3.5.3 Construction Att.3 Fabrication.doc

TANKAGE PACKAGE & ASSOCIATED INTERCONNECTING PIPING

RUWAIS REFINERY EXPANSION PROJECT

TAKREER PROJECT NO. 5578

TENDER ENQUIRY NO. 09-5578-E-4

Construction Sequence

1. General

In general, the sequence of construction activities shall be as described below:

Mobilization for the construction phase shall start immediately after possession of the job site. Early activities will include but not limited to permitting activities, temporary construction facilities, soil improvement and preparation at Site.

The ‘peak time’ of the construction activities is scheduled to start 10 months after start of possession of the Site, until about 2 months before Mechanical Completion. During this period of time, inter-disciplines coordination is at utmost important in ensuring works shall be performed strictly according to the overall project and the detail construction schedule.

After overall construction achieve around 70% of progress, the overall construction activities will be driven by requirement for Commissioning activities towards achieving the Mechanical Completion. At that point, the construction schedule/progress might need to be re-visited to make sure that current and subsequent construction activities are in line and suitable in achieving this goal.

The scopes and phases of the construction activities are summarized as follows: Early implementation of site temporary facilities such as site offices, warehouse, prayer

room, workers canteen, workers toilet, gate and guardhouses, road, drainage and fencing together with all site utilities. During construction of the temporary facilities, few portal cabins shall be mobilized and to be used as early site office for site staffs.

Early implementation of soil improvement to allow for early stability of soil and early mobilization followed by the mobilization temporary facilities subcontractor and permanent earthworks.

Infrastructure works which include road, perimeter fencing, water & sewer drainage, underground fire water piping, paving and lighting. If possible the permanent perimeter fencing and roadwork to be done as part of temporary facilities scope.

Gradual mobilization of Civil construction team and Civil Subcontractors for general excavation is planned to commence about immediately after jobsite possession. Priority will be given on major and essential foundation to ensure sufficient work fronts for other disciplines to mobilize.

Underground facilities will be scheduled to start early especially within areas required concrete pavement. Then steel structures and pipe rack structure erection will commence.

Fabrication of Tank steel plates and Structural steel shall be done in Subcontractor’s workshops.

Piping fabrication will be done in Site fabrication shop. The pipe spools erection is planned to commence 4 months after the piping fabrication work has started. Dedicated erection Piping team shall be mobilized about 2-3 month in advance to maintain the productivity of the spools fabrication.

Tank’s mechanical erection (i.e. shell plates for bottom, annular then wall and roofing) shall start immediately after every tank’s concrete works (foundation and base). Erection activities will focus on the critical tanks i.e. Naptha, Gas Oil, Crude, Jet Fuel, Gasoline-95 and Propylene tanks.

Some of the early activities of the Electrical and Instrumentation works shall be the installation of ducts and conduits at conceal areas, below concrete pavement, below

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ground level etc. For mobilization of E&I construction team are planned 2-3 months before their respective main works.

Insulation and Painting workforces are required to be mobilized early for activities like painting of piping spools, erected steel structures for pipe supports etc. Permits shall be sought in advance to allow for setting-up of blasting and painting yard within the jobsite.

Other independence activities such as tank bund wall, roads and landscaping construction works will be scheduled properly for not to give any negative impact on main construction activities.

Most of the pre-commissioning activities will involve construction personnel, subcontractor and vendors. The pre-commissioning supervision team will be mobilized as per submitted Manpower Breakdown in Section 2.1 Planning Evaluation Formats.

Path of Construction

Based on the COMPANY specified Milestones for Engineering, Site Handover Dates, Mechanical Completion and Commissioning, CONTRACTOR has come up with the proposed construction schedule and the Path of Construction. The Path of Construction hereto is given by individual tank geographical area, and considering construction start dates the Path of Construction is as follows:

