process vessels.
The evaluation of TENORM impact in water management shall be considered.
It is important that systems for water treatment and waste disposal will investigate options before
installing water treatment. If possible, pilot tests are a good way to determine how much waste the
system will produce and whether the system will be able to dispose of the amount, concentration
and type of waste.
6.15.13 PROHIBITED SUBSTANCES
The use of certain materials is restricted, including but not limited to:
Asbestos
2-naphthylamine
4-aminobiphenyl
Benzidine and related salts
4-nitrodiphenyl
Carbon tetrachloride
CFCs (chlorofluorocarbons)
Cadmium Compounds
Halogenated Hydrocarbons
Mercury compounds
PCBs (Polychlorobiphenyls) And other compounds based on the above
Arsenic compounds
Benzene
Bitumen
Chloroform
Hexavalent chromium (VI) and chromates
Ethylene glycol monoethyl ether (2- Ethoxyethanol)
Ethylene glycol monoethyl ether (2- Ethoxyethylacetate)
Ethylene glycol monomethyl ether (2-Methoxyethylacetate)
Formaldehyde
n-Hexane
Isocyanates
Lead compounds
Methane dichloride
Nickel compounds
Trichloroethylene
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1,1,1-Trichloroethane
6.16
ENVIRONMENTAL STANDARDS
Regulations applicable to CAFC project facilities include international, national and any other
requirements. All projects undertaken in Algeria are subject to all national environmental legislation and
all international legislation to which Algeria has ratified and/or signed.
All the emissions from the facilities shall meet, the requirements to ensure the control of pollution caused
by facilities activities. The aim shall be to minimize wastes and other gaseous or liquid emissions
categorized as follows:
Air emission;
Waste water discharges;
Soil contamination and groundwater protection;
Solid and liquid waste management;
Spills.
It also shall be taken into account:
the mitigation of noise and vibrations sources, to improve working conditions across every
plant areas;
the evaluation of terrestrial impacts and project footprint.
6.16.1 PROJECT ENVIRONMENT REQUIREMENTS
CONTRACTOR shall update during the EPC phase the project environment requirements document
developed during the FEED according to the results of the project ESHIA, therefore submit it to the
CONTRACTING AUTHORITY for review and approval; the scope shall cover all areas of wastes limited
to emissions to air, effluent discharges, solid waste and sludge and noise.
In additions the report will address occupation health and occupational noise limits ensuring that they are
never reached.
It also shall be taken into account the mitigation of noise and vibrations sources, to improve working
conditions across every plant areas and minimize the impacts outside the plant fence. All environmental
parameters which characterize the emissions from the plants shall comply with the limits detailed in local
laws and recognized international standards, as detailed in the following sections.
6.16.2 NOISE CONTROL
CONTRACTOR shall ensure that all equipment meets the noise requirements specified in the FEED
package in Annex I – “Technical”. CONTRACTOR shall update the equipment noise data sheets as
necessary prior to issue of the equipment packages for enquiry, to achieve the overall noise limitations
for the facility. CONTRACTOR shall provide Acoustic Insulation as necessary to meet the overall facilities
noise criteria.
CONTRACTOR shall also carry out noise and vibration studies throughout the design to ensure that
sound levels do not exceed those permitted and that no acoustic „vibration‟ could occur and propagate to
impinge upon the integrity of structures and equipment to the detriment of the facility and Plant Safety,
Operability and Reliability.
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A noise and vibration survey shall be carried out on site by the CONTRACTOR to confirm that the design
intent has been achieved. CONTRACTOR shall be responsible for any corrective actions resulting from
the noise survey.
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7. MATERIALS PROCUREMENT AND MANAGEMENT
7.1 GENERAL
The Contracting Authority has a contractual responsibility and an obligation to give priority to
Algerian goods and services insofar as their price availability and performance shall be
competitive in relation to those of a similar nature, which can be provided by non-Algerian
businesses. Whereby competitiveness shall be evaluated according to the following criteria:
For the providers of services: Experience in Algeria and/or other
references, implemented technical resources, speed of
performance of services, competence of staff employed, price of
service for provision in Algeria.
For product suppliers: Quality of products, equipment and goods
supplied, price for delivery of goods in Algeria, speed of delivery.
The Contractor is advised that the Contracting Authority consider it a condition precedent that
the Contractor provides the same obligation.
7.2 SCOPE
The Contractor shall be fully responsible for all work associated with the procurement of all
Materials and Equipment.
This includes all work necessary for the Contractor to make an award to a Contracting
Authority approved Supplier as attached in Annex VIII – “List of Subcontractors and proposed
Suppliers and Vendors” of the Contract preparation of Drawings and Specifications,
preparation of bid lists, preparation of bid packages, bidding, bid evaluation including
clarification meetings, awarding, scheduling, Supplier kickoff meetings, approval of Supplier
documents, expediting, inspection, witness testing and acceptance, transportation, receiving
inspection, commissioning, data books, as-built Drawings, etc.
Bid Evaluation Procedures shall be subject to approval by the Contracting Authority. Award of
all major equipment items to be defined by Contracting Authority shall be subject to
Contracting Authority approval.
7.3 PROCUREMENT ORGANISATION
The Contractor shall establish a Procurement and Materials Management Team for the
Contract, led by an experienced Materials Manager or equivalent that is responsible to the
Contractor‟s Project Manager for all Supply Management and supply activity (ref. Annex XIII –
“Quality Plan”.
The team shall comprise procurement professionals deemed appropriate for procurement,
expediting, delivery, care, management and certification of all Materials and Equipment,
including consumables, used in the supply and construction of the works. It shall include
Head Office Team Members, local procurement officers and remote international expediting
and inspection resources as required. If the Contractor proposes to source Subcontract
Personnel to support the Teams, then the organisation presented shall include those
Personnel.
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7.4 PROCUREMENT METHODS AND PROCEDURES
The Contractor shall prepare Project specific procedures for procurement based on the
Contractor‟s corporate standards, which encompass all purchasing and materials
management activities, progress assessment and reporting, materials identification and
tracking.
However, Contractor shall comply with the minimum requirements of the
Contracting Authority procedures.
The Contractor shall detail the procurement strategy, plan and procedures to be followed to
enable monitoring of progress and material cost. The Contractor shall detail the Procurement
Policy including the items listed below:
Local and International Procurement offices
Project procurement organisation
Authorisation levels
Proposed country of source, including level of procurement from
Algerian Suppliers.
Procurement of all equipment and bulk materials shall be subject to Contracting Authority
review. Contracting Authority shall be copied on all correspondence and be given the
opportunity to participate in all technical meetings between the Contractor and the Supplier.
Contracting Authority shall also have the right to review the technical sections of the
Supplier‟s bid along with the Contractor‟s technical bid evaluation.
7.5 APPROVED SUPPLIERS LIST
An Approved Suppliers List is included in Annex VIII – “List of Subcontractors and proposed
Suppliers and Vendors” of the Contract. This shall be used for the procurement of all
equipment and bulk materials. This list also applies to Suppliers for Packaged equipment.
The Contractor shall include these Suppliers on bid lists for Materials and Equipment. The
addition of Suppliers not currently shown on the list shall be subject to the review/agreement
of Contracting Authority. The Contractor shall request additions to the approved list at least
two weeks in advance of issuing the bid package to Suppliers.
The following categories from the approved project listing are deemed to be “Key
Subcontracts”:
Surface Facilities, Prefabrication, Construction and Installation
Civil works and Roads
Buildings
Metallic Structures
Inland Freight
Ocean Freight
Medium and Low voltage switchboards, DCP and UPS panels
Transformers
Distribution boards
Integrated Control Systems Package (ESD/DCS/F&G)
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Control Valves
Manual Valves
Relief Valves
Choke Valves
Mechanical HIPPS Valves
Wellhead control Panel / HPU
Flow control butterfly Valves
Emergency Power Generation
Flash Gas Compressors
Gearbox
Couplings
Shaft Seals
Centrifugal Pumps
Other API Centrifugal Pumps
Booster and Export Pumps for Oil (to be purchased from the
same supplier as for MLE)
Pumps general service/Chemicals
Water Injection Pumps
Oil Stabilisers,
Oil Desalters (electric precipitators)
Separators
Pressure Vessels, General
Scrubbers
Column Trays
LT KO Drums (SS)
Gas Dehydration Package
Off spec Storage Tank (Oil )
Produced Water Treatment Package
Flare Package
Heat Exchangers
Pipelines
Additionally, the following categories of equipment are “Principal Equipment” and as such the
agreed vendor list for these items are deemed to be frozen for the duration of the EPC
Contract and no amendments or additions will be considered:
Integrated Control Systems Package (ESD/DCS/F&G)
Flash Gas Compressors
Gas injection compressors
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Booster and Export Pumps for Oil
Oil Stabilisers
Oil Desalters (electric precipitators)
Separators
LT KO Drums (SS)
Control Valves
Safety Valves
Manual Valves (Insulation Valves)
7.6 BID PACKAGES
The Contractor shall ensure that all equipment bid packages include a reimbursable element
for training of Contracting Authority Personnel by the Supplier, either at the Construction Site
or at the nearest Supplier location (whichever provides the lowest overall cost for training).
Contracting Authority shall be consulted for agreement on this prior to contract award.
For those courses at the Construction Site, the Contractor shall provide suitable training
centre.
Enquiry documents for shall be subject to review by Contracting Authority prior to issue.
Contractor shall prepare an un-priced bid tabulation and recommendation for Contracting
Authority‟s review and approval for major equipment. Contracting Authority reserves the right
to approve or disapprove the selected Supplier.
Un-priced Purchase Orders for shall be subject to review by Contracting Authority prior to
commitment.
The Contractor shall make use of Criticality Assessment Programmes to assess and specify
inspection, quality control and test requirements for all items ordered. The Contractor shall
conduct all necessary technical clarifications of the bids and shall hold clarification meetings
with Suppliers to enable Supplier designs and the Contractor‟s design to be efficiently
integrated.
The Contractor shall ensure that all equipment bid packages include for the provision of all
necessary Vendor support at the Site during construction, pre-commissioning, commissioning
and start-up. The Contractor shall obtain written guarantees from Suppliers that the
appropriate level of support shall be provided at the Site, at the appropriate time. The vendor
support requirements shall be stated in the Contractor‟s Execution Proposal. Due to the
criticality of Vendor packages the Contracting Authority reserve the right to review and confirm
suitability of Vendor proposed representatives for key packages.
7.7 SUPPLIER QUALITY MANAGEMENT
The Contractor shall develop a plan for the control of Suppliers‟ goods and services, in
accordance with this Scope of Work.
7.8 SUPPLIER INTERFACE MEETINGS
The Contractor shall schedule periodic Supplier interface meetings appropriate to the work
scope for each Supplier, which shall be used as a basis for progressing and reporting
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Supplier status. The Contractor shall issue minutes of these meetings and these minutes
shall be held in the Order File. All minutes shall be subject to Contracting Authority informal
audit at any time. The Contracting Authority‟s Representatives shall be notified of, and invited
to, all Supplier interface meetings at least seven days in advance.
7.9 MATERIALS STATUS REPORTING
The Contractor shall develop and implement a system for reporting status of all materials
progress. Each Purchase Order shall be tracked from Bid Evaluation, Placement of Order,
manufacturing sequence to delivery to Construction site.
The Contractor shall prepare and issue, as a minimum, the following weekly materials status
reports:
Procurement package/Purchase Order status report(s) detailing
the current progress/status of all activities up to, and including
Purchase Order award. This is to cover the full listing of all
category(s) of materials that the Contractor is directly responsible
for.
Expediting and Inspection Status report(s) covering all activities
after Purchase Order award. This is to cover expediting status by
line item and Inspection status by line item.
Traffic/freight status by line item, showing status and location up
to receipt at the Contractor‟s storage yard.
Material identified as surplus or scrap.
On receipt of material at the construction site, the Contractor shall log all material received
and prepare a register of all Materials and Equipment identifying the purpose or intended
purpose of the material.
7.10
INSPECTION AND EXPEDITING
The Contractor shall implement an inspection and progress monitoring programme. The
Contractor and Contracting Authority shall jointly agree on the inspection required for the
equipment items. The Contractor shall be responsible for all costs associated with Supplier
inspection and progress monitoring program. The Contractor shall invite the Contracting
Authority representative to participate in all major package pre-inspection meetings
Contractor shall ensure that it package equipment engineers maintain status involvement and
are responsible to ensure all aspects of expediting are maintained.
The Contractor shall submit resumes for the proposed Supplier inspectors to Contracting
Authority for approval. If, after a period of time on the job, at the Contracting Authority sole
discretion, Contracting Authority determines that an inspector is not suitable for the work the
inspector shall be replaced.
The Contractor shall ensure that all the inspection requirements of the Algerian regulatory
bodies are met. This shall include but not be limited to any necessary payments and
coordinating visits to design offices, construction sites and supplier locations. Algerian
regulatory bodies include but are not limited to DPEM, CTC, ARPT, ARH and ONML.
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PROTECTION, PACKING, MARKING AND SHIPPING REQUIREMENTS
The Contractor shall prepare and issue with all orders for equipment a specification for
adequate protection and preservation of the equipment during transport to, and storage at, the
construction site. Contractor shall develop Specifications to set out Contracting Authority‟s
minimum requirements for handling, preservation and storage of equipment.
