pdoc-596-pep-01 project execution plan(rev 3)

ClientPETRODAR OPERATING

COMPAN Y LIMITED

PMC:

CHINA PETROLEUMENGINEERING &

CONSTRUCTION CORPORATION

DOCUMENT No.: PDOC-596-PEP-01

CONTRACT No: PDOC/23/08-596

Palougue Produced Water Project Phase I

PROJECT EXECUTION PLAN

REVISION RECORD

Rev. No. Submission Date Revision Details Prepared

By Approved By PDOC

A Jan 24 2008 Submitted for approval Caihongwei Gosong

B Apr 19 2008 Submitted for approval Caihongwei Gosong

CONSTRUCTION DEPARTMENT PROCEDURE

MELUT BASIN OIL DEVELOPMENT PROJECT—UPSTREAM FACILITIESPalouge Produced Water project Phase I

DOCUMENT NAME: PROJECT EXECUTION PLAN PROCEDURE NO.: PDOC-596-PEP-01

CONTENTS1. General......................................................................................................................................................1

1.1 Contents of Execution Plan................................................................................................................11.2 Purpose of Execution Plan..................................................................................................................11.3 Objectives of Project..........................................................................................................................11.4 Essentials and Measures.....................................................................................................................2

2. Engineering...............................................................................................................................................42.1 Introduction........................................................................................................................................42.2 Project Mission Statement..................................................................................................................42.3 Staffing...............................................................................................................................................42.4 Engineering........................................................................................................................................62.5 Procurement Support………………………………………………………………………………..82.6 Construction Support........................................................................................................................112.7 Comunication/training Support…………………………………………………………………….13

3. Procurement............................................................................................................................................143.1 Introduction......................................................................................................................................143.2 Organization and Responsibilities....................................................................................................143.3 Purchasing........................................................................................................................................153.4 Requisition and Inquiry....................................................................................................................173.5 Bid Evaluation and Vendor Selection...............................................................................................183.6 Expediting........................................................................................................................................193.7 Inspection & Testing……………………………………………………………………………….193.8 Shipment & Air Freighting………………………………………………………………………..203.9 Inland Transportation........................................................................................................................213.10 Logistic Support………………………………………………………………………………….223.11 Reciept of Material at Site…………………………………………………………………………243.12 Warehouse and Stock Pile Area ………………………………………………………………….253.13 Spare Parts and Consumble……………………………………………………………………….263.14 Tax Exemption Application............................................................................................................273.15 Use of Local Products and Services...............................................................................................273.16 warranty from Manufaturer …………………………………………………………………… 273.17 Material Control.............................................................................................................................283.18 Management of Surplus Materials..................................................................................................29

4. Construction……………………………………………………………………………………………..294.1 General.............................................................................................................................................294.2 Construction Arrangement and Preparatory Work…………………………………………………324.3 Construction Plan.............................................................................................................................354.4 Statement of Labor Management and Industrial Relations...............................................................434.5 Civil works.......................................................................................................................................444.6 16" Main Water Line……………………………………………………………………………….474.7 4000m3 …………………………………………………………………………………………….52

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MELUT BASIN OIL DEVELOPMENT PROJECT—UPSTREAM FACILITIESPalouge Produced Water project Phase I


4.8 6.6KV Water Injection Pump & Diesel Engine Mud Pump……………………………………….554.9 Diesel Engine System………………………………………………………………………………574.10 Electrical Installation…………………………………………………………………………….584.11 Installation of Instrument Equipment…………………………………………………………….644.12 Cable Laying Down & Wiring……………………………………………………………………654.13 Material Handling Storage & Delivery……………………………………………………………664.14 Construction Quality Management………………………………………………………………684.15 Construction Quality Control…………………………………………………………………… 694.16 Construction Quality Assurance Measure………………………………………………………..704.17 Important Quality Control Measurement in Each Discipline…………………………………….724.18 Safety Security Policies in Construction…………………………………………………………744.19 Construction Management………………………………………………………………………..774.13 Camp Living Facilities and Temporary Construction Facilities Layout.........................................78

5. Commissioning........................................................................................................................................825.1 Overview…………………………………………………………………………………………825.2 Pre-Commissioning ………………………………………………………………………………825.3 Commissioning Organization …………………………………………………………………….835.4 Commissioning Responsibility …………………………………………………………………….845.5 Commissioning Plan………………………………………………………………………………..845.6 Commissioning Schedule…………………………………………………………………………855.7 Commissioning Procedure Development………………………………………………………….855.8 Provisional Acceptance ……………………………………………………………………………865.9 Performance Testing………………………………………………………………………………875.10 Line of Communication ……………………………………………………………………………875.11 Owner Involvement…………………………………………………………………………………875.12 Hand Over………………………………………………………………………………………….87 Appendix: Project schedule (P3) Project Organization Chart Progress Measurement Chart with weight ages S-Curves

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MELUT BASIN OIL DEVELOPMENT PROJECT:-- UPSTREAM FACILITIESPalouge Produced Water Project Phase I


1. General

1.1 Contents of Execution Plan

In accordance with the instructions given in CONTRACT, CPECC has prepared the Project

Execution Plan which covers whole Scope of Work, all phases and aspects related to

Project execution. The description of the plan is provided in the subsections entitled as

follows: EngineeringProcurementConstructionCommissioningThis plan provides sufficient detail to ensure Owner that CPECC has the full knowledge of

the Scope of Work and is capable of performing the Work in accordance with the

requirements of CONTRACT.

1.2 Purpose of Execution Plan

This plan is formulated to present the strategic principles and concrete approaches for

execution of the Project, leading the Project activities to proceed well organized and

scheduled way, and in a safe and efficient manner to realize good performance in all phases

in terms of schedule and quality, so as to ensure the final success of this Project.Based on the actual situation, achievements, status of engineering and procurement,

availability of material, manpower and equipment, and other conditions, this plan will

subject to revision from time to time throughout the Project execution to maintain

continuous improvement and synchronize with the actual progress of the Project.

1.3 Objectives of Project

CPECC will make every endeavor to achieve the following major objectives of this Project: To ascertain and confirm the adequacy of specification and design information

included in the LOA and Contract documents. Commission 2 sets of water injection pumps and 4 sets of mud pumps .and to achieve

the Sectional Mechanical Completion of two(2) mud pumps within five (5)months

from the Contract Effective Date.

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To provide and commission all equipment and facilities that will meet the functional

requirements as envisaged in the CONTRACT. To warrant that CPECC has fully performed the Scope of WORK as stipulated in the

CONTRACT.

1.4 Essentials and Measures

1.4.1 Early Preparation and Fast MobilizationCPECC will plan the formation of project management team and construction team,

deployment of construction equipment and materials, and get information regarding the

possibility and availability for fast mobilization of the humane and material resources as

required by project execution. The manpower mobilization shall be performed in a progressive manner in accordance with

Project execution plan and schedule. The key personnel responsible for different functions

will be immediately take the office, and the involved individual discipline personnel shall

be mobilized as required prior to actual start of their respectively responsible activities.With careful planning, CPECC will ascertain the deployment of construction equipment,

rectify any deficiency and maintain them in good condition to be ready for operation prior

to commencement of construction activities. 1.4.2 Timely Performance of Engineering Design

Through the experience in previous project execution, CPECC has realized that timely

performance of engineering design is most critical to provide the indispensable condition

for procurement and construction activities to be possibly performed on schedule.

Therefore, the engineering group will immediately start the engineering performance in a

professional and efficient manner. Engineering group shall verify and update the information already supplied by the Owner

to ascertain its adequacy, update and perform any investigation if necessary, and also verify

and confirm all the Basic Design documents received from the Owner and incorporate any

changes as required to complete the Work. In order to make the engineering activities go smoothly and avoid the repetition of design

jobs, and to ensure the timely submission and approval of engineering documents, a good

coordination channel between the Contractor and Owner will be effectively established and

maintained throughout the whole engineering phase. To ensure the difficulties in civil work construction created by rainy season is reduced to

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the maximum extent, CPECC will try the best to issue as early as possible the construction

drawing for civil work, especially for those activities difficult to perform in wet condition. CPECC understand piling drawing is critical to achieve two mud pump first operation

within 5 months. CPECC will also give the prioritized consideration to the issuance of

relevant engineering documents for expeditious procurement of long lead items.1.4.3 Expeditious Procurement Activities

The timely delivery to site of Project equipment and materials is the basic condition for

ensuring the completion of construction activities on schedule. Therefore, the procurement

group shall maintain efficient performance in procurement activities, for which close

contact and collaboration with engineering group is necessary.The procurement activities shall be planned around the overall Project phases so that timely

availability of materials for critical paths can be guaranteed. The long delivery, critical

items will be ordered on priority basis to meet their delivery at site as per Project schedule.1.4.4 Quality and Safety

“Quality Fundamental” and “Safety First” shall be always kept in the mind of everybody of

CPECC throughout the Project execution.Along with the effective operation of a certified Quality System, CPECC shall stick to

observation and implementation of all the standards, codes and specifications as required

by the Contract and no quality compromise is allowed. All the activities in different phases

shall be performed and completed in accordance with the approved procedures, and shall be

subject to supervision and quality inspection by CPECC’s quality inspectors and PDOC’s

representatives. Any non-compliance as found must be rectified.CPECC will attach as well great importance to safety all the time to provide a safe

environment to CPECC employees, visitors, Owner’s and subcontractor’s personnel and

minimize the losses caused by unsafe acts, conditions or omissions. All the applicable

safety regulations are mandatory and personnel at all level of CPECC management shall be

held accountable for their safety responsibilities. All CPECC individual employees will be

trained and encouraged to understand and promote the safety standards all the time and to

cooperate with the company safety program in every aspect to ensure the Project is

executed safely and smoothly.

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2. Engineering

2.1 Introduction

CPECC, as a Main Contractor, will provide the “single source” responsibility for all aspects

of the project execution, which involves overall project management, engineering,

procurement, construction, site coordination, quality assurance/quality control, HSE,

project controls, training, commissioning and reporting.China Petroleum Engineering Co., Ltd (CPE), as an Engineering Subcontractor to CPECC,

will provide all services as may be required for smooth execution of this Project, mainly as

engineering design, procurement assistance, construction support as well as training and

commissioning instructions. CPECC will appoint a responsible person and some major

discipline engineers taking the function of supervision of engineering work and

coordination between the Engineering Subcontractor, CPECC and the Owner for the

purpose of ensuring all the engineering activities to be performed in conformity with the

requirements of the Contract and to timely satisfy the needs by procurement, construction

and commissioning, so as to achieve the final success of this Project in terms of quality and

schedule.

2.2 Project Mission Statement

To assist the main contractor, CPECC, as required to ensure the successful execution of this

project, complete the project within the budget and schedule constraints laid out in the

Contract, and to achieve a quality that meets or exceeds the requirements for accuracy and

presentation of Client.

2.3 Staffing

2.3.1 PDOC & CPECC StaffingPDOC staffing will compose of the following: Project Manager Project Team Leader Project CoordinatorThe personnel who will be assigned to the above posts will be introduced during Kick-Off

Meeting. However, PDOC will appoint a CTS representative to be responsible for the

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Project Management role for this project who is the approving body for all the issued for

approval documents/drawings required on this project. CPECC as the main contractor who will be responsible for the Engineering, Procurement,

Construction and Commissioning (EPCC) of this project will directly communicate with

CTS (PDOC). CPE will be reporting to CPECC for all engineering matter of this project.

2.3.2 CPECC OfficeCPECC/CPE’s proposed Engineering Office for the execution of this project is the office in

Khartoum, Sudan.

2.3.3 CPE’s ResponsibilitiesCPE, as the Engineering Sub-contractor of CPECC, is overall responsible for the correct

and timely execution of the engineering work scope. CPE will undertake the following activities: Detailed Engineering Project Controls on Engineering Work including planning & controls, and reporting Support on Procurement Services such as preparation of MTO’s and Technical

Evaluation of vendor proposal. Technical Assistance during construction and commissioning activities Prepare as-built documentation and project dossier Co-ordination with CPECC

2.3.4 OrganizationProject Organization Chart will be submitted to CPECC showing the Key Personnel and

Management Level. The following Key Positions serve in the Roles as described and are

accountable for the Responsibilities as briefly outlined below:

Project ManagerAccountable to CPECC and CPE Management, for the overall successful execution of the Project.Ensures that all Engineering services are provided in accordance with the Project Schedule.Assist CPECC in the execution of the Overall Project Plan.Provide engineering representation to the Owner as requested by CPECC.Report to CPECC Team LeaderFocal point for all correspondence for the Engineering Services.

Project EngineerResponsible for assisting the Project Manager in executing the overall Project. He is responsible for the technical work under their review.Directs daily activities of the project team.Responsible for meeting engineering productivity objectives

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Responsible for overseeing engineering and design and coordinating inter-disciplinary work.Responsible for the development and implementation of project procedures and the project quality plan.Responsible for coordinating document control.Responsible for auditing quality system.

Project Control Engineer

Responsible to ensure conformance with budget and schedule goals.Assist project management in identifying variances, formulating recovery plans, revising and updating schedules, processing change orders and preparing cost and hour reports and forecastsWill provide all the reporting requirements as referenced in Project Reporting.

QA / QC Representative

Not directly involved in Project Execution. Responsible for checking, verifying and validating the design in accordance with the Quality Assurance Plan included in CPE’s Quality Procedures

The above personnel are identified on the Organization Chart with extensive work

experience and to be approved by CPECC.

2.4 Engineering

2.4.1 Front End engineering & Design (Feed ) Verification

The engineering team recognizes the value of providing a quality product , and confirms

that the technical document include the specification and drawings provided by PDOC .Feed verification covers all disciplines, including electrical, civil/structure tank and CP etc.

During this stage the output of engineering activities can be summarized as follows:Plot plan & tank equipment Lay outsPFD’s &P & I D’sPiping GAD’s and isometricsLine routing PlanPiling lay out PlanSubstation HousingTank installation Structure steel Area Classification DrawingTank CP systemLoad list MCC single line diagramTransformer6.6 KV switchgear and soft start

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Instrument location PlanCable schedule

2.4.2 Site SurveyThe Site Survey will include the following details: Site description details Accompany CPECC’s sub-contractor for Geo-technical & topographical survey

selecting route

2.4.3 Coordination ProcedureContractual correspondence shall be between CPECC/PDOC’s projects manager, such

letters shall be through faxes or hand-delivered; CPE shall prepare Minutes of meetings

with CPECC or PDOC and release. Any comments shall be recorded in the following

meeting minutes; Significant telephone conversations shall similarly be confirmed in

writing; All correspondence will deal with a single subject, be dated, assigned a unique

identification number, logged and become part of the project records.Site Instructions shall be confirmed in writing, using a numbered site instruction, signed by

CPECC and CPE.Progress Reports for Engineering Works will be prepared by CPE and submitted to CPECC

in a weekly basis. On the last week of the month a comprehensive Monthly Report will be

prepared by CPE; A separate Monthly Report with man-hours spent information will be

prepared for CPE internal use.The Project Plan will be defined by a comprehensive schedule. Performance will be

evaluated and compared with the plan as part of the regular reporting progress.CPE shall obtain all required passes and permits from the appropriate authorities. Site visit

and all work requiring a Site Work Permit will be coordinated with CPECC with adequate

advance planning so as not to incur delays. No work will be undertaken without the

required permits.In the event that instruction received by CPECC may lead to a Change in the Scope or the

Schedule of the Project, the concerned Discipline Engineer shall initiate a Change Order

Notification to identify the impact. The Change Order Notification will describe the source

and nature of the deviation from the scope of work or schedule and provide an estimate of

the cost of the deviation; The Project Manager shall review the Change Order Notification

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and review against CPE’s obligations and requirements in the Agreement. The Project

Manager will decide whatever a Change Order Proposal needs to be submitted to CPECC;

The Change Order will not be implemented unless approved by the CPECC in the form of

Agreement amendment.

.2.4.4 Vendor Data SubmittalsVendor drawings and data are reviewed for conformance with Material Requisition

specifications, annotated with comments, stamped and signed and returned to the vendor in

a timely manner. All Vendor deliverables shall be subject to Vendor Squad Check as

follows: DCC prepares the Vendor Squad Check Form and informs through email the Lead

Discipline Engineers concerned. Each Engineer shall properly review and mark-up the documentation indicating the

required action in the Vendor Squad Check Form. DCC will provide for the distribution of the revised Squad Check Documentation to

Vendor, CPECC and Project File. Vendor Data of main equipments shall be submitted to PDOC for review.2.4.5 Technical Bid EvaluationsTechnical proposals submitted by manufacturers, fabricators, vendors and suppliers are

evaluated on technical merit. The emphasis of these evaluations is on thoroughness and

completeness, ensuring that all issues are resolved before a commitment to purchase is

made, or a contract is awarded. Engineering reviews and compares the bids and makes a

recommendation for purchase and award. As specified in Procurement Procedure, a

technical bid tabulation spreadsheet is prepared comparing the bids.

2.5 Procurement Support

Procurement will initially run parallel to Detailed Engineering and Design in order to allow

review of vendors’ drawings and inclusion/modifications to construction drawings.