Sequence of Tank Erection Tank ID1 - Naphtha Storage Tank 1041-F-0122 - HT LGO Storage Tank 1041-F-0303 - SR HGO Intermediate Storage Tank 1041-F-0204 - Mixed C4/Alkylation Feed Storage Sphere 1041-D-0055 - Gas Oil Storage Tank 1041-F-0266 - HT HGO Storage Tank 1041-F-0317 - Mixed C4/Alkylation Feed Storage Sphere 1041-D-0068 - Naphtha Storage Tank 1041-F-0139 - Heavy Naphtha Storage Tank 1041-F-00910 - Mixed C4/Alkylation Feed Storage Sphere 1041-D-00711 - Gas Oil Storage Tank 1041-F-02712 - SR Kerosene Intermediate Storage Tank 1041-F-01613 - Mixed C4/Alkylation Feed Storage Sphere 1041-D-00814 - Crude Storage Tank 1041-F-00115 - Naphtha Storage Tank 1041-F-01416 - SR LGO Intermediate Storage Tank 1041-F-01817 - Mixed C4/Alkylation Feed Storage Sphere 1041-D-00918 - Crude Storage Tank 1041-F-00219 - Gas Oil Storage Tank 1041-F-02820 - Mixed C4/Alkylation Feed Storage Sphere 1041-D-01021 - Crude Storage Tank 1041-F-00322 - Naphtha Storage Tank 1041-F-01523 - LCO Intermediate Storage Tank 1041-F-07924 - Cracked LPG Storage Sphere 1041-D-01325 - Gasoline-95 Storage Tank 1041-F-04926 - Propylene Tank 1041-F-065

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27 - Jet Fuel Storage Tank 1041-F-02228 - Gas Oil Storage Tank 1041-F-02929 - SR AR Intermediate Storage Tank 1041-F-09030 - LCO Intermediate Storage Tank 1041-F-08031 - Cracked LPG Storage Sphere 1041-D-01432 - Gasoline-95 Storage Tank 1041-F-05033 - Gasoline-91 Storage Tank 1041-F-08734 - Propylene Tank 1041-F-06635 - Jet Fuel Storage Tank 1041-F-02336 - SR AR Intermediate Storage Tank 1041-F-09137 - Treated SR Reformate Storage Tank 1041-F-04638 - Cracked LPG Storage Sphere 1041-D-01539 - Gasoline-95 Storage Tank 1041-F-05140 - Propylene Tank 1041-F-06741 - Jet Fuel Storage Tank 1041-F-02442 - Bunker Storage Tank 1041-F-06143 - SR AR Intermediate Storage Tank 1041-F-09244 - Treated SR Reformate Storage Tank 1041-F-04745 - Cracked LPG Storage Sphere 1041-D-01646 - Gasoline-91 Storage Tank 1041-F-08647 - Jet Fuel Storage Tank 1041-F-02548 - Bunker Storage Tank 1041-F-06249 - Whole Cracked Naphtha Intermediate Tank 1041-F-04050 - Hydrotreated Light Cracked Naphtha Tank 1041-F-04251 - Mixed Butane Intermediate Storage Sphere 1041-D-01752 - Bunker Storage Tank 1041-F-06353 - Whole Cracked Naphtha Intermediate Tank 1041-F-04154 - Hydrotreated Light Cracked Naphtha Tank 1041-F-04355 - Bunker Storage Tank 1041-F-06456 - Alkylate Storage Tank 1041-F-05357 - Hydrotreated Heavy Cracked Naphtha Tank 1041-F-04458 - Gasoline-98 Storage Tank 1041-F-05559 - Alkylate Storage Tank 1041-F-05460 - Hydrotreated Heavy Cracked Naphtha Tank 1041-F-04561 - Gasoline-98 Storage Tank 1041-F-05662 - Straight Run Sloops Storage Tank 1041-F-08163 - CFPP Additive Tank 1041-F-03464 - Cracked Sloops Storage Tank 1041-F-08265 - Cetane Improver Tank 1041-F-03366 - Straight Run/Cracked Sloops Storage Tank 1041-F-08367 - Lubricity Additive Tank 1041-F-03568 - Light Naphtha Storage Tank 1041-F-00769 - Stability Additive Tank 1041-F-036

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70 - Heavy Sloops Storage Tank 1041-F-08471 - Anti Oxidant Additive Tank 1041-F-03872 - Slurry Oil Storage Tank 1041-F-05773 - Slurry Oil Storage Tank 1041-F-05874 - Slurry Oil Storage Tank 1041-F-05975 - Slurry Oil Storage Tank 1041-F-060

2. Temporary Facilities

To achieve the objective of a “clean site” philosophy, some basic criteria and precedence are settled as indicated in the following:

It is assumed that the worksite area for Tankage works of the Ruwais Refinery Expansion Project, temporary facilities and camps will be received cleared and graded to a given level and accessible to main roads and main utilities tie-in at battery limit (power, water, sewage and drain system), already prepared by other Contractor of COMPANY. Further Site development and improvements will be done by CONTRACTOR.