The Contractor shall ensure that all Suppliers make specific offloading and storage
recommendations within their bids, relative to the packaging offered. Such recommendations
shall cover the maintenance and preservation during (a) storage and (b) following unpacking
and after installation at site but prior to commissioning.
The Contractor shall determine whether there is any requirement for long term preservation
as a result of schedule delays. The Contractor shall ensure sufficient resources and
consumables are available for this purpose, if deemed necessary.
Consistent with Algerian regulations, the Contractor shall ensure that „Release dossiers‟ are
included with each shipment. These dossiers shall contain all documentation applicable to
the shipment to allow the Contractor to immediately issue the equipment for installation.
Suppliers shall be required to comply with all requirements associated with transportation of
hazardous goods, including all Algerian regulations and those in force in the countries of
origin and transit.
7.12
SUPPLIER DOCUMENTATION
A Supplier Data Requirements list shall be included as part of each bid package and
purchase order or contract.
The Contractor shall ensure that all Supplier documentation is received in a timely manner in
order to ensure input to design, construction, Mechanical Completion and Commissioning
procedures.
The Contractor shall deliver final certified equipment dossiers (MDR‟s) for all equipment.
7.13
CUSTOMS CLEARANCE
The Contractor is responsible for Custom Clearance at point of entry to Algeria and shall
prepare all necessary manifests and information required for custom clearance in respect of
all Materials and Equipment.
The Contractor shall be responsible for all costs incurred as the equipment passes the ships
rail at the port of entry to Algeria including taxes, customs duties, agents fees/ commissions,
port fees, handling, mooring, storage, transportation to the CONTRACTOR‟S storage yard, as
well as any other applicable charges except as excluded in the terms of the Contract.
Upon receiving items the Contractor shall immediately check all documentation, unload,
inspect, report any damage, and properly store the equipment. Any damage identified after
the Contractor‟s receiving inspection may be for the Contractor‟s account.
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7.14
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SPARES
7.14.1 General
The Contractor shall be responsible for the procurement, expediting and delivery of all spares
for Contractor procured equipment to the Contracting Authority warehouse facility at MLE.
Spares delivered prior to the completion and handover of the warehouse shall remain in
Contractor care and custody until they can be stored in the Contracting Authority warehouse.
The Contractor shall request each Supplier to include a clause, which limits the allowable
escalation of costs for spares for 10 years following the placement of the Purchase Order.
7.14.2 Insurance Spares
The Contractor shall review the master equipment list and recommend insurance spares for
equipment to Contracting Authority. The requirement for insurance spares shall be advised by
Contracting Authority, following consideration of the Contractor‟s recommendation.
The respective orders for equipment placed by the Contractor shall include an option for the
supply and delivery of those insurance spares on the understanding that the order for the
spares may be assigned to Contracting Authority within six months of order placement by the
Contractor.
The Contractor shall be reimbursed third party Supplier documented cost (e.g. Purchase
Order value) for the spares from the Provisional Sum Price. All other costs required to
purchase the spares are deemed to be included in the lump sum Contract Price. Contractor
shall be responsible for the procurement, expediting and delivery of all spares to Contracting
Authority‟s warehouse at MLE.
7.14.3 Operating Spares
The Contractor shall include in the commercial offer the cost of the recommended two year
Operated Spare Parts as a Provisional Sum and identify this as a separate price. Contracting
Authority intends to use the higher price of the EPC Tender offer for spares in the final price
comparison between the two contractors. Contracting Authority shall endeavour to advise the
Contractor the requirements for Operating Spares within 12 weeks of receipt of the list so that
the Contractor can place orders for these spares.
The recommendations shall be detailed by completing the SPIR form. It is the responsibility of
the Contractor to ensure SPIRs are accurately completed. The SPIR form should be
completed in accordance with Contracting Authority requirements (Procedure Sonatrach de
Codification) and implemented to Computerized Management System as described in Annex
XII “CAFC plant Operability and Maintainability requirements for EPC Contractors”.
The Contractor shall be reimbursed third party Supplier documented cost (e.g. Purchase
Order value) for the spares from the Provisional Sum Price. All other costs required to
purchase the spares are deemed to be included in the Contractor management costs. The
Contractor shall be responsible for the procurement, expediting and delivery of all spares to
Contracting Authority‟s warehouse at MLE.
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7.14.4 Commissioning and Start-Up Spares
The Contractor, shall instruct all Suppliers to provide costs for Commissioning and Start-Up
spares for the facilities. Therefore it shall be the responsibility of the Contractor and Suppliers
to ensure sufficient spares are retained on site to Commission and Start-Up the facilities and
equipment, any/all commissioning spares not used shall be provided to Contracting Authority.
All Commissioning and Start-Up spares shall be provided by the Contractor as part of
Contract Price Lump Sum.
7.14.5 Cataloguing Spares
The Contractor shall catalogue all procured spares in a form compatible with the Contracting
Authority‟s chosen computerised maintenance management system (CMMS)
7.15
SPECIAL TOOLS
The Contractor as part of the Materials and Equipment supply shall provide special tools for
the installation and maintenance of Materials and Equipment as part of Contract Price Lump
Sum.
7.16
LOGISTICS
The Contractor should provide a plan with its tender in Schedule 13 of the ITT on how it shall
develop a logistics strategy and execution plan to be agreed by Contracting Authority and
form part of the Contract in Annex II – “Extent and Limit of Supplies and Services”. This
should cover:
Plans for Air, Sea and Road transportation of materials to Algeria
Inland transportation of materials and transportation of Personnel
Freight Forwarding and customs clearance
The logistics organization
Material packaging handling and inventory control procedures
Supply base/warehousing equipment and facilities
How you intend to interface with the appropriate Algerian
authorities at all levels
Opportunities for cost saving by sharing with other Projects
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8. TECHNICAL INTEGRITY MANAGEMENT
8.1 MANAGEMENT SYSTEM
The Contractor shall submit a preliminary Technical Integrity Management plan with his bid
documentation. The proposed system shall ensure effective technical management and
technical integrity compliance whilst ensuring that optimum value solutions are adopted. The
system shall fully satisfy the CAFC Project HSE Requirements included in this document and
Annex XI – “Health, Safety and Environment” of the Contract, and meet the requirements of:
ISO 9001, 2008, “Quality Systems - Model for Quality Assurance
in Design/Development, Production, Installation, and Servicing”,
ISO 9004-1, 2000, “Quality Management and Quality System
Elements - Guidelines”,
ISO14001 2004 “Environmental Management Systems.”,
OHSAS 18001:1999 Amendment 2002 “ Occupational Health
and Safety Management Systems”
Implementation shall be in accordance with the Contractor‟s standard management systems,
which include Quality, Safety, and Environmental Systems and shall be fully detailed in a
project specific Technical Integrity Plan.
The System detail and an outline of the Integrity Plan should be included within the
Contractor‟s Execution Proposal in Schedule 5 of Part B1 of the Schedule and to form part of
Annex XVI – “Contract Administration Manual” of the Contract.
The system shall provide for the planned and systematic control of all Technical Integrity
related activities performed during Design, Procurement, Construction, Pre-Commissioning,
Commissioning and Start-Up.
The Contractor‟s System Manuals and particularly the Integrity Plan together with all
related/referenced procedures shall be submitted to the Contracting Authority‟s
Representatives for Review, Comment and APPROVAL.
The Contractor shall provide evidence from an Accredited Certification Body of their proposed
System Certification or a recent compliance audit report and attestation from a Contracting
Authority‟s approved (third party) auditing body confirming Quality System Compliance.
ISO Accreditation or Compliance evidence must be submitted within the Contractor‟s
Execution Proposal to form part of Annex XVI – “Contract Administration Manual” of the
Contract.
The Contractor shall ensure that all major Subcontractors and JV Partners have Systems
which comply with this section and that they are seamlessly interfaced for the Project.
Contractor shall supply details on how any major Subcontractors or JV Partners shall comply
with the overall Technical Integrity Management Requirements within his Execution Proposal
in Schedule 5 of Part B1 of the Schedule and to form part of Annex XVI – “Contract
Administration Manual” of the Contract.
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8.2 INTEGRITY PLAN
The Integrity Plan shall include:
a)
Narrative details of how the Contractor interprets the individual technical integrity
elements of ISO 9001/ 9004, ISO 14001, BS 8800, this Section of the Scope of Work
and the HSE Section of the Scope of Work for the application of the Project work
scope including the controls and verification to be put in place to assure Integrity
during each stage of the design, procurement, construction, Pre-Commissioning,
Commissioning and Start-Up.
b)
Detail in a matrix format how the Contractor‟s system addresses the detail noted
above. It should reference responsible parties within the Contractor‟s organisation for
the implementation/control of each area, the applicable procedures used to
control/assure each area and the verifying documents produced for each area (see
Figure 1 for sample format).
Combination of „a‟ and „b‟ is acceptable if the narrative detail is included in the Matrix.
Plans shall be developed for the full CONTRACT SCOPE and shall be included within the
Contractor‟s Execution Proposal in Schedule 5 of Part B1 of the Schedule and to form part of
Annex XVI – “Contract Administration Manual” of the Contract.
The Plan shall detail co-ordination, control and assurance of all interfaces, including JV‟s and
multiple sites.
8.3 SYSTEM REQUIREMENTS
This section describes the Contracting Authority specific requirements/ interpretations that
shall be incorporated into the appropriate sections of the Contractor‟s standard Management
Systems for the Project.
8.3.1
General
The Contractor‟s Management Systems shall cover all management aspects and shall impose
the same requirements on Subcontractors and suppliers. The System shall ensure the work
as a whole is included, from Project initiation to completion of Start-Up. This shall include:
Review and monitoring of the Systems by an independent Quality
Assurance organisation, within the Contractor‟s organisation,
staffed with sufficient resources to perform the work.
Details of the organisation and proposed resources for this
Project shall be submitted to the Contracting Authority‟s
Representatives together with the CV‟s of QA Managers and QC
Managers for home office.
A well defined and documented policy signed by the most senior
Contractor management, and demonstrating the Contractor
commitment to the Project Integrity requirements shall be issued.
This policy statement shall be included within the Contractor‟s
Execution Proposal in Schedule 13 of Part B1 of the ITT and form
part of the Contract in Annex II – “Extent and Limit of Supplies
and Services”
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Methods of performing Project planning in accordance with the
Contract requirements.
As a minimum, procedures shall identify the responsibility for
each design and construction activity and provide a mechanism
for the timely production of all working procedures and discipline
interfaces necessary to fulfil the specified requirements and to
meet the Project work schedule.
Details of provisional procedures should be included within the
Contractor‟s Execution Proposal in Schedule 13 of Part B1 of the
ITT and form part of the Contract in Annex II – “Extent and Limit
of Supplies and Services”.
Document Control Procedures to control status and ensure only
the latest approved revision of documents are available for work.
Procedures and instructions for the control and verification of
design documents and design activities, including design review,
design verification, any required design validation and design
changes at the home office and field office.
A copy of the Contractor‟s standard procedures for the home
office shall be submitted to the Contracting Authority
Representative.
Methods for setting staff and workforce competence levels,
selection, and training. This shall include setting qualifications
and experience for professional staff as well as setting
qualifications, experience and if necessary trade testing for
technician and construction craft staff.
Implementation of Audit programmes.
8.3.2
Specific Points to be addressed in the Technical Integrity Plan
a)
b)
c)
d)
The Basis of the Engineering Design Detail including environmental requirements,
special local design requirements, statutory requirements, base specification and
codes of practice to be followed for each discipline.
Risk / criticality assessment and management plans.
Philosophy for the control, review, verification and validation of design documents and
design activities, including design changes at the home and field offices.
Design Deviation procedure detailing reason for proposed deviation, drawings and
documents/specifications affected, technical justification, cost impact and schedule
impact. System shall ensure that all design deviations can be cross-referenced to the
appropriate Construction Completion sub-section and input into a Construction
Completion database to ensure closure prior to final sign off.
It should also be noted that:
A design deviation, approved by the Contracting Authority, shall
be required for all changes to the Contract specifications or
where Contracting Authority has approved the original design
documents.
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Field design change system shall be utilised for all design
changes after any document/drawing has been issued for
construction.
The change control procedures shall address the following
points:
The technical integrity of facilities and equipment
Accountability for approving changes within Contractor and
Contracting Authority.
a level of evaluation which is proportionate to the risk
acquisition of required permits
alterations to operating procedures and design documents
communication of potential consequences and action required
time limitations
personnel training requirements
Re-HAZOP of changes and HSE Stage review
Cross reference to Construction Completion System number
The change control procedures for the home and field offices shall also cover all
temporary design changes and ensure that execution time is managed and they do
not exceed the approved scope or time limitation.
e)
f)
g)
h)
i)
j)
8.3.3
Procedure for developing Inspection and Test Plans (ITP‟s) including format and
requirements.
Philosophy and plans for performing internal audits of quality related activities and
external audits of suppliers and Subcontractors.
Methods of identifying, performing, and documenting competence and training on the
Project.
Strategy to be followed during Construction including development of method
statements and construction ITP format/requirements.
