AL-HASSAN ENGINEERING CO. S.A.O.GPROJECT: AMAL POWER STATION

PDO CONTRACT NO: C-310987

DOCUMENT NO.AML-391-AA -6944-0032-000

21st March 12 – 20th April 12

MONTHLY PROGRESS REPORT

Doc. No: AML-394-AA-6944-0032-000 Rev. No : 01 Date: 25.04.12 Page 2 of 57

AL-HASSAN ENGINEERNG CO. SAOGPROJECT: AMAL POWER STATION

(PDO CONTRACT NO: C-310987)

AML-391-AA-6944-0032-000

01 25.04.12 1 to 57 For Approval A.R.D K.G.B.

Document No Rev Date No. of Description Prepared Reviewed Approved

No `Pages By by by PDO

TABLE OF CONTENTS

Page

Section 1 Contract Particulars

1.01 Salient Features of the Contract7

1.02 Contract Scope of Work in brief8

Section 2 Project Summary Report

2.01 Project Progress Statistics11

2.02 Narrative Summary Report12

2.03 Over-all Progress Curve for the Project12

2.04 Areas of Concern12

Section 3 Detailed Report

3.01 Health, Safety and Environment (HSE)14

3.02 Engineering & Design Documents14

3.03 Procurement14

3.04 Manufacturing14

3.05 Delivery14

3.06 Mobilization14

3.07 On plot construction and commissioning15

3.08 Off Plot construction and Commissioning17

3.09 Equipment Deployment17

3.10 Manpower Deployment19

3.11 Quality Assurance20

3.12 Plan for Next month21

3.13 Contract Financials23

Section 4 Appendices

I Project Milestone Dates 26

II Project Schedule (Updated) 31

III Drawing Control Register 32

IV Material Tracking Register 33

V Critical Project Material List 34

VI Health & Safety Statistics (Monthly Return) 35

VII HSE Audit / Inspection Schedule 36

VIII HSE Training Matrix 38

IX Quality internal and external audit schedule 39

X Summary of progress 40

XI S-curve for Engineering Progress 42

XII S-curve for Procurement Progress 43

XIII S-curve for Construction progress 44

XIV S-curve for Overall progress 45

XV S-curve for VOWD 46

XVI Manpower & Equipment Histogram 47

XVII Subcontract Details 48

XVIII Variations Register 50

XIX Omanisation Requirement 51

XX SPIR Progress 53

XXI Progress Photographs 55

SECTION 1

CONTRACT PARTICULARS

1.01 Salient Features of the Contract

Project Title : Amal Power Station

Company / Employer : Petroleum Development Oman LLC

Company Contract Holder : Mr. Harith M Al Amry – UIE/5

Company Representative : Mr. Saud Al Habsi – UIE/52

Contractor : Al-Hassan Engg. Co. S.A.O.G

Contract Value : Rial Omani 22,950,786/-

Effective Date of Contract : 24th June 2009

Commencement Date : 4th July 2009

Contract Duration : 730 Days

Substantial Completion : 5th April 2011

Completion Date : 4th July 2011

Engineering Sub-Contractor : Mott MacDonald & Company LLC, Oman

SAP Purchase Order No : 4500439405

1.02: Contract Scope of Work in Brief:

The Amal Power Station will be of modular construction and will

comprise initially of two Frame 9E Gas Turbine Generator (GTG)

units.

Construction and commissioning of Amal Power plant

comprising two frame 9E Gas turbine units– Installed

capacity 252 MW.

Provision will be made for the future addition of Once

through Heat Recovery Generators (OTHRS’s) on the

back end of the GTG.

Amal Power Station with Frame 9E GTG’s will have an

ISO rated installed capacity of 252MW. At a site ambient

temperature of 48 deg C, corresponding to maximum

summer temperatures, this will drop to 197.4MW.

Each GTG unit will be unitised such that any equipment

failures associated with one GTG unit will not cause a trip

of an adjacent GTG unit.

The fuel gas for Amal Power Plant will be supplied from

18” Hubara to Amal Pipeline and the tie-in point for fuel

gas will be provided on 18” bypass line near Amal pie

receiver A-2075.

A unitized gas treatment trains will be provided to ensure

the gas delivered to the gas turbine meets the gas

turbine Original Equipment Manufacturer’s (OEM)

requirements at all times.

The Amal Power Station is designed for unmanned

operation and under normal operation will be remotely

controlled by SCADA and monitored from the Yibal/QA

Master Control Room with backup from the Marmul\Nimr

Control Room.