At the early mobilization stage CONTRACTOR personnel will utilize site office provided by temporary facilities Subcontractor. And temporarily, CONTRACTOR personnel will be accommodated in apartments in the near town of Abu Dhabi City.

At that time, the preparation of internal area for the site temporary facilities, including provisional roads, paved areas, drainage, fence, lighting, utility network, and then installation of temporary facilities, is progressively commencing.

Likewise, the preparation of internal area for the camp accommodation, including provisional roads and drainage, paved areas, drainage, fence, lighting, utility network, and then installation of the camp buildings, is gradually taking shape.

In the month M03 the first activities will start at site. They will be mainly related to the installation of the site office buildings, and initial site facilities such as material receiving facilities (warehouse and laydown yards) and construction shops.

Expectedly, at month M04 site offices will be in operation so the Site Management Team can operate efficiently within the area of the installations.

3. Site Preparation and Soil Improvement

The first priority is to obtain permit from COMPANY for the execution of the site preparation (development) including access to the various areas in accordance with the Site Handover Dates and baseline schedule.

A topographic survey will be developed based on datum points from COMPANY. During this period, official coordination meetings will be established with COMPANY Site Representative to properly evaluate and rectify all problems arising during construction operations.

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The existing surface will be inspected for soft spots by proof rolling and compaction tests as necessary. All soft spots, debris and contamination will be removed from the area. The suitable material delivered by trucks/ trailers will be unloaded at the required areas. The approved fill material shall be spreaded and leveled then shall be sprayed by water tankers and mixed to achieve the optimum moisture content and the maximum dry density after compaction. The fill material will be laid in layers approximate 300mm in loose condition and compacted to 95% of the maximum dry density using vibrating roller or vibrating plate depending on the nature and location of work to be done. During the filling operation the thickness of the layers and the number of passes by the equipment being used for compacting the materials will be monitored, to insure that the type of compaction equipment being used is suitable for the thickness of fill being laid. Tolerance for grading work shall be ± 200 mm of required elevation as shown in the civil construction drawings. The laboratory testing for the suitability of the materials and the method of compaction will be inspected. The degree of compaction of the filling materials will be monitored and recorded during the operation by in situ and laboratory testing. Upon completion of the filling operation the final trimming and shaping will be monitored and visually checked.

4. Civil, Foundations and Concrete Work

The first construction activity at the beginning of month M8 will be the excavation for tank’s concrete foundation. Survey checks will be necessary to spot the areas and final depth elevations.

Tank Foundations

At that time, Civil construction team will start foundation excavations for Naptha F-012, HT LGO F-030, SR LGO F-020, and Mixed C4/Alkytation D-005 tanks in construction Areas 4, 5 & 6 respectively, and subsequent concrete foundation works according to construction schedule.

Overall foundation work for all tanks and other foundations (pipepacks, sleepers, etc) takes 23 months to complete.

Propylene Tank Concrete Wall and Roofing

Each Propylene tank concrete walls and roofing will take 4 months to construct. All Propylene tanks require 6 months which will start by month M19 for F-065, then F-066 and F-067. Wall climbing formwork system is the adopted construction methodology to mold in-situ the outer tank concrete walls. A concrete placing boom will assist construction teams to pour concrete directly onto the walls and over the tank roofing.

Others Foundations

By month M14 excavations for piperack foundations within the common areas will commence, also other foundations (e.g. firefighting foundation) will commence in accordance with the construction schedule.

The foundations of other structures will proceed and the in-situ casting of elevated concrete structures will start and in this period both the installation of pre-cast concrete will commence.

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The pre-fabrication of pre-cast concrete includes casting of drainage, manholes, handholes, miscellaneous and small foundations, and so on.