Procurement and expediting activities as listed below will be the responsibility of CPE’s

Procurement Engineer. Preparation of Material Requisition (MR) documentation. Issue Material Take Offs, MR’s to CPECC. Maintain/update RFQ log form. Obtain quotations from PDOC’s approved vendors. Evaluate vendor’s technical quotations.

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Issue Technical Evaluation Report (TER) to CPECC. Expedite/follow-up final vendor documents/drawings. Maintain/update Vendor Documentation Status Log.

2.5.1 Code of EthicsThe conduct of engineers engaged in procurement services is critical to the reputation and

long-term success of CPE. Thus, it is essential that employees strictly adhere to, and

comply with General Professional Ethics, and to the following specific requirements: Consider first the Client’s reasonable interest and second CPE interest in all

Procurement activities. Buy without prejudice, seeking to obtain the maximum, ultimate value for each dollar

of expenditure. Follow practical and cost-effective methods for conducting procurement services. Subscribe to, and work for, honesty in buying and selling, and denounce all forms of

bribery; do not accept gifts or hospitality other than minor items of promotional value. Strive constantly to acquire up-to-date knowledge with regard to Vendor’s materials,

manufacturing processes, and available services. Accord prompt and courteous reception to all those, who come on a legitimate

business mission. Respect the confidentiality of supplier’s, and vendor’s quotations and technical

information.

2.5.2 Material RequisitionFor all project requirements of materials, equipment and services, there must be a Material

Requisition (MR) with reference number in each equipment and materials per discipline.

Although in each discipline the responsible person may originate the request, the Project

Engineer and Project Manager must approve it, after he has ascertained the actual necessity

based on the Procurement Plan.The relevant Discipline Engineer will prepare the scope of work, data sheet, vendor data

requirement form, recommended accessories (spares) form, field service rate table for

commissioning and provision for training, source inspection plan, inspection levels,

technical specification and necessary drawings to be included in the MR. The Technical Bid

Evaluation Spread Sheet Form has been prepared by the discipline engineer to indicate all

main characteristics upon which the technical evaluation should be based such as per the

client requirements. The MR assembled as above shall be address by Document Controller and sent to CPECC

Project Manager for further obtaining technical and commercial bids from various vendors

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included in the PDOC Approved Vendors List.The Procurement shall maintain and regularly update the RFQ Log by recording all MR’s

and TER’s issued and their status. Relevant questions from the suppliers and/or updates to

the MR will be included and transmitted to CPECC for onward transmission to the

involved suppliers.All relevant data, i.e. technical specification, related documents and drawings etc., received

from the vendors will be tabulated in the Technical Bid Evaluation Spread Sheet Form by

the relevant Discipline Engineer.The final TER which contains the technically acceptable vendors will be submitted to

CPECC. CPECC is responsible to decide to whom to award the order based on the final

TER and commercial evaluation done by CPECC.

2.5.3 Third Party Inspection Coordination for Critical ItemsCPE will propose to CPECC / PDOC a list of critical items requiring Third Party

Inspection. A reputed Inspection Agency who will carry out all inspection services will be

recommended to CPECC for their approval. If required, CPE procurement engineer is responsible for the coordination between

manufacturer and inspector to ensure that the proper QA/QC supporting documentation is

accompanying the materials being delivered.

2.5.4 Final Vendor DocumentationVendor documentation is required to confirm design and manufacturing to satisfy the

requirements of the purchase order, provide the engineering and design data to integrate the

goods into the remainder of the facilities provide the client with information to operate and

maintain the equipment and create the data files of the equipment and materials.CPE lead engineer is responsible to define the requirement of vendor documentation on the

Vendor Data Requirement Form (VDRF). This shall define the item/types/quantities of data

to be provided by the Vendor. CPECC is responsible to follow up the required data to

vendors.

2.6 Construction Support

2.6.1 GeneralConstruction activities will be carried out by CPECC. CPE will provide the required

support relative to engineering/construction interfaces.

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The Engineering Procedure addressing Engineering and Construction Interface shall be

produced. It will cover follows as a minimum: Issuance and administration of Field Change Instruction (FCI) for amendment of or

additions to engineering drawings and associated design documents such as Correction of errors and additions to the Issued for Construction (IFC) drawings; PDOC or CPECC design change request during construction.

Preparation of As-Built Drawings. Initiation and administration of and response to technically related queries from the

field. It serves as a coordination point for all pertinent data relating to construction. It

provides an easy reference and an accurate information transfer mode for all members of the project management team.

Throughout the course of project, CPE will closely monitor the progress of the engineering

works and will inform CPECC to continuously plan, monitor and control all construction

activities to ensure successful completion of the project in accordance with all approved

drawings, specifications, standards, schedules and project goals.

2.6.2 Engineering and Construction InterfaceCPE will prepare and issue engineering design documents to CPECC for PDOC

constructability review and approval.PDOC or CPECC will provide all mark-ups of documents that require to be as-built. This

information will be obtained from the start up. CPE will do all back drafting to update the

related drawings up to as built status based on the approved red line mark-up drawings.CPE will provide material take-offs and requisitions as per construction requirements.CPE Project Manager shall be responsible for coordination of jobsite activities with

CPECC Site Manager and PDOC.

2.6.3 Field Change Instruction (FCI)ResponsibilityFCI’s shall be issued by CPECC’s Construction Manager and or CPE Project Manager.

CPECC Construction Manager or his designate shall sign all FCI’s. CPE document controller will log all FCI’s and distribute to obtain the necessary approvals.

Approval of home office generated FCI’s will be by CPE Project Manager or his designate.

These documents will carry an identification number for reference purposes.The amendment or addition defined in an approved FCI shall be executed by CPECC

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construction staff.PROCEDUREAll reference is to be made to the latest, approved for construction drawings. Reference to

the latest drawing index. No other revision to IFC drawings or documents will be made unless directed by CPECC

or PDOC.All approved FCI’s will be incorporated in the “As-Built” drawings at the completion of

construction. FCI’s shall be employed to add or to amend IFC drawings or design. The FCI

shall then be attached to the master copy of the related drawings and incorporated in the

“As-Built”. FCI’s shall be employed to execute changes to IFC engineering drawings or design

documents that are necessitated by: Vendor data received after the IFC drawing cut-off date. PDOC directions issued in the field. Design errors or omissions.The details of the design change shall be entered on the attached FCI form by CPE engineer

and or CPECC field engineer. Any necessary design sketches shall be prepared and

attached to FCI form and shall be referenced on the form. This should be marked with the

FCI reference number. FCI’s logs will be maintained by CPECC site coordinator. If

additional materials are required for the approved changes, a referenced bill of materials

will accompany the FCI.2.6.4 Field Queries

It is intended to ensure that all queries are initiated, identified, logged and responded to in a

timely and effective manner.Either the CPECC field technical staff or CPE site representative during commissioning

period will raise the technical query.CPE Project Engineer will be responsible for identifying the Field Query, assigning the

work and ensuring completion. CPE Project Secretary will be responsible for maintaining

an up-to-date Field Queries log and hard copy. The appropriate disciplines will be

responsible for providing technical content of the reply.The recipient of the response in the field (CPECC Site Manager or CPE site representative)

shall ensure that the response is distributed to all appropriate parties.2.6.5 Prepare As-Built

Following the complete construction of Project, all relevant drawings and associated

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documents shall be updated to represent the actual installation.CPECC as a main construction contractor is responsible for the mark-up (by hand) of the

drawings. All drawing mark-ups are to be completed in English. As-built mark-ups shall be

produced to reflect any modifications during construction or changes due to operations

requirements. Red Color mark-up corresponds to identify the additions and corrected

information. Blue Color mark-up corresponds to identify the deletions. Black Color to

identify the additional notes and comments to clarify information. These notes are for

reference only and are not to be incorporated in the final As-built. This should be verified

and signed by PDOC. CPE will revise all IFC drawings based on the field records/changes, approved mark-up

drawings and re-issue all drawings “As-Built” upon completion of the project as per

contract agreement. The accuracy of the final as-built drawing will be dependant on the

quality of redline mark-ups.The “As-Built” drawings shall be issued as per CONTRACT requirement.

2.7 Communication / Training Support

Under the intended Contract for this Project, CPE are providing Detailed Engineering

Design and Procurement / Commissioning support services only. Therefore, responsibility

for pre-commissioning, commissioning, start-up and handover for the facilities lies with

CPECC.For CPE’s hand over scope shall be considered the point when Project Dossiers and

Manuals are forwarded to CPECC, with only commissioning support and as-built activities

remaining.Pre-commissioning, commissioning and start-up support shall take the form of: Response to field inquiries on an as needed basis; Site visits and training / technical assistance by CPE and/or Vendor representatives as

required.As-built shall be completed once approved marked up (red line) drawings have been

received from CPECC.

3. Procurement

3.1 Introduction

The procurement plan is figured out to guide the procurement work to be performed by

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CPECC to ensure that all material and equipment necessary to complete this project will be

procured in conformity to the requirements by CONTRACT in terms of quality and

schedule.Procurement activities shall be planned around the overall project schedule to ensure timely

availability of materials as required by construction. CPECC shall prepare a Bill of

Materials and establish a procurement schedule. This schedule shall include appropriate full

duration for the Owner approval cycle for procurement documents.After bid are awarded, CPECC shall prepare procurement procedures and submit to the

Owner for approval. The procedures shall detail all aspects of procurement as required by

the Scope of Work, including preparation of Request for Quotation or Proposal, proposed

manufacturers list, evaluation of quotations/proposals, Owner review/audit, placement of

purchase order or contract, expediting, third party inspection, marshalling/storage,

importation and transportation to Site.

3.2 Organization and Responsibilities

After contract award, a Procurement Department will be duly formed same as other

functional departments for execution of the project. A procurement manager will be

responsible overall procurement management. Under the manager are buyers, expeditors

and engineers at different posts working on various procurement related activities.The Procurement Department shall take the functions and duties mainly at the following

aspects: Purchasing Expediting Inspection and testing Shipment and freight forwarding Tax exemption for imported materials and equipment Customs clearance Storage Spare parts and consumables preparation Material control and tracking

The Procurement Department shall be wholly responsible for fulfillment of Contractor’s

duties and obligations stipulated in the Contract with regard to procurement, particularly as

follows:

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To procure all equipment, material, transportation, freight forwarding, custom

brokerages, labor, subcontracts, supplies and services required for the Work, except the

items supplied by the Owner. To prepare bid requests, bid evaluations, requisitions and purchase orders in all

disciplines, and review, revise and accept vendor data in all disciplines and meanwhile

with the Owner review and acceptance. Requisitions, TBE and un-priced P.O.’s that

has been accepted by vendors for the critical and long lead items will be submitted,

within 45 days after contract effective date., to Owner for review and approval. To obtain the Owner acceptance of suppliers prior to issuance of Request for Quotation

for items supplied by the Contractor, including any changes or substitutions. In order to maintain the efficient performance of procurement activities, Procurement

Department will work alongside with Engineering Department/Engineering Subcontractor.

This effort will improve in the project schedule and allow timely resolution of all technical

and commercial concerns with the vendors. Procurement Department will also closely collaborate with Project Control Department to

well know the overall progress of project and needs by construction team on availability of

materials and equipment to be installed or commissioned.In addition, Procurement Department shall establish an effective communication channel

with the Owner’s department concerned for smooth liaison with the Owner, so as to timely

obtain the comments and approvals from the Owner regarding the procurement activities.CPECC shall endeavor to maximize the Sudanese content of its supply providing that

goods, services and personnel can be obtained on equally advantageous conditions without

compromising safety, quality and the suitability of the purpose for which the goods,

services and personnel are intended.

3.3 Purchasing

Main equipment as diesel engine MUD PUMP and 6.6 Water Injection PUMP,

Transformer (supply power to 6.6 KV Water Injection PUMP) , Water Draw OFF, 16’’ main

water line are purchased by PDOC .CPECC shall only be responsible for the following

purchasing of these small items as indicate in the table as per Contract requirements.

S/No. Equipment Description Quantity

1. 33KV/400KV Transformer 1set

2. MCC 1set

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S/No. Equipment Description Quantity

3. Tank Plate 1 batch

4. Tank CP Material 1batch

5. Steel structure 1batch

6. Small pipe and total fittings 1batch

7. Housing material 1batch

8. Instrument 1batch

9. Cable and bulk material 1 batch

10.

Purchase of equipment and materials as per the Owner Approved Manufacturers List

(AML) and in accordance with the Project schedule requirements. Processing of requisitions from Engineering, the inquiry and P.O. requisition shall include

all the techno-commercial requirements related with the items being procured, spares,

inspection and testing, documentation in line with the Contract; Prepare inquiry status report, purchase order status report and procurement expediting

report and update the same and issue on a monthly basis; Preparing purchase orders with purchase specifications complete with all attachments and

applicable inspection, testing and documentation requirements, spare parts requirements,

vendor’s field assistance requirements and the Owner’s specified requirements for

procurement related activities as applicable; Together with Engineering, review vendor’s drawings/documents for conformance to

project specifications, applicable standards, codes, the Owner’s requirements, etc.; Ensure adequate inspection, verification of material & test certificates are performed and

release note is issued prior to packing and dispatch from vendors’ works as applicable; Carry out Factory Acceptance Tests (FAT) for critical items if necessary and applicable.

3.4 Requisition and Inquiry

Procurement Department will collaborate closely with Engineering to assure timely issuance

of requisitions to meet the project schedule. Procurement coordinators will be assigned for

the purpose of maintaining a close attach with Engineering and Project Control. Generally,

long lead items will be engineered first in the design effort. So far as possible, requisitions

will be issued accompanied by complete drawings and specifications. However, orders may

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be placed prior to the completion of design for long lead bulk materials. Initial bulk

material orders may, therefore, represent a portion of the ultimate order quantity for earlier

delivery with balance amounts to be defined and delivered later on.Approved Manufacturers ListPurchasing inquiry will be prepared and issued in accordance with the material and

equipment requisition provided by Engineering. The vendors/manufacturers to be invited to

bid will be selected from AML. CPECC has noted the Owner requires that only equipment

or material vendors listed on AML is to be purchased by the Contractor, subject to the

following clarification:⑴ Use of equipment models with less than 5 years proven record, even listed on the AML,

shall be subject to the prior acceptance of the Owner.⑵ In the event that CPECC is unable to purchase in accordance with the AML due to: The required equipment or material is not listed in any of the AML categories, or Inability of any listed AML manufacturer to supply in accordance with specification and

data sheets.CPECC will propose to the Owner, in writing, an optional item, vendor or manufacturer

specification for approval, which shall be considered on a case-by-case basis by the Owner,

and shall secure the Owner written approval to the proposal prior to proceeding with

purchase. The requisitions and documentation of selected vendor for the critical path

equipment/material purchase orders will be submitted to Owner for review and approval.

Such critical P.O.’s shall be identified by Owner in first five weeks of the project.Inquiry will be international tendering except local procured materials. All quotations will

be by sealed bids. Quotation by fax will be only applicable to the small value inquiry.Inquiry sent to bidders will be complete with all technical and commercial requirements,

including instruction to bidder, terms and conditions, site service agreement, and shipping

and marking instruction to vendor, engineering requisition with detail description of scope

of work, spares, inspection and testing, drawings, statutory approvals as applicable and

relative specifications, etc.

3.5 Bid Evaluation and Vendor Selection

CPECC shall procure all equipment and materials in accordance with the Contract

specifications and Contractor supplied and Owner accepted data sheets. CPECC shall

submit Technical Bid Evaluation Report of the proposed vendor for Owner review.

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The technical bid evaluation shall contain the following information: Evaluation of minimum three vendors offers. Complete description of items with specifications or applicable data. All deviations and exceptions from the Contract requirements shall be clearly

highlighted. Justification of the Contractor’s recommendation of the proposed supplier. Recommended spare parts. Requirement of the vendor representative for testing and pre-commissioning.

Separate technical and commercial evaluation on bids will be made to ensure the materials

and equipment to be purchased satisfying the specifications and offered with competitive

price as well. The sealed bids received from vendors will be opened under presence of two

procurement staff. The procurement manager or deputy manager will be present in such

opening. The evaluation at least for three vendor offers will be secured.The technical evaluation will consider such aspects as standardizing, technical capabilities

of equipment and materials offered, cost of operation, flexibility and ease of operation, cost

and ease of maintenance, service factor, interchange ability and spare parts availability.After evaluation and comparison of the bids, the optimum one, viewed from both technical

wise and commercial wise, shall be accepted for contract award. Award to the lowest priced

bid shall be subjected to the technical acceptability of the bid.CPECC will prepare a Requisition Status Report and a Purchase Order Status Report which

shall include the information as detailed in CONTRACT. CPECC shall update these reports

weekly and shall submit them to the Owner.In addition, CPECC shall prepare a Vendor Information List (VIL) which shall include the

data as required in CONTRACT, and shall be updated and issued to the Owner monthly.

3.6 Expediting

CPECC shall undertake all expediting necessary to achieve or improve the required

delivery dates while maintaining the purchase order design specification and conditions.

Any actual or potential deviation or slippage from these requirements shall be immediately

informed to the Owner.CPECC will prepare and submit expediting procedure for the Owner's review and approval.