Facilities Service water, DM water, Instrument air system

incorporating screw type compressors and membrane

dryers will be provided.

Facilities for transferring Diesel fuel to the Emergency

DG set will be provided.

Gas turbines shall be free issued by PDO. Design, supply

of BOP is part of AHEC scope.

Design and construction of Unit Electrical buildings and

Gas treatment plant building.

Design, supply and construction of OHL from Nimr

Central to LILO location AP05(28 KM) and from LILO

location AP05 to Thuleilat ( 70 KM)

HVAC System.

Power Station internal and external communication with

provision of CCTV.

Fire detection and alarm system.

Scope includes interfacing with GTG OEM supplier/

Vendor.

Pre commissioning and commissioning.

SECTION 2

PROJECT SUMMARY REPORT

2.01 Project Progress Highlights:

Highlights of April, 2012.

10.1 KM New OHL erection and bolt tightening 34 / 34

no’s completed.

10.1 KM New OHL ELM conductor stringing completed

except 2 shut down location.

10.1 KM OHL OPGW installation works in progress.

Unit # 1 & 2 punch point attending in progress.

2.02 Narrative Summary Report

Project progress during the month of March 21st to April 20th is summarized as follows

Overall project progress for the month has reported

0.05% against the planned progress 0.10%.

Cumulative overall progress for the month has reported

99.85% against the planned progress 100%.

Cumulative engineering progress for the month has

reported 100% against the planned progress 100%.

Cumulative Procurement /Manufacturing/ delivery

progress is 100% against the planned progress 100%.

Cumulative construction progress for the month is

99.58% against the planned progress 100%

2.03 Overall progress curve for the project

As per section 4, Appendix XII

2.04 AREAS OF CONCERN

Receipt of inputs from PDO/BHEL –

1. Unit # 2 - CO2 system connecting Hose. CO2 panel

battery back up for unit # 1 & 2.

2. Unit # 2 - 125V - DCDB - Variable Resistor - 01 set. (3

no’s) for DC Jacking oil pump cubicle.

3. Lube oil NRV, Step down transformer (220V/110V) for

the MOV's in U#2 Accessory Base. Shaft for ABOC

Fan#7 bearing block

4. Refer critical material list for balance materials.

Other area of concerns –

1. Communication between Marks V1 and DCS.

2. MFM – SCADA communication.

3. Passing of ESD valve in GTP

SECTION 3

DETAILED REPORTS

3.01: Health, Safety and Environment (HSE).

Major highlights of the month:

Weekly HSE gate meeting conducting on every

Saturday.

Conducting daily tool box for driver and work force

before starting of work.

HSE Monthly meeting conducted.

Vehicle inspection completed 50% along with plant

department.

3.02: Engineering & design documents

Major highlights of the month:

3.03: Procurement

Major highlights of the month:

3.04: Manufacturing

Major highlights of the month :

3.05: Delivery

3.06: Mobilization:

Major highlights of the month:

Mobilization and demobilization of manpower and

equipment in progress.

3.07: On plot Construction and commissioning.

Major highlights of the month:

Civil

Unit # 2 - Punch point attending in progress.

Unit # 2 – Test pack submission completed.

Mechanical

Unit # 2

Unit # 2 – Punch point attending works completed.

Unit # 2 – Test pack submission completed.

ELECTRICAL

Unit -1

Punch point attending in progress.

Test pack submission completed except 1 package.

Unit -2

Punch point attending in progress.

Test pack submission in progress for 6 packages.

Instrumentation

Unit # 1 & 2 – Punch point attending works 95%

completed.

Unit # 1 & 2 Test pack preparation and submission in

progress for 10 packages.

Testing

Pre Commissioning and Commissioning

Unit-1 & 2

Unit # 1 & 2 - DCS punch point attending in progress

DCS SAT 84% completed.

Alarm rationalization 45% completed.

3.08: Off plot Construction and commissioning.

Major highlights of the month:

AP07 to Nimr Central OHL

Tower assembly 34/ 34 completed. Tower erection

34 /34 completed.

Stringing for 9 section completed out of 10 sections.

FOC stringing works in progress.

Spacer damper installation works completed.