Underground E&I and Piping

The underground civil works for UG E&I cables, UG pipeline, valve box, etc. are will start in accordance with the path of construction agreed with engineering for the release of construction drawings. The basis of the path of construction will be:

Early release of critical areas of structural steel erection and piping installation; thus, the piperack, sleeperways and structures will be high priority

Completion of major equipment foundations to allow direct installation of equipment and steel on delivery

Installation and testing of underground piping and cable ducts to suit the area completion schedule and reduce the duration of open trenches

Roads and Paving

Completion of area paving in compliance with a clean site philosophy (ensuring all civil work within an area is complete and the area has been paved prior to commencing above-ground work) will result in improved productivity for mechanical disciplines and minimizes interferences. Careful sequencing of civil work will be performed to enable electrical and instrumentation work to progress without unduly delaying civil completion activities such as areas of paving and final grading.

Road and passage crossing will be carefully planned and coordinated in order to maintain an acceptable accessibility. Plans are to have the paved area in the offsite area be ready before above ground piping installation begins.

5. Tanks

It is envisaged that the erection storage tanks will be performed on a combination of subcontracts and direct hire basis, applying our technical experience for such specialty works.

Pre-assembly approach for some tank steel plates and steel structures form a part of construction strategy to execute construction work to high safety standards and the required quality within the demanding project time schedule.

Lifting lugs, special lifting beams and transportation saddles are to be provided. Transports are to be arranged for delivery to Site to “under hook” position.

Tank Shell Plates

Installation of tanks shell plates will be initiated by Tanks construction team. Standard tanks of single walled type consist of:

Tank bottom plate and annular plates Tank shell plates (wall) Tank roof plates

For the floating roof tanks, the steel plates are consisting of the following: Tank bottom plate and annular plates

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Tank shell plates (wall) Tank lower deck plates and upper deck plates

For the Propylene tanks (double walled), the steel plates are consisting of the following: Inner tank bottom plate and inner annular plates Wall liner plate and inner tank shell plates Roof liner plate and suspended ceiling plates

The tank shell plate installation commences on month M10 for Mixed C4/Alkylation D-005 sphere tank. For big capacity tanks, 11 months is required to install mother than 4,100 tons of shell plates for each Crude tank. Total 24 months is required for installation of shell pates for all tanks. The overall tanks shell plates are expected to be installed by month M32, finally with Slurry Oil F-060 tank.

Tank Roofing Structures

A pre-assembly of tank roofing structures will be done by assembling 4 pieces of roofing frames adjacent to its locations, to create 1 frame block. The 1 frame block of roofing structures will then be assembled inside the tank bottom, once the tank’s concreting reaches Level 3 and has installed temporary center, middle and outer supports.

Roof Air Lift for Propylene Tank

After pre-stressing of concrete wall preparation for tank airlift is needed. Tanks air lifting will be done one tank at a time in accordance with the construction schedule. The first tank roof air lift is anticipated to commence around month M21 for Propylene F-065 tank.

Preparations for roof air lift are done prior to its commencement, as a minimum: Complete “Ready for Air Lift” activities Install scaffolding for welding roof, leveling wires, etc. Air blowers, electric power, welding equipment, jig, tools Closing and sealing wall openings, roof peripheral sealing and entry/ exit air lock Monitoring device for pressure and level and communication (e.g. 2-way radio) Orientation for roof alignment and roof balance All necessary precautions

Every tank will undergo a trial roof lifting of around 300mm height, to check balance of roof, pressure stability, opening ratio and sealing condition. The roof air lifting operation is limited to the maximum speed of 600 mm/min.

6. Structural Steel

Structural steel works schedule to commence by month M14 in common Area-4. The Site works for structural steel piperacks and pipe covers:

Minor pre-fabrication (if any) Pre-assembly (on-ground) Erection of steel framework onto foundations Steelwork pre-painted in the works prior to erection with touch-up only on Site after

erection Fireproofing at pre-cast yard, with make up of joints only on Site

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All means of access to carry out erection of the works.

Steelwork supplies and pre-fabrication will be organized to suit the priorities set, and wherever possible, pre-assembly will take place at the earliest possible time. Splice positions/ joints etc. will be critically reviewed at the design stage to ensure easy constructability.

To enable efficient and economical work of Structural construction team, it is essential that adequately large, level and dry laydown areas for steel work be provided.

For maximum safety, steel structures and access platforms will be fully grated-out and handrailed as much as possible, prior to release to follow on activities such as installation of piping, electrical, and instrumentation.