The expediting work will be carried out in accordance with the approved procedure. CPECC shall perform expediting of equipment, materials, vendors and manufacturer’s

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data, manufacturer’s technical assistance from bid invitation to delivery to Site for vendor

and manufacturer’s items including the materials on suborders.CPECC shall similarly expedite all replacement materials and associated documents, which

are the subject of guarantee or insurance claims. Such expediting shall be performed, as

necessary, for the duration of the Contract.Compliance with delivery schedules will be enhanced by assignment of desk expediters,

field expediters and/or by intervention of management as necessary. The expediters will

send and receive expediting information by means of telephone, fax, e-mail or letter. The

regular expediting actions and/or visits shall be performed to ensure the purchase order

commitments are being met. More frequent expediting actions and/or visits will be

arranged, if the order execution is lagging behind the schedule and is likely to affect the

delivery and overall Project schedule. In order to meet the project schedule, CPECC will take appropriate remedial action with

vendors and suppliers in case they are behind schedule. CPECC will promptly recommend

appropriate alternative remedial action to the Owner and implement the same.Regular status reports will be issued highlighting problems, concerns and corrective actions

taken.

3.7 Inspection and Testing

CPECC shall be responsible for inspection of equipment and materials, and will engage a

reputable third party inspection company acceptable to the Owner to perform inspection of

major equipment and materials procured by CPECC. CPECC shall submit to the Owner for approval a proposed list of equipment and materials

subject to third party inspection. CPECC shall also submit to the Owner for approval an

Inspection and Test Plan which shall identify all witness and hold points as required during

manufacture, assembly, testing and final inspection. To facilitate the Owner’s planning,

CPECC shall issue to Owner a monthly look-ahead for all inspection visits. In addition,

CPECC shall send to the Owner 5 working days in advance a written notice for inspection

visit in Sudan and 10 working days in advance a written notice for inspection visit outside

Sudan. Upon completion of inspection of material or equipment and/or review of the

Manufacturing Data Records, CPECC inspectors shall fill out an Inspection Release

Certificate indicating that it has been fully inspected. The Inspection Release Certificate

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shall be signed by CPECC inspectors. CPECC shall maintain a status log to be issued to

Owner for all Inspection Notice, Inspection Report and Inspection Release Certificate

issued on each Purchase Order.

3.8 Shipment and Air Freighting

CPECC will be responsible for approving the release of completed goods for shipment after

satisfactory completion of final inspections and will execute forwarding activities for all

equipment/material. CPECC shall ensure that the methods of transportation and packing used are suitable for

the type of material and comply with environmental requirements. Packing shall take into

account the type of rough handling which may occur during operations such as loading on

or off ships, and shall be designed to prevent damage to the materials.CPECC shall inform Owner every week with advance information on the arrival of

shipments and the nature of the material in every shipment. CPECC shall provide

information to Owner with 30 days notice on packing, handling, route survey and transport

of material involving special heavy lift and oversized cargo prior to shipment.CPECC shall provide insurance for transportation in accordance with the Contract. CPECC

shall employ a registered forwarding agent at each entry point into the Republic of Sudan.

CPECC shall liaise closely with Sudan Port authorities and airport authorities and shall

agree on detailed procedures with them.CPECC shall be responsible for air-freighting of materials and equipment in the event this

mode of transportation becomes necessary in order to meet the Project schedule

requirements as set forth in the Contract or as it may have been changed in accordance with

the Contract.

3.9 Inland Transportation

CPECC has acquired many successful transportation experiences from previous projects in

Sudan. CPECC is fully aware of the difficulty of inland transportation in Sudan. In order to

provide the better transportation service for this project, a full investigation on Sudan’s

custom requirements and inland transportation condition will be made by CPECC at the

project outset. This will be essential for future traffic management and performance

because Sudan has a long rainy season and the Site is located remotely from traffic centers. Cargoes arrived from overseas locations to Port of Sudan / Khartoum Airport need to go

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through some regulatory and customs formalities. A local broker entrusted by CPECC will

handle, under instruction and supervision by CPECC responsible person on the following

issues: Define the time limit for inland forwarder. Receive and review the shipping documents in advance of cargo arrival. Apply Owner’s approval for tax exemption. Pre-notice ETA of concerned cargo and follow-up the updated ETA from local shipping

agent and make notification accordingly. Prepare all required customs forms and complete the customs formalities within 3

days. In emergency of shortage of original B/L, co-ordinate with shipping co. to get telex

release of concerned cargo. Co-ordinate with the Port Authority and the local carrier for loading and delivering the

cargo to the site. If any damage or loss or short landing happened prior to our acceptance of cargo, make

it clear which side should be responsible and arrange insurance survey in time and

obtain the short landing and/or discrepancy certificate from shipping agent/port

authorities. Notify the CPECC Logistic Coordinator of any problems or discrepancies associated

with the import shipment. Transfer the import certificate of concerned cargo and other custom documents to

consignee.

To guarantee the on-time and safe delivery, a qualified and experienced local forwarder

shall be selected through bidding evaluation, and the following requirements shall be

fulfilled: Try to arrange all shipping cargo to be transported by direct way upon the vessel

arrival of Port Sudan. For heavy or oversize cargo, after review with Owner, CPECC Logistic Coordinator

will make a use of handling facilities of port and arrange the direct transportation with

inland carrier. Such deliveries of special cargo are usually as a part of a master plan in

which all phases of transportation from the factory in origin to the jobsite are closely

intertwined. A wireless communication and tracing system must be established for follow up the

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current status of on-way cargo. A delivery time limit must be imposed upon inland forwarder. During rainy season some urgent cargo, if possible, will be delivered by air from Port

Sudan/Khartoum Airport direct to jobsite. For sensitive and expensive cargo, prior to loading and off-loading, an expert of this

field must be present.The CPECC Logistic Coordinator will issue regular reports concerning local customs

maters and port matters. The international freight forwarder (having a local office) may also be utilized to

coordinate these activities.

3.10 Logistic Support

The logistic office set up at Port Sudan, Khartoum and worksite will be responsible for all

traffic, local purchasing & warehousing operations. All controls and procedures will be

updated periodically to ensure management and control is maintained to meet job

requirements. Local procurement will work closely with the Project Manager and

Engineering group to ensure adequate support to the Project.Logistic offices will perform the following as minimum functions: Prepare qualified bidders list of local companies for provision of equipment, materials,

supplies and services. Purchase all necessary material required for support of construction including the items

listed above but not limited to. Responsible for expediting and inspection, coordination of all local purchases and

material shipments, including expediting materials that may be purchased from local

vendors. Responsible for coordinating all customs clearance work between CPECC and the

freight forwarder for all project related materials and equipment and the import

documentation required for the same. Responsible for routing and tracing all local purchases and material shipments. Responsible for receipt of all Project materials, including issuance of material

receiving reports, UOS&D reports as may be required. Responsible for filing insurance damage claims and coordinating resolution of

UOS&D reports.

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Responsible for the control and operation of the warehouse group and the maintenance

of equipment while in storage and the issuance and disbursement of all Project related

equipment, materials and supplies.

CustomsCustoms clearances for all procured Project materials shall be processed through a local

customs broker entrusted by CPECC. TrafficThe local traffic group shall be responsible for the following: Monitor all shipments scheduled to arrive at local sea ports and airports to ensure the

necessary Customs documentation (commercial invoices, packing lists, ocean bills of

lading, certificates of origin, insurance certificates, etc.) to be available prior to the

arrival of the cargo. Work closely with the Project customs broker personnel to ensure proper classification

of materials as to import category and tariff heading, and assist with the translation of

documents by providing technical definitions. Maintain logs of inbound cargo shipments, assign control numbers for all documents,

packages and posting each step of the processing through final clearance and dispatch,

expedite the Project customs broker’s personnel as may be necessary, to ensure the

expeditious release of all Project cargo and materials. Ensure the expeditious handling, customs clearance and movement of

personal/household effects for all employees, including family and single status

personnel. Liaison with local purchasing to route and trace locally procured materials. Coordinate with the contracted trucker(s) including the maintenance, incoming freight

logs, both ocean and air, dispatch logs, preparation of shipping notices, load

inspections, tracing and processing of freight claims. Obtain gate passes from Owner for all material and equipment deliveries. Prepare and distribute of ocean and air cargo reports, also daily shipping reports to

other local procurement groups, construction group, engineering group or other

disciplines as required. Coordinate insurance claims with Owner’s insurance company. Ensure Owner receives advance notification of all heavy and oversized equipment.

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Material Receiving and WarehousingThis group shall be responsible for the following: Coordinate with the local buyers/expediters and the personnel in charge for traffic and

customs affairs to receive and disburse all Project procured materials and supplies. Supervise a warehouse that may be deemed necessary to receive and store Project

procured materials. Verify received cargo, check the quantities against bills of lading, freight bills, airway

bills, including inspection of cargo for any visible in-transit damage. Check in detail the materials to ensure conformance to packing slip(s) and purchase

orders. Construction, engineering and supplier quality personnel may assist in technical

inspection if required. Prepare material receiving reports and any UOS&D reports, as may be required from

time to time and the notification of the field material requisition originator that

materials have arrived. Store and protect procured materials, segregate and disburse as required, including

consumable supplies, small tools, etc., within the warehouse and storage yards. A material withdrawal form shall be prepared for all disbursements and must bear the

necessary approval signatures prior to release of any materials. Coordination with Traffic for damaged material returns for repair or replacement.

3.11 Receipt of Materials at Site

CPECC will compile all fabrication and manufacturing data dossiers/reports containing

mill test certificates, machinery test certificates and all other relevant inspection data after

delivery of equipment to Site, as applicable.Warehouseman should inspect the relevant documents including invoice, packing list, mill

test certificate, operating and maintenance manual, inspection certificate, spares list

(commissioning spare list), vendor drawings, certificate of origin, etc. before the arrival of

goods at site.After offloading, a detailed check of the equipment/material shall be conducted according

to the delivery document. If there are any discrepancies or damage a UOS&D report will be

issued in a timely manner. Warehouseman will notify CPECC quality inspector and Owner engineer of all imminent

deliveries of CPECC supplied equipment and materials. After initial inspection, all

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equipment and material being delivered direct to the Site will be inspected by CPECC

inspector and Owner engineer on arrival. CPECC quality inspector and Owner engineer

will indicate their acceptance or rejection of the equipment/material. Accepted material will

be notified to the material controller of a receiving inspection report. In the case of non-

compliance equipment/material found, quality inspector will complete a non-compliance

report. Copies of the non-compliance report and the UOS&D report will be forwarded to

expeditor for liaison with the relevant disciplines to clear the UOS&D in the most

expeditious manner. Warehouseman will notify quality inspector when the

equipment/material is available for re-inspection, upon released by quality inspector the

UOS&D will be closed out and equipment /material made available for construction use.After completion of receipt, certification check and quality inspection, material receiving

report will be issued for each delivery against the shipping documents.

3.12 Warehouse and Stock Pile Area

CPECC will utilize a central warehouse and stock pile yards, to receive, store, protect, issue

and, when necessary, surplus all project equipment and materials. Handing, preservation

and storage of equipment will be carried out in accordance with vendor’s instruction, also

with the Owner requirements.A comprehensive safety plan will be initiated involving training, worker awareness,

teamwork, an attitude of concern for others and individual employee safety recognition.

Regular inspection of stored items will be carried out to verify adequacy of storage

protection provided.

Inside Storage (Warehouse)The central warehouse will provide security and protection for all weather sensitive

materials or equipment, such as electrical fittings, instruments, 2” and below pipe fittings,

valves, switchgear, spare parts and all other items designated for covered storage. This will

generally be through the use of the central warehouse but may, at times, have to be

satellite/auxiliary warehousing or through the use of C-Vans as long as they meet the

minimum storage requirements. If required, some materials and equipment will be stored in

air conditioned enclosed storage.

Outside Storage (Stock Pile Yard)

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These yards will be enclosed by fencing with gate to control all incoming and outgoing

traffic. Materials will be stored off the ground by use of pallets, rough lumber, cross ties or

a like. Element protection as necessary will be accomplished by the proper use of

polyethylene, tarps or temporary structures. All weather roadways will be provided around

and within receiving and storage areas and will be maintained with through space for trucks

and operation of lifting equipment. The area will be secured by fencing no lower than 2.5

meters with barbed wire on the top. There will be 6 meters wide traffic gates in at least two

points. There will be personal gates next to these and in other strategic locations that will

be approximately 1.5 meters wide and 2 meters clear height. There should be sufficient

loading/unloading areas to accommodate trucks, trailers, cranes, forklifts and C-Vans

simultaneously. There will be absolutely No Smoking in any of the material storage areas.

3.13 Spare Parts and Consumables

As part of Request for Quotation, all the vendors will be required to quote for

commissioning and start-up spare parts, capital spare parts and 2 years operation spare parts

in accordance with the Owner requirements.CPECC will supply commissioning and start-up spare parts as necessary up to the

Provisional Acceptance by Owner, the cost of which is included in the Contract Price.

CPECC will provide a detailed list for 2 years normal operation, and the spare parts

information shall be submitted in the Spare Part Inter-Changeability Form (SPIR). CPECC

will also provide a list of parts of equipment, equipment assemblies or complete items of

equipment which are required for replacement of items not subject to deterioration by

normal use but whose failure is critical for continual operation of the facilities.

3.14 Tax Exemption Application

With the exception of import duties on materials and equipment to be incorporated into the

Work or to be supplied to Owner as ether spare parts or as consumables imported for

exclusive use under the Contract, CPECC shall be responsible for obtaining all necessary

documents and permits.

3.15 Use of Local Products and Services

CPECC will source materials and equipment locally so far as possible, providing that the

service, materials and equipment can be obtained on equally advantageous conditions

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without compromising safety, quality and the suitability of the purpose for which the

service, materials and equipment re intended.As per CPECC experience, CPECC may procure some material from local market for civil

work, e.g., cement, reinforcement bar, concrete block, wood, etc. CPECC may also procure

most consumable gas, i.e. oxygen, acetylene, argon from local manufacturers and suppliers.CPECC will subcontract all custom clearance and inland transportation to local companies

3.16 Warranty from Manufacturer

CPECC will secure warranties from manufacturers and vendors of equipment, machinery,

and materials or supplies purchased by CPECC and used in the Work. Such warranties will

be assigned to the Owner to the full extent thereof. Each purchase order for equipment, materials or supplies will bear the following clauses:All articles, materials and work supplied by sellers shall be of good quality and free from

any defects. However, purchaser's failure to inspect or reject any article, material or work

shall not relieve seller of any warranties or obligations provided hereunder.Seller warrants that if any article, material, or work furnished fails to conform to the

purpose expressly specified or manifestly implied in this order or is otherwise found to be

defective (excluding wear and tear from normal use and not due to conditions more severe

than stated or implied in this order), then seller shall promptly correct or replace the

deficient article or material delivered to purchaser at the address prescribed on this order at

seller's sole expense.The articles, materials, or work to be furnished are to be used in a facility being constructed

by purchaser for the Owner. It is understood and agreed that all of the rights and benefits

accruing hereunder, including without limitation, all warranties and guarantees shall accrue

in favor of both purchaser and the Owner and may be enforced by either of them.All the vendors will be required to provide twelve months warranty after Provisional

Acceptance Certificate.

3.17 Material Control

Sound material management will be essential to the project success. The sheer volume of

purchases orders, the number and geographical diversity of vendors, the numerous steps

and activities in the procurement process and the critical schedules create a very complex

system to be managed.

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Accordingly, a detailed computer system will be used to track permanent activity,

beginning with engineering requisitions and following through the entire procurement and

materials control cycle including warehousing and final issue at the construction sites. This

system will collect and maintain scheduling, requisitioning, purchasing, inspection,

expediting, delivery, shipping, site warehouse inventory and field issue status. Information

from this system will be used to provide the required periodic reporting on procurement

activities.CPECC will prepare and submit material control procedure for receiving, storage, issuance

and track ability of material or equipment for Owner review and approval. The material

control work will be carried out in accordance with the approved procedure.CPECC will plan and exercise materials control through computerized tracking and record

of materials receipt and handling at site for the project material control. Prepare and update

the computerized material tracking reports, UOS&D reports, material inventory records on

a regular basis. A detailed material status report showing all milestones from receipt of the

engineering requisition through to delivery of all goods and documentation will be prepared

and updated by the Procurement Department on a monthly basis. Sample of material status

report form computer inventory system is attached herewith.CPECC will take prompt procurement action on all UOS&D reports to ensure timely

availability or replacements for the short/damaged items in line with the construction

requirements.CPECC will ensure that the specifications, drawings, test certificates, installation and

maintenance instructions for all equipment and materials from vendors, are available at site,

for ready reference during the construction phase.

3.18 Management of Surplus Materials

All the surplus materials will be stored properly and the surplus report will be issued to

concerned parties.Any surplus material, which has been issued to construction, will be removed from Site and

return to warehouse after the Work completion. The warehouse will repeat the receiving,

inspection, storing procedures and update the inventory records.Upon completion of the Work, CPECC shall furnish Owner a list of all surplus and price at

which CPECC offers to sell each item to Owner.