3.09: Plant And Equipment Deployed At Site:

1. Station wagon 5

2. Pickup 3

3. Potable water tanker 5000 Gallon 1

4. Tipper 1

5. Diesel Tanker 1

6. Shovel/Loader 1

7. Grader 0

8. Bucket truck 0

9. 62 Seat Big bus 0

10. Crew cab 3

11. 7 Ton Truck 1

12. Box Tailor 1

13 7 Ton Hiab 1

14 Brackish water tanker 1

15 Excavator 1

16 1 T Roller 1

17 JCB 1

18 10 T Roller 0

19 Concrete Mixture machine 0

20 Power generator portable 2

21 Plate compactor 2

22 Jumping compactor 2

23 Welding machine 2

24 Air compressor 3

25 24 Seater Bus 2

26 Crane 140 T 0

27 Crane 50/25 T 2

28 Generator 225 KV 0

29 Ambulance 1

30 Folk lift 1

31 Transit Mixer 1

32 Cement Bulker 0

33 Batching plant 1

34 Waste Disposal Truck 1

35 60 Seated Big Bus 1

36 Bobcat 0

37 Vibrator 2

38 Generator 350 KVA 0

39 Hydra 1

40 Truck Gas 0

3.10: Manpower Deployment:

Project Office at Muscat

1. Project Manager 1

2. Interface Manager

3. Planning Manager 1

4. Procurement Manager

5. Design Manager

6. Design Electrical Engineer

7. Design Civil Engineer

8. Project Coordinator

9. Cost Accountant 1

10. Draughts man 1

11 Secretary

12 Drivers (Omani) 2

MMC (Engg. Consultant) Office at Muscat

1. Project Manager

2. Civil Discipline

3. Electrical Discipline

4. Mechanical Discipline

5. Process Discipline

6. C & I Discipline

7. Piping Discipline

Manpower Deployed at Site

1. Staff ( Expat) 30

2. Staff (Omani) 10

3. JE (Expat) 92

4. JE (Omani) 59

5 Sub contract 35

3.11: Quality Assurance:

Major Highlights of the Month:

Unit # 2 - Tests pack preparation and submission for

Electrical and instrumentation in progress.

Mark up drawings preparation and submission works in

progress.

3.12, Plan for Next Month:

Health, Safety and Environment .

Inspection of plant and equipments.

Conducting monthly HSE Meeting.

Gate meeting on every Saturday

Tool box talk for driver and work force

Driver’s forum.

Mobilization:

Manpower and equipment mobilization and

demobilization.

On Plot Construction / Commissioning: Civil

Punch point attending works to complete.

Mechanical

Punch point close out.

Electrical

UEB # 1 & 2

De energizing of temporary transformer. Termination of

cables for SUAT.

Punch point attending

Commissioning

Unit # 1 – Reliability run to start

Unit # 2 – DLN tuning.

Unit # 1 & 2 – Marks V1 e and DCS communication

establishment through Matrikon.

Instrumentation

Punch point close out.

Off Plot Construction:

AP07 to NIMR CENTRAL(TWIN ELM)

Shut down jobs at Tower location 2 & 3 and 34 & 35 to

complete.

OPGW stringing works to complete.

Aviation light and sphere installation works to complete.

QUALITY ASSURANCE

Unit # 1 – Balance test pack submission for CO2, EDG

and CEMS.

Unit # 2 – Test pack submission for Electrical and

instrumentation packages.

Unit # 1 & 2 – As built drawings submission and approval.

CONTRACT FINANCIALS:

Milestone 1 payment invoice submitted on 26.08.09

payment received on 05.10.09.

Milestone 2a payment invoice submitted on 26.08.09

payment received on 05.10.09.

Milestone 02B payment invoice submitted on 18.11.09,

payment received on 26.12.09.

Milestone 03 invoice submitted on 05.03.10, payment

received on 09.04.10.

Milestone 02D payment invoice submitted on 10.04.10,

payment received on 28.05.2010.

Milestone 02C payment invoice submitted on 15.05.10,

Payment received on 14.06.10.

Milestone 05A payment invoice submitted on 24.04.10,

payment received on 28.05.10.

Mile stone 06A payment invoice submitted on 16.07.2010,

payment received on 06th September 2010.

Mile stone 04 A documents submitted and approved,

Invoice submitted on 19th August 2010, payment received

on 30th September 2010.

Mile stone 05 B documents submitted for approval,

payment received on 26th December 2010.

Mile stone MS 04B completion certificate received.

Payment received on 30th April 2011.

Mile stone MS 06 C completion certificate received.

Payment received on 30th April 2011.

Mile stone MS 06 D completion certificate received.

Payment received on 27th August 2011.

Mile stone MS 06 E completion certificate received.

Payment received on 27th August 2011.

Mile stone MS 06 B completion certificate received.

Payment received on 13th September 2011.

Mile stone MS 07 B completion certificate received.