Methods for planning, controlling and verifying Construction Completion of the Work
to the specified requirements, including Handover Certification requirements. Strategy
for the control and delivery of Contractor‟s design, Supplier and construction drawings
/ records, operation/ maintenance manuals and certification. This shall include how all
of these documents shall be compiled, numbered and indexed to match the Project
standard numbering system, the medium (paper/ electronic) they shall be provided in
and the number of copies that shall be handed over to the Contracting Authority.
Development of Constructability, Operations and Maintenance Philosophies taking
into account Contracting Authority life cycle costs.
Specific points to be addressed by the Contractor
Contractor shall ensure that the following points are addressed in its Project and Construction
Execution Plans submitted in Schedules 13 and 14 of Part B1 of the ITT and to be inserted in
Annex II – “Extent and Limits of Supplies and Services”
a. Implementation of all strategies identified in Section 7.3.2
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b. Methods for ensuring that purchasing documents contain all necessary commercial,
technical, and quality requirements and data.
c. Optimisation of risk/criticality assessment.
d. Procedures and methods for verification of purchased Materials and Equipment, and
services by inspection, surveillance, and compliance audit. The procedures shall provide
for interfaces necessary to co-ordinate with the Contracting Authority representatives.
Note Contracting Authority intends to undertake a limited audit approach over Supplier
activities.
e. A procedure for identification, reporting, tracking and resolution of non-conformance‟s in
the Supplier shops and at construction sites. These shall be database cross-referenced
to the construction completion database to ensure closure before sign off.
f. Field Non-conformance Reports (NCR‟s) shall require field Concession Requests to be
raised where equipment is repaired (i.e. not in a new condition) or accepted in a
condition which does not meet the design specifications. Contracting Authority
APPROVAL shall be required for all Concession Requests.
g. Procedures for the control, storage, and maintenance of material or equipment supplied
by the Contracting Authority.
h. Methods for the qualification, process control and documentation of all construction
activities to meet the specified technical, safety and quality requirements. This shall
include developing specific procedures/method statements, detailing how, what and
where an activity shall be performed together with the responsible persons and the
verifying document produced. This shall take into account the output from the
documented design review clash check, maintainability and constructability reviews etc.
i. Methods for inspection and testing of material and equipment at the storage and
construction sites.
j. Finalisation of procedures for the control of field design changes as detailed above.
k. Methods for the control, storage, and calibration of inspection, measuring, and test
equipment.
l. Methods for tracking inspection and test status of Materials and Equipment.
m. Procedure for documenting and controlling corrective action.
n. Procedure for the handling, storage and preservation of Materials and Equipment.
o. Methods for control, storage and handover of spare parts and associated documentation.
p. Procedures for the identification, control and documentation of specialist Supplier
representative work scope at the field during Mechanical Completion and Commissioning
activities.
q. Implementation of the QC systems.
r. Implementation of the Mechanical Completion systems.
8.3.4
General Notes to System Requirements
Where the word „documented‟ is included here and in the ISO/ BS series, written
procedures/work instructions shall be in place to direct and control the Work.
Where Joint Ventures are involved at any stage, specific details shall be provided to
demonstrate how the individual quality systems and technical management systems of
different JV members shall interface and efficiently work together.
The overall Technical Integrity Plan and related procedures shall be approved within one
month of Contract Award (to a minimum level of „approved with comments‟).
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8.3.5
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Risk Assessment and Management Programmes
In order to assure all the design and specification areas are addressed and meet the
requirements of MLE Project HSE Expectations, ISO 9001:2008 Section 4.4/ISO 9004-1
Section 8.0, the Contractor shall carry out a full assessment exercise on every discipline
area/system to enable individual Integrity programmes to be developed. This shall include all
aspects and items.
The Contractor shall develop or provide his standard proven procedure for assigning
risk/criticality ratings. This should be a formalised technique for measuring the relative
importance to be assigned to a specific area based on the risk/consequence that failure would
have on health, safety, the environment or the construction operational integrity or Project
delivery. The system should include provision for engineering judgement and review of the
proposed ratings. The procedure should include aspects such as:
Occupational safety
Technical safety / integrity
Environmental impact
Operational significance
Availability and accessibility for repair / replacement
Design maturity
Complexity of manufacture / construction / installation
Economics
Delivery impact on schedule
A draft assessment procedure, or previous example shall be submitted to Contracting
Authority‟s Representatives. Contractor shall also submit suggested criticality ratings for all
major items of equipment.
The results of the risk assessment shall be used to develop the minimum assurance and
Integrity Management requirements to be applied during design, procurement and
construction activities for each level of assessed risk/ criticality. It should be noted that this
shall involve higher level of control above standard code requirements for high risk/ criticality
areas and may involve upgrading requirements from other areas of the Contract. Where the
Contract requirement is higher than the calculated Risk the Contract shall normally be
applied.
The Contractor shall develop Integrity programmes for every work/discipline area during
engineering. The programmes shall be approved by the Contracting Authority‟s
Representatives.
The Contractor shall provide, within his execution proposal, the proposed Integrity programme
samples for each risk/ criticality level (typically 1, 2, 3 and 4 where 1 is the highest level).
These programmes shall cover the following areas, identifying the individual controls to be
implemented for design, procurement and construction. The proposed programmes should
cover as a minimum:
Structural / Civil Engineering
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Rotating Machinery
Piping
Pressure Vessels
Electrical Systems (including field equipment)
Instrument Systems (including field equipment)
Packages
8.3.6
Audits
Throughout all stages of the Contract, the Contractor shall develop an internal and external
system and technical compliance audit programme for the Contracting Authority approval.
This shall include as a minimum an audit of every section/discipline of the Project against
CAFC Project HSE Expectations in Annex XI – “Health, Safety and Environment”, ISO
9001/9004, ISO 14001, BS 8800 the Project environmental and safety system and the
approved Project procedures and specifications. Copies of all audit reports and corrective
actions shall be handed to the Contracting Authority‟s Representatives in a timely manner.
Where deficiencies are identified, follow up audits shall be required to address them and
confirm close out/compliance.
The audit programme shall be issued within 1 month of Contract award, and shall cover as a
minimum the programme for the first 3 months. A rolling programme shall be re-issued on a
regular basis thereafter every 3 months.
A draft of the proposed Contractor‟s audit programme shall be submitted within the
Contractor‟s Execution Proposal in Schedule 5 “Project Management and Controls/Progress
Management” of the ITT. Follow up audits shall be conducted at regular intervals on key
areas in accordance with the approved audit programme.
Contracting Authority shall have the right to conduct their own independent Technical, Safety,
Environmental, Quality and Commercial audits. The Contractor shall make available all
necessary staff and resources to assist the Contracting Authority in completing such audits in
a timely and efficient manner. Contractor costs for this assistance shall be included within the
Contract.
Contracting Authority may achieve their aims for technical auditing by active participation of
the Contractor‟s own planned technical audits.
All High/ Medium Risk/ Criticality 1 and 2 Suppliers/Subcontractors shall have a compliance
audit performed on them by the Contractor, except where Contractor can provide documented
evidence of recent satisfactory audit or performance for the Contracting Authority approval.
All criticality 1 and 2 Suppliers/Subcontractors must have previous audit records or quality
verification evidence satisfactory to the Contracting Authority‟s Representatives before award
of purchase order/subcontract.
Where a Suppliers/Subcontractor proposes to subcontract more than 25% of any stage of the
actual Construction (i.e. design, procurement, and manufacturing or construction stages) the
same criteria as above shall be applied by the Contractor, except that the audit shall be a joint
exercise with the main vendor/Subcontractor.
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QC staff shall not be involved as auditors since they are not independent of the
CONSTRUCTION and audits shall include an assessment of the performance/effectiveness
of the QC function.
8.3.7
8.3.7.1
Quality Control
General
The Contractor shall have an independent QC organisation (independent from QA,
construction and other line functions) within his overall organisation with sufficient resources
to oversee the Construction. The Contractor shall provide details of his organisation, including
the ratios of QC staff to construction staff for each discipline together with key quality control
personnel CV‟s. The qualifications and competence of these personnel shall be subject to
review and approval by Contracting Authority.
The execution of vendor and field quality control shall be fully documented in procedures to
be approved by the Contracting Authority. These shall include but not be limited to the
minimum requirements included in the Contract, the Project specifications and approved
quality programmes.
No vendor or field construction work shall start without full approval of the relevant QA and
QC procedures with all comments incorporated.
8.3.7.2
Supplier/Subcontractor QC
For all activities, Inspection and Test Plans (ITP‟s) shall be developed and implemented by
the Contractor, Subcontractors and Suppliers. These shall cover the following areas in a
matrix format:
Quality verification activity/stage
Reference document/procedure or method statement to perform
activity including specific reference to actual section/page
Acceptance criteria
Records produced
The ITP shall cover the major quality related activities in chronological order from initial
drawings through manufacturing/construction, process controls to final testing, documentation
and certification.
Against each activity/stage space shall be provided for all parties including the Contracting
Authority to mark their QC involvement. .
Contracting Authority shall have the right to review and approve all ITP‟s and procedures and
add their comment/actual witness involvement. Contracting Authority intervention / witness
shall be decided in accordance with risk/ criticality output.
All Contractor Supplier inspection reports and release notes shall be made available to
Contracting Authority, if/when requested. These reports shall typically include:
Documentation approval status
Problems/areas of concern
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New and outstanding non-conformance‟s
Detail reference to ITP stage
Written detail of work performed and acceptability to acceptance
criteria
Contracting Authority shall have the right to witness any test. Where Contracting Authority
have marked involvement on the ITP, written notice should be given 14 working days in
advance and confirmation of the stage 72 hours prior to the actual activity.
Contracting Authority shall also have the right to call for inspection hold points. The same
conditions for notification shall apply. Contracting Authority however does not intend to
specify hold points unless exceptional circumstances arise. Any delays due to late notification
or late cancellation shall be borne by Contractor.
Where materials are ordered and manufacturing is scheduled to start before full ITP approval,
the Contractor shall ensure that as a minimum commented approval of relevant sections of
the ITP is obtained prior to the work starting.
The Contractor shall hold pre-inspection meetings (PIM‟s) with all high and medium risk/
criticality Suppliers/Subcontractors and on construction before any physical work commence.
These meetings shall confirm that all technical points understood, the relevant documentation
are approved, and that all QC activities to be undertaken are recorded on the ITP and
understood. Third Parties should attend where they are to be involved in the inspection
activities. Contracting Authority may also attend these meetings.
8.3.7.3
Supplier Release
The Contractor shall put in place a release certificate scheme which identifies that all
documents are approved, that there are no outstanding technical queries or concessions not
fully closed out and that the release inspector is fully aware of the final approved document
status. The release certificate shall be used as the trigger to allow the inspector to release
the equipment AND Materials and Equipment if he finds the final inspection acceptable.
A copy of this certificate shall be forwarded to the Contracting Authority‟s Representatives
if/when requested.
8.3.7.4
Construction QC
All activities shall be clearly defined in procedures/method statements, detailing the scope of
work, how it shall be performed, where it shall be performed, who is responsible for the actual
activity, which is responsible for verifying the activity and which record/verification document
shall be produced.
All stages of construction shall be controlled in ITP‟s identical to the above Supplier/
Subcontractor format detailing the quality verifications performed by the Contractor‟s
construction and quality control organisations with allowance for the Contracting Authority QC
surveillance/witness mark up.
Pre-inspection meetings shall be held at the work location/ start before the start of all physical
work as described above for Supplier/Subcontractor activities.
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All QC activities and status/records shall be compiled on a database referencing the
appropriate ITP, procedure and certification so that the QC status can be continually
monitored as work progress. Details of the proposed system shall be submitted in Schedule 9
of Part B1 of the ITT and form part of the Contract in Annex XIII – “Quality”.
Contracting Authority shall be provided with a weekly update of all QC problems on
Construction together with a regular and brief description of all non-conformances issued.
The Contractor‟s QC Manager shall be delegated the clear power and immediate access to
Contractor senior management to stop any work that is non-conforming.
As part of his own management system, Contracting Authority shall use the non-conformance
system operated by the Contractor to raise any construction non-conformance‟s found. The
Contractor shall handle these non-conformances in accordance with the approved procedure.
This shall involve the preparation of a corrective action within 72 hours. Where such nonconformances are identified as major the affected work shall be stopped.
Where the Contracting Authority‟s Representatives has concerns over the quality of work he
shall have the right to re-test. Where work is covered over the re-test shall include removal of
covering. No work shall be covered without the approved procedures and ITP‟s being
followed, therefore construction activities shall not be started until confirmation that all QC
activities have been signed off.
Contractor shall establish a construction quality audit schedule which shall be updated on a
rolling quarterly basis. A joint Contractor/Contracting Authority/Subcontractor QC walkabout
shall be established and carried out on a weekly basis. This forum allows all parties to see
evidence of best practices (and unsatisfactory practices).
8.3.7.5
Document Control/Quality Records
The Contractor shall implement a computerised document control system for all documents,
drawing and quality records from the initial engineering stage through construction to final
document handover.
The system shall provide up to date approval status/tracking of documents, revision control
and controlled issue to all parties involved in the construction.
The Contracting Authority‟s Representatives shall be provided with regular updated registers
from the system and remote electronic access to the system so he can check document
status to programme and the revision and approval status.