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4. Construction

4.1 General

4.1.1 The Outline of the Project1) The Title of the Project

Melut Basin Oil Project – Upstream Facilities EPCC of Palouge Produced Water Phase I2) The Owner:

Petrodar Operating Company Ltd (PDOC).3) The Scope of Work of the ProjectProduced water from produced water skim Tank T-2330A of Palouge FPF transfer to new construct 4000m3 buffer tank by 16’ water lines, then inject to proposed wells by 4sets of 1400KW Mud Pump and 2sets of 6.6KV Water Injection Pump.That means one new Pump station need to be constructed.And install 4 water draw off pump which flow rate 150 m3/ /h .to replace old 2sets of draw off pump which flow rate is 50m3 /h in old palouge FPF.4) The Construction Location of the ProjectPUMP station is outside south east to Palouge FPF

5) Main Facilities in the Project16’ water line 600m4000 m3 buffer tank4 sets of 1400KW diesel engine drive mud pump2sets of 800HP 6.6KV water injection pump.2 sets of 4000KVA 33/6.6KV transformer for water injection Pump.One MCC& 6.6KV switchgear and soft start room.4 draw off water pump.6) Key dates of the Project:

Contract Effective date: Dec 1，2008

Mobilization to the site: Before February 20 , 2009Sectional Mechanical complete date of two mud pump from by-pass line

: May 1， 2009

Provisional Acceptance date: October 1 20097) Geographical ConditionsThe site area belongs to a part of the Sudan Savanna belt, and the climate is tropical. There

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are two-season patterns in one year, a wet and dry. The dry season is from November to

next year May and the wet from June to October. Maximum rainfall for 24 hours is 131.4mm during rainy season, the ground vegetation is

flourish and most of them are flooded by water. And the area is subject to considerable

wind often accompanied with drifting sand and considerable thunderstorms and lightning in

rainy season.8) Transportation a) Highway

It is 1200km asphalt-paved road from Port Sudan to Rabak and 300km off-road from

Rabak to PALOGUE. The off-road is in poor condition and thus the transportation is

restricted to a 90km mountainous passage from Agaba to Port Sudan. The grading on this

passage is approximately 1000’~3000’/15km. Some portions of the road will require

temporary constructed by-pass road and some portions are impassable during the wet

season. Bridges and the Wad Madani bridges on the Blue Nile, approximately 1000km from

Port Sudan, load-limited and to pass the bridge require special design of trailers with proper

distribution of weight, reviewed and approved by consultant of the authority of Road &

Bridges Corp. Based on our observation the load on the road from Port Sudan to the

construction site is limited to 88 tons. The off-road portion of between Rabak to PALOGUE

will require some earth-movement and construction equipment to follow such convoy for

paving- filling of deep valley – pulling. The road is generally in a good condition in dry

seasons (from December to May), therefore, we have to deliver large-sized equipment and

bulk materials to the site prior to the raining season. Some equipment and materials for

urgent use, such as food and other living requisites will be shipped by air. Utilizing the

highway is our first choice of the proposed transportation method.b) Railway

It is approximately 1200km from Port Sudan through Khartoum to Rabak by railway. But

when the material arrives in Rabak, it needs to be delivered PALOGUE by truck. It has

been observed that this part of the road – 300km is in a very bad condition making the

highway transportation extremely difficult during the wet season.c) Airfreight

Miniature airliner or cargo aircraft can fly from Khartoum to PALOGUE ( if the

PALOGUE airport can be used) and it takes two (2) hours. Working staffs and some

materials for urgent use can be transported by air, but the cost is extremely high.

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d) Local resources 1) Local labor

Basically there are almost none permanent residents in PALOGUE Oilfield due to the

inclement natural conditions in this area. Currently, the only people who live there are the

ones who deal with oil exploration, development and production. The labors needed in the

project will be employed from outside this area. CPECC will employ Sudanese local

qualified labors as many as possible. This means we will try our best to hire local skillful or

semi-skillful labors. In particular, we are planning to subcontract civil work to Sudanese

civil construction teams with vast local experience and strength.2) Local Industrial Resources

PUMP station is near PALOGUE FPF . we no need to build local infrastructure .CPECC

Palouge camp can be used.

3) Local Material for Civil WorkThere are sandstone resources that can be used for foundation layers near the oilfield and

PALOGUE region. Sand, stone, concrete and wood material need to be purchased

elsewhere far off PALOGUE. Silica sand suitable for sand blasting can be obtained from a

place approximately 80km to 140km from PALOGUE. 4.1.2 Features of the Project

The general features of the project are: large size equipment , short construction period,

inclement natural condition, poor construction condition at site.1) Short Construction Period

The construction period, from the Contract effective date to sectional mechanical

completion, is within5 months , Total provisional acceptance date is 1 October 2009

covering 1 rainy season . but we shall try to finish most installation before rainy season.

This posses greater difficulty to the project arrangement. It is a fast-track construction

project.2) Poor Natural Conditions

Water pump station is located in poor natural conditions. it is very dry and hot in dry

seasons and heavy rain in raining seasons accompanying thunder and strong wind. The

black cotton soil on surface is dilative and loose after rain, which is detrimental to

construction activities. The measures for waterproof, leakage protection and water drainage

system must be taken during construction period. Raining in the wet season may cause

delay progress of construction, which makes it difficult to do any outdoor activities.

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We must pay more attention to the personal safety and health aspect. All necessary

prevention measures including prevention against hazards related to such as mosquitoes

and poisonous snake must be taken.3) Difficult Transportation

There exists great difficulties to transport equipment and materials required from Port

Sudan to PALOGUE Construction Site due to conditions described above. CPECC plans to

deliver the majority of equipment and materials for this project to the Construction Site in

dry season. The weight of individual equipment to be transported will be limited not to

exceed 88 tons to fit the road conditions of Sudan.

4.2 Construction Arrangement and Preparatory Work

4.2.1Construction Mobilization and PreparationIn consideration of the tight construction schedule, and all the expected difficulties during

the wet and dry seasons. After this project is awarded to CPECC by PDOC, immediately

mobilization and preparation should be carried out by CPECC.The proposed mobilization and preparatory work includes, but not limited to, the

following:1) Project management office and its staffing for all the preparatory work.2) A Project kick-off meeting will be held and attended by all management staffs. The

Project Manager will explain the importance of this Project to the petroleum industry

and economic development of the Republic of Sudan, a project outline, local

environment, climate, and transportation conditions of the project location will also be

introduced. Meanwhile the project manager should also state the CPECC general

execution plan of this project.3) The relevant staffs will be appointed to do the preparation work including but not

limited to the following: Project Management regulations and rules. Necessary documentation for Project Management. Layout of work. Engineering and design for the Project. Control and management program plan for equipment manufacturing, fabrication and

transportation to the Site. Familiar with Owner’s requirements of construction quality and all the Owners

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specifications. Preparation of construction procedures and quality control documents. Necessary local training, on matters such as the situation of Republic of Sudan and

its laws and Heath, Safety and Environment (HSE) to the staffs and workers. Subcontractors shall be selected, especially the subcontracts for civil work and

transportation shall be finalized and executed in time. 4.2.2 Construction Guideline

The construction guideline for the project is to ensure the project to be put into

commissioning and operation in time to satisfy Gymury FPF commissioning and operation

with high quality. All the construction activities will follow principles as follows: Well organized, systematic approach Arranging. Guaranteed Quality, Strict Management. Client first, Service Satisfactory. Safety first, Prevention First. Progress Controlled, Schedule Ensured.

4.2.3 Construction Arrangement 1) Scientific Arrangement and Elaborate Organization

The “Project Management method” will be adopted by CPECC based on the Project

features to organize construction activities. CPECC will implement scientific arrangement,

strict management and elaborate organization in the course of construction and comply with

the requirements of Owner. The following philosophy shall be adhered to : Underground work first, then the above ground work. Civil earth work first, then installation. Equipment first, then piping. Installation of large scale equipment first, then small equipment. Critical items first, then general items..

2) Different Critical Work in different Periods The overall project is divided into 5 phases in order to ensure the project completion

Provisional Acceptance . Phase 1: Engineering shall be finished by the end of February 2009 especially piling

drawing shall be finished before 25 Jan 2009. Phase 2: Issuing of construction drawings, and to start procurement work for materials. Critical work: To finish engineering design by the end of February of 2009 and to finish

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placing purchase order by APR 20 2009. Finish purchasing and transportation of material by the end of May 2009. .

Phase 3: 16’ main water line welding. Factory air pipe and mud pump diesel pipe

construction. Duration: 1 Mar 2009- 30 Mar 2009 Critical work: NDT of main 16’ pipe , pressure testing and pigging ,painting and

coating. Phase 4: Two mud pump Sectional Completion by the end of APR 2009. Critical work: 4 sets Mud pump installation under Guidance of vender. Commissioning of two sets of mud pump Connection of by-pass water line. 16’ Main pipe shut down tie -in

Phase 5: 4000m3 tank installation , Duration : 5 APR 2009-28 June 2009Critical work: CP installation of tank NDT of welding Water filling test Blasting and paintingPhase 6 : 2 sets of 6.6KV water injection pump installation under Guidance of vender. 6.6Kv switchgear and MCC installation. Duration : 1 Jul 2009 –20 AGU 2009Critical work: Transformer installation 6.6 Kv soft start installation Substation housing installationPhase 7: Final commissioning Duration : 25 AGU 2009 – 18 SEP 2009.Critical work: transformer test Injection Pump commissioning By pass line transfer to tank System put into use

4.3 Construction Plan

4.3.1 Project Progress Schedule

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In the light of above features and owner’s requirements ,the project shall be

sectional completion two mud pump by the end of APR .2009Total finish shall be by the end of SEP. So the following points will be prioritized so

that the project can be accomplished in time.Please refer to construction progress schedule for progress attached..Please refer to Project Organization Chart attached.

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CONSTRUCTION DEPARTMENT PROCEDURE MELUT BASIN OIL DEVELOPMENT PROJECT--UPSTREAM FACILITIES: PALOGUE produced water phase I


4.3.2 Construction Man-power SchedulePlease see the ( Construction Manpower schedule)

CONSTRUCTION MANPOWER SCHEDULE(man-days)

CATEGORIES OF PERSONNEL2008 2009Dec Jan Feb Mar Apr may June July Agu Sep Nov Dec

Construction managment 5 5 7 10 10 10 10 10 5 5

Construction Engineer 2 2 3 3 3 3 3 3 2 2

Construction Superintendents 2 2 2 2 2 2 2

Forman 1 2 4 4 4 4 2 2

Inspectors 2 2 2 2 1 1 `

Surveyors 3 1 2 2 2 2 2 1 1

drivers 2 4 5 5 5 5 1 1

Electrician 4 4 10 10 5 5

Electrical Welders 8 15 15 15 6 3 3

Gas welders 2 3 3 2 2 1 1

Piling operators 7

riggers 1 2 2 2 1 1

others 3 20 20 20 20 10 10

Subtotal 7 7 22 38 72 72 86 67 33 33

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CONSTRUCTION DEPARTMENT PROCEDURE MELUT BASIN OIL DEVELOPMENT PROJECT:Palougue Produced Water Phase I


4.3.3 Construction Equipment and Tools PlanPlease see List of Proposed Construction Equipment

LIST OF PROPOSED CONSTRUCTION EQUIPMENT

Item No Categories of Equipment Size/Type UnitQty

Own Rental To be Purchased

1 Crane 25t Each 2 1

2 Crane 15t Each 2

3 Truck 15t Each 2

4 Trailer 40t Each 1

5 Bus 50seats Each 1

6 Medium Bus 20 seats Each 1

7 Pick up TOYOYA Each 6

8 JEEP TOYOTA Each 2

9 Walkie-talkie each 20

10 winch 2t each 1

11 Clevis 10t each 20

12 Clevis 5t each 20

13 Clevis 3t Each 20

14 Wire rope 6×37+1 Φ26 Meter 96

15 Wire rope 6×37+1 Φ19.5 Meter 96

16 Chain block 5t Each 4


Page 37 of 126






19 Jack 20t Each 6

20 Jack 10t Each 6

21 Nylon slinging belt 10t Piece 12



24 Civil machinery

25 Concrete mixer 400L Each 2

26 Mortar mixer 200Z Each 2

27 Concrete vibrating rod Φ50 Piece 4

28 Concrete vibrating plane Each 2

29 Steel bar straightener Φ6-10 Each 1

30 Steel bar cutting machine Φ6-40 Each 1

31 Steel bar bending machine Φ6-40 Each 1

32 Electrical carpentry saw and planer Each 1

33 Excavator 1 m3 Each 6

34 Compactor HW01 Each 2

35 Dumping truck 16m3 Each 6

36 Mortar dumper 1t Each 2

37 Scraper Each 2

38 Bulldozer D85 Each 2

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39 Loader CAT950 Each 1

40 Water waggon 20m3 Each 1

41 Piling machine 1

42 Welding and cutting equipment

43 D.C. Welding machine Lincon V400-s Each 4

44 Mobil diesel welding machine Miller DU-OP Each 20

45 Mobil diesel welding machine Miller BigeBlue 502D Each 20

46 Semi-auto cutting machine GCD-150A Each 4

47 Pipe facing machine ISY-350-1 Each 4

48 Electrode oven 500℃ Each 2

49 Electrode thermostat box 300℃ Each 2

50 Metal machining equipment

51 Grinding machine Φ100 Each 60

52 Grinding machine Φ150 Each 60

53 Disk cutting machine Φ400 Each 4

54 Electrical die threading machine 1/2"-3" Each 2

55 Electrical hand drill Φ13 Each 6

56 Impacting drill Each 2

57 Hydromatic pipe-bending machine 1/2"-4" Each 2

58 Universal equipment

59 Generator set 46kw Each 2

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60 Generator set 20kw Each 2

61 Air compressor 1.25Map 0.8m3/min Each 2

62 Air compressor 0.8Map 18m3/min Each 3

63 Electrical pressure-testing pump 0-35MPa Each 4

64 Diving pump 4” Each 2

65 X-ray fault detector 250EG Each 2

66 X-ray fault detector 300EG Each 2

67 Ultrasonic fault detector CTS-22 Each 1

68 Magnetic particle fault detector Each 1

69 Thickness measurer Each 4

70 Hardometer Each 2

71 Auto film developing AGDA Each 2

72 Film developing and fixing machine Each 2

73 Blasting equipment Set 4

74 Paint spraying machine Each 2

75 Roll aluminum plate machine Each 1

76 Edge roll for aluminum plate Each 1

77 Insulation equipment for pipeline Set 1

78 Internal epoxy coating equipment set 1

79 Internal PEX for trunklines set 1

80 Theodolite J-6 Each 2

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81 Levelling instrument S-2 Each 2

82 Overall surveying instrument Each 2

83 GPS Each 2

84 Spark holiday detector HJ-4 Each 6

85 Film thickness measurer DUC-ST10 Each 4

86 Infra-red temperature detector TCM-312 Each 2

87 Moisture meter YMWS-A2 Each 4

88 Anemometer AVW-01 Each 2

89 Auto pressure & temperature recorder FCX-C Each 4

90 Weld measure Each 8

91 Process instrument signal testing set F743B Each 2

92 Digital multimeter F930FG Each 2

93 Piston manometer 0-25Mpa Each 2

94 Standard pressure gauge 0-25Mpa Set 4

95 Smart instrument communicator ROSEMOUNT Each 1

96 Megger (motorized) 500V/1000V Each 2

97 Voltage meter 0.5,≌0-500V Each 2

98 AC/DC amperemeter 0.5 0-1000mA Each 2

99 AC/DC amperemeter 0.5≌0-100uA Each 2

100 Earthing resistance tester Each 2

101 Torque wrench Set 6

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102 Heavy wrench Set 2

103 Universal mechanic tool Set 6

104 Universal construction device Set 6

105 Arc fusion splicing machine Type-36 Set 2

106 Optical time domain reflectometer MW9670 set 2

107 Light source LP-5210 Set 2

108 Optical power meter GN-6025 set 4

109 Optical cable cutter Ericssion set 4

110 Stripping pincer Set 4

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MELUT BASIN OIL DEVELOPMENT PROJECT—UPSTREAM FACILITIESPALOGUE Produced Water Phase I


4.4 Statement of Labor Management and Industrial Relations

1) During 1998-2008, more than ten local Sudanese subcontractors participated in

subcontract work for CPECC, in the field of civil and power transmission line

construction. For example, Heglig service Co, subcontractor of civil work,

Elnourus Neifidi Transport Co. (subcontractor of transportation), Future, Bee

and Keer Co. Etc. All of them possess certain technical strength and sound

reputation and maintain a good working relationship with CPECC. 2) Sudan has a large resource of manpower, among them many possess certain

skills and have worked for CPECC projects. It is CPECC's intention to continue

the engagement of local technicians and labors. We understand the procedure of

hiring local labor and are familiar with Sudanese labor law. In our future

projects in Sudan, all engagement of local labor will be handled through local

labor office and authority. All local employees whether having worked for

CPECC before or not will be required to contract with us through local labor

management office in order to prevent any disputes. All local employees will

be given a basic work training course organized by CPECC. In the meanwhile,

CPECC shall provide local employees with accommodation, necessary

insurance covering accidental risk. Labor protection appliances and medical

care will also be provided to local employees. After the execution of project,

termination of employment shall only be settled through local labor

management office.3) CPECC hereby solemnly commits to Employer that we will do our best to use

local labor, to increase the employment opportunities, and to provide necessary

working training for those local employees hired by CPECC. We will maintain

the good relationship established with local companies, and carry out our work

in strict accordance with Sudanese relevant law and regulations. In order to

avoid any kind of disputes between CPECC and local labors, CPECC will have

legal consultant during construction and warranty period. All the time, any

disputes (if any) happened will be settled immediately by CPECC pursuant to

stipulation in contract and CPECC will bear the responsibility itself without

impact on Employer. Employer shall bear no responsibility for any disputes

between CPECC and local labor/s.

