MAC/MEC Project Execution Guidelines

DOC# DPGP-PROC-MAC/08

Issuing Org Owner:

Title

MAC Project Execution Requirements

Rev.0

Approved By:

Date: 26-Sep-08

DRAGADOS

PROYECTOS INDUSTRIALES DE MXICO, S.A. DE C.V.

DIRECCIN DE PROYECTOS PETRLEO Y PETROQUMICA

MAC PROJECT EXECUTION

REQUIREMENTS

Document No. DPPP-PROC-MAC/08

Contents

1.0 Purpose................................................................................................................ 2

2.0 References........................................................................................................... 2

3.0 Scope.................................................................................................................... 2

4.0 Terms and Definitions......................................................................................... 2

5.0 MAC Project Organization .................................................................................. 5

6.0 Roles and Responsibilities............................................................................... 10

7.0 Responsibility Matrices .................................................................................... 10

8.0 Interface Management....................................................................................... 16

9.0 Execution Requirements .................................................................................. 17

1.0 Purpose

This guideline describes the minimum requirements for the Main Automation Contractors (MAC) project execution. This applies to the project activities required to execute a project from the FEED phase through "Site Completions" phase. It represents the foundation of the steps that make up the overall MAC project execution including the project specific documents that will need to be developed for each project:

2.0 References

This guideline serves to provide project personnel with project management bestpractices for medium to large MAC projects and is an integral part of the ABB MACProject Execution Model. It is not intended nor should it be construed as being a replacement for any process or procedure that may exist in the ABB Project Management Process Navigator or local Quality Management System. It is complementary to existing processes and is intended to assist project personnel in the development of project specific procedures pertaining to a MAC scope. Any procedure developed using these guidelines must comply with the ABB standard processes and local quality management system requirements as appropriate.

3.0 Scope

This guideline is provided to address the scope of work for all phases of a MAC/MEC contract including:

Front End Engineering and Design (FEED)

Detailed Design, Equipment Manufacture and Factory Testing

Site Completions

The guideline is developed primarily to address medium to large projects for MAC/MEC scope however the content is considered good project management practice and can therefore be utilized on a project of any size irrespective of the scope of work.

4.0 Terms and Definitions

As Shipped Documentation Design documents and deliverables that are updated and revised as required due to changes, deviations, and modifications identified during the Factory Acceptance Test of the deliverable.

As Built Documentation Design documents and deliverables that are updated and revised as required due to changes, deviations, and modifications identified during the site completions phase. This also includes the support engineering activity for project completion and turnover.

DFO Documents for Operations. These are required MAC documents by the client for all MAC deliverables on the project issued in a pre-specified format after the completions of detailed engineering phase

HAZOP Review and Input MACs participation in the Hazard and Operational Safety review before final design conducted by the respective EPC as a joint team effort by the appropriate engineering team members, the regulatory personnel, and Customer representatives. This review provides opportunities for the HAZOP team to exploit MACs knowledge and experience to help the cause and effects matrix development by the EPC(s).

ICSS - Integrated Controls and Safety System consisted of PCS, PSD, ESD and F&G systems.

IFA Issued for Approval. The first revision level of issuance of MAC documents to client for approval during the FEED phase.

IFD Issued For Design. Revision level of MAC documents at the detailed engineering phase of the project. At this level all MAC documents are brought to IFD status after all the design requirements have been incorporated in to the documents and approved by the client.

IFC Issued For Construction. Revision level of MAC documents at the detailed engineering phase of the project. At this level all MAC documents are brought to IFC status after all the final design changes and requirements have been incorporated in to the documents and approved by the client.

Integrated Factory Acceptance Test (FAT) Procedure A documented plan for testing procedures and requirements for the ICSS equipment integrated with the third party devices in the MACs staging facility to check all the hardware and software design and operability requirements for the ICSS defined by the MAC design specifications and guidelines.

Interface Management A formal work process which involves project interfaces and communication between multiple project participants and third party suppliers by means of pre-determined agreements and meetings as they relate to the responsibility matrices for each project contracting entity.