The configuration of the system shall be compatible with Contracting Authority's electronic
data management system (EDAM).
The Contractor shall provide details prior to Contract Award of how he shall compile, index
and control Supplier and construction QC verification records and certification. The
Contractor shall also provide details of the system he shall use to verify Construction
Completion of all engineering and construction work.
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The Contractor shall provide details of how all drawings, documents and records shall be
formatted, indexed and handed over to the Contracting Authority in a consistent format in
accordance with the requirements of the Contract.
Contractor shall provide fire-safe and environmental protected storage for all documents
throughout the Contract. Document format indexing system, storage and packaging shall be
approved by the Contracting Authority
Contractor‟s document control system shall be able to interface with the Contracting Authority
document control system (EDAM) for transfer and control of all documents,
The Contractor shall provide the Contracting Authority‟s Representatives with working copies
of key design, Supplier and Subcontractor documents and drawings as part of the Contract.
The Contracting Authority‟s Representatives shall identify the documents he wishes to have
copies of for comment, and information purposes by mark up of the document registers. This
may include multiple copies of some documents, e.g. plot plans, P&ID‟s to facilitate timely
review.
In addition, the Contractor shall provide reasonable numbers of working copies of drawings
and documents as requested by the Contracting Authority Representative on an ad-hoc basis.
The Contractor shall include within his document control system a procedure for control,
recording and close out of Contracting Authority comments. However, Company procedures
will always have precedence.
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9. CONSTRUCTION
9.1 GENERAL
The scope of Work is generally as outlined in the Drawings and other information as
contained in FEED Package.
The Work shall be carried out on a Brownfield area as well as on pipeline routes requiring
rights of way. All measures shall be put in place to ensure that the execution of construction
activities is carried out consistently with ALARP principles.
Contractor must include consideration of the above and the restrictions that this may impose
on over and above those experienced at a purely Greenfield location.
For work on the Greenfield area the Contractor shall implement its own permit to work
system. This permit to work system and any associated processes and procedures
(isolations, risk assessments, etc) shall be provided to the Contracting Authority for review as
part of the Contractors tender.
For all works involving activities on the existing facilities the Permit to Work system in force in
MLE plant will be implemented. This permit to work system and any associated processes
and procedures (isolations, risk assessments, etc) shall be provided by the Contracting
Authority for review.
The Contractor‟s services shall include, but not be limited to, the following:
1.
Administration, planning, management and control services, as required to effectively
control the execution and timely completion of the Work. The Contractor shall provide
an organisation chart identifying all posts in the organisation and the names of
individuals occupying managerial or lead engineer positions, for each of the
construction sites and for any support bases in Algeria. The reporting relationship
between the Construction teams and the rest of the Project management shall be
shown on the same or an additional organisation chart.
2.
Provision of all direct and indirect labour or subcontracted services inclusive of tools,
equipment, facility and consumable materials necessary to undertake the Work.
3.
Responsibility for management of interfaces between disciplines and Subcontractors
to ensure completion of the Work. Supervisors and superintendents shall require to
have sufficient fluency in French or Arabic, or ready access to a translator, to ensure
that supervision and control of all work is carried out efficiently and safely.
4.
Provision of a Construction HSE Plan in accordance with Contracting Authority
requirements which will include procedures, risk assessments, tool box talks to cover
all types of work including confirmed space entry, multi-crane lifts, etc.
5.
Receipt, offloading, storage and preservation of all materials.
6.
Provision of a materials management system to enable full control of warehouse and
storage yard materials.
7.
Security of the materials stored on the Site.
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8.
Medical services and safety provision, as required by Algerian law and as defined in
Annex XI – “Health, Safety and Environment” of the Contract. Contractor is
responsible for providing medical services and medivac facilities for all for Contracting
Authority‟s and Contractor‟s staff and visitors, and for Subcontractors, if they do not
have their own services. Medical services are to be accessible for all Contracting
Authority personnel in emergencies.
9.
Identification, engineering and implementation of all temporary facilities required to
complete construction, Commissioning and Start-Up of the Work.
10.
Care and maintenance of all capital equipment comprising part of the Permanent
Work.
11.
Provision of Site Services to support construction.
12.
Provision and servicing of office and living accommodation and facilities for
Contractor‟s and Contracting Authority staff and visitors at all the construction sites.
13.
Management of security on the sites and in all areas of sub-contract activity, if away
from the main sites.
14.
Management of the interface with Algerian Regulatory Approval Agencies relating to
the performance of the Works, except in instances where it is agreed that Contracting
Authority or others shall manage, like ARH.
15.
Provision of general logistic administrative assistance for obtaining permits, visas,
accommodation, hotel rates, car rental, transportation, etc. for Contracting Authority
Personnel.
9.2 CONSTRUCTION ENGINEERING AND TEMPORARY WORKS
The Contractor‟s Construction Engineering services shall include, but not be limited to, the
following:
1.
The design of all Temporary Works and facilities.
2.
The preparation of all required construction, fabrication and erection Drawings.
3.
Method Statements, Risk Assessment, Job Safety Analysis etc. for all activities.
4.
Transport and lifting plans and support documentation for all major lifts and
movements of major items of equipment or material etc.
5.
The design of temporary power generation and electrical distribution systems required
for site establishment, installation and Commissioning up to Provisional Acceptance.
6.
The design and provision of temporary power generation and associated equipment
to allow start up of the facility prior to establishment of power supply from MLE 60 kV
GIS – Contractor shall substantiate the sizing of the temporary power generator.
7.
The design of all temporary facilities and materials required for testing, Precommissioning and Commissioning activities for all piping, equipment and other
systems which are part of the Work;
8.
The provision and implementation of a bill of materials reporting system, with issue of
exception reports to the Contracting Authority.
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9.
The design and production of all drawings, procedures and support documentation
required for the installation of the Permanent Works;
10.
The preparation of all “as-built” and certification documentation, and in particular the
provision of “as-built” key drawings in readiness for Commissioning.
11.
The design of the construction site support facilities includes site accommodation for
Contractor personnel.
12.
The preparation of all necessary fabrication Specifications.
13.
The preparation of hydrotest procedures and corresponding hydrotest test packs.
14.
The preparation of system Handover Procedures.
9.3 SITE PREPARATION
The Contractor shall ensure that all facilities and other Sites are suitable for the Work and
shall provide all relevant technical data, design calculations and Drawings as required to
ensure satisfactory compliance with Contracting Authority requirements.
The Contractor shall provide adequate open storage areas, as well as covered storage space.
Controlled environment storage facilities shall also be provided for equipment or material that
is sensitive to temperature or humidity.
The Contractor shall provide at the Sites all necessary construction workshops, fabrication
and testing facilities, machinery, facility and equipment necessary to complete the Work. This
shall include a separate instrument/electric workshop and Inspection facilities.
The Contractor shall provide all access roads to site, from existing roads. Contractor shall
minimise unnecessary additional tracks in the desert and environmentally sensitive areas as
defined in the environmental baseline report.
The Contractor shall provide office accommodation facilities at site, including office space for
the use of Contracting Authority.
9.4 SITE CONSTRUCTION FACILITIES
The Contractor shall provide all services required to support the construction phase of the
work and these shall include, as a minimum:
Temporary construction camps for the field centre. The camp
must be laid out and located with agreement with Contracting
Authority.
All necessary fully equipped office and accommodation facilities
for Contractor‟s personnel
All necessary office facilities for Contracting Authority personnel
(30).
The Contractor shall provide and be responsible for office and
accommodation, catering, and transportation of the Contracting
Authority personnel and visitors during construction to the
standards to be defined by Contracting Authority.
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Food storage, preparation and dining facilities for Contractor
personnel
Leisure facilities for Contractor personnel
Sewage treatment and disposal for the facilities
Drainage facilities
Transport vehicles and drivers for Contracting Authority,
Contractor and Subcontractor personnel and construction
materiel
First Aid and Medical Centre
Temporary power generation and distribution for Contracting
Authority, Contractor and Subcontractor personnel and
construction activities
Telecommunications facilities at each site to allow control of the
Work and communication with Home Offices
Fire-fighting facilities
Concrete batching plant as required
Vehicle parking areas (with sunshade & hardstanding)
Waste collection and disposal facilities, including refuse
incineration and disposal, construction waste disposal and
hazardous chemical/substance disposal.
Refuelling, fuel and Maintenance facilities for Contractor and
Subcontractor provided equipment and vehicles
IT facilities and systems at each site for Contractor and
Subcontractor personnel with links to home office data and
systems and to Contracting Authority at site
Utility systems for life support and construction needs, except
where prior agreement has been reached to tie into existing
infrastructure.
Secure outdoor and covered storage for Contracting Authority
Materials and Equipment. Covered storage shall include bonded
areas and air-conditioned areas sealed against dust ingress for
storage and inspection of delicate items.
Vehicle marshalling point for
procurement/construction traffic.
control
of
logistics
and
The Contractor is responsible for layout of temporary construction camps and personnel
safety during CPF Commissioning and Start-Up. This may involve relocation of personnel
when commissioning commences.
The Contractor shall provide facilities for the storage and issue of diesel fuel, chemicals, paint
and other toxic and hazardous materials. These areas shall be covered with the ground
paved and kerbed to prevent spillage‟s contaminating the earth. These areas are to be
located sufficiently away from accommodation or office spaces. Adequate drainage and
treatment facilities shall be provided.
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The Contractor shall provide temporary HVAC services for the CER and LER.
The Contractor shall remove all the temporary facilities upon completion of the Work. The
temporary site shall be returned, as near as possible, to its original condition.
The Contractor shall produce procedures for spillage cleanup, disposal and site remediation
for approval by Contracting Authority. The Contractor is responsible for clearing up all
spillages such as fuel oil and chemicals, immediately after they occur, and disposal. Final
clean-up and site remediation shall to be done prior to Contract completion.
9.5 STORAGE OF EQUIPMENT AT SITE
9.5.1
General
The Contractor shall provide Storage, Preservation and Maintenance Procedures
incorporating Supplier‟s recommendations prior to the receipt of equipment on site. These
Procedures shall consider any Long Term preservation requirements. The storage and
maintenance procedure shall be supported by an ITP and this shall be documented within
Contractor QC System.
The Contractor shall inspect all equipment and devices upon receipt at site and submit a full
written report to the Contracting Authority‟s Representatives. The report shall include a listing
of any defects or transit damage including Overage/Shortage/Damage Reports.
The Contractor shall protect the Materials and Equipment against mechanical damage and
ingress of dust, sand, moisture, welding sparks, sand and grit blasting and other foreign
matter by providing suitable protective covers.
The Contractor shall carry out regular inspections and presentation checks of the equipment
and devices for the duration of the period of storage. All inspections shall be fully
documented and submitted to the Contracting Authority‟s Representatives.
If long term storage is required the Contractor shall ensure long term preservation procedures
are followed and instigated as recommended by the Supplier.
9.5.2
Mechanical
All mechanical and packaged equipment delivered and accepted on Sites shall be under the
responsibility of the Contractor throughout the construction and Commissioning phases until
the issuance of Provisional Acceptance by Contracting Authority.
Prior to permanent installation the equipment shall be stored in a controlled environment, as
necessary, and maintained in accordance with the Supplier‟s recommendations on
preservation and maintenance of the equipment. Adequate consumables such as oils and
greases, temporary aids, packings, etc. shall be supplied by the Contractor. First fill
requirements for all equipments will be provided by Contractor.
The Contractor shall rotate periodically all rotating equipment shafts in order to prevent
bearing damage and shall maintain suitable records.
The Contractor shall ensure that all equipment when stored is adequately supported and has
sufficient access to inspect and maintain the equipment in accordance with the Supplier‟s
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recommendations. No equipment shall be stored directly onto the ground without timber
packings which allow for air circulation.
9.5.3
Instrument/Electrical/Telecommunications
The Contractor shall provide controlled environment storage for control panels, sensitive
instrumentation and telecommunications equipment and electrical equipment to ensure that
there is no degradation arising from temperature, humidity and dust effects.
The Contractor shall be responsible for taking delivery of all items of Materials and
Equipment, for their storage in suitable clean and dry areas and for their proper protection
both during storage and after installation.
The Contractor shall ensure that corrosion inhibitors are used and that anti-condensation
heaters are energised, where fitted, when environmental conditions warrant.
9.6 SITE CONSTRUCTION
9.6.1
General
The Contractor shall ensure that the installation of all Materials and Equipment complies fully
with statutory requirements, standards and codes detailed.
The Contractor shall keep the work areas, and areas occupied by Subcontractors, in a clean
and orderly fashion at all times. Unwanted scrap, waste materials, etc. shall be segregated
and removed from site at appropriate intervals.
The Contractor shall ensure that all items are checked against AFC data sheets and purchase
orders prior to acceptance. Name plate details and inscriptions shall also be inspected to
ensure that the correct items have been delivered.
The Contractor shall ensure that all his personnel are fully competent tradespersons skilled in
the particular field of work in which they are engaged.
The Contractor shall ensure that a high level of qualified supervision is available permanently
on-site to oversee and check the works undertaken by all Subcontractors. The minimum
supervision to labour ratio shall be 1:10
The Contractor shall take full responsibility for the quality of the Work performed by all
Subcontractors.