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4.5 Civil works

4.5.1 ScopeThe civil works of the project shall include the followings: earth work, concrete work,

piling, assembly of building and structure, fencing etc.4.5.2 Earth work

1) Scope of activities includes removal of garbage, topsoil, vegetation, etc. on site,

earth excavation, backfilling and final grading.2) Removal of garbage, topsoil, vegetation, etc. on site.a) CPECC shall submit the following documents to Owner for approval Protective measures taken for public and private properties affected during

construction (If any). Removal of any structures hindrances and obstructions on the surface or

underground (If any).b) CPECC shall complete the topographic survey of the area and define correct location and

elevation to ensure construction to be performed in accordance with the design drawings

prior to commence of work.

c)Over-excavated surfaces arisen from removing garbage or tree roots shall be

refilled and compacted according to requirement. d) Scraped depth of the site surface within the boundary defined by drawings shall

meet requirements of the design and Owner3) Earth Excavationa) Excavation work is composed of removal and transportation of excavated

materials and disposal of surplus material from excavation.b) Excavation work should be in accordance with the approved design drawings, or

Owner's instructions. Where mechanical excavation is for equipment

foundations, a bottom layer of 200mm shall be manually removed.c) Excavation and grading below the designed foundation shall be completed prior

to the commencement of excavations for foundations, underground pipe

networks and utilities.d) Surplus earth excavated shall be transported to the place where the Owner

designates as the location of surplus material.e) When earth excavating and grading reach the design elevation, CPECC shall

report in writing to the Owner for approval. Only upon the Owner’s approval

can the foundation construction or pipeline work be commenced.

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f) Over excavation, no matter caused by any reason, shall be back filled and

compacted according to specifications.g) During excavations, CPECC shall take necessary measures to avoid cave-ins and

landslides to protect existing facilities.h) Locations and elevations of pipe trenches and equipment foundations shall be

defined in accordance with dimensions and slopes shown on the design

drawings.i) The width of pipe trench shall meet requirements for pipeline construction and

for compaction of back filled soil. j) Measures shall be taken to avoid landslides or collapse of the ditch wall.k) The trench bottom should be evenly compacted to bear the weight of pipelines.

All organic material shall be removed and over excavation shall be back filled

and compacted.l) Each layer of fill shall be compacted in accordance with the design

requirements.m) Within two meters away from underground pipelines and cables, manual

excavation shall replace mechanical excavation.n) At road crossings, measures shall be taken to keep the road unobstructed as

required by Owner.4) Backfilla) CPECC should notify the Owner 3 days before filling and back filling.b) Granule material of structural back filling should be clean, finely graded and

inorganic.c) General engineered fill materials shall comprise clean, well-graded granular

soils or inorganic and low-plastic cohesive soils.d) After the pipeline is laid and inspected by Owner, the trench shall be back filled

in due time. When the backfill reaches a height of 1/4 pipe diameter all

provisional supports and guards should be removed and the back filling should

continue. e) To achieve the maximum density, the back fillings should be compacted in the

optimum water cut. Watering if it is too dry and airing if it is too wet.f) For site fill and bund fill, the maximum dry density shall achieve 95%.g) The final height of back filled soil shall be 150mm above the surrounding

surface.

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h) Owner will supervise the whole filling compaction work. CPECC shall be

responsible for the density tests of each fill layer. 5) Final Grading on Site Final grading includes excavation, back filling, compaction, disposal of material,

road pavement, etc. For the area around wellhead, the surface shall be graded in a slope with 150mm

top layer of gravel to drain water out. During the final grading, sufficient drainage shall be provided to drain water

from the site. Drain ditches shall have the correct elevation, slope and size as specified on

design drawings. After the completion of grading, CPECC shall clean up the site. All discarded

materials shall be disposed of as per the Owner's requirement.All damages to existing structures, roads, etc. that occurred during the construction

period shall be restored to its original appearance as per Owner's requirement before

CPECC leaves the site.4.5.3 Piling

1) Piling shall be performed under the supervision of relative civil technical

personnel. 2) The locations of all underground and aboveground facilities shall be defined

before piling.3) All piles in a common group shall be driven to the same tip elevation.4) Pile cap plates for steel piles shall be located exactly as shown on the drawings.5) Centre lines of plate and pile may not be in alignment due to horizontal

tolerance allowed for driving of the piles.6) Piles shall be driven with drop hammers, diesel, impact hammers or other

method approved by Owner. Contractor shall ensure that the equipment is in

good working order before starting the work.7) Piles shall be driven continuously without interruption to achieve the

conditions as specified on the drawings using drop hammers with a minimum

rated driving energy of 32,000 joules and a minimum striking weight equal to

the weight of the pile but not less than 1,300 kg.4.5.4 Fencing

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1) Scope of works includes Fencing of wellhead area and OGM areas with wire

meshes.2) Fencing shall be installed according to design drawings.3) All the fencing work shall be performed by skilled and experienced fence

erectors in accordance with the construction drawings.4) Steel posts for fencing and concrete foundation shall be constructed as per

design drawing.5) Wire meshes for fencing shall be lapped and properly tensioned to avoid any

deformation.

4.6 16” main water line

4.6.1 General Procedure for 16’’ construction refers to the flow chart A. PDOC provides line pipes with FBE coating. Joint coating shall be down on

site. 16’’ have internal liquid epoxy coating.

4.6.2 Setting out and Trenching The survey team sets out the route and sets up stakes according to the drawings.

The survey team shall verify all existing elevations, bends and straight-line

sections. All existing utilities shall be marked and protected from damage. All

additional marks shall be laid out at this time. Any discrepancy of the

information from that in the drawings has to be recorded and submitted to the

Owner representative in writing for final decision. Excavation shall be done with trenching machine, digging by hand shall be

done when coming into close contact with the elevation of pipe bottom, trench

depth and width shall be in accordance with requirements in drawings. All pipelines, cables, foundations, encountered during trenching shall be

protected. The Owner shall be contacted who will in turn consult related

department to prevent accident or damage. Any unqualified trench shall be repaired or retrenched to meet specified

requirements after inspection.4.6.3 Stringing and Line up

Wire rope slings shall not be used under any circumstances for handling pipe.

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Slings to be utilized in handling the pipe shall be free from damage to pipe or

pipe coating. The stringing of pipe along the route shall be done in a manner to minimize

joint overlap. The interior of all pipes shall be carefully examined for the presence of foreign

matter before the pipes are lined up for welding. All such foreign matter shall

be removed. The open ends of pipes shall be securely closed in the end of each

day's work. The open ends shall not be reopened until work is resumed at that

point. The beveled ends of pipes shall be cleaned by wire brushes or grinders before

welding, for a minimum distance of 25 mm (1 inch) from the prepared edge on

both the inside and outside of the pipe. The external line-up clamps shall be firmly held in position until the root pass

is 100 percent complete and the pipe has been properly supported. Prior to welding, the internal diameters of flange valves, tees, elbows, bends

etc, shall be measured to ensure that the internal bore will allow the passage of

a pig fitted with a gauging plate of 95% of the nominal bore, branch

connections shall not protrude inside the pipe.4.6.4 Lowering in

Welding, NDT and coating & insulation records shall be inspected and accepted by

Owner before pipe is lowering in, and the ditch should be inspected to ensure no rocks,

hard objects, organic material etc which could damage the pipe coating & insulation is

present in the trench. After piping has been inspected and tested, the pipe can be

lowered in. Care should be taken during the lowering of pipe to prevent damage to the

coating &insulation. A hole shall be excavated around the joint to give welder freedom

of access to the weld. The welded joint shall be coated and insulated after welding and

the coating shall be tested and accepted.4.6.5 Backfilling

1) After lowering-in and inspection have been made, the following work shall be

completed and in conformity with requirements of the Contract prior to back

filling: Control marks (attached on pipeline). Coating. Status of trench.

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Collected final documents.2) The written acceptance will be issued by responsible inspector and Owner

before backfilling. No organic material, rocks etc. shall be allowed in the ditch.

Adequate facilities shall be prepared to drain water out of trench if required. All

material used for backfill shall be of an acceptable quality, and free from rocks,

roots etc. After the ditch has been back filled above the surrounding ground,

backfill shall be compacted and tamped, the remaining backfill shall be spread

over the pipelines.4.6.6 Tie-in

1) Tie-in refer to work done to connect the sections of old pipeline. 2) According to .site visit and agree with production. Tie in point shall be at

operating section of existing 16’ pipe on pipe rack. 3) A elbow section shall be cut after shutdown, and one new16’ T connection shall

be welded to replace elbow to achieve connect new 16’ pipe to old pipe.4) The welded joints will be RT tested and visually checked. NDT and coating

records shall be inspected and accepted by Owner before pipe is put into use.4.6.7 Pigging

After the pipeline installation has been completed, blinds at both ends of the

pipeline shall be removed and pigging equipment shall be installed. The

finished pipelines shall be free from foreign materials and objects. All valves

of the pipeline shall be in open position. Sizing pigs, brushes and scrapers shall

be air driven through all lines and the Owner shall be present. Prior to cleaning the pipeline, pig launcher and receiver should be welded to the

beginning and end of the pipeline. Air inlet and outlet pipes for the launchers

shall be installed and connected to a compressor. The sizing pig and scraper

should be installed in the launcher, and the pig is launched by compressed air.

All rust, dust and other foreign material shall be blown out of the pig receiver. When scrapers and foreign material arrives at the receiver, air pressure shall be

turned off and the receivers shall be depressurized before it is opened to

remove all equipment and clean out debris. The pipeline shall be pigged several

times until the piping interior is clean as specified and the QC engineer and

Owner are satisfied. Scrapers shall be used for pipeline cleaning. If the scraper becomes stuck, the

pressure can be increased until movement occurs again. If the scraper becomes

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stuck and can not be dislodged by an increase in air pressure, second pig of

larger diameter can be used to induce movement. Pigging of the pipeline shall be performed until cleaning is acceptable. In order

to determine the location of the pig in case of missing, audio monitors shall be

installed along the pipeline. When the scrapers are placed inside the launcher, they should be carefully

checked to ensure that clearance between the scrapers and the pipe wall are

within tolerance. If there are small amounts of foreign material in the pipeline and the resistance

is low, the scraper speed must be controlled to avoid damage to the receiver.4.6.8 Hydrostatic Test

1) The pipeline can be separated into several segments for test according to water

availability, elevation etc. After separate tests are completed, the segments will

be joined. The final welded joints will be PT and RT tested and visually

checked. Strength test will not be done for these joints again.2) Preparation prior to hydrostatic test: All welds repair and NDT have been completed, which can be considered as a

stop point. Pigging has be completed and accepted by Owner. Application form and safety provisions for testing have been approved.

Temporary provisions for testing are prepared ready. Pressure gauges shall have been calibrated. Pressure gauges shall be installed at

an appropriate location of the pipe section to be tested and a thermometer shall

also be installed if necessary. All the QC forms to be filled in according to the quality plan and procedure shall

be completed and approved by QC department and departments concerned.3) Pressure testing. Test pressure shall be in conformity to the pipeline sheet and related

requirements. A vent valve shall be installed at the highest position to vent out all the air in

the pipeline. When filling the pipe, a pig shall be put in pipe, and it will run

ahead of the water to drive air out so that air does not become trapped behind

the pig. When testing commences, the pressure shall be gradually increased up

to the 50% full test pressure and then stop and let stabilized for at least 1 hour.

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If there is no pressure drop or leak, pressure shall be increased to the test

pressure. The piping system shall be checked thoroughly. If the pressure drops

no more than 1% during 24 hours the test can be accepted. All leaks or pressure

drops shall be detected and repaired by the testing crew. Prior to repair, all

water in the system shall be discharged. The water used for test must be clean

and free of silt, suspended materials or harmful corrosive composition. After

the test, the water will be properly drained or pumped to the next section to be

tested.4.6.9 Road crossing

For this project, one FPF road shall be crossed . The pipeline construction will

be strictly in accordance with the requirements and specifications specified

under the bid documents. Identifications for construction and lighting equipment shall be placed at the

road sections where the crossing operations is in progress after approval of

local traffic authority and owner and before commencement of work. A steel plate or other materials to ensure re-opening of the road shall be placed

over the pipeline crossing ditch at the end of work. A steel plate or other materials to ensure re-opening of the road shall be placed

over the pipeline crossing ditch at the end of work. For pipeline crossing by ditching & backfilling method, the pipe ditch shall be

backfilled immediately after the crossing pipeline has been installed on the

bottom of the ditch. Each lift of backfilling shall be correctly compacted to the

levels of existing road base and surface prior to commencement of work. The road surface shall be restored according to the original requirements of the

road. The pipeline route will cross and tracks or roads at an angle as close as close as

90C to reduce the length of the crossing.4.7 4000m3 Buffer TANK(FIELD FABRICATING TANK)

4000m3 buffer tank shall be fabricated in the field, duplex assembled and installed by way of upside-down mounting in the field.

4.7.1 The construction procedure of the buffer tank shall be upside-down mounting:a. Foundation inspection acceptanceb. Materials acceptancec. Prefabrication of the storage tank

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d. Bottom plate corrosion protection e. Installation of the bottom platef. Shell plate installation of the first ringg. Roof plate installationh. Installation of roof railsi. Shell plate installationj. Accessories installationk. Hydro testl. Corrosion protection and insulation

4.7.2 Foundation Inspection Acceptance(1) CPECC and the OWNER representative shall check surface size of the foundation in

accordance with the foundation engineering documents prior to the installation.(2) The elevation and levelness of concrete bearing ring-beam shall be in accordance

with the drawings and the specifications.(3) The surface of the sand layer shall be leveled and free of protrusions, sags and

cracks. The slope shall be in accordance with the drawings and the specifications.4.7.3 Materials Inspection Acceptance(1) The storage tank shall be checked with respect to the quality certificate of steel and

welding materials, if doubts exist, then chemical analysis and recheck are required.

Uncertified materials shall not be permitted.(2) The steel plate shall be checked with respect to material, surface condition, size and

quantity in accordance with the requirements. It is not permitted if the corrosion

allowance of the steel plate tolerance is above that of the steel plate thickness

allowance when repairing gouges.4.7.4. Storage Tank Prefabrication(1) The component prefabrication shall be carried out according to the installation

procedure. The major components shall be composed and fabricated in accordance with the drawings .

(2) The plate and welding groove shall be machined with the methods of automatic and semi-automatic flame cutting .The edge of bottom edge plate shall be machined with the method of manual flame cutting.

(3) Plate edge surfaces shall be smoothly fabricated and free of such defects as slag’s, laminations or cracks .

(4) The components shall be checked with the template to assure precision during prefabricating.

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(5) Valid measures shall be carried out to prevent the components from deformation, damage or rust in the period of storage, transportation and field piling-up.

4.7.5 Bottom Plate Installation(1) Prior to the bottom plate laying, it shall be sandblasted and coated against corrosion,

50mm edge of the plate edges shall not be coated.(2) Edge plates shall be laid symmetrically both sides and the seams are to be welded

with base plates. The two moving plates shall be prepared as per actual sizes.(3) The laying of central plate segments shall be carried out from the center to both

sides and generally long plates shall be laid prior to septarian plates. Three overlapping plates shall be angle cut in accordance with the requirements of the drawings.

(4) The bottom welding shall be strictly carried out in accordance with the Welding Procedure.

(5) The welds of the bottom plate shall be vacuum tested and free from leakage.4.7.6 Roof Plate Installation(1) The first ring of shell plates shall be installed on the bottom plates, then the top angle

installed and support legs or pontoons fabricated prior to the assembling of the roof plates.

(2) The clearance between every adjacent weld of the roof plates shall be in accordance with the drawings and the specifications.

(3) Support columns for tank roof shall keep straight and vertical allowance shall not be more than 0.1% of column height.(4) Roof plates shall be symmetrically assembled as per the drawn mean line. The

overlapping width of roof plates shall be in accordance with drawings and specifications.

4.7.7 Shell Plate Installation(1) The shell plate of the first ring shall be installed and welded to the roof plate, then be

lifted up with chain blocks and the other shell plates will be installed until the last ring of shell plates.

(2) The enclosing plate shall be hoisted to its position according to the composition diagram and then clamped. After the installation of the enclosing plates, the clearance of the vertical joints and the verticality shall be adjusted and the levelness of upper ring surveyed. The misalignments of girth welds shall be 20% less and that of vertical welds shall be 10% less than the shell thickness of the upper plate.