Steel structure tank accessories including tank access walkway, platform, staircases, ladders, hoist, monorails, handrails and guard rails will resume installation once concreting of tank roofing are fully done. Structural steel piperack members will be erected using approved rigging methods and to be welded or bolted on their structural steel or concrete supports.

The fireproofing and pipe support design (including time of completion) shall take into account the intent to fireproof off-site before erection. Pipe supports should therefore be attached to steelwork before fireproofing or the design should allow for “clamp type’ rather than welding, or embedment pieces should be allowed within the design before fireproofing.

All structural steelwork will be fireproofed on concrete pre-cast yard, to the maximum possible extent considering economics before erection (if fireproofing is required to a structural element). This is of the utmost importance to obviate the need for breaking out fireproofing for attachment purposes. This approach will greatly improve schedule and cost impacts on site.

Normal pipe supports to be provided on a supply, pre-fabricated and painted basis by vendor. Special pipe supports and spring hangers will be designed and supplied by the specialist vendors.

7. Mechanical and Equipment

Equipment delivery will be arranged by procurement to meet the erection schedule. As an integral part of the purchase order, a detailed erection, pre-commissioning procedure and schedule will be required to vendor, if practical. Whenever possible, equipment will be installed directly onto the foundations or platform supports upon arrival at the site.

Heavy or critical lift operation (if any) is planned to self-perform. CONTRACTOR and COMPANY will check and approve all rigging plan prior to lifting operating.

Equipments like pump including motor unit should be ordered under the concept of fully assembled, painted, tested and inspected prior to shipment to site, any interconnecting pipework etc. to be provided an a fully prefabricated, tested, painted and inspected state.

Vendor’s erection supervisory services and pre-commissioning engineering services shall also be established at the bid stage and included in the base purchase order evaluation for the equipment. Pumps, fans, motors, etc. should be delivered already mounted on its steel base plates.

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All vendors’ documentation, drawings, certification of materials, inspection reports erection procedure and schedule, etc. must be received at site prior to the delivery of the equipment.

Equipment Fabrication and Dressing

As foreseen, the package equipment items will be manufactured by the respective vendors of the following:

Tank Booster Pumps Tank Draw-off Pumps Tank Blending Pumps Tank Shipping Pumps Tank Feed Pumps Tank Dosing Pumps Tank Unloading Pumps Tank Circulation Pumps Tank Transfer Pumps Propylene Compressors Propylene Flash Drums Propylene K.O. Drum Tank Farm Flare K.O. Drum

All vendor supplied packages shall be delivered in a minimum economic number of assemblies and shall be completed, tested and pre-commissioned in accordance with the requirement of the project specifications. These should all be procured, tested, internally lined (if any) inspected; finish painted complete with all internals and lifting lugs fitted ex-works.

Generally, mechanical equipment scope is consists of the following activities: Offloading and storage. Geometrical control of the equipment support frame. Verification of correctness of anchor positions. Supply and installation of shims under the equipment. Transportation of all equipment from the storage area to the location to be installed. Prior to start any lifting of skid or equipment, the crane used will be checked for stability

to securely lift the given weight to the given distance. Lifting installation and adjustment on final position of the equipment. Once the equipment is at its final position, the next stage is to complete any required

shimming and alignment of the equipment package, the following activities have to be completed prior to the hook up of any piping, instrument and electrical cables etc.

Removal of any fastenings, lifting lugs, temporary bracing. Reinstall any structures, i.e. ladders etc., that have been removed for transportation. With the assistance of the vendor representative ensure that all activities as recommended

by the vendor are carried out are in total compliance with the instructions contained in the supplier’s installation and instruction manual.

Grouting, anchor bolt tightening and touch-ups. Preservation and maintenance after installation.

8. Piping

General

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Piping on tanks and in piperack should as a minimum be fully detailed on general arrangement piping layout drawings and on isometric drawings. Isometrics should be fully and accurately dimensioned for all piping 2” diameter and above to allow for shop pre-fabrication, and to show all welded attachments to the pipework. Large bore pipework should be treated as a priority for engineering and procurement. Piping smaller than 2” diameter should be dimensioned approximately, with a note to indicate that dimensions should be field checked before fabrication. However, all requirements for hot expansion should be indicated on isometrics.