Materials and Equipment to be supplied by the Contractor and Subcontractors shall be new
(unless otherwise agreed) and suitable for the intended use and location.
Lifting or slinging of equipment shall be undertaken in accordance with the Lifting Operations
and Lifting Equipment Practice to be approved by the Contracting Authority.
Contractor shall implement and manage a Contracting Authority approved scaffolding
management system.
The Contractor shall co-ordinate and ensure the attendance of Supplier representatives, as
necessary, to assist in installation, protection and Commissioning.
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Civil Works
Contractor shall endorse and use the as-is final state of the early site preparation as the basis
for execution of the Project. Any further site preparations required for the requirements of the
Project are Contractor‟s responsibility and are part of the Work.
The Contractor shall complete all civil works required for construction. This shall include, but
not be limited to, all activities associated with and the provision of all machinery and
construction activities including, but not limited to the following:
Survey work and geotechnical investigations
Earthworks
Sewers, storm water, contaminated water and oily water drainage
Storm water / effluent treated water discharge channel
Roadworks, including permanent access
Fencing
Foundations
Pipeline trenches
Cable trenches for buried cables, both permanent and temporary
Building transit frames
Landscaping
Shuttering
Batch Plant
Road crossings
All Work shall be undertaken in accordance with the drawings and specifications developed
and approved during the detailed design phase of this Contract.
The Contractor shall complete all construction Specifications and Procedures prior to
commencement of work on site. These documents shall be subject to review by Contracting
Authority.
The Contractor shall ensure that all civil construction works are subject to regular quality
control checks and inspections, in accordance with the Specifications and agreed Inspection
and Test Plans. These activities shall include, but not be limited to, the following:
Inspection of excavations to ensure that adequate safety
provisions are in place to prevent accidents and that adequate
provision has been taken to prevent damage to existing
structures or services adjacent to the works.
Establishment of a written permit system to allow any blasting
work on the Site.
Inspection of backfill and compaction works to ensure complete
compliance with Specifications and Drawings. All compaction
testing shall be carried out by qualified personnel approved by
Contracting Authority.
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Inspection of all sub-grade surfaces for roads. This shall include
checking of levels, batters, widths and alignments.
Testing of road sub-base, base course and aggregate materials.
Inspection of road sub-base/base construction to ensure
compliance with Specifications.
Inspection and testing of all concrete pavement work and
materials to ensure compliance with Specifications.
Inspection and testing of all structural concrete work and material
to ensure compliance with Specifications.
Inspection of application of all bitumen and asphaltic concrete
road surfaces.
Inspection and testing of sewers, drainage pipes and manholes.
Inspection of construction and finishing of all open drains to
ensure compliance with Specifications.
Inspection of construction and placement of evaporation pond
sub-surface liners to ensure that the work has been completed in
accordance with Supplier instructions/recommendations.
Ensure all necessary equipment (including standby equipment)
and experienced manpower is available at the Sites to enable
placement, compaction, and finishing of all concrete and
reinforcement work, in compliance with the Specifications.
Provide all materials necessary to ensure curing of concrete
complying with the Specifications.
Ensure all cement used for the Work complies with the
Specifications. No blended cement shall be used.
Inspect all concrete mix delivered to the Site and supervise all
concrete testing to ensure compliance with the Specifications.
Remove from the Site all concrete that does not conform with the
Specifications.
Supervise and inspect all reinforcement fixing to ensure
compliance with Drawings and Specifications.
Supervise and inspect assembly of all formwork to ensure
construction is adequate to safely support the concrete pour in
accordance with the Specifications.
Supervise placement of all equipment and structural anchor bolts
to ensure compliance with Drawings and Specifications.
Ensure placement of membranes under all concrete slabs in
accordance with the Drawings and Specifications.
Ensure all work, stages of work, materials and processes, shall
be made available for, and be subject to, the inspection and
approval by Contracting Authority, CTC, ONML, DPEM as may
be required.
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9.6.3
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Mechanical Equipment
The Contractor shall carry out the installation of all equipment. The Contractor‟s scope of
Work shall include, but not be limited to, the following:Fabrication and/or installation of mechanical equipment, pressure
vessels, storage tanks, static and packaged equipment and all
items identified in the equipment List
Fabrication and installation of all steelwork supports
Sealing, grouting, bolting and seal welding of equipment in
accordance with the Specifications
The Contractor shall take all necessary steps to protect the equipment from damage during
installation and shall ensure that the Supplier‟s recommendations on lifting aids and the
slinging of the equipment are followed.
The Contractor shall, where applicable, use only the special tools and equipment provided by
the Supplier. Special tools shall be left with the equipment.
The Contractor shall ensure that all preservation fluids are removed from equipment and that
all temporary aids and attachments are removed prior to function testing. The equipment
shall then be made ready for testing in accordance with the Supplier‟s recommendations.
This shall include the supply of all flushing oils and First Fill lubricating oils.
The Contractor shall ensure that all motor drivers are checked and tested for correct rotation
prior to final coupling.
The Contractor shall produce and follow Function Testing and Start-Up Procedures in order to
ensure system/equipment integrity.
After installation and completion of testing prior to handover the Contractor shall ensure the
equipment is fully maintained and shall continue to perform all maintenance activities required
to maintain the integrity of the equipment until Conditional Acceptance. A record of these
activities shall be maintained.
9.6.4
Piping Systems
The Contractor shall carry out the fabrication, installation and Mechanical Completion of all
process and utilities piping systems, including all associated supports, in accordance with the
Specifications. The Contractor‟s Scope of Work shall include, but not be limited to, the
following:
Identification of systems for hydrotest, production of hydrotest
test packs and issuance of Mechanical Completion certificates
Fabrication, installation, supporting, cleaning (including chemical
cleaning), flushing, protective coating, inspection (including, but
not limited to NDT), pressure testing, coating, insulation and of all
pipework, valves and fittings for all of the facilities.
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Contractor shall implement a joint integrity management
programme acceptable to Contracting Authority to ensure
minimum leaks during N2 leak testing to be incorporated in its
flange management system. This programme shall be the subject
of an ITP and shall be recorded in the Contractor QC system. All
flanged joints shall be torqued to pre-determined settings. All
flanges shall be tagged with the applied torque settings and the
name of the individual making the joint. Joint tags shall only be
removed after successful leak testing.
Pipework in critical systems shall be cleaned by the Contractor to
the satisfaction of the Contracting Authority. Methods employed
may include retrojetting, pull through, potblowing, etc, however
Contractor shall make provision for internal inspection of critical
systems by means of access points, CCTV/Boroscope, etc. The
Contractor shall provide and maintain end caps to close off open
ended piping systems.
The Contractor shall be responsible for the preparation and testing of all welding procedures
and welder qualifications as required to satisfy the requirements of the Specifications.
9.6.5
Gathering Systems
The Contractor shall carry out the fabrication, installation and Mechanical Completion of all Oil
and Production System and Water and Gas Injection System piping, including all associated
supports, in accordance with the Specifications. The Contractor‟s Scope of Work shall
include, but not be limited to, the following:
identification of systems for hydrotest, production of hydrotest
test packs and issue of Mechanical Completion certificates
fabrication, installation, supporting, trenching, burial, cleaning
(including chemical cleaning), flushing, protective coating,
inspection (including, but not limited to NDT), pressure testing,
coating, insulation, Commissioning and reinstatement of all
pipework, valves and fittings for all of the facilities.
Following pressure testing, Oil gathering systems shall be
dewatered and left in inert conditions prior to Commissioning.
Contractor shall implement a joint integrity programme
acceptable to Contracting Authority to ensure minimum leaks
during leak testing. This programme shall be the subject of an
ITP and shall be recorded in the Contractor QC system. All joints
shall be torqued to pre-determined settings. All flanges shall be
tagged with the applied torque settings and the name of the
individual making the joint. Joint tags shall only be removed after
successful leak testing.
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SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Pipework shall be cleaned by the Contractor to the satisfaction of
the Contracting Authority. Methods employed may include
retrojetting, pull through, potblowing, etc, however Contractor
shall make provision for internal inspection of critical systems by
means of access points, CCTV/Boroscope, etc. The Contractor
shall provide and maintain end caps to close off open ended
piping systems.
Contractor shall be responsible for the preparation and testing of all welding procedures and
welder qualifications as required satisfying the requirements of the Specifications.
9.6.6
Structural
The Contractor shall fabricate, assemble, erect, inspect and dimensionally check and provide
protective coating of all structures including, but not limited to service support racks,
platforms, ladders, hand rails, structural steel, foundations, equipment supports and
Mechanical Completion in accordance with Drawings and Specifications.
The Contractor‟s Scope of Work shall include, but not be limited to, the following:
Implement all necessary survey work and foundation testing prior
to design of structures.
Supervise production of all design and shop drawings and
fabrication of steel structures.
Ensure all structural work complies with dimensional tolerances
and quality requirements given in the Specifications.
Inspection of all steelwork prior to departure from fabrication
workshop to ensure all steelwork, loose pieces and bolts are
coated, marked and tagged in accordance with the
Specifications.
Provision of suitable transportation and storage facilities for
steelwork in accordance with Specifications.
Inspection and supervision of site erection to ensure compliance
with Specifications.
Ensure all repairs to damaged protective coating are completed
in a manner consistent with Specifications.
Provide material
Specifications.
9.6.7
certificates
for
steelwork
as
per
the
Instruments, Electrical and Telecommunications
The Contractor shall install all electrical systems, field and panel mounted instruments,
telecommunications
systems
and
cables
in
accordance
with
Supplier
instructions/recommendations and Project Specifications and drawings.
The Contractor shall provide and install power cables and TLC cables along the whole
gathering system network.
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Central Area Field Complex Project
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The Contractor shall ensure that all certified equipment has been labelled or marked by the
manufacturer with the correct certification protection type, gas group and temperature
classification where applicable and that the appropriate certificate has been supplied.
The Contractor shall not permit any cutting, drilling or welding of any certified equipment nor
the painting of flame path gaps.
Contractor shall have in place a Cable Management Procedure that shall include testing of
cable on delivery.
Before installing any major item of equipment, the Contractor shall ensure that all floors are
suitably finished, floor foundations are adequate and fixings and access ways are suitable for
the equipment to be installed.
The Contractor shall ensure that all panels are mounted in the correct order/sequence as
shown on the installation Drawings and that all circuit designation labels are checked for
correct identification.
The Contractor shall, where applicable, use only the special tools and equipment provided by
the Supplier. Special tools shall be left with the equipment.
The Contractor shall ensure that equipment is not installed until all welding, painting, finishing
and fireproofing in the location concerned has been completed or that adequate protection
has been provided.
Prior to installation, the Contractor shall check the proposed location of all of the equipment
and supports in order to ensure that clashes do not occur, that adequate access for
maintenance is available and that adequate access for cable termination, including proper
cable bending radii, has been provided.
The Contractor shall ensure that all cables run in continuous lengths from points of design to
destination. Joints or splices are not acceptable, except in the case of optical fibre cabling
where joints shall be minimised.
The Contractor shall ensure that all cables are handled and installed in a manner which does
not cause damage by abrasion or excessive tension.
The Contractor shall ensure that all cables are identified by means of indestructible, clearly
legible markers showing their respective numbers as indicated on the cable schedule. The
cable markers shall be located at each end of the cable, at both sides of any transits, at each
change in direction and at 20 metre intervals along the entire cable run.
The Contractor shall supply and install cable core markers designated with a unique number
of each cable core in all instrumentation, control and telecommunications cables at each
terminal/connection point, as indicated in the cable schedule and termination drawings.
The Contractor shall ensure that all multi-cable transit units are gas, water and fire tight, and
have the same blast/fire rating as the wall, ceiling or floor in which they are installed.
Sufficient transits shall be installed to permit the passage of the maximum number of cables
capable of being installed on the associated cable ladders, trays or trenches.
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Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
The Contractor shall ensure that hydraulic and pneumatic tubing is installed in accordance
with the Hook-up Drawings and the Specifications.
All instruments shall be prepared for installation and calibrated in a clean workshop area.
9.6.8
HVAC Systems
HVAC systems for controlled environment areas shall be installed strictly in accordance with
the design Specifications, Drawings and data sheets, including recommendations by
Suppliers.
Systems and equipment shall be common for all areas as far as reasonably practicable.
The Contractor shall undertake all function testing checks.
individually tested prior to a full F&G system shutdown test.
9.6.9
All fire dampers shall be
Safety Equipment
The Contractor shall install all Safety systems and equipment, including emergency
equipment, First Aid equipment, etc., as defined in the Specifications.
The Contractor shall implement Inspection and Test Plans to control the installation and
testing of safety systems and equipment. Such plans shall be subject to review by
Contracting Authority Safety Representative and by the appropriate Algerian Authorities.
Systems and equipment to be installed and tested by the Contractor shall include, but not be
limited to, the following:
Fire and Gas Detection Equipment.
The Contractor shall install fire and gas detectors throughout the
Facilities in accordance with the Specifications. The Contractor
shall ensure that area coverage is sufficient to meet fire and gas
system performance requirements and shall additionally include
provision for an independent audit by Contracting Authority for
detection coverage.
The Contractor shall implement all fire and gas detection
equipment loop checks and calibration tests in accordance with
Supplier‟s procedures.