(3) The welds shall be detected in accordance with the requirements. The clamps shall be removed , and dents polished, and internal welds be ground with high velocity abrasive machine or polishing machine.

(4) The assembled welding shall be in accordance with the follows:a. The shell height deviation allowance shall be in accordance with the drawings and the

specifications.b. The deviation allowance of the wall verticality shall be no more than 0.5% of shell

height.Page 53 of 88




c. The clamps shall be removed from the wall and the dents and welding residues repaired.

d. After the welding of the tank bottom, the local concave-convex deformation shall be in accordance with the drawings..

4.7.8 Welding and Flaw Detection The welding and flaw detection of the bottom plate, shell plate and roof plate shall

be carried out in accordance with the structural steel welding procedure 4.7.9 Accessories Installation(1) The installation of the ladders, heaters and platforms shall be carried out as per

drawings and specifications. (2) The center position deviation of the pipe adapter of the tank opening shall be as per

requirements of drawings and specifications. Deviation of extension for pipe adapter shall be in accordance with drawings and specifications. The curvature of the opening patching plate shall be the uniform as that of the tank.

4.7.10 Hydro-Test(1) All accessories and components welded with the tank shall be finished completely

and the welding seam relating to leakage test shall not be painted.(2) Hydro test shall be slowly performed and be observed as respects of the foundation

settling, strength and tightness leakage status of the tank, tank bottom and the roof.(3) The foundation settling test shall be carried out to assure the unevenly settling within

the deviation allowance until the stability is obtained. The bottom shall be qualified against leakage. The wall and the roof shall be free of leakage and abnormal deformation..

(4) The heater hydro-test shall be carried out in accordance with the specifications and sustain the test pressure for a specified period.

4.7.11 Corrosion Protection And Insulation(1) Corrosion protection shall be carried out in accordance with corrosion procedure.(2) The equipment requiring insulation shall be carried out in accordance with insulation

procedure.4.7.12 The temporary supports and other foreign materials of the tank shall be removed,

inspected and accepted by OWNER and closure record affixed.4.8 6.6KV water injection pump and diesel engine Mud pump

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4.8.1 General

(1) Foundations shall be completed and checked for correctness and levelness as per drawings and specifications. Prior to installation, foundation shall be clean with correct anchor bolt holes location, centerlines marked, elevations and levels established for correctness. Shimming and wedging shall be carried out as per drawings and specifications.

(2) As required, perform on-site installation of the various equipments as per approved construction drawings and specifications, and instruction by a manufacturer/vendor representative.

(3) Final insulation jacketing shall be completed so that there will not be an excessive amount of scaffolding erected in the plant areas where operators will work during start-up. The number of insulation crews still working in the area shall not be excessive.

(4) At the time of Mechanical Completion all fire proofing and rough insulation shall be completed, i.e. all equipment, piping, instruments, instrument leads, etc. requiring insulation for heat conservation shall be covered so that start-up operations will not be delayed due to excessive heat loss. Insulation required for personnel protection shall also be completed. Only areas that would be required to be open for tightness testing (flanges, valve stems, etc.) will not be covered prior to Mechanical Completion. Exposed insulation is to be properly protected and sealed.

4.8.2 Rotating Equipment Installation (1) Prior to installation, inspection for equipment acceptance to be carried out.

Equipment installation includes loading, hauling, unloading, inspection, lifting, shimming, aligning, placing, and securing in its final position.

(2) Remove all temporary supports, bracing or other foreign objects that were installed in the equipment or machinery to prevent damage during shipment, storage and erection, and repair any damage sustained. This may need vendor assistance.

(3) Before positioning the equipment, it shall be checked against the drawings to verify the pipe installation of flanges, nozzles, junction boxes, couplings and other items that require external connection.

(4) CPECC to prepare lifting and rigging plan for all heavy lifts taking into consideration location and other activities such as equipment insulation, structural platforms and ladders, instrumentation, piping erection and other work which can possibly be accomplished prior to final erection of equipment, saving scaffolding and basket work.

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(5) The foundation and anchor bolts preparation shall be completed and checked by CPECC’s QC inspector prior to installation of equipment.

(6) Prepare foundation surface, install equipment, and level the equipment as per approved drawings and specifications.

(7) Inspect and check the work during the construction stage, and perform such non-operational tests as are necessary to assure the integrity of the installation in accordance with the issued for construction drawings, specifications and vendor instructions.

(8) Flush systems and perform initial charge of all lubricants. Dispose of all flushing oil to an area approved by OWNER.

(9) Conduct all operational tightness tests.(10) Qualified craftsman with experience in installing rotating equipment will be

assigned at site during the erection, installation, commissioning and start-up period with vendor assistance as required for all special equipment.

4.8.3 Pumps(1) Rotate pumps by hand to ascertain that they turn freely.(2) Align pump with driver after coupling installation; ensure that the axial and radial

deviations, and axial clearances are within the approved tolerances.(3) Disconnect the coupling, check motor for rotation, run-in for two (2) hours

uncoupled and check bearings. Submerged pump/motor may be run-in coupled. After motor No-load test, re-couple pump to motor.

(4) Install proper lubricants (fuel, coolant) prior to commissioning after review with OWNER.

(5) If the pump is to be used for flushing, install temporary packing if permanent packing or mechanical seal is not suitable for flushing.

(6) Install strainers in the suction piping to prevent foreign objects from entering the pump during commissioning and initial operating period.

(7) Reinstall permanent packing or mechanical seal on any pumps used for flushing.(8) Check that machinery guards are available and should be fitted as per drawings and

vendor’s recommendations.(9) Check and run-in pumps, maintain them after Mechanical Completion. (10) When necessary, clean strainers by operators after pumps have been in operation for

a reasonable period.(11) Check the general compatibility of the pumps with respect to any cavitations

problem, discharge head, excessive vibrations, excessive noise, etc. which may hint at abnormal operation of the pump.

(12) Obtain the assistance of manufacturers if required.

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4.9 Diesel Engine System

(1) Vendor equipment drawings shall be reviewed together with the specification requirements

before commencing work.

(2) Foundation surfaces shall be clean prior to install.

(3) Before installation, all locations, elevations and orientations of the equipment foundations,

anchor bolts shall be checked and verified in accordance with approved drawings and

specifications.

(4) Remove all the protective covers from all openings.

(5) Data lines of levels, and/or axis shall be marked/painted on the foundation.

(6) Ensure steel packs/shims of adequate number are provided and leveled to the required elevation

on each side of holding down bolt as per specifications and vendor’s recommendations.

(7) Level the diesel engine sets with packs/shims supporting the base plate near the foundation

bolts and at any point of the base plate carrying a substantial weight load.

(8) It is very important that the siesel set base be set level to avoid any mechanical difficulties with

the pump drive sets.

(9) Check alignment in accordance with vendor’s recommendations. When the unit has been

leveled and aligned, the holding down bolts should be gently and evenly tightened.

(10) Check rotation of driver and it is correct and rotating freely after the final tightening of

holding down bolts and pipe flange bolts.

(11) Chemically clean any completed lube and seal oil system, when specified. Dispose of wastes

and cleaning media in accordance with OWNER instructions.

(12) When specified, the lube oil, control oil and oil cooling systems with flushing oil and

circulate for cleaning purposes. Dispose of any flushing oil in accordance with OWNER

instructions.

(13) Arrange for pipe work to be finalized to the engine sets. It include diesel pipe and start air

pipe .Support the pipes independently by the use of proper pipe supports.

(14) Charge the lube oil, diesel and water-cooling systems based on recommended of

manufacturer .

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(15) Perform all the tests as specified in the relevant data sheets and specifications.

4.10 Electrical installation

Introduction Electrical works of the project include 2 sets of 33kv/6.6KV and one 33kv/0.4kv

transformer, MCC for sand Pump ,6.6KV switchgear and soft starter for 6.6KV

water injection pump. lighting, earthing, cathodic protection system . The power transformer supplied from near by overhead transmission line which

shall be installed by others. Installation of earthing systems

1) The location for earthing electrodes and the route for earthing trunk shall be

determined as per design drawings and site circumstances prior to trenching.

The depth of trenches is not less than 600mm, earthing electrodes shall be so

buried that their top ends are 100mm below ground. 2) Earthing electrodes shall be copper bars with diameter of 20mm and length of

3m. Removable connections are available between earthing electrodes and the

earthing grid. The underground connections in the earthing system are

accomplished by fusion welding.3) The both ends of main electrical equipment, including switchgears, shall be

earthed.4) The earthing resistance of the system shall not be more than 10Ω.

Installation of cathodic protection systems of tankInstallation of cathodic protection systems shall be referred to installation procedure.1) Installation of rectifier unitsa) Prior to installation, check and ensure the nameplate parameters in accordance

with the unit data sheets and ensure the unit and meter surface free from

chemical damage.b) Unit foundation shall be level and flat in surface and correct in location.c) The location of cable inlet and outlet shall be correct.d) Rectifier unit shall be installed tightly and reliably.

2) Installation of tank bottom anode bed, this job must be down before tank

foundation completed.a) Prior to anode installation, check the type and specification in accordance with

the construction drawings and ensure anode to be free from any damage.

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b) Ensure the installation depth and the space between the location of anode ground

bed and the protected pipes to be in accordance with the construction drawings.c) The insulation resistance shall be measured prior to laying of anode cables.

Laying route and location of anode cable shall be in compliance with the

construction drawings. d) The connection of anode cables shall be tight and its sealing shall be in

accordance with specification and manufacturer’s instruction manual.e) The space between anode ground bed surface and non-piping structure (eg. cable

etc.) shall be as a minimum of 0.3m.3) Installation of the junction box Prior to installation of the junction box, check and ensure the specification and

type to comply with the construction drawings without mechanical damage. Installation location and height of the junction box shall be in compliance with

the detailed construction drawings. The laying route of cables shall be as per that shown in the construction

drawings.4) Cable connection The connection of cables in the junction boxes shall be reliable and tight with

correct and complete marks. And the inlet and outlet of cable shall be glanded

properly. The connection location of negative cable with pipeline shall be as per that

shown in the construction drawings. The connection of negative cable with pipeline shall be accomplished by

thermite welding or with stainless band and the painting shall be applied to

coat the connection. T joint shall be applied to connection between anode cables and positive

cables. The joint shall be insulated with heat shrinkage material.5) Inspection and testing of systems Testing and inspection of the connection of installed cathodic protection system

with cables ensures it to be proper. Measurement and adjustment of the output voltage of rectifier makes it to be

compliance with the design value. Measurement of natural potential. Performance of system hook-up and energizing and measurement of the

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energized/protected potential. Measuring and recording total current output and settings at the CP stations.6) Installation of insulation joints The insulation joints shall be installed for pipeline in compliance with the

location as specified in construction drawings. Prior to installation, check insulation washers, insulation bushing and such like

to ensure them to be free from cracks or defects. Installation of insulation joints as per detailed construction drawings. Measure the joints insulation resistance with 500v M meter to ensure the

measured value shall be over 1 M.Installation and testing of transformers

1) Inspections prior to installation A check shall be made for complete shop certificates and technical documents.

An acceptance inspection of transformer foundations shall be carried out by

electrical engineer in connection with civil and QC personnel. An inspection of oil tank shall be performed for complete accessories, perfect

porcelain parts, tight seal and good appearance without corrosion and

mechanical damage. A check shall be made for complete bolts of tank covers, tight fastening without

leakage, and clear level indication.2) Installation of transformers When transformers are put in place, attention shall be paid to ensure their

orientation in accordance with drawings. When they are lifted, the sling

deviation from plumb line shall be less than 30°, and collision and severe

vibration shall be avoided. For a transformer with gas relay, it shall be installed in such a manner that its

top cover has an ascent of 1%-1.5% along the gas flow direction of the gas

relay. Transformers shall be so installed that the center lines of bushings are

coincident with those of duct busbars and the height of bushings is matched

with that of duct busbars. After transformers are put in place, their roller shall be locked with removable

brakes. Ensure the earthing of transformer and foundation to be perfect.3) Testing of transformers

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DC resistance of windings along with bushings will be measured, the measured

values compared with product data at the same temperature, the difference shall

not exceed the specified value. Measurement shall be made at all the taps. Transformation ratio of each tap will be measured and compared with the data

in the nameplate, the difference is little and is in accordance with the

transformation ratio law.Vector groups identification shall be in accordance with the design requirements

and marking in the nameplate. Insulation resistance and absorption ratio of windings along with bushings shall

be measured and be in accordance with the requirements. The power frequency voltage withstanding test shall be performed on the

windings along with bushings pursuant to the specification requirements only

during FAT. Insulation oil test.

MCC and 6.6KV Switchgear installation1) Installation of Switchgear (MCC and 6.6KV Switchgear)

Inspection by opening package against the construction details and progress

status with the QC personnel and make a record based on the result of

inspection. The switchgear shall be bolted after its alignment. An inspection shall be made

for horizontality, verticality of each cabinet and front face deviation and gap

between cabinets in accordance with relevant regulations. Switchgear shall be grounded in accordance with construction details.

Inspection equipment earthing system and measure the grounding resistance. After installation, check the mechanical interlock and electrical interlock to

ensure they are exact and check the contacts to see if they are tight. Check breakers with track and distribution units with drawer for the alignment

of drawout mechanism to make sure they can move freely, units of same type

can be interchangeable. Panel body and interior devices shall be connected firmly with all structural

members, check the fuses, CT&PT, indicators and relay to ensure they are all in

compliance with design requirements.2) The Installation of Electrical Units of High and Low Voltage:

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If breakers and switchgears are packed in separate cases, check the breakers

and controlling mechanism when received to ensure the parts are complete, free

from mechanical damage or corrosion, and insulation parts shall not be found

deformation or damped. The connection parts at the end of insulation brace shall be stable and firm. The

porcelain-busing surface shall be smooth, free from cracks or damages. The action of breaker combined with controlling mechanism shall be correct

and exact, free from blockade. The indications for switch- on and switch-off

shall be correct. The action of auxiliary switch shall be correct and reliable. The installation of isolating switch and load switch Mechanism/driving unit/auxiliary switch and interlock device shall be stable

installed, the action flexible and reliable, and position indication correct. The asynchronous value of 3 phases shall conform to the technical regulation of

the product when switch is on. The contact shall contact well and firmly when the switch is on.

Lighting installation1) The Installation of Light Fixtures:

Check the type and specification of light fixtures to ensure they are in

compliance with area classification regulations. Select light fixture and installation mode in accordance with engineering

drawings. The lighting fixture shall have complete set of fitting parts, free from

mechanical damage, deformation, cracks on lamp or paint stripped and it shall

be in good insulation as well. In accordance with engineering drawings, finish the assembling of light fixtures

and pole and complete installation shall be uniform. Upon completion the

fixture shall be powered up for the lighting test. The switch height of light fixture installed in a same place shall be uniform. On

every layer of equipment platforms, the light fixtures shall be symmetrically

arranged and aligned. The light fixture and support shall be fixed firmly and stable. The light fixtures

shall be beautifully installed and in good order. The pole shall be straight,

stable and the welding points shall be treated with paint. The orientation in which the light fixture installed shall be adjusted to give

optimum lighting distribution; it can conform with the operating requirements.

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Attention should be given to installation of light fixture when high-pressure

sodium light is installed. Upon the installation completion of explosion-proof light fixture, the

connection interfaces shall be glanded. Before streetlights are erected, the assembly of the fixture shall be first fitted on

the ground, and then, examine and test wiring connections and insulation

resistance. After the lights is powered and lit, lift the assembly fixture with a

crane and firmly fix it on the ground.2) The Installation of Socket

Check the type and specifications of socket to ensure they are in compliance

with the requirements of area classification. The height of sockets installed in the same place shall be identical and the

orientation in which the light sockets installed shall satisfy the operating

requirements. The connection of socket and cable shall be in compliance with the terminal

mark. The cable inlet of socket installed in anti-explosion area shall be well glanded. Clear marks shall be made for sockets of different voltage levels.

HV cable Termination The fabrication for the terminals of power cables shall be undertaken by the

competent personnel who are familiar with the fabrication process as per the

detailed sketches supplied by the manufacturers. When fabricating the HV cable terminals and mid-joints in outdoor spots, no

dust or foreign materials shall be permitted to fall into the insulation.

Construction under the foggy or raining condition shall be forbidden. The lead-sheathed cables shall be lead-sealed. The lead-sheathed and armored-

layer of all terminals of cables shall be well earthed. The HV cables terminals shall be made of thermal shrinkage materials and

carried with the devices of stress relieving, cable shielding, and armored

earthing etc. Before the cables are finally connected, the testing for conduction and

insulation resistance shall be made. The DC withstand voltage test shall be

made to the high-voltage cables as per the relevant stipulation.