Piping Fabrication

Piping spool fabrication of carbon steel pipework will be carried-out onshore at purpose built temporary fabrication shops. Piping fabrication will be closely monitored to ensure quality and progress. Fabrication will he prioritized to match available work faces, commencing in the rack an end thereafter based on equipment deliveries in all other areas. The earliest practical art to pipe fabrication and erection will be targeted based on material and isometric drawing deliveries.

Small bore piping configuration will be evaluated to maximize practical shop fabrication of small bore spools. The balance of small bore piping will be field run

Piping fabrication team shall optimize the space and schedule the critical activities during pre-fabrication to the maximum possible extent. Piping fabrication will be separated by piping materials to avoid contamination between materials during fabrication phase.

Where special materials are concerned vendors fabrication services be used purchasing of spool pieces with the checking of all pipe’s actual installation dimensions at site before final fabrication.

As practical, piping site erection will be done only when sufficient numbers of pipe spools are ready from yard to avoid mobilization of incomplete piping lines during erection. All fabricated spools will be painted to full paint system if possible. For flange type connection, the complete testing including pressure test shall be done at the fabrication yard.

Pipe Installation for Tank

Erection of tank piping will begin by which covers the following piping components tanks, as below:

Tank internal and external piping Liquid inlets Vapor outlets Cool-down line Purge/venting system

Pipe Installation for Piperack and Pipe Sleepers

The piping installation will commence in the piperack/ pipe sleeper areas immediately after the release of sufficient area from Structural and Civil construction team, the purpose to sustain a constant piping effort where progress can be achieved early in the construction schedule.

For safety and access reasons, the complete scaffolding, board-out or netting of the underside of piperacks will be installed to alleviate the access problems frequently encountered at grade level.

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9. Hydrostatic Pressure Test

Tank Hydrotest

After the tank has passed series of welding tests (NDT, PWHT, etc.) tanks is hydro-tested starting at month M17 with Mixed C4/Alkylation D-005, then D-006 sphere tanks. Our hydrotest program are planned to carry-out within 18 months, ending with the hydrotest of Propylene F-067 tank by month M34. Hydrotest works is among critical activities in construction and in the Project, and so, CONTRACTOR considers using of alternate test water (saltwater), re-use of potable test water and design of hydrotest circuits in pattern with start-up systems.

Hydro test water shall be potable water with chloride level less than 30ppm. Alternately salt water will be used for hydro-testing of the tanks. Where seawater is used, corrosion inhibitors shall be used to limit corrosion and will be subject to agreement with COMPANY.

The design of hydrotest circuits will be carried-out on Site after the start-up systems and priorities have been defined. Each test circuit will be defined by mark-up flow sheets and drawings etc. and a complete test dossier will be produced. The order of testing of tanks and piping will be planned out so that test water is re-used to the maximum extent possible. This requirement will enable immediate release of the line after test for painting without further delays and checking of outstanding work. It will also discipline the control of completion.

A full procedure for the hydro-testing of system tank and its related piping and pump wells will be developed in conjunction with the requirements of project specification. The outer tank and the pressure and vacuum relief valves will undergo pneumatic test.

Piping Hydrotest

Piping hydrotest for Area 6’s common area piping is projected to start by month M28. U/G pipe pressure testing will be given priority in order to reduce the interference with all other construction activities and will be installed in a sequence to facilitate early preliminary testing and backfilling of the area.

Once piping at the pipe rack and pipe sleepers are installed interim hydro-tests shall be carried-out. Early sequencing of hydro-testing, flushing and cleaning and pre-commissioning activities, adequate flanges, and or valves should be provided at each sub-header take-off from the main lines to enable sections of the systems to be easily isolated.

10. Electrical

During month M20, electrical installation will commence for Area-4 common electrical works in the area, which covers, laying of cables, cable tray installation, lighting, etc.

Electrical activities will start by laying of UG cables. The work of installing cable trays will start after the erection of piperacks and major structures, following on to cable tray runs on the installed tanks or equipment. All cable trays will be checked for continuity and resistance to earth.

Lighting will be given a high priority during design, procurement and construction so that plant lighting can be energized, thus increasing overall illumination with the attendant safety benefits.