I

nspection/Factory Acceptance Test Inspection and testing of purchased equipment for verification of Suppliers compliance with the requirements. Acceptable tests allow release at suppliers location for shipping to the fabrication/integration site(s).

Logistics Transportation and shipping of equipment and materials from point of origin to their ultimate contractual destinations.

Lump Sum Type of compensation which has a fixed contractual price by client for certain MAC deliverables and services during the different phases of the project. Depending on the contract, these goods and services include but not limited to the ICSS hardware, software with configuration and graphics developments, Process Transmitters and Control Valves.

Manufacture The incorporation of materials, fabrication, assembly, integration and testing of equipment within the requirements of a Purchase Order.

P&ID Review A meeting with appropriate participants from the respective EPC(s) and the client company to integrate MACs knowledge and experience into instrumentation and controls aspect of the P&ID development during the FEED phase. This review provides opportunities for MAC to be involved early in the design development with the EPC(s) to define the requirements earlier instead of further in the more detailed engineering phase of the project

PO Purchase Order (PO). The PO document defines MAC requirements for schedule, cost, terms & conditions, and scope of supply for services and/or equipment.

POR Purchase Order Requisition. The final technical description of the scope of supply, coupled with the related specifications and commercial terms that becomes the basis of the Purchase Order.

Pre-Commissioning Functional check of systems and components by the respective EPC and the client before they are transported to the integration site. Components may be pre-commissioned at the subcontractor(s), vendor(s) or fabricator(s) facility. Equipment is energized during this activity. At this stage MAC is asked to be in a support role for its deliverables.

Reimbursable - Type of compensation which has a fixed contractual price by client for certain MAC deliverables and services during the different phases of the project.

RFQ The Request for Quotation. A procurement document requesting suppliers to provide pricing, schedule and terms for providing equipment and materials for Projects requirements. It requires input from all members of the integrated Supply Chain Management Team bringing together the technical and commercial requirements into a clear, concise and complete RFQ package. This is done initially at the FEED phase of the project as part of the Class III (+/-15%) estimate.

Responsibility Matrix A project document that is developed during the FEED to define the responsibilities of each direct contracting entity including EPC, MAC and other direct contractors.

ROS Dates - Required on Site Dates Dates equipment is required at the fabricators work site or actual job site.

Site Completion Plan Plan, procedures, scopes of work for site completions phase of the project through the successful acceptance by the Customer. Major activities addressed include site resourcing, site acceptance testing, commissioning support, preparing documents for operation and compiling all turnover documents.

Smart Plant Intools Unless it specified otherwise by the client Intergraphs Smart Plant Intools will be utilized for Instrument Index, Data Sheets, Wiring as well as configuration aspect of the MAC deliverables.

Stand Alone Factory Acceptance Test (FAT) Procedure A documented plan for testing procedures and requirements for each of the MAC purchased ICSS deliverable in the vendor shop. Establishes the quality control requirements in material and workmanship for the deliverable as well as the compliance with the design requirements. The requirement for the FAT will also be included in the associated Purchase Order Requisition document.

VDR The Vendor Data Requirement List, that includes the critical data deliverables required to be submitted by the Supplier or Subcontractor.

5.0 MAC Project Organization

The following sample charts show a typical MAC functional organization from the FEED phase through the Completions phase. These charts are indicative of a MAC scope however it should be noted that the actual organization structure may differ for each MAC project. The functional titles represent the project specific responsibilities. Although the title, positions and/or the number of personnel performing multiple responsibilities may change from one project to another depending on the specific project, the functionalities of these positions will be very similar Due to the potential different construction site schedules by different EPCs there may also be an overlapping phase from the Detailed Engineering Phase to the Completions phase. At this phase it is expected that MAC will mobile its site team for one EPC and maintain the detailed engineering team for the other EPC at the same time. MAC project manager along with site completions manager will ensure that adequate resources will be available during these phases. In the situation where the MAC scope includes a Lump Sum element, the Project Manager will also ensure that a degree of separation between personnel working on reimbursable activities and those working on Lump Sum activities is maintained through these different phases.