Active Fire Protection
The Contractor shall install and test active fire protection
systems, including firewater and automatic / manual CO 2 systems
in accordance with the Specifications
Passive Fire Protection
The Contractor shall apply passive fire protection to equipment
and structures as defined in the Specifications
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
The Contractor shall nominate a Supplier or Subcontractor for the
supply and application of the passive fire protection and shall
submit the nomination to Contracting Authority for review.
The application of passive fire protection shall be undertaken only
by trained and qualified personnel approved by the nominated
Supplier.
Upon completion of the construction work and before application
for Mechanical Completion the Contractor shall repair any
damage to the passive fire protection that has occurred during
construction activities.
All repairs shall be undertaken in
accordance with Supplier approved procedures.
Escape Routes.
The Contractor shall provide escape routes throughout the
Facilities in accordance with the Specifications. The Contractor
shall, on completion of construction, verify that all escape routes
are clearly marked and are not obstructed by equipment prior to
completion of the Work.
Safety Signs.
The Contractor shall install safety signs throughout the sites. All
signs shall be provided in French, Arabic and English and shall
include pictorial representations of the objective at the sign,
wherever possible.
Safety Equipment.
The Contractor shall procure and install throughout the sites
safety equipment, including firefighting equipment, First Aid
equipment, safety showers and eye washes, in accordance with
Specifications.
9.6.10 Corrosion Protection and Painting
The Contractor shall coat all surfaces in accordance with the Paint & Coatings Specifications
Call in the chapter 3.1.1.1 of this document.
The Contractor‟s Scope of Work shall include, but not be limited to, the following:
Application of corrosion protection coatings to all internal and
external surfaces as required, following any request included in
the properly paint/coating functional specifications, regarding all
the phasis of the work. The Contractor shall make good, and
continue to make good throughout the duration of the Contract,
any defects in the surface finishes and all damaged areas
whether caused by accidental damage, design revision, rework or
out-of-sequence work;
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Marking of colour code and of direction arrows for all pipework,
valves and equipment in accordance with the Paint & Coatings
Specifications Call in the chapter 3.1.1.1 of this document.
9.6.11 Welding Procedures/Welder Qualification
The Contractor shall be responsible for the preparation and testing of all relevant welding
procedures WPS/PQR. The Contractor shall be responsible for all welder qualifications in
accordance with the Specifications.
9.7 PRECOMMISSIONING ACTIVITIES UP TO MECHANICAL COMPLETION
The Contractor shall prepare procedures which outline the activities required for achieving
Mechanical Completion for all the systems and disciplines and Contracting Authority‟s QA
requirements. These procedures shall be submitted to Contracting Authority for review.
As part of the construction activities the Contractor shall undertake all inspection and testing
actions necessary to prove and validate the correct and complete execution of the Work.
Pre-Commissioning is a series of inspections and static tests, to check the conformity of
components and systems. Pre-Commissioning activities are to be carried out to achieve
Mechanical Completion. Pre-commissioning activities need to be carried out on a system by
system basis.
The Contractor shall prepare precommissioning plans and procedures for activities up to
Mechanical Completion and these shall include, but are not limited to, the following actions:
1. Factory Acceptance Tests (FAT) of all packages/equipment delivered to Construction
Site as applicable
2. Conformity checks
Check conformance with P & ID‟s, Line Lists and relevant
Drawings, as constructed inspections with reference to project
and Vendor Docs
Visual inspection for damage or incomplete work
NDE of welds
Alignment and levelling checks of equipment
Visual examination of excavations prior to foundation
construction and at various stages of concrete construction
process including standard material testing
3. Static and De-energised tests
Hydrostatic and pneumatic pressure testing of piping systems
and pipelines. Fluids used for pressure testing shall be of quality
acceptable for all materials in contact with the fluid.
Flushing and drying of piping systems
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Inerting
Insulation and continuity tests
Earth loop impedance tests
Megger volt tests on electric cables
Instrumenst calibration
Coating integrity tests
All other applicable tests
Completion of all associated and necessary documentation
Completion of all check sheets
The Contractor shall undertake and be responsible for all testing in accordance with the
appropriate Specifications.
Specialist support services shall be provided as required for any testing of Contractor
designed and Specialist Supplier systems and equipment.
The Contractor shall submit full details of the test methods, test equipment, records and
identification.
The Contractor shall provide a system that tracks progress and status of certification by
system and sub-system/discipline, so that readiness of systems for Commissioning purposes
can be readily assessed.
Mechanical Completion shall include, without limitation, the following work:
All spades, orifice plates and the like shall be in position, as per
the P & ID‟s
All drivers and driven machinery shall be aligned according to
Suppliers specifications
All electrical circuits shall have been tested and all electrical
equipment shall be ready to receive power. Motors, where
stipulated, shall have performed their “no load” run. Contracting
Authority shall issue an “Livening Up” certificate prior to
energisation of any electrical systems.
All necessary pressure and vacuum tests shall have been
witnessed, as necessary, by the representatives of appropriate
Algerian authorities
All pipework supports shall be in place and spring hangers stops
removed
All relevant certification documentation shall be signed as
complete, assembled, and compiled for future reference
Incomplete items shall be detailed on punch lists, split by system.
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Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Punchlist items shall be categorised as follows:
CATEGORY A item:
This means that this item is not complete and the remaining
work must be mandatory completed prior to achieve Mechanical
Completion
CATEGORY B Item:
This means that this item is not complete and the remaining
work must be completed prior to introduction of hydrocarbons
and Start-Up.
CATEGORY C Item:
This means that this item is not complete and the remaining
work may be completed during or after Start-Up.
Punchlists for each system shall be reviewed by the Contracting Authority. Contracting
Authority shall be provided access to the Completion databases to allow such reviews.
As construction and pre-commissioning activities have been carried out, the Contractor shall
submit “Mechanical Completion” certificates for each and all systems to be approved by
Contracting Authority. Such certificates will include punch lists, showing that all Categories A
items have been properly cleared.
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Part D - Scope of Work
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
10. COMMISSIONING AND START UP
All the explanations, responsibilities, activities, handover and acceptance procedures
contained in this section for Commissioning and Start-Up apply on a system by system basis.
The Contractor shall appoint a person responsible for the purposes of Commissioning. This is
likely to be the Contractor Commissioning Manager. This person shall ensure that the
activities proposed by the Contracting Authority and the execution of these activities have the
full agreement of the Contractor.
10.1
COMMISSIONING OF UTILITIES AND PROCESS SYSTEMS WITH INERT FLUIDS
Commissioning of Utilities and process systems with inert fluids is a series of dynamic and
tests, to check the functionality of components and systems. Commissioning commences
after Mechanical Completion.
Commissioning is the functional verification of Equipment, Systems, Areas and Facilities. It
involves the functional testing and adjustment of a system, to ensure compliance with
drawings, specifications and contractual requirements.
Commissioning involves the dynamic running of systems to further check out the functionality
and integrity of complete systems, and continues on from Mechanical Completion. It is the
last series of checks before running the process systems on hydrocarbons. It includes the
operation of the utilities systems to progress the commissioning of process systems.
For utilities systems and systems not requiring production hydrocarbon gas for full operation,
Commissioning involves all activities needed to make these fully operational and ready for
handover to Contracting Authority. Commissioning shall involve for example running the
temporary generator (minimum rating to be substantiated by Contractor) and emergency
power generator (which operate on diesel) to provide power to the site.
For hydrocarbon gas process systems, Commissioning is the last series of checks before
introducing hydrocarbons, and all such further work necessary to bring the various sections
and components of the facility to a state of readiness for the introduction of hydrocarbons and
their safe start-up and operation.
The Contractor shall prepare commissioning plans and procedures and these shall include,
but are not limited to, the following actions:
Dynamic Verifications
Functional (hot) instrument loop checks
Uncoupled motor runs
Alignment procedures
Stroke all valves
Shutdown functional tests
F&G calibration & functional tests
Electrical distribution network testing
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Electrical isolations / de-isolations. The Contractor shall comply
with Contracting Authority isolation standards.
Control system site integration and acceptance testing
Site Acceptace Tests of packages / equipment, including
mobilization and demobilization of relevant Vendors as required
De-preservation, preservation and re-preservation
Safety isolations
Site familiarisation and orientation of Operations personnel.
Operational tests of Utilities and Process Systems
Running-in and on-line tests for a significant period of time of
plant utilities & whwnever applicable of main process equipment
in closed loop with inert fluids
ICSS, including F&G, DCS and ESD system set-up and tests
including Supplier Packages. These set ups and tests shall
include Site Integration Tests (SITs) ensuring that Supplier
Packages fully integrate into the ICSS with expected functionality.
These are to be followed by a global Site Acceptance Test (SAT)
for the ICSS.
Pre-Start Up Activities
Cleaning of critical piping systems and equipment by retro-jetting
or chemical cleaning or other appropriate methods. Critical
systems shall be defined and agreed with Contracting Authority
and shall include but shall not be limited to compressor suction
pipework between the suction scrubber and the compressor inlet,
compressor discharge pipework and recycle lines (including the
discharge coolers), fuel and seal gas systems, columns,
Gathering System etc. System cleanliness shall be
demonstrated. Methods to demonstrate cleaniness shall be
defined and agreed with Contraction Authority. Detailed design of
these and other critical systems shall be designed to facilitate
these activities. . Demonstration of system cleanliness is a key
requirement prior to ready for Start-Up and the introduction of
hydrocarbons. Contractor shall outline his plans for chemical
cleaning as part of his bid, confirming the requirement stated
here.
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Leak testing. All leak testing and purging shall be carried out
using a third party specialist and independant high pressure
nitrogen supply, under the responsibility and supervision of the
Contractor. System leak testing shall be carried out to 95% of the
system PSV set-point. Leaks shall be detected by taping flanges
where possible and using a pin hole with soapy bubble. Visible
significant bubbling shall constitute a leak. All leaks shall be
repaired with the system de-pressured. Pressurisation to leak
test pressure shall be done in 3 stages i.e. 30%, 60% and 100%
with a 30 minute hold time to the next pressure level and final
held at 100% of test pressure for 1 hour.
Nitrogen purging of all pressure systems
Facility isolations and valve line up for non-hydrocarbon systems.
The Contractor shall comply with Contracting Authority‟s isolation
standards.
Testing of active fire protection systems, including automatic /
manual CO2 systems in accordance with the specifications
As built documentation
Incorporation of Commissioning defects into Master punchlist
Site familiarisation, training and orientation of Operations
personnel
De-preservation, preservation and re-preservation
As systems are commissioned and brought into operations, or being ready for introduction of
hydrocarbons, the Contractor shall submit “Ready for Start-up” clearance for each system to
be approved by Contracting Authority. When all systems certificated are approved, the
Contractor can submit the “Ready for Start-up” Certificate for approval by Contracting
Authority, after which Start-Up shall begin. Such certificate will show that all Category B punch
list items have been properly cleared by Contractor.
10.2
START UP
Start Up is defined as the commencement of the introduction of hydrocarbons into the
Permanent Works to continue to commission the process systems. It occurs only after all
checks, inspections, Pre-Commissioning and Commissioning activities have been
successfully completed and accepted by Contracting Authority, and when all Ready for StartUp clearances for each system and the Ready for Start-up Certificate have been approved by
Contracting Authority, when all Category A and B punchlist items and HSE and operability
defects have been satisfactorily cleared, and when all documentation necessary for safe
operation of the facilities, certification, etc. has been provided to Contracting Authority.
The Contractor shall remain responsible for the care and maintenance of the facilities during
the Start-Up and until signature by Contracting Authority of the Provisional Acceptance
Certificate. The Contractor shall direct the Start-Up with the assistance of the Contracting
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Authority and shall be responsible for the management of HSE during this period. The
Contractor permit to work system, using SH-FCP approved forms, shall be in force and shall
be managed and operated by the Contractor‟s Personnel.
Contracting Authority reserves the right to stop work at any site if it considers the activity to be
an unsafe act, or poses environmental risk.
The Contractor with assistance from the Contracting Authority shall prepare a Start-Up plan
for approval by the Contracting Authority. A daily Start-Up meeting shall be held during the
Start-Up period. The Contracting Authority shall present all daily activities and associated
procedures and processes to the Contractor at this meeting. Activities shall be proposed at
the meeting at least 24 hours prior to their execution. The timing of activities shall be agreed
between the Contractor and the Contracting Authority. This meeting shall be minuted by the
Contractor. The minutes shall be reviewed and approved by the Contracting Authority and the
Contractor. They shall be signed by representatives of both parties and filed. The Contracting
Authority shall also present a 7 day lookahead.
No Start-Up activities shall take place without being minuted at the daily Start-Up meeting.
Start-Up shall include activities to be agreed with the Contracting Authority.
At the end of the Start-Up activities, when the facilities are operating sufficiently reliably and
stably, the Contractor shall request permission to perform the Provisional Acceptance Test.
The Provisional Acceptance Test shall have been successfully completed when all the
equipment has operated together at 100% of design criteria without trips or major alarms for a
period
of
96
hours.