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All the cables shall have the labels attached on both ends of the cables which

mark the cable numbers, types, specifications, starting points and terminal

points from the cable lists. The labels shall not be attached on the connection

spots and controlling station of motors.4.11 Installation of Instrument Equipment

The height (from center of instrument to floor or platform) of installed local

instrument shall comply with the requirement, Display instrument shall be

installed at visible places. Instrument shall be installed, far away from magnetic fields and heat sources,

kept at vibration free places, and protected from corrosion. In-line installed instrument or measuring elements shall be removed from the

lines, when pipelines are purged; and re-installed after purging. Instrument shall be installed at places providing easy access for reading. Instrument supports shall be secure and safe and they shall be coated.1) Pressure instrument

For pressure tapping of pressure instrument, dynamic pressure affection shall

be avoided as possible.2) Temperature instrument Thermometers shall be installed in the places where mediums flow smoothly

and the correct temperature can be reflected. The sensors of thermometers shall be installed near the centerline of piping. For

piping smaller than DN80, expanded tubes shall be added pursuant to design

stipulation. Bi-metal thermometers shall be protected from bending and deformation of

protection tubes in storage, transportation, installation and use, when they have

to be rotated in installation, exerting force on the instrument shall be avoid in

all cases. Bulb thermometers (temperature switches) shall be inspected for damage of the

pressure tapping and seal face before installation, a pre-installation shall be

made prior to the actual installation. The Bulbs shall be able to be installed and

removed freely. They shall be fully submerged in the medium. Capillaries shall

be protected and shall be secured with tapes after actual installation. The

bending radius shall be in accordance with the technical requirement.3) Control valves

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Control valves shall be installed vertically in the places where operation and

maintenance are easy, supports shall be installed if necessary. The height of valve pedestal above floor shall be in accordance with the

requirement. The solenoid valve separately installed shall be as near to the actuator as

possible without interfering normal operation and maintenance.4) Field control panels Installation of field control panels facilitates operation and maintenance. Field control panels shall possess safe and secure protection earth bars. Qualified personnel shall check board-installed instrument of field control

panels.4.12 Cable Laying Down and Wiring

1) Cable arrived at site shall be checked to make sure that their types,

specifications and quantities are in conformity with the design requirements, no

visual damages and defects exist and certificates are provided.2) A list for cable allocations shall be prepared according to the actual length of

cables delivered to site and the length for laying. The sequence for laying down

shall be arranged and decided according to site situation.3) After the construction of cable trays (trenches) is completed the foreign

materials shall be removed from inside and cables will be laid down until

conditions permit.4) Prior to laying down, cables shall be inspected and tested for their continuity

and insulation property and records shall be made in time.5) The surface color of intrinsic cable is blue and they shall be laid down separate

from the non-intrinsic cables.6) Generally, cables will be laid down in a single action, Caution shall be taken to

protect cables from damage. Indelible identification marks shall be tied at the

each end of the cable. The arrangement of cables in trays (trenches) shall be

neat. When cables are laid in vertical, suitable supports will be provided to

secure them.7) After completion of cable laying, a further inspection and test for their

continuity and insulation property shall be carried out. A record for cable laying

and for re-measurement of insulation resistance shall be completed. When

confirmed satisfactory the cable tray covers shall be installed as soon as

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possible to protect cables from mechanical damage and fire.8) When cables are laid down in trenches, sand or soft soil will be filled and

compacted in accordance the drawing requirements.9) Electrical continuity shall be well maintained for the cable shields. One end of

the cable shield shall be earthed on the side of the control room. Unless

required otherwise in the design documents, the indoor cables shall be earthed

at the place defined in the design drawings.10) Field-mounted instruments shall be earthed in accordance with the requirement

in design documents and instruction.11) After completion of instrument loop tests, the entrance of cables beneath a

cabinet shall be cleaned for protection. The method of sealing and type of

material used will be decided before the cabinets are delivered.

4.13 Material Handling, Storage and Delivering

Material Handling1) Materials shall be handled with suitable slings, pipe hooks, leather belts and steel

plate clamps to prevent damage to the materials. If wire ropes are used, liners should

be placed between the rope and the material.

2) If sections of steels or steel plate are handled, the distance between wire ropes

and the weight of the material shall be considered to prevent damage or deformation

of the materials.

3) Caution shall be marked on the material packages, which are not to be compacted

or inverted, each package shall be handled as a unit.

4) If damaged equipment are found during handling, the damaged equipment shall be recorded, and the purchasing department shall be informed.

5) The equipment and material shall be marked during handling and transportation,

the marks or tags shall not be removed, damaged or erased.

Material Receipts and Storage

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1) The warehouse shall be constructed close to the living areas with smaller size

stores on each site location. All stores must be within the construction area.2) Material control shall establish a material receipt, storage and issue system

ensuring withdrawals are made using a Material Withdrawal Request (MWR)

authorized by the Construction Manager.3) Receipts must be checked for correct quality, specification quantity, and

model/tag numbers against Drawings as necessary, coding against the packing

list and purchase order. A Materials Receipt Report (MRR) must be raised and

issued to QC.4) The QC department shall ensure all equipment and materials comply with the

technical specifications and the second clause herein and sign off the MRR if

satisfied. Items lacking certification shall be quarantined until all deficiencies

are satisfied. 5) For Material discrepancies, damages, shortages, overages, non-conformity with

the PO or specification requirements QC shall raise a Non-Conformity Report

(NCR) to Material Control to issue and unacceptable Overage, Shortage and

Damage Report (UOS&D, interfacing with procurement and engineering to

resolve.6) Damaged/defective materials shall be quarantined and tagged ”Not for Use”.7) The engineer shall decide whether defective materials can be used and the use

of material not complying with the specification is subject to PDOC written

approval.8) All packed materials shall be repacked after inspecting if not used immediately.9) Material Control shall protect materials against damage during receipt, storage

and issue, corrosion and deterioration ensuring the Manufacturer’s necessary

Lifting, handling storage and preservation procedures are available and

followed.10) Welding Materials shall be stored and locked in a secured dedicated warehouse

and controlled by specific personnel using temperature and humidity control

equipment as necessary. 11) Steel products shall be stored together on ‘sleepers to prevent soil contact, but

segregated according to grade, size and clearly tagged.12) The distance between supports shall prevent steel pipe plates and sections from

distorting. Stacking height restricted to prevent weight damage and toppling.

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Wedges/stops shall be placed at stack ends to prevent collapsing and rolling.

Protective Materials shall be used for coated pipe.13) Where possible major and heavy equipment must be shipped direct to the job

site to reduce handling.14) Special tools must be stored separately, signed out for use, signed in on return

and maintained in good order.15) Cable can be stored outside, on sleepers to prevent soil contact. Cable reels

shall be hooded to protect against sunlight.

4.14 Construction Quality Management

1) CPECC establishes a QA/QC department under project management office. The

QAQ/QC department is responsible for quality management, supervision and

inspection. There are some full-time QA engineers and QC inspectors in the

QA/QC department and construction teams. They will be in charge of the

quality management, supervision and inspection, carrying out the project

quality plan and the documents of ISO 9000 quality system strictly under the

owner’s supervision.2) The project management office shall establish a quality assurance system

in accordance with ISO 9000 quality system, prepare procedure documents

for construction and for construction quality control prior to construction.

Construction and inspection activities shall be carried out in accordance

with the contract, the specifications and the procedure documents.

4.15 Construction Quality Control (QC)

1) All QC operations are responsible for enforcing the quality system thus

ensuring engineering meets the required quality objectives.2) A specific quality inspection plan shall be prepared for each discipline.

Inspection Hold Points shall be determined for key and major operational

sequences. The QC Engineer will not permit work to proceed to the next step

until he/she has inspected the Hold Point and issued an Inspection Release

Note.3) Quality supervision of four levels as follows: Level A - Quality supervision is carried out by PDOC or the supervision

company.

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Level B - by the project QA/QC Management engineers. Level C - by the subcontractors or the construction teams. Level D - by the construction groups.4) The method for quality management, awards and penalties will be

implemented. QA/QC has the right to inspect the quality of construction teams

or subcontractors covering any discipline at any time during construction. They

have the authority to reject construction work stating the reasons, and the right

to issue time-limited list of remedial actions(s) required, placing a hold on

further work until the rectification until satisfied all corrections have met the

QA/QC requirements.5) A weekly Quality meeting will be held to discuss current issues and progress

and the overall quality inspection and monthly to discuss and evaluate the

operations of the quality assurance system and to analyze engineering quality

and effect a program of actions to resolve any outstanding issues.6) Feasible and practicable measures shall be taken in rainy and windy seasons to

provide good to guarantee the welding quality.7) Strict inspections and quality checks of operational sequences shall be

conducted. When construction is complete, the records shall be audited.

Inspection of key operational sequences against hold-points shall be carried

out in accordance with the requirements in the procedure documents and in the

presence of representatives of parties (Owner, Supervision Company and

Contractor). The construction activities of the next operational sequence cannot

be performed until the sequential action immediately prior has been accepted

and confirmed in writing.

4.16 Construction Quality Assurance Measures

Assurance Measures1) CPECC’S shall be fully implement its QA policies. Effective quality assurance

system shall be established and maintained throughout the construction phase.

The Quality plan and quality management regulations shall be prepared and

carried out in during construction. 2) Construction crews will be trained in accordance with the requirements of the

quality system to ensure the engineering quality. Staffs will be educated to set

up the consciousness of “Quality First and Customer Foremost”, to be familiar

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with and to follow the codes, the specifications, the standards and the

procedures, to receive the supervision and the inspection of PDOC and the

supervision company and to perform the instructions from their representatives.3) Measures to be takena) Establishment of the quality system and completion of the quality management

organization. The project Management Office will ensure QA/QC will to meet the full

requirements of the specifications international standards and ISO 9000

standard, “quality management and quality assurance. Only certified and competent full-time quality management personnel will be

assigned. The quality management department has the right to conduct

surveillance inspection and award and penalize accordingly. The quality

management department is responsible for inspection, acceptance and treatment

of routine quality issues. The Quality Assurance Engineer of the project is the responsible person in

charge of construction methodology, the quality assurance persons are those

who are in charge of monitoring the quality construction teams and

subcontractors. Prior to construction, all the staffs and management will be familiarized with

the necessary codes, specifications, standards and quality requirements and

construction drawings related to the project. They shall read and review the

construction drawings on as necessary on an inter-disciplinary squad-check

basis to familiarize themselves with the layouts and inter-connections of

different materials and equipment and draw up any special operational

procedures and stipulate any hold points. As materials and equipment arrive, they shall be checked against the material

requisition specifications, drawings in terms of size and quantity and against

international codes and standards. An acceptance Note will then be issued. If they are rejected, the reasons will be

given on the rejection note, prohibiting their use, and outlining a course of

remedial action or they are replaced as necessary. All raw materials, fittings, parts, components, equipment for project use must

be supplied with material certificates and shop certificates. For special

materials, attention shall be paid to identification, marking and marking for

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cutting (ensuring records are made at the time and properly kept). Testing and metering apparatus or equipment shall have valid up to date

calibration certificates. They shall be maintained and stored in accordance with

the relevant regulations to ensure their accuracy.b) Carrying out strict process quality control CPECC’ will be fully responsible to the Owner for the timeliness and quality of

construction, project handover and subsequent ease during project operation. The Handover shall be carried out in accordance with the stipulations in the

“Table for quality Control of Operational Sequences of Project Construction” to

insure against starting the next sequence from an unacceptable sequence.

Periodic and non-periodic inspections shall be organized by discipline

technicians and quality inspectors to improve construction quality and correct

quality nonconformities arising in construction. For key spots and difficult points in project construction, key and specialized

operational sequences shall be established in accordance with CPECC’S quality

manual and the hold-point inspections shall be made for key points in

accordance with the specified inspection manners and conditions against the

specified inspection tables by the dedicated inspectors.c) Thoroughly manage quality well into construction, such as pressure testing,

commissioning and start up. For mechanically completed systems (items), an overall inspection shall be made

before commissioning. This is to confirm the construction of the key activities

and processes satisfy the requirements in specifications and standards. Checks

are carried out to ensure correct materials and fittings are used in the high

pressure and temperature systems, no additional stress is exerted on the rotary

equipment by piping, indicators and alarm apparatus operate correctly,

sensitively and reliably, and records, information, data, drawings and their

copies are complete, and correct. A dedicated department with sufficient manpower for pressure testing and

commissioning will be established. It shall prepare procedures and obtain

approval from the owner or the supervision company prior to pressure testing

and commissioning. Where quality problems are discovered during testing and commissioning or

later discovered during operation, and it is established that they resulted from

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construction, they shall be immediately rectified without preconditions. If they

are caused by product defects, manufacturers shall be informed and asked to

mobilize their necessary specialist(s)/site service engineers to resolve as

necessary matter of priority. Records and information about project quality shall be collected and filed in

time. As-built documents shall be sorted, compiled and bound in volumes in

accordance with the specified requirements, and handed over to the owner

through the formal procedures.4.17 Important Quality Control Measurement In Each Discipline

1) Civil Conduct tests on raw materials such as cement, steel etc. Mix Ratio test of concrete and mortar. Use of locating formwork for anchor bolts to embedded. Piling according to specification.2) Welding Make sure that materials and fittings are in good quality, pay attention to

acceptance preservation and marking. During the period of construction, inspect the first completed weld, before

allowing welding to continue. Welding parameters should satisfy WPS and welders shall be qualified

accordingly before they can proceed with welding. Records for all Welding activities shall be made for process control. Ensure that any system to be pressure tested is totally completed and, that

installation is in accordance with P&ID, isometric drawings, and other relevant

data requirements.3) Static equipment and steel structure Attention shall be paid to quality control of prefabrication of members. Assembling and fixing scheme should be prepared, and members shall be

inspected for correct dimension. Temporary fasten measures shall be taken for beams to be butt welded.4) Equipment hoisting Work out lifting technical scheme, set up site commanding system. Prior to lifting, an overall inspection shall be made for correct condition of

hoisting equipment and tools.

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All the hoisting activities shall be under the command of the site commander.5) Electricity

Electricians shall report to duty with certificates.6) Instrumentation. Make sure that the calibration certificates of instruments and devices are valid. Calibration room shall be provided with air conditioners to meet the ambient

requirements. Instruments calibrating staff shall be qualified. Pre-commissioning scheme shall be prepared in detail.7) Painting and coating Painting material shall be checked for complete inspection reports and

certificates. Coating and painting shall not be done until surface preparation is acceptable. The next procedure shall not be continued until OWNER regard the hold point

is acceptable.

4.18 Safety Security Policies in Construction

General CPECC management regulation and ISO14000 program about safety in

production shall be followed at all time. The project director is designated as

the first-person in charge of HSE management with the promise of strictly by

the regulations of health, safety and environment; respecting local customs;

ensuring safety production. Safety is number one, education as leading, work for improving the safety

quality of staff, carry out the safety education and provide regular, especially

to drivers, operators in high overhead place and those who work in hazardous

zone. Promote the safety consciousness among staff. Conduct regular safety

examinations to avoid any possible accidents from occurring. The safeguard

department is examination and direction to safety construction on site. Project managers are the first-person taking charge of the safety in production.

Chief engineers are in charge of the safety of technology. Safeguard

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department is in charge of safety supervisions and examinations. Operators

comply with their own operating regulations and establish posts responsibility

system of safety in production. Identify the function of each management department. Establish and complete

the management regulations to form a integral safety management system and

a complete safety management network. Management Measures1) The staff attended the construction must receive HSE training education. The

certificate shall be obtained after passing of the test. Personnel engaged in

special types of work shall obtain the safety training about technology and go

to posts with safety operation certificates. All the construction staff shall be

familiar with HSE management regulations of PDOC upon their arrival at site.2) The construction teams must be told about the detail technology. The whole

staff shall obtain the education about health, safety and environment before

starting work.3) Carry out the safeguard regulations of the project strictly. Go to work in frocks

and wearing the safety helmets. The safety belts must be tied when operating

in overhead place. The examination to be made by specified safety personnel,

none of unqualified man is allowed to enter the construction site.4) Aiming at the safety technical measures taken in, during the construction of

facilities and pipelines and during execution of non-destructive examinations,

welding, hydraulic pressure tests, gas sealing tests, and electric and

instruments test, etc. the detail management measures about health, safety and

environment shall be established.5) Safety inspection is to eliminate the unsafe factors during the construction and

is to prevent the happening of accident. Specified safety officers examine the

site at all the time to find out dangerous elements and eliminate them in time.

In case of finding unsafe elements, they have the right to stop work and take

action, and report to construction team(subcontractor) for rectification. The

construction teams shall perform self-examinations daily.6) Do seasonal examinations. Prevent sliding, electric striking and mosquito

biting in rainy season; and prevent heatstroke and fire in dry seasons to protect

the safety of personnel and facilities.7) The full-time personnel take charge of inspections, examinations and

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emergency reactions and the contact with local relevant departments. Work

teams shall address health, safety and environment before work and make

records on daily meetings.8) Insist on work permission system prior to entering into construction site. If

any welding or gas cutting operation is needed, the safety inspector shall

transact hot work permission. 9) When operating in a container, it is necessary that a person shall be on watch.