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The electrical installation for Propylene tank is as follows: Base slab heating system Protective devices Sensors indicators and controllers Transfer switch (for emergency heating power supply) Lighting Earthing and bonding Lightning protection Aircraft warning lights

11. Instrumentation & Control Systems

General

Instrumentation installation works will be divided into two working groups, one concentrating on cable laying and the other with the instrumentation equipments and controls. These parallel activities will ensure that the whole instrumentation system is tested and completed as soon as possible. The installations of fire alarm cabling, gas detection and plant emergency alarm system will commence in parallel with the instrumentation works.

The instrument stand materials and fabrication will be indicated on drawings. On installing stands, the instruments will be removed for calibration and storage until required for testing and loop checking. Stands will be installed even if instruments are not available to enable services to the instruments to commence. Pulse and pneumatic lines will be installed to the valve manifold on completion of the piping tapping point.

Instrumentation will only commence after substantial piping erection progress has been made. The earliest practical start to cable terminations will be made both in the field and at substations.

Field Instrument Installation

Throughout the construction period, instruments will be adequately protected before commencement and after completion of the work. Also panels will be kept clean and free from ingress. All instruments will be installed according to the Project Specifications.

The main air distribution piping runs will be supplied by the piping part and will be provided with adequate valve take-off points. Instruments and tubes will be installed such as to facilitate easy maintenance without creating any obstruction to exits and passages. Also they will be carefully routed from excessive vibration.

All instrument tubing will be protected and run in such a way as not to restrict areas of assess for operators, emergency exits, etc. Location and accessibility of all locally mounted items are to be correctly positioned for easy readings to be taken. Also tapping points are to be chosen to keep impulse lines as short as possible while minimizing the requirement for temporary platforms.

Safety relief valves will be protected from damage and installed in the designated plane, which is normally vertical, thereby maintaining their set points. All instruments will be positioned to minimize stress, which could cause calibrations malfunction and harmful effects.

Propylene Tank Instrumentation

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Instrumentation and control equipments to be installed for Propylene tanks are: Cool-down Sensors Leak detection system Fire and gas detection system Tank gauging system Temperature sensors Level Instruments

FGS, Sensors, Gauging, etc.

The workstations related equipments, cabinets and panels shall be installed in-place using safe lifting methods and bolted on steel structural supports or base. The cabinets and/or panels shall be lifted into position in accordance with the manufacturer’s recommendation to ensure that no damage to the board or mounted equipment occurs. The positioning and anchorage shall be in accordance to manufacturer/vendor’s recommendation. Before any cables are connected, the equipment shall be checked for tightness of bolted connections within the equipment to manufacturer’s recommend values using a torque wrench and correctness of alignment.

Instrument Terminations

Terminations of control cables, instrument cables and data cables shall be executed using insulated cable lugs. Attachment of cable unions to the cables and to the equipment on gas protected appliances will be executed with due special care and by personnel with necessary qualifications and experience. Faults discovered during inspection will be rectified before proceeding further. All previously inspected equipment or circuits affected or disturbed by such repairs will be liable to re-testing.

Earthing instruments will be checked for acceptable resistance. All intrinsically safe instrument earths will be checked for resistance and insulation in accordance with specifications. Checks will be performed to ensure that all cable screens, armor and instruments are earthed only at the respective isolated earth points, as detailed on the design drawings.

Intrinsically safe circuits will be tested to confirm that installed capacitance and L/R ratios are within the specified tolerances required by the certificates. Wiring will be tested for insulation using voltages compatible with the wiring tested.

Instrument air tubing and impulse lines will be disconnected from the instruments and checked for continuity and correct identification by blowing out with clean dry air or nitrogen. Before reconnection, lines will be blown out for a sufficient period of time to remove all foreign matter.

Instrument Calibration

All instrumentation will be checked and/or calibrated as described within the instrument installation specification. During calibration checks all information will be recorded on the calibration Test sheets provided. The vendor’s instructions will be used to make routine adjustments for calibration.

The vendor will provide accurately recorded calibration and test results for acceptance. The order of such calibration will normally be in accordance with the pre-commissioning schedule. The techniques will ensure verification of the instrument vendor’s specified accuracy and performance

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data, including checking linearity and hysteresis of instrument mechanisms. After calibration, each instrument will be clearly marked, by means of adhesive tape labels, as having been calibrated, the date and the calibration sheet number.