Refer
to
document
Annexe I – “Technical”
and
Annexe VI - “Performances Guaranties”
The Contractor shall provide all the necessary resources to support the Start-Up. This shall
include commissioning support, specialist support (vendor/supplier), engineering support, and
assistance for the above activities until Conditional Acceptance. The Contractor shall provide
the following team (as a minimum) for the Start-Up activities:
Major Equipment Vendor Rotating machinery field engineers
Major Equipment Vendor Engine controls engineers
Major Equipment
technicians
Vendor
Rotating
machinery
Major Equipment Vendor E&I technician
Third party vibration monitoring specialist
Contractor‟s Start-up engineer
Contractor‟s Production technician x 2
Contractor‟s Control room technician
Contractor‟s Instrument technician x 2
Contractor‟s Mechanical technician
Contractor‟s Electrical technician
ICSS Vendor Control systems Engineer x 2
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
Condition monitoring system engineer
Once the Start-Up activities and the Performance Test have been carried out successfully, the
Provisional Acceptance Certificate shall be offered up by the Contractor to the Contracting
Authority for signature. Any minor reservation remaining at this stage will be recorded as such
in the Provisional Acceptance Certificate.
10.3
RESPONSIBILITIES
The Contractor shall be responsible for all activities as defined above.
The Contractor shall ensure sufficient time in the overall project programme to carry out the
Start-Up activities and the Performance Test for satisfactory reliable operation of the facilities.
The Contractor shall propose a programme and schedule for Commissioning as part of their
lump sum to be agreed with Contracting Authority during clarifications.
The Contractor shall provide all the necessary resources (specialist personnel,
vendor/supplier representatives, labour, Materials and Equipment) during Commissioning.
The Contractor shall provide a temporary diesel electrical generator set to carry out all the
Commissioning activities and to mitigate against any Start-Up delays which might occur in the
event of late connection to MLE 60 kV GIS for power supply or any interruption to such
supply.
The Contracting Authority may wish to provide personnel to support Commissioning activities.
If so, the Contractor shall integrate the Contracting Authority Personnel under the Contractor‟s
supervision. Responsibility for the execution of the Commissioning shall remain with the
Contractor.
The Contractor shall be responsible for all interfaces between Construction, and Operations
on Commissioning activities. All isolations shall be managed by Contractor up to Start-Up and
thereafter by Contracting Authority.
The Contractor shall be responsible for assisting the Contracting Authority in obtaining all the
approvals and consents required from the Authorities for Commissioning and shall be
responsible for providing the support required for the necessary approvals for the introduction
of the first hydrocarbon gas into to the facilities.
10.4
HEALTH, SAFETY AND ENVIRONMENT CONSIDERATIONS
The Contractor shall implement the agreed HSE standards throughout Commissioning. The
Contractor shall ensure that all the Subcontractors work to the same detailed HSE standards
for the duration of their work activities.
Contractor shall implement an overall HSE Management System meeting current best
practice e.g. ISO 14001, OHSAS 18001, OGP Report 376, OGP Report 291 and ensure
interfaces with Contracting Authority and other participants are managed. Contractor‟s HSE
Management System shall be documented and meet the requirements of OGP Report 343.
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Central Area Field Complex Project
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The Contractor shall ensure that safe systems of work are implemented from the
commencement of Commissioning to protect people from hazards.
The Contractor shall be responsible for overall emergency response management during
Commissioning. For incidents resulting from any activities the Contractor shall have standalone emergency response capability, including emergency management, emergency plan
and all associated systems.
The Contractor shall continue to use his permit to work system during Commissioning. An
adequate energy isolation procedure shall be put in place as soon as a system is made live
with electricity, pressurised and/or flammable fluids. This shall be included with the
Contractor‟s bid for approval by the Contracting Authority. The Contractor‟s permit to work
system shall be submitted with the Contractor‟s bid for approval by the Contracting Authority.
This shall be rigidly enforced throughout Commissioning up to Provisional Acceptance. The
Contracting Authority‟s permit to work system shall be introduced on and from Provisional
Acceptance.
Hazards associated with all Commissioning and operational jobs shall be identified and risks
analysed by the Contractor. Risk mitigation/elimination measures shall be stated on all work
permits. Additionally, toolbox talks shall be carried out before all operational tasks involving all
non-operational personnel. All work shall be adequately planned.
Simultaneous operations (SIMOPS) involving operations with construction/existing production
or maintenance activities in MLE CPF, etc. shall be identified and planned beforehand.
Specific procedures shall be written by the Contractor for all simultaneous operations.
The Contractor shall ensure that all personnel involved in Commissioning undergo a
comprehensive site familiarisation and job induction training programme, and specific permit
to work system training in both the Contractor‟s and Contracting Authority‟s systems.
The Contractor shall ensure that the labour-force is represented at regular HSE briefings and
meetings.
The Contractor shall ensure that the hazards associated with major activities are identified,
understood, and eliminated wherever possible. The Contractor shall prepare method
statements and procedures for major activities.
During Commissioning, the Contractor shall install all permanent Safety systems and
equipment, including emergency equipment, First Aid equipment, eye washes, etc. The
Contractor shall replace these if damaged.
The Contractor shall install temporary safety signs throughout the facilities during
Commissioning to supplement the permanent safety systems. All signs shall be provided in
French, English, and Arabic, and shall include pictorial representations of the objective at the
sign, wherever possible.
Lifting or slinging of equipment shall be undertaken in accordance with the Lifting Operations
and Lifting Equipment Practice.
The Contractor shall erect barriers to restrict movements whilst equipment is under potentially
hazardous test, and when it is in operation.
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Central Area Field Complex Project
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The Contractor shall maintain all escape routes throughout the execution of Commissioning.
The Contractor shall identify and plan all the licences, consents, and approvals from the
appropriate Authorities required for all Commissioning activities described above.
The Contractor shall ensure that atmospheric emissions, solid wastes, and liquid discharges
are kept to an absolute minimum during Commissioning.
The Contractor shall ensure adequate communication during Commissioning and Start-Up
and provide sufficient intrinsically safe radios to those involved in the work. The Contractor
shall also provide radios to the Contracting Authority operations staff involved in operations
and maintenance routines prior to the issue of the Provisional Acceptance Certificate.
The Contractor shall compile a register of all safety equipment and devices, showing location
and status of functional and final checks during Commissioning.
Contractor shall carry out a liaison risk assessment for the workforce including
Subcontractors.
Contractor shall operate under the direction of the Contracting Authority liaison management
system whilst in Algeria
10.5
PLANNING
The Contractor shall be responsible for adequate planning of Precommissioning &
Commissioning.
All completion activities shall be based on commissioning packages, and planned on a
system, sub-system prioritised basis, in a fully integrated network, in order to meet both the
Start-Up date and an optimal sequence of completion
The Contractor shall propose a programme and schedule for Commissioning as part of their
lump sum Contract Price.
The Contractor shall be adequately represented with commissioning specialists during the
detailed engineering and construction phases. Amongst other activities, the Contractor‟s
commissioning representatives shall be involved in:
Design interfaces (specifying system boundary limits, system
isolations)
Participation in HAZOP‟s
Equipment selection, and test run procedures
Facility layout
Constructability reviews
Commissioning operability
Preparation of Pre-Commissioning, Commissioning and Start-Up
procedures and plans, including the sequence by which systems
are commissioned.
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Studies into the acceleration of Commissioning and early Start
Up, whilst minimising environmental emissions and wastes.
These shall include the use of temporary generators as an
alternative to the main power from MLE during initial startup and
an investigation into the requirements of the CAFC Start Up.
Gaining approvals required by the Algerian authorities, and
licences and consents required for the Pre-Commissioning,
Commissioning and Start-Up process.
The Contractor shall incorporate best practices and lessons learned from projects recently
commissioned in southern Algeria into Pre-Commissioning, Commissioning, and Start-Up
plans.
The Contractor shall integrate into his project execution team representatives from critical
equipment vendors, e.g. compression suppliers, to ensure healthy close-working relationships
through out the project, and to ensure lessons learned from earlier projects are incorporated.
10.6
PRE-COMMISSIONING, COMMISSIONING AND START-UP ACTIVITIES
The Contractor shall produce Pre-Commissioning, Commissioning and Start-up procedures
and method statements detailing the activities to be carried out, for Contracting Authority
review and approval.
The Contractor shall ensure that the Computerised Maintenance Management System
(CMMS) is on-line and available for use at the commencement of Commissioning. The
Contractor shall support initial use of the CMMS starting from commissioning, assist with data
entry and work processing. The Contractor shall ensure through facilitation, training and
support of the Company‟s maintenance personnel (including tracking and reporting on CMMS
usage) that all maintenance / repair & defect activities, and all planned maintenance activities
due on the Permanent Work throughout Commissioning are effected through, entered in,
documented and closed out on the CMMS.
The Contractor shall supply and maintain a project completion and certification system tool for
all phases including Pre-Commissioning, Commissioning and Start-Up up to Conditional
Acceptance.
Operating and maintenance manuals shall be prepared by the Contractor. The manuals shall
be provided to the Contracting Authority 10 months prior to Start-Up.
The Contractor shall provide and be responsible for office and accommodation, messing, and
transportation of the Contracting Authority‟s Personnel and visitors until signing of the
Provisional Acceptance Certificate to the standards to be defined by Contracting Authority.
10.7
GENERAL PROCEDURES
The Contractor shall prepare procedures which detail how the Commissioning activities shall
be carried out for each piece of equipment and system, for the Contracting Authority to review
and approve. For process systems, Commissioning activities should be split between
activities prior to hydrocarbons and activities after introduction of hydrocarbons.
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The Contractor shall also prepare Start Up procedures for the facilities, with input from
Suppliers and Contracting Authority to be prepared 10 months in advance of Start-Up. The
Start-Up procedure shall be agreed by the Contracting Authority and the Contractor.
Contractor shall provide a of list of procedures that shall be prepared by the Contractor 10
months in advance of Commissioning to reviewed and approved by Contracting Authority.
The total list includes, but is not limited to the following:
Flushing of pipework
Commissioning
and
mechanical
systems
prior
to
Control of cleanliness of all facilities prior to Commissioning
Chemical cleaning and passivation of systems
Commissioning and Start-Up procedures
Operating procedures,
emergency situations
covering
normal,
abnormal,
and
Tightness test/leak testing and joint management. Joint
management shall include a tagging procedure recording flange,
bolt and torque parameters and the individual responsible for
making the joint.
Equipment, piping and pipelines inerting procedure
Isolation procedure for working safely on equipment and facilities.
Contractor to adopt the Contracting Authority‟s isolation standard
following the livening of electrical equipment and introduction of
hydrocarbons. The competency of responsible individuals within
the Contractors organisation shall be demonstrated as per
Contracting Authority procedures.
Compressor factory and site test runs
Control of emissions, waste, discharges, and water abstraction
Verification of compliance of critical equipment
Progress reporting
SIMOPS (construction/operations interface) procedures
Safe Systems of Work Procedures (Permit to Work)
Procedures for working at heights, in confined spaces, locking
out and tagging live/pressurised systems.
10.8
HANDOVER AND ACCEPTANCE PROCEDURES
Contractor shall develop and maintain a Project completion and certification tool during all
phases including handover to operation. This tool shall enable the tracking of the status all
systems and equipment through the process of Mechanical Completion, Pre-Commissioning,
Live Commissioning and Start-Up. This completion tool shall be the basis for issuing
certificates for document completion of the different phases.
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The Contractor may be required to provide essential resources and support for 3 months
following the signing of the Provisional Acceptance Certificate (reimbursable basis). These
resources shall be drawn from the Contractor‟s site team and shall be agreed during Start-Up.
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Precommissioning, Commissioning, and Performance test battery limits prior to handover to
Operations are summarised in the following figure:
Handover and Acceptance Procedures shall be based on the following principles:
Ready for Start-Up clearance of each particular system by the
Contractor indicates that the system is ready for the introduction
of hydrocarbon gas.
Ready for Start-Up Certificate will be issued upon clearance of all
systems being achieved.
Provisional Acceptance by the Contracting Authority shall occur
when Performance Tests have been successfully completed. A
Provisional Acceptance Certificate shall be offered up to the
Contracting Authority by the Contractor. The 2 year Warranty
Period shall run from the date of issue of the Provisional
Acceptance Certificate.
Final Acceptance by the Contracting Authority occurs on the
expiry of the Warranty Period. A Final Acceptance Certificate
shall be offered up to the Contracting Authority by the Contractor.
The Contractor shall complete all outstanding work and punchlist items, as quickly as
practicable and, in any case, before offering to the Contracting Authority a Provisional
Acceptance Certificate.
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From the date of signing the Provisional Acceptance Certificate, the Contracting Authority
shall assume full responsibility for the operation and routine maintenance of the facilities.
Provisional Acceptance cannot be achieved until:
All punchlist items are satisfactorily closed out
As built drawings and documentation, including manuals, are
available (in paper and electronic format)
The Provisional Acceptance Certificate has been issued and the
Performance Tests have been satisfactorily completed.
Final Acceptance cannot be achieved until:
All Provisional Acceptance conditions have been met
Defect-free operation for 24 months following Provisional
Acceptance.
10.9
PERFORMANCE TESTING
The Performance Test shall be carried out at a time when both parties agree that
Commissioning is complete and the facilities are operating sufficiently reliably and stably to
conduct a meaningful test as defined in Annex VII – “Performance Guarantees”. Operational
reasons, outside the control of Contracting Authority, may dictate precise windows, during
which the Performance Test can be undertaken.