For lighting, the power supply shall be 36v. If the construction is carried out at

night, enough lighting shall be provided.10) The team rooms, construction facilities, engineering equipment, materials and

semi finished articles on the site shall be laid out in accordance with the

requirements of construction organization design.11) The welding clamp cables, rubber tubes for gas torches, riggings and other

tools used in construction shall be taken back and put in order or stored in

warehouse.12) Enhance the power management. The temporary cables, switches, power

facilities shall be complete protected with good earthing connections. The

electrician on duty shall examine that every day. In case of finding problems,

he shall settle them at once.13) Electrical testing shall to be carried out by more than two persons.14) The insulation of electrical facilities shall be protected from becoming damp

and pollution. Dampen electrical equipment shall be dried.15) The high voltage test and complicated system test must be examined by the

personnel who in charge of technology before starting. A no-load test shall be

carried out before the load test when testing switchgears, relevant handles

shall be taken down or locked and warning card shall be hung to prevent

wrong switching on. 16) No person is permitted to stand under the crane booms during the lifting

operation. All the riggings shall be strictly checked before lifting. A dangerous

area shall be marked out when lifting bulk materials. The warning cards shall

be set up when X-ray detection or gas pressure test is carried out to prevent

unauthorized persons from entering the operation area.17) The facilities of drainage, lightning protection and fire fighting shall conform

to HSE management regulations. Combustible, explosive, poisonous and

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harmful articles shall be stored in special containers.18) The sources of power, water and gas shall be cut off after day's work. Remains

and rubbish shall be cleaned away from the work area and disposed and buried

in accordance with the rules.19) The construction site shall be managed pursuant to the general plan. The

temporary facilities, material yard and equipment shall be laid out as per lay

out drawings design. Site materials shall be kept in good order and the utility

facilities shall be set up in order. Remove the temporary facilities and clean

away the rubbish in time, and keep the area tidy and clean after the completion

of construction. a) rubber tubes of gas torches shall be brought back in tool rooms and put in

good order after day's work.b) The tools shall be returned to toolboxes to prevent from missing. Civilized

construction management system shall be performed. Examination activities

shall be hold timely and award will be given good management and

punishment for poor management. 20) Emergency safety measures shall be taken for commissioning and warranty

period.21) Fire-fighting facilities on site shall be examined and changed regularly. The

fire permit shall be got and fire fighting measures taken, if the fire is used near

the combustible and explosive. The junction boxes in hazardous area shall be

of explosion proof type. Smoking is prohibited in hazardous areas. Oxygen

cylinders and acetylene cylinders shall be protected against the isolation and

put them separately with a safety distance. Warning signs shall be set up in

dangerous area.22) The switchboxes at site shall be protected by water-proof shelters, and electric

leakage protection shall provide. The electrical facilities shall be well earthed.

Operation of "power on" or "power off" shall be carried out in accordance with

work ticket system, warning sign shall be set up. When cables are laid down

under the ground, conduits shall be used for road crossing.23) Machines and tools shall be operated by specified personnel, they go to posts

with certificates and comply with relative safety operating regulations.

4.19 Construction Management

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Handling of Site Changes and Query1) Drawing Revision at SiteDuring construction, as found a drawing unreasonable or a substitute material

necessary, CPECC Site representative will write to Owner Site representative, the

involved work can proceed only after obtaining the approval of Owner Site

representative. If Owner finds a design not in compliance with specification or not

satisfying operation requirement, for ensuring construction progress, Owner Site

representatives can write directly to CPECC Site Representative asking for

modification of this design. All above modifications shall be indicated with red

mark-up in the drawings, which, after verification by Owner Site representative, shall

be incorporated in as-built drawings.2) Site Change OrderFor the modification or any work raised by Owner beyond Contractor’s Scope of

Work specified in CONTRACT, they shall be treated in accordance with

CONTRACT Condition of Contract for Change Orders. If any discrepancy occur

between two parties, the work can be done first as per required by Owner, the

discrepancy may be resolved later on by consultation.Construction Practices

1) Construction Meetinga) In order to ensure right progress of construction, CPECC will have a meeting

every night attended by achieves of all departments to check daily

achievement, problems or concerns appeared and resolution to be taken, and

the planning for the next day.b) For ensuring safety of construction at Site, a Tool Box Meeting shall be held

every morning at Site prior to commencement of work, briefing major jobs and

safety precautions, which normally lasts for a couple of minutes.c) In critical stage of construction, CPECC Site representative will report to

Owner Site representative every morning, mainly about the major achievement

and concerns, for the purpose of ensuring smooth progress of construction

through joint efforts made by two parties.2) Distribution of Construction DocumentsThe Owner’s documents, drawings or other Project related documents as received

shall be distributed as per the instruction of CPECC Site representative to relevant

department or individuals for taking necessary action. All the original copies of

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documents shall be kept by Document Control Department. The vendors’ documents shall be administrated by Procurement Department, which

shall be borrowed to discipline engineers for needs by installation or related activities

during construction.The equipment and material receiving inspection reporting documents shall be kept

in order by Procurement Department.The correspondences between the departments shall be received and distributed by

the document control personnel of the departments.All the documents signed off by Owner for inspection and for test record shall be

kept by QA/QC Department.

4.20 Camp Living Facilities and Temporary Construction Facilities Layout

Camp Living FacilitiesFor providing convenience to construction, we will use existing CPECC Palougue

camp During construction site, the Owner’s personnel office will be furnished with

all equipment and facilities as specified in CONTRACT Scope of Work.The Owner’s personnel office is in CPECC camp. , CPECC Palougue camp covering about 180,000 m2, having 4 office building, 10

dormitory buildings, 2 dining-room, 1 maintenance workshop, 1 warehouse, 1

roofless storage yard about 60 ,000 m2 and parking areas for parking about 80

vehicles. This camp shall satisfy the needs of accommodation for about 600 CPECC

personnel and 100 local employees.CPECC use 3 nos. 400KW generators to supply power to the camp. CPECC will drill

wells for obtaining water for living purpose.In order to facilitate the communication between the site and the camp, radio

communication system between camp and site has equipped with some walkie-

talkies.Most of living incidental will be purchased in Khartoum and local, partially from

China. CPECC will set up an office in Khartoum and Port Sudan for providing

logistic support such as the convenience of procedure of construction permit,

material custom clearance, arrival of construction personnel and provision of daily

living needs. Temporary Construction Facilities Layout

The Contractor shall be responsible, at his own cost and expense, for the electricity

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and water for construction as per the Contract. In order to facilitate the construction, we have built simple warehouse reformed

from containers and office in the scheduled space near maintenance workshop. In

order to facilitate construction and avoid material re-handling, we will put most of

equipment and material on the site and the expensive and key equipment and

material in the camp warehouse. The tool houses, the planned number of which shall

be 4, and simple break rooms, the number of which shall be 4 and they will all be

equipped with air conditioning. The radiographic test shall be arranged so far as possible to be performed at night

time and all necessary safety precautions shall be taken at RT performance site,

ensuring no person within the dangerous area. All RT related equipment shall be well

stored under supervision of assigned person.To facilitate construction activities and to accelerate construction progress, an

approximate 6,000m2 fabrication yard and a 6,000m2 sand blasting, painting and

insulation fabrication yard will be built near the camp.

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5. Commissioning5.1 Overview

This section will describe the commissioning plan, schedule and procedure in order to meet the requirements specified in CONTRACT.

Commission two 6.6KV water injection pumps and 4 1400KW mud pumps .produced water from Palouge skim tank T-2330 ,transfer to 4000m3 buffer tank, then inject water to wells by water injection pumps and mud pumps.

5.2 Precommissioning 5.2.1 General Description of Pre-commissioning

1) CPECC shall completely check, clean and pre-commissioning all systems and

equipment before commissioning. Owner representative shall witness field tests.

a)16” main water hydrotesting and pigging. b) Water filling test of 4000m3 buffer tank. c)Earething and cathodic protection system. d) Testing on transforms.e)Testing on diesel engine and 6.6KV pump soft starter.f)Lighting and air-conditions.2) Check out lists for all instruments, electrical loops, rotating equipment, etc. shall

be prepared and submitted to Owner for review and approval one month prior to

pre-commissioning.3) Furnish, install and conduct tests where required in the presence of Owner’s

Representative. Clean-up and inspect all systems fabricated and installed CPECC

to provide a complete operating unit in accordance with all Work requirements4) Prepare system test and /or individual line test descriptions complete with

identification of test objectives and a list of equipment and lines to be included in

the test for approval by Owner.5) Follow Vendor’s recommendations and procedures for installing and checking

out equipment and obtain vendor’s agreement that equipment is satisfactorily

installed.6) Prepare pre-commissioning materials and spare parts.7) All rotating equipment shall be rotationally checked. All instruments shall be

loop and functional checked. All valves shall be stroked. All temporary blind

flanges have been backouted.8) Check and rectify all controllers, alarms and shutdown devices.

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9) To complete and clear all major punchlist items that affect the safety, operability

and integrity of the Pumping Facilities.5.2.2 Inspection Prior to Precommissioning

Scope of inspections prior to pre-commissioning shall include, but not be limited to

the following: All materials and works are subject to visual inspection for surface defects. All welds shall be inspected in accordance with the specifications. Welds found

to be outside the defect tolerance shall be repaired or replaced. Complete records

of all weld inspections shall be maintained by CPECC and furnished to owner

regularly. Visually inspect of all instrument and ensure that the installations conform with

the AFC drawings and shall meet the requirement of applicable codes and area. Conduct inspections of all equipment, check nameplate rating, check electrical

connection data, layout and ensure conformity to Inspection on safety features

and earthing system of electrical. Visual inspection and ensure correct assembly of all equipment, correct torque of

all bolts and nuts, lubrication of all moving part and correct

insulation/installation of instrument and electrical.5.2.3 Documents Inspection

Confirm the following documents prior to pre-commissioning: Holiday test reports on outer coating of pipeline. Pigging record. Hydrotest package of pipeline ( include traceability report ). Trench inspection report. Low-in inspection report. Backfilling inspection report. Mark up drawing. Coating inspection report. Insulation inspection report.

5.3 Commissioning Organization Commissioning team will be assembled during the detailed engineering phase

and will consist of commissioning manager, plan/scheduling engineer, procedure/co-ordination engineers for management and process, instrument, mechanical and electrical engineers for technical support.

The commissioning personnel shall be experienced and qualified in similar field production facilities.

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The commissioning manager will be appointed by project manager and keep close relationship with procurement, HSE, construction and other department manager, when needed, for the commissioning work.

Engineering /vendor’s commissioning specialists shall be present at job site for technical support service.

5.4 Commissioning Responsibility1) The commissioning responsibility is briefly described below, which will be detailed after the

establishment of the commissioning team.

a) Commissioning Department Preparation and compilation of plan, schedule and procedure for all

commissioning activities. Review of operation and maintenance manual. Review of commissioning spare parts list. Pre-start-up audit.b) Procurement Department

Arrangement and expediting of vendor’s representatives to be present at job site based on commissioning schedule.Purchase and storage of commissioning spare parts and consumables.

c) HSE Department Safety training of all commissioning personnel. Safety audit which shall be carried out before produced water feeding. Daily HSE management meeting during commissioning phase.d) Construction Department Final leak test for piping. Function testing of instrument, control and safety system including loop

checking. Electrical equipment system testing, test on lighting, power. Maintenance support for commissioning at job site.e) Other Department Arrange for engineering engineers and commissioning specialists to be present

at job site for the commissioning period.5.5 Commissioning Plan

1) The commissioning plan shall be prepared and compiled by CPECC and report to PDOC, to discuss the total commissioning plan with PALOGUE FPF.

2) The content of the plan is listed below for reference. Preface. Detailed design data, fluid flow rate for commissioning and start-up. Commissioning and start-up sequence and schedule. Manpower and equipment resources, consumables.

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Emergency maintenance service.5.6 Commissioning Schedule

The personnel of commissioning department will be at the construction site four weeks before mechanical completion and pre-commissioning to be familiar with the Project. The commissioning schedule will detail all activities.

The schedule shall also indicate the engineering engineers and vendor’s specialists who will participate in the commissioning.

Vendor’s specialists will be requested to support the commissioning. The engineering technical service shall at least include process, mechanical,

electrical, instrument and telecommunication. The vendor’s specialists would be invited to job site, if any default or

deficiencies are found and technical support is needed.5.7 Commissioning Procedure Development

a) Inspection and Preparation Prior to Commissioning1) All instruments have been calibrated for operation.2) The instruments have been calibrated, ready for operation.3) Examine all electrical connections and earthing connections for completion and

security.4) Operators are familiar with operating manual and relevant vendors’ data.5) All required personnel, equipment and tools and recording forms are ready for

operation.6) Inspection and Preparation Confirm all mechanical completion records have been signed off and there are

no a category punch items. Ensure that prior to start up that the area is suitably barricaded off, suitable

firefighting equipment and the relevant permit to work are in place.7) Piping

Ensure that all piping /pipeline is ready to receive water .8) Confirm that drain system is available and that all drain valves are correctly lined

up for operation.9) Vent Point

All vent point vents shall be provided with 3/4” vent valves and flexible hose with drain containers. The vent shall be plugged after commissioning completed.

b) Commissioning ProcedureAs a general description of commissioning and startup for the project, the major

procedure is summarized as follows:1) First stage two mud pump put into use from by pass 16’ water line( round tank).

Open valves for by pass line and drain water to Mud pump.

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2) Second stage , from buffer tank drain water to the water injection system close

valves which connected to by pass 16’ water line . and open valves connect to

tank suction and outlet. In the second stage , commissioning activities as below: Commissioning and startup for electrical system to ensure that all electrical

systems are powered properly, Commissioning and Startup for Instrumentation System to ensure correct

operating parameters. Commissioning and Startup for 6.6kv water Injection soft starter System. Commissioning and Startup for Cathodic Protection System.

5.8 Provisional Acceptancea) Application of Provisional Acceptance

When CPECC has completed the installation, it satisfies the following criteria: It conforms to all specifications and drawings It is free of any defective fabrication, installation and construction. It is free of any defect in engineering. It meets all requirements of a certifying authority, if any. Equipment and materials are fit for the intended purpose. All commissioning activities have been completed and the system is ready

for service.CPECC will initiate notification for provisional acceptance one month before the Provisional

Acceptance Date, as the whole system could not be put into service for process start-up

without provisional acceptance certificate signed by PDOC.

b) Step for Hand-Over DocumentsOnce the Provisional Acceptance Certificate for Project is issued by PDOC and received by CPECC, the work is considered being handed over to PDOC. The provisional acceptance dossiers shall include the following:

Operation and maintenance manual. Commissioning procedures. Commissioning plan and schedule. All calibration sheets and records. Set points of relays, protective devices. Alarm, range control and trip setting register/schedule. All vendor data book and utility equipment site acceptance tests reports and

certificates of utility equipment. Performance tests sheets for process equipment which shall be handed-over

after 72hours stable operation.

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The hand over document may be prepared portion by portion which will be made applicable for provisional acceptance.

5.9 Performance TestingCPECC shall prepare and compile Performance Test (PT) plan, which shall detail the measuring equipment/instruments to be used, the method of sampling and sample analysis. CPECC shall also have the following responsibilities: Achievement of stable operation in accordance with the Design Basis and Scope

of Work. Close liaison and co-ordination with PDOC operations. CPECC will confirm: 72 hour continuous operation shall be considered to satisfy all the requirements for the performance testing (CPECC will not take the responsibility if the features of products supplied by PDOC would not satisfy the requirements of design.).

5.10 Line of CommunicationCPECC realizes that close liaison and communication with PDOC is very important. CPECC will attend commission meetings with PDOC. PDOC’s supervisory staff will work side by side with CPECC’s commissioning personnel. However CPECC shall assume responsibility for commissioning until provisional acceptance by PDOC.

5.11 Owner InvolvementDuring commissioning phase, PDOC shall play a very important role and close cooperation shall be kept. Expected PDOC involvement is described below. Provision of experienced, qualified, trained and certified operation personnel

who shall be organized as an integral operation and maintenance team. Assurance of operation team to be mobilized to site at least four weeks before

water filling to process system. Provision of safety audit to authorize the project for commissioning and start-up. Arrange for the vendors installation assistance and commissioning team.

5.12 Handover5.12.1 Handover Discussion

A successful handover requires agreement with the constructor as to scope of work

and responsibility. Because checklists for each tagged item indicate activities that are

the responsibility of the construction contractor and which are the responsibility of

the commissioning team, these checklists provide a very detailed delineation and

definition of handover. All checklists will be reviewed early on by construction

supervisory staff and the Office Commissioning Planning Organization for

concurrence on scope. Therefore, the checklist concept helps assure a smooth

transition at handover.

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Another requirement of a successful and trouble-free handover is the sufficient

planning of the handover process and early agreement on this procedure by all parties

involved.5.12.2 Handover Procedure

Initially CPECC Interim operation group and owner’s staff will begin to develop deficiency lists by system well before Mechanical Completion. If these lists are excessively long, then operation may elect not to accept a handover of a system.Close to the system handover date communicated by Construction to Operation, a

joint Owner/CPECC P&ID walkdown will rigorously detail deficiencies that indicate

non-conformance with project specifications, deviations or omissions from P&ID

drawings, operability problems or safety concerns. These items will be given priority

and returned to construction for completion or rectification. Any design changes will

be negotiated through an agreed upon change order system. Handover of each system

with remaining items outstanding will be verified by CPECC Interim Operation

Group and commissioning activities can commence. Remaining items are worked off

by construction, design changes implemented and the systems and areas are turned

over. The Interim Operation Group can then demonstrate performance test by

package and system as per the startup schedule.

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