12. Painting

Tanks

Tank painting activities will start by M19 for Mixed C4/Alkylation D-005 tank. Tank painting activity for tanks involves blasting and painting of:

Shell plates (bottom, wall, roof steel plates) All other metallic surfaces including aluminum and stainless steel Tank concrete wall and roofing for Propylene tanks (no blasting required)

It is considered that several plates prior to delivery at the jobsite are blasted and primed in accordance with approved specifications. Painting activities should be at a minimum to avoid interruption with other related works.

Piping, Structural and Equipments

CONTRACTOR intends that numerous structural and equipments painting are done at pre-fabrication shop, and only requires minor painting activities at the Site.

Painting work for piping begins after receipt from piping materials from pre-fabrication. Fabricated spools will be applied with initial layers coatings and finish coated at the fabrication shop area, thus leaving field painting of piping to a minimum.

Painting works should consider of the following: Small bore, less than 2 inches diameter will be field run and field fitted. Therefore, the

specification should allow for hand or power wire brushing on site, for primer and finish coats.

For flanged spools, it is recommended that the piping fabricator is responsible for the finish coats ex-works prior to erection.

For welded short spools to be primed ex works and finish-coated on site. Rack pipework, finish coated prior to erection, where possible and if schedule allows. All

pipework painting to be the responsibility of the shop Painting team. All equipment to be delivered finish-painted or insulated as appropriate where possible. A certain amount of rework / touch-up must be expected with this approach. However, the

costs of touch-up are infinitesimal compared with the costs of the supply and erection of scaffolding for finish painting on site.

All equipment will arrive at the site with a finish coat of paint, thus leaving field painting of equipment to a minimum involving touch-up only.

Field insulation and painting follows equipment and piping erection.

13. Insulation

Piping Insulation

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Insulation of piping will not commence until substantial amounts of pipework have been hydro-tested. Fabrication of insulation cladding offsite will commence at the earliest possible time and will be in line with the piping and testing programs. The cladding fabrication will be batched by test circuits so that when a hydrotest has been successfully completed the entire cladding is available for installation. Leads and tails will be run grouped together, minimizing the extent of insulation. The Insulation construction team will require draftsman to enable site run piping to be dimensioned and cladding fabricated as per the method for large bore.

The overall effect of this method will maximize work away from the construction area and minimize installation time for insulation after hydro-testing.

Propylene Tank Insulation

The tank bottom liner plates shall be completed before tank bottom insulation can begin. Bottom insulation materials covers placing of foam glass cellular block, reinforced concrete ring, perlite (granular ore), sand layers and fiber glass blanket.

For tank’s shell and roofing, after the tank has passed hydro-testing, tank insulation will commence with placing the following wall and roofing insulation materials, namely:

Wall insulation - perlite (granular ore) Suspended deck insulation - fiber glass blankets Roof nozzles and internal piping - fiber glass blankets

14. Mechanical Completion

It is of fundamental importance that when isometrics, etc. are being checked for completeness, that punch list is a combined list jointly established with COMPANY.

In general Mechanical Completion shall be achieved when the installation, system, or portion of the installation has reached the point where all Construction activities have been completed and the installation can be safely pre-commissioned, even if some trim, paint, insulation and other physical aspects (not required for operation) may continue to be implemented during pre-commissioning.

For all systems, an agreed procedure for punch listing involving COMPANY’s team will be in place to avoid rework and duplication of effort. Punch-out of the systems will commence well in advance of the required schedule date for handover.

All punch lists (if any) must be compiled simultaneously and produced as a combined document. The purpose of this requirement is to prevent schedule delays. Not withstanding the above, however, it is the responsibility of the CONTRACTOR’s supervisor to ensure that it’s Subcontractors completes all work as part of his general progress, thus limiting the number to items that may appear on punch lists.

Pre-commissioning team will mark up PiD’s to define the extent of each start-up system and, in conjunction with the Construction and Planning teams these systems will be allocated completion dates. Each start-up system will be fully detailed to define the scope of work for each discipline i.e.:

Equipment listing

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Isometric drawing listing Instrument listing Motor listing, etc.

This will be computerized to enable various types of reports to be generated. The above also refers to other disciplines and also to handover requirements for systems.

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3.5.3 Construction Att.3 Fabrication.doc

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Transcript of 3.5.3 Construction Att.3 Fabrication.doc