Payment received on 23rd October 2011.

Mile stone MS 05 C completion certificate received.

Payment due on 12th December 2011.

Mile Stone 07 A and 08 completion certificate received

50%. Payment received on 9th January 2012.

Mile Stone 07 A and 08 completion certificate for balance

50% received. Invoice submitted for payment.

Mile stone 09 completion certificate for 50% received.

Invoice submitted for payment.

SECTION 4

APPENDICES

APPENDICES-I

PROJECT MILESTONE DATES

Project Milestone Schedule / Dates

Milestone

Description Weight-age

Amount in

Million R.O

Sch. Comple

tion

Act Completion date

Payment Receive

d

Remarks

MS-1 Mobilization 6% 1.37715-Aug-

0915-Aug-

0905-Oct-

09MS-2a PO for 3 critical

items 6% 1.377 18-Aug-

09 18-Aug- 05-Oct-

( Generator transformer,GCB,6.6KV switchgear

0909

MS-2b

PO issue for wooden poles and steel towers of OHL

4% 0.91817-Nov-

0917-Nov-

0926-Dec-

09

MS-2c

Upon completion of issue of PO for remaining engineered item purchase order for electrical ,C &

4% 0.91815-Feb-

1002-May-

1014-Jun-

10

MS-2d

Upon the completion of issue of PO for remaining engineered item purchase orders for mechanical

5% 1.147 13-Jan-10

25-Mar-10

28-May-10

MS-3Site Establishment

5% 1.14711-Dec-

0902-Mar-

1009-Apr-

10

MS-4a

Upon Completion of Engineering activities for Design review, IPF/HAZOP,SAFOP

2% 0.45931-Mar-

1019-Aug-

1030 –

Sep-10

MS-4b

Upon Completion of Remaining Engineering activities

4% 0.918 29-Jul-10

16-Mar-11

30-Apr-11

Milestone

Description Weight-age

Amount in

Million R.O

Sch. complet

ion

Act Completion date

Payment Receive

d

Remarks

Ms-5a

Upon Completion of following Civil work Amal power station site leveling & grading

2% 0.45924-Feb-

1015-Apr-

1028-May-

10

Ms-5b Upon Completion of following Civil work UEB, GTP, GTG and Off

10% 2.295 27-Sep-10

27-Sep-10

26-Dec-10

base foundation.

Ms-5c

Upon Completion of following Civil work balance foundation, fencing on plot and off plot, Road works.

3% 0.68811-Mar-

1110-Nov-

1109-Jan-

12

Ms-6a

Upon receipt at Site of following Equipment (including documentation) materials for OHL (wooden poles, steel towers, FOC)

4% 0.918 19-Jun-10

16-Jul-106-Sep-10

MS-6b

Upon receipt at Site of following Equipment (including documentation) ( Generator transformers,15/6.6KV transformer, Control & automation cable, bus duct )

10%2.295

16-Nov-10

25-Jun-11

13-Sep-11

Milestone

Description Weight-age

Amount in

Million R.O

Sch. complet

ion

Act Completion date

Payment Receive

d

Remarks

Ms-6c

Upon receipt at Site of following Equipment (including documentation)(GCB,6.6KV switchgear,415V switchgear,6.6KV cables & termination)

4% 0.918 3-Oct-1020-Mar-

1130-Apr-

11

Ms-6d Upon receipt at Site of following Equipment (including documentation)( vent system ,drain

3% 0.688 22-Jul-10

25-Jun-11 27-Aug-

11

system)

Ms-6e

Upon receipt at Site of following Equipment (including documentation)( DC and AC UPS, EDG, Instrument air compressor, DCS)

4% 0.91803-Sep-

10

23-Jun-11

27-Aug-11

Ms-7a

Upon completion of 132kv switchyard works at Nimr West 132kv Substation including

2% 0.45903-Nov-

10

Ms-7b

Upon completion of 132kv OHL’S

2% 0.459

23-Oct-10

15-Jul -11

23-Oct-11

Milestone

Description Weight-age

Amount in

Million R.O

Sch. complet

ion

Act Completion date

Payment Receive

d

Remarks

Ms-8

Upon completion of pre-commissioning of GTG package including all auxiliaries (pre-commissioning completed, ready for introduction of hydrocarbons)

5% 1.14716-Jan-

1130-Jan-12

Ms-9

Upon Substantial Completion of the Work for GTG Package

9% 2.06505-Apr-

11

Ms-10

Upon Completion of the Work (Demobilization)