MAC FUNCTIONAL ORGANIZATION (SAMPLE)

FEED PHASE

AQI VAN LAS PGINAS 6, 7, 8 Y 9 DEL DOCUMENTO ORIGINAL (SUSTITUIR)

6.0 Roles and Responsibilities

Refer to the MAC Resource Management Guideline document for the detailed descriptions of the roles and responsibilities for each team member of the MAC organization. The titles may change but the functionality and responsibilities of these positions will exist within the MAC organization. Each MAC Guideline document also includes descriptions of the specific roles and the responsibilities of the MAC team relating to the subject of the guideline document.

7.0 Responsibility Matrices

The division of responsibilities between MAC and the EPCs for each phase of project execution is defined in the Project Responsibility Matrix developed during the FEED phase. The MAC Project Manager along with the clients project management team will be involved with the development of these matrices. The following are generic responsibility matrix templates. The specific division of responsibilities as well as the further detailed content of the matrices may change from one project to another based on the client and the contract scope.

Sample Matrix of Responsibilities for the FEED Phase

AQI VAN LAS PGINAS 11, 12, 13, 14 Y 15 DEL DOCUMENTO ORIGINAL (SUSTITUIR)

8.0 Interface Management

Interface Management is one of the most important project processes for the successful execution of a MAC project. The emphasis of interface management is the integration of the MAC work processes with the work processes of the other project entities such as other EPCs, customer and suppliers to ensure a common approach to execution in addition to the needed information exchange between the parties by the agreed format, schedule and content.Interface Management is based on the Interface Management Procedure and will involve both external and internal parties to MAC. MAC Interface manager will start holding regularly scheduled Interface Meetings and/or teleconferences between MAC and each other project contractors regarding the MAC scope of work. At these meeting statuses of these Interface Agreements and the potential new interface agreements are discussed. Interface Agreements are generated via using the Interface Management database and/or spread sheet that will be in accordance with the client defined format. Based on the scope, MAC will generate Interface Agreements requesting the needed information from each EPC in order that MAC can plan and proceed with its design. The following are some samples of interface agreement subjects that MAC may generate; Required on Site Dates for the MAC deliverables

+/-85% I/O entry completion by the EPC in the Smart Plant/Intools database by a certain date

Field JB wiring completion for marshalling in the Smart Plant/Intools database by a certain date

Datasheet entries for process information for MAC Instrumentation in the Smart Plant/Intools database

Control Logic write-ups by a certain date IFD and IFC F&G Layout Drawings by a certain date

IFD and IFC Cause and Effect Diagrams by a certain date Interface Data for the third party device integration with ABBs 800XA PCS Alarm and S/D value list by a certain date

Site Completions Scope and Schedule

Similarly, the other contractors will request the required information from MAC for their scope of work via initiating interface agreements with MAC. In addition MAC will create Interface Agreements with its own sub-suppliers to ensure compliance with the requirements detailed in the PO. These internal interface agreements will cover the following;

Vendor Document Request List Schedule

Hardware Freeze Date

Compliance statement for technical requirements

Long term technical support requirements

Fat Results

External Interface Agreements and their status get reported to the client at the agreed intervals during the lifecycle of the project. The status of these interface agreements between MAC and the other parties is one of the measures of project progress.