The Performance Test procedure shall be developed and agreed during clarifications prior to
Contract award and shall include a summer and winter test.
In the event that Contracting Authority cannot provide a suitable opportunity or conditions to
conduct the Performance Test within 24 months after signature by the Contracting Authority of
the Provisional Acceptance Certificate, the responsibility of the Contractor in this regard shall
be relinquished.
If reservoir fluids, having the characteristics stated in the specifications, are not available for
use during the test runs of the facilities, any Performance and Utilities Warranty, which forms
part of the Contract, shall be correspondingly adjusted. This shall be achieved using standard
chemical engineering practice and agreed between both parties.
10.10
FAILURE OF FACILITIES TO PERFORM
In the event that the Works or any section thereof fails to operate in accordance with the
design premise or the Contract, the Contractor shall at its own expense carry out appropriate
remedial design and construction work and provide necessary replacement materials,
equipment and facilities. On completion of such remedial work the Contractor shall
demonstrate that the design criteria have been met.
10.11
TRAINING
The Contractor shall provide training and training aids for the Contracting Authority and
Contracting Authority operational staff. This shall include the following training for critical
packages:
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Attendance at FATs and at critical tests/inspections
Supplier on-the-job training during site Pre-Commissioning & Live
Commissioning activities
training on main equipments including: operation, mechanical,
electrical, instrumentation, DCS, telecommunication et safety.
Specific Supplier classroom training programmes on site (in
English & French)
Training programmes shall be drawn up by the Contractor and
reviewed by the Contracting Authority
The critical packages are:
Gas injection driven Compressors
Off gas compressors
ICSS (including DCS, F&G and ESD)
Electrical and instrumentation
The Contractor shall also organise a general classroom session with centrifugal compressor
simulator training (operation) and on-the-job training for the non-critical systems and
equipment not covered above. The number and duration of each course will be developed by
the contractor according to the needs of the future plant;
The Contractor shall ensure that all major equipment critical packages include a fixed
proposal and cost element for training of the Contracting Authority personnel by the Supplier
at the construction sites prior to placing the order. These proposals shall be reviewed with the
Contracting Authority. Training costs shall include all overseas training costs including local
transportation and full hotel accommodation. . This is to be estimated at US $250.00 per day
per person and be reimbursable.
For courses at the construction sites, the Contractor shall provide a Training office.
The Contractor shall ensure that the training provided is in English and French and is of a
standard, which contributes to the overall competence of the Contracting Authority operational
staff.
10.12
VENDOR SUPPORT
The Contractor shall arrange for vendors of critical equipment to attend site to support
installation, Pre-Commissioning, Live Commissioning and Start Up, and further, the
Contractor shall agree with the Contracting Authority the equipment over and above critical
equipment which requires vendor support on site.
The Contractor may be required to arrange for vendors of critical equipment to be available
for the Contracting Authority on a reimbursable basis, as required by Contracting Authority to
support operation for up to 3 months following Provisional Acceptance.
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10.13
Sonatrach / FCP
Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
DOCUMENTATION
The Contractor shall provide good quality as-built drawings and documents as outlined in
Annex V – “Documents to be submitted to the Contracting Authority” in French and English
(both hard-copy and electronic format). The listing of required drawings and documents, and
their format, shall be agreed between the Contractor and the Contracting Authority.
The Contractor shall ensure that all Supplier documentation is received in a timely manner in
order to ensure it can be incorporated in Pre-Commissioning, Live Commissioning, and StartUp procedures.
The Contractor shall compile the necessary drawings and documents in the required format
for the certification and approvals authorities.
10.14
ENGINEERING SUPPORT
The Contractor shall provide discipline engineering support, as necessary, through to
Provisional Acceptance.
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Tender No.
Central Area Field Complex Project
SH-FCP-EPC-PREQUAL-CAFCHUILE 2011-01
11. SPECIAL NOTES REGARDING CAFC OIL PROJECT
The Scope of Wok (SOW) as indicated in all the technical documentation contained in the ITT
Annex 1 is derived from the original competitive FEED for the development of the total CAFC
facilities which included the SOW for both OIL and GAS projects.
Subsequent to the completion of the competitive FEED, the project was split into two separate
projects:CAFC Oil
CAFC Gas Gathering
This ITT refers to the CAFC Oil Project, and any residual reference to CAFC Gas Gathering in
the ITT documentation should be ignored, or at best used “for information only”.
This Section (11. Special Notes Regarding CAFC Oil Project) is intended to advise last minute
changes or updates to the basic technical documentation contained in the ITT Annex 1.
11.1 CAFC OIL GATHERING SYSTEM
1. The original competitive FEED documents were prepared for the total CAFC facilities
including the lean and rich gas gathering system consisting of 10 lean gas wells, 7 rich gas
wells, 17 gas flowlines, 3 gas manifolds stations and 2 gas trunklines. The lean and rich gas
gathering system is presently under implementation as a separate project and does not form
part of this Work. The Gas Gathering system is expected to be commissioned before, and be
in operation during, the construction phase of the CAFC oil project.
2. The lean and rich gas wells are located in the same area as the oil wells and some of the gas
flowlines and trunklines are run in the same pipeline corridors as the oil flowlines and
trunklines. Contractor must consider existence of these live facilities in close proximity of the
work sites in design and construction of the CAFC oil facilities.
3. Power supply for some oil wells and manifolds is to be taken from the nearby gas well pads
/manifolds as detailed in the FEED documents
4. The well names and locations of some of the oil producer, gas injection and water injection
wells have been revised. These are also preliminary and are subject to change during the
EPC phase.
5. To avoid any confusion, the manifold MOP-01 shall be split into two separate manifolds at the
same location. Each manifold shall be connected to a maximum of 8 wells and will be
dedicated to each trunkline F6-1 and F6-2 separately. Note that the separation distance
between the manifolds shall be determined according to FERA rules and guidelines.
6.
The Tagi, F6-1 and F6-2 oil flowlines and trunklines shall be submitted to 100% X-ray
inspection in accordance with the “Algerian safety regulation for transportation pipelines
intended for combustible gas”.
OLD WELL NAMES AND LOCATIONS
Well Name
X meters
Y meters
1. F6-1 Oil Wells Names & Locations:
NEW WELL NAMES AND LOCATIONS
Well Name
X meters
Y meters
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MZLS-3
364096
3340185
MZLN-8
368639
3344047
CAFC F6-1 - A
363960
3337010
CAFC F6-1 - B
357065
3341350
CAFC F6-1 - C
370450
3333570
CAFC F6-1 - D
356600
3342500
CAFC F6-1 - E
356600
3343500
CAFC F6-1 - F
359410
3343800
CAFC F6-1 - G
358125
3341480
CAFC F6-1 - H
360790
3339620
CAFC F6-1 - I
362210
3340320
CAFC F6-1 - L
362770
3337520
CAFC F6-1 - M
365400
3339720
CAFC F6-1 - N
365790
3337010
CAFC F6-1 - O
358555
3340505
2. F6-2 Oil Wells Names & Locations
LEW-1
357003
3340422
LEW-3
356065
3341620
LES-4
369067
3336614
F6-2 Oil A
358970
3340105
F6-2 Oil B
358970
3341190
F6-2 Oil C
357970
3340860
F6-2 Oil D
357260
3342375
F6-2 Oil E
355255
3342550
F6-2 Oil F
357970
3341970
3. TAGI Oil Wells Names & Locations
MZLS-3
MZLN-8
CAFC F6-1 - A
CAFC F6-1 - B
CAFC F6-1 - C
CAFC F6-1 - D
CAFC F6-1 - E
CAFC F6-1 - F
CAFC F6-1 - G
CAFC F6-1 - H
CAFC F6-1 - I
CAFC F6-1 - L
CAFC F6-1 - M
CAFC F6-1 - N
CAFC F6-1 - O
364096
368639
363960
357065
370450
356600
356600
359410
358125
360790
362210
362770
365400
365790
358555
3340185
3344047
3337010
3341350
3333570
3342500
3343500
3343800
3341480
3339620
3340320
3337520
3339720
3337010
3340505
LEW-1
LEW-3
LES-4
F6-2 Oil A
LEW-5
F6-2 Oil C
F6-2 Oil D
F6-2 Oil E
LEW-4
357003
356065
369067
358970
359431
357970
357260
355255
357880
3340422
3341620
3336614
3340105
3340697
3340860
3342375
3342550
3342140
LES-3
370958
3337287
LES-3
370958
3337287
LES-6
371435
3338221
LES-6
371435
3338221
LES-7
372521
3339204
LES-19 Hor
371947
3339140
LES-8
372386
3340637
LES-8
372386
3340637
LES-10
373100
3338851
LES-10
373100
3338851
LES-11
370550
3340160
TAGI OIL V8
370849
3340006
LES-12
371139
3338041
TAGI Oil V1
371139
3338041
LES-13
374500
3341975
TAGI OIL V3
371300
3336900
LES-14
373100
3338980
LES-20 Hor
371937
3339169
LES-15
372762
3340261
LES-22 Dir
372829
3340050
LES-16
370848
3336789
TAGI OIL V5
370550
3337300
LES-17
370860
3338687
TAGI Oil V4
370860
3338687
LES-18
371736
3339366
LES-11 Hor
371454
3340693
LES-19
370526
3341246
TAGI Oil V6
370526
3341246
LES-20
371660
3339997
TAGI Oil V7
371660
3339997
LES-21
371099
3339785
LEC-3
371498
3341512
LES-22
370228
3338600
LES-21 Hor
371535
3337160
4. TAGI Gas Injection Wells Names & Locations
LEC-2
372682
3342017
LEC-2
372682
3342017
LES-GI 1
373950
3342234
LEC-4 GI
374140
3342490
LES-GI-2
371640
3342080
LES-7
372521
3339204
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5. TAGI Water Injection Wells Names & Locations
LES-WI 1
368787
3337598
LES-18 WI
369750
3338141
LES-WI 2
369247
3339884
LES-16 WI
369362
3339747
LES-WI-3
368985
3335174
LES-17 WI
368985
3335174
LES-WI-4
372510
3338225
LES-WI-4
372510
3338225
6. Water Source Wells Names & Locations
Water Prod. 1
372375
3340920
Water Prod. 1
372375
3340920
Water Prod. 2
371400
3339535
Water Prod. 2
371400
3339535
Water Prod. 3
373695
3338270
Water Prod. 3
373695
3338270
11.2 PIPING SPECS
Piping specs originally included in the competitive FEED have been further developed during
the CAFC Gas Project and are to be used for the Oil Project. The main difference relates to
the 600# piping classes where the Gas Project uses RTJ flanged connections instead of RF.
There are a few minor differences in other classes.
SEE ATTATCHMENT G
11.3LEGEND SHEETS
The development of the CAFC Gas Gathering Project has produced a set of P&ID Legend
Sheets which reflect the changes in piping classes noted above as well as further
developments during the detail design. These Gas Project P&ID legend Sheets are to be
integrated into the Oil Project and a set of Oil Project P&ID Legend Sheets developed during
the detail design which is mutually compatible with the Gas Project.
SEE ATTACHMENT H
11.4FLOWLINE MODIFICATIONS
In addition to the instrumentation shown on the P&ID‟s, all flowlines are to include for a
Temperature and Pressure Indicator (TI & PI) at the end of each flowline.
11.5 INSTRUMENTATION MODIFICATIONS
All the instrumentation devices shall be provided with Ex-i (and not Ex-d) electrical execution.
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11.6 RING MAIN UNIT PACKAGE
The CAFC GAS Project has developed the technical specifications for the Active and Passive
Cooled Shelters.
The ring main unit consists of No.5 Manifolds, No.1 Wellsite and all the other wells, in which
will be installed electrical/instrumentation shelters complete with all necessary electrical and
instrumentation equipment (in separate rooms). In the manifolds and wellsite will be installed
shelters active cooled (ACS) type while in each well will be installed shelters passive cooled
(PCS) type.
The ACS will be complete with MV and LV switchboards, MV/LV transformers, UPS and
batteries, RTU SCADA, SHD, IDS and TETRA System if necessary.
The PCS will be complete with LV switchboards, UPS and batteries, RTU SCADA, SHD and
IDS.
These shelters shall have also F&G system, with detectors, etc.
As for the Gas Gathering system, the connection between No.5 Manifolds and No.1 Wellsite
shall foresee an interlock (mechanical) philosophy between the disconnector and the earthing
switch installed in the same panel and a key interlock between the earthing switch and the
disconnector installed in the site connected to.
The closing of all earthing switch shall be possible only in case that the disconnector
downstream and the disconnector upstream shall be open.
12.
ATTACHMENTS
TIE-IN INTERFACE MLE & CAFC
ATTACHMENT
ATTACHMENT
ATTACHMENT
ATTACHMENT
ATTACHMENT
ATTACHMENT
ATTACHMENT
A
B
C
D
E
F
I
ATTACHMENT G
PIPING CLASS SPECIFICATION
ATTACHMENT H
LEGEND SHEETS
Document Number: 141200DPFM11760 rev. 02 sheets 1 to 6 dated 14/10/2011
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Part D - Scope of Work