6%1.377 04-Jul-

11

APPENDICES II

INTERGRATED OVERALL PROJECT SCHEDULE

APPENDICES-III

DRAWING CONTROL REGISTER

APPENDICES-IV

MATERIAL TRACKING REGISTER

APPENDICES-V

CRITICAL PROJECT MATERIAL LIST

APPENDICES-VI

HEALTH & SAFETY STATISTICS

APPENDICES-VII

HSE AUDIT/INSPECTION SCHEDULE

# Subject Auditor Schedule Month

Actual Month

Remarks

1 Journey management

HSE Advisor + Site Manager

August 09October 09

2 Road transport safety

HSE Advisor + Manager HSE+ Construction Manager

October 09November

09

3 Lifting equipment and lifting gears

Site HSE Advisor + Project Manager

November 09

November 09

4 Welding and gas cutting

Site HSE Advisor + Corp. HSE Manager

December 09

April 2010

5 Catering Site HSE Advisor February 2010

March 2010

6 Welding Site HSE Manager March 2010

April 2010

7 Transportation of compressed gas cylinder

Site HSE Manager + Project Manager May 2010 May 2010

8 Radiography Site HSE Manager + Construction Manager

June 2010 Nov 2010

9 Scaffolding Site HSE Manager July 2010 July 2010

10 Waste Disposal Site HSE Manager Aug 2010 Oct 2010

APPENDICES-VIII

HSE TRAINING MATRIX

APPENDICES-IX

QUALITY INTERNAL AND EXTERNAL AUDIT SCHEDULE

APPENDICES-X

SUMMARY OF PROGRESS

DESCRIPTIONMONTHLY

PLANNEDMONTHLY ACTUAL

CUMULATIVE PLANNED

CUMULATIVE ACTUAL

ENGINEERING 100.00% 100%

PROCUREMENT 100.00% 100%

CONSTRUCTION 0.24% 0.12% 100% 99.58%

OVERALL 0.10% 0.05% 100% 99.85%

APPENDICES-XI

S-CURVE FOR ENGINEERING PROGRESS

APPENDICES-XII

S-CURVE FOR PROCUREMENT PROGRESS

APPENDICES-XIII

S-CURVE FOR CONSTRUCTION PROGRESS

APPENDICES-XIV

S-CURVE FOR OVERALL PROGRESS

APPENDICES-XV

S-CURVE FOR VOWD PROGRESS

APPENDICES-XVI

MANPOWER & EQUIPMENT HISTOGRAM

APPENDICES-XVII

SUBCONTRACT DETAILS

Sl no Description of subcontract Subcontractor

1 Design consultant Mott Macdonald & co LLC

2 Topographical survey AZD land survey LLC

3 Soil investigation Fugro middle east & Partners LLC

4 Lab Technician for soil testing Fugro middle east & Partners LLC

5 Grading and backfilling Sayouh Mahwees Trading and

contracting company LCC

6 Catering Socat universal sodexho

7 Pole hole drilling Ray Oman LLC

8 Block works & slope protection, Cable

trench works

Al Badea National trading & Cont. Est

9 Block works Durat Al – Ghubra trading

10 Pole Hole drilling Powertech Engineering LLC

11 Rock Anchoring and Grouting for tower

foundation

IBN Salim Al Hadi trading

12 NDT Hi Tech Inspections services LLC

13 Back filling works & Cable trench works Harweel International LLC

14 Wadi protection works Al Badea National trading & Cont. Est

15 Reaming works Singh Tool industries India

16 On plot Telecommunication M/s Bhawan projects and telecom

17 Off Plot Telecommunication ORB communications network LLC

18 Excavation and backfilling of tower

foundation

United International LLC

19 Tower Foundation concreting Global Design trading LLC

APPENDICES-XVIII

VARIATION REGISTER

APPENDICES-XIX

OMANISATION REQUIREMENTS

OPAL – CVC certificate submitted to PDO.

All drivers shall be Omani nationals.

APPENDICES-XX

SPIR PROGRESS

SPIR FORMS ATTACHED FOR FOLLOWING

MATERIALS

125 V DC UPS

I P Bus Duct

142 MVA Generator Transformer

14 MVA M V UAT

1.6 MV LV Transformer

2.25 MV LV Transformer

240 V AC UPS

Generator circuit breaker

MAC system

HVAC system

Instrument air compressor

415 V GTP UAS

415 V GTP UAS Sub DB

6.6 KV MVUAS

415 V LVMCC

Emergency Diesel Generator

GTP skids

APPENDICES-XXI

PROGRESS PHOTOGRAPHS