9.0 Execution Requirements

The MAC Project Execution Requirement Map shown below provides a framework model for the MAC Execution process elements for the FEED, Detailed Engineering and Site Completions phases of the project. The map illustrates how these processes interact with the other EPCs engineering and design and their related deliverables. The key elements of the map have been numbered and the requirements for each step have been included in Table 9.1. The latest revision of this drawing must be referred. The key inputs to the MAC processes from the EPCs and client are also shown as they apply from the engineering steps to quality management systems. The systems and processes internal to the EPCs, Client and the MAC will interact with each other as needed in order to achieve the best project execution. This is achieved through the Interface Management Process as described previously. During the EPC Execution phase, the MAC Project Manager will have the opportunity to adjust the project-specific MAC Project Execution Map to fit the final contract, and/or budget requirements as well as the agreed responsibility matrix. Any adjustments made during this phase will maintain conformance to the minimum elements and requirements outlined in Table 9.1 It is each Project managers responsibility to review the MAC Project Execution requirements for each step and utilize ABB work processes to satisfy these requirements. Digression from any management procedures to meet project specific requirements must first receive approval from the documents owner(s). Other reference documents may be used as a resource to assist in completing each activity. MAC will be responsible for the project wide Smart Plant Instrumentation (SPI) implementation, administration and coordination from the FEED all the way through the completions phase. The FEED phase involves the development of Common Design Guidelines and Philosophies by MAC. These guidelines will be the foundation for all activities performed during the detailed engineering and design phase. The FEED phase usually involves the MAC working in conjunction with the client and a single FEED engineering contractor under direct contract with the client. During this phase the detailed responsibility matrix is developed with the client in relation to the MAC scope of work. The MAC, interfacing with the FEED engineering contractor performing activities such as P&ID reviews and developing standardization specification for instrumentation and automation, will develop a +/-15% cost estimate for the MAC scope of work for all project phases. This estimate will be the baseline for all MAC activities for the subsequent phases, In the Detailed Engineering and Design Phase, there may be multiple EPCs that will be involved with engineering, procurement and construction for their respective process facilities. MAC will interface with each EPC to obtain their needed design documentation such as hard I/O quantities, P&IDs and Instrument Index via formal interface agreements to determine and develop the specific technical requirements for the ICSS, Instrumentation and field devices. At this stage MAC will also update the common design guidelines developed in the FEED phase according to the EPC design Documentts and will bring them to the IFD level maturity. These EPC specific requirements along with the common design guidelines will be the basis for quotations for MAC deliverables. After the detailed engineering quotations MAC will determine the BOM for its goods and services and will compare them with the baseline estimate established during the FEED phase. After formal approval by the client for any changes in the design deliverables MAC will proceed with the purchase orders, engineering and design activities for hardware and software. Formal interface management is crucial in this phase since multiple EPC coordination and standardization enforcement will be done by MAC. At the end of this phase all MAC deliverables will be 100% tested before they are readied for shipment to the respective job sites per the required on site dates. If the MAC anticipates that required EPC data will not be received by the agreed date via interface agreement MAC will propose other potential design options for its deliverables to fulfill the ROS dates. MACs supply chain management processes will also engage in this phase through the MAC procurement lead for purchase orders, warranty issues, logistics and shipment related activities Site Completions plan development will start during the detailed engineering and design phase to plan ahead. Most likely, there will be an overlapping phase from the detailed engineering and design to the site completions since at some point the detailed engineering and design may be finished for one EPC site requiring MAC team mobilization for that particular site while the detailed engineering and design activities still continue for the other EPCs. At this stage MAC will appoint a completion manager as well as a site specific MAC coordinator for each EPC. The MAC activities will involve Site Acceptance Testing, as-building MAC design documents, developing documents for operations as well as supporting EPCs in commissioning, loop checking and start-up activities. In this phase, MAC will also have the operator training responsibility according to the operator training plan developed during the detailed engineering and design phase. This training will utilize the operator training hardware and software purchased by MAC. Depending on the scope of the project, the Site Completions phase may include the module fabricators yard(s), onshore facilities and offshore platform sites. After the client has granted the relevant Acceptance Certification for MAC deliverables at the end of plant start-up the MAC project manager will complete the project close-out activities and issue the formal project close-out report. The project close-out report will be the basis for the lessons learned activities performed with MAC team in conjunction with MAC suppliers and the client. The lessons learned output and the closeout report will be used by subsequent MACproject teams as appropriate.

AQI VAN LAS PGINAS 20 A LA 45 DEL DOCUMENTO ORIGINAL (SUSTITUIR)