KOM - Amal HRSG Final.ppt

*AMAL HRSG 1 PROJECT C311/333Kick Off Meeting

( Wednesday 4th April 12, Muscat )

*Marmul Polymer flood project:Hurdles and learningsMany soft issues rather than pure technicalOman - South Oman- Marmul field with surrounding RTQ fields (similar reservoir and reservoir fluids)

KOM Agenda : -AMAL HRSG 1 PROJECT

TIMETOPICSPEAKER13.30 to 13.40Assembly13.41 13.50Welcome AddressPROJECT MANAGER13.51- 14.10Introduction of PDO & AHEC delegates14.11 14.20Project IntroductionAHEC14.21 15.00Kick-off PresentationAHEC & PDO15.01 15.20Discussions15.21 15.30Close Out AHEC

AMAL HRSG 1 PROJECTProject :AMAL HEAT RECOVERY STEAM GENERATOR -1

Owner:Petroleum Development Oman (PDO)

EPC Contractor:Al Hassan Engineering Co. S.A.O.G.

Location:South of Oman and approximately 1 KM to the South west of Existing Amal Sub station

Scope:EPC of Heat Recovery Steam Generator project.

Contract Value:6.93 Million RO

Duration:660 Days

Start Date:21-Mar-12

Completion:10-Jan-14

PROJECT OBJECTIVESTo meet the future steam demand in AMAL West field, the Company plans to install a Heat Recovery Steam Generator unit at AMAL Power Plant. The HRSG shall be installed at the back end of an existing GE Frame 9E Gas Turbine with a target net average calendar day per year steam production of 6,000 tonnes per day at a delivery pressure of 100 barg and 80% quality.

AMAL HRSG 1 PROJECT

*SCOPE OF WORK

Install and commissioning a new HRSG at the back of Amal Power station gas turbine. The HRSG will have capability of producing 6000 tons of steam per day. (The HRSG, Pumps and DCS will be procured and free issued by PDO)

Install high pressure feed water pumps, instrument air compressors and associated electrical switchgears systems.

Design and Construction of Utility building to house the electrical switchgears and controls systems (DCS, IPS, etc.)

Design, supply and installation of Switchgears, UPS, Instrument Air compressors & piping works.

Civil and mechanical work associated with the above.

AMAL HRSG 1 PROJECT

*AMAL HRSG 1 PROJECT

Supply and Installation of overflow interconnection piping from HRSG to HRSG blow down Pit to Existing Amal steam blow down pit.

Design and construction of HRSG blow down pit.

HVAC System.

Design, supply and installation of balance of plant Piping works

Fire detection and alarm system.

Scope includes interfacing with HRSG OEM supplier/ Vendor.

Pre commissioning and Commissioning.


1.pdf


Organisation Chart

37.pdf


*AMAL HRSG 1 PROJECTStaffing of Contract and Project Management

*Project Manager : Shall be overall responsible for the complete project and focal point for PDO for execution of the project. His responsibility includes Engineering, Procurement, Project Management, Construction, Safety, Contract Management and Quality till successful completion of the project. All other personnel w.r.t. project execution will be under his guidance as per the project organization chart.

*Construction Manager: He shall be the site in charge for the construction activity and full responsible for keeping the Project Manager updated of the proceedings of the construction on regular basis as per reporting procedure, including safety & Quality.

* Engineering Manager: Shall be responsible for the proper interfacing and co-ordination between the design consultant, PDO, PDOs PMC, AHEC Project procurement & Construction team. He shall optimize the engineering activities in such a manner that the project objectives w.r.t engineering shall meet the Companys expectations with respect to schedule, quality of materials and service.


*Project Management:

The project management primarily be a Head Office based activity involving project controls, Engineering coordination, Procurement, Cost control, Contracts administration and construction activity monitoring include safety & quality administration.

Change control and monitoring shall fall under the purview of Project ManagerAMAL HRSG 1 PROJECT

*AMAL HRSG 1 PROJECTKey personnel CVs

* Key personnel inline with Contract requirement are already identified for the project* Their respective CVs shall be Submitted to PDO focal point.

Project Manager/ Contracts ManagerKrishnaraj G BEngineering ManagerMurali KrishnaConstruction ManagerM N TamodharanInterface ManagerKarthikeyanConstruction Engineers (CME&I)Procurement ManagerGirishCommissioning ManagerPlanning ManagerArun Roshan DSouzaLead Site QA/QC EngineerKopula SudakharHSE Manager Binil MohanQC Inspector (CME&I)


*AMAL HRSG 1 PROJECTDesign Verification

FEED Documentation Review & Verification to ensure

Completeness, Correctness and compliance to the design intent.Suitability of the FEED Package for Detailed Engineering.Verification Scope change management.Document Numbering & Equipment numbering philosophy.Drawing and Document format.

To achieve above objective, following Key FEED documents will be reviewed.

Plot Plan / LayoutsGeneral Arrangement DrawingsPEFSEquipment / Material Selection and SizingIndividual Discipline deliverables as necessary

* Design Review* HAZOP Review* SAFOP Review* IPF Review


*AMAL HRSG 1 PROJECTMobilization Plan

Engineering

* Mott Macdonald / TR Engineering to be finalised as a Design consultant * All Engineering will carried out at Design consultant office at Muscat for the entire project

Procurement

* Procurement shall be handled by a dedicated team consisting of discipline wise procurement engineers already identified. The team will be headed by Procurement manager


*AMAL HRSG 1 PROJECTScheduling and Execution of the work

We have prepared Level 3 schedule in consultation with all proposed discipline Engineers and the same shall be circulated to the respective personnel for the timely, safe & efficient execution of the project

Project controls under the guidance of Project Manager shall closely be monitored by all Discipline Heads / Planning Engineers and keep comparing the actual deliverables to the baseline schedule and take corrective action as and when required to enable proper aligning of the project schedule to client requirement and contract.

Planning will be monitored since start of the project to the end of the project. The monitoring of the project is the continuous process.

Reporting shall be done and submitted to PDO as per contract documents C8 Procedure for Contractors.


*AMAL HRSG 1 PROJECTTesting, Commissioning & Training

* All testing of equipment will be carried out by PDO approved testing engineer.

* Approved commissioning Engineer will be mobilized 120 days prior to start of pre commissioning activities.

* The commissioning plan will be prepared as per PR 1159 detailing all aspects of the pre commissioning and commissioning.

* Commissioning plan will be prepared 3 months in advance including activity checklist and approval will obtained before start of commissioning activities.

* Acceptance test will be carried out in accordance with the requirement of C6-21 and ISO 2314. During this acceptance test the plant will be operated by company staff.


*AMAL HRSG 1 PROJECTFinal Documentation

* As Built Drawings.

* Operating and Maintenance manual.

* Vendor bulletins and operating instructions.

* Design reference manual as per SP 1132.

* Plant data book.

*Complete drawing register as per the requirement of SP1003.

*Commissioning Reports.

*A Documentary video (DVD Format) on project history from award to commissioning

*AMAL HRSG 1 PROJECTHistogram of resource levels.

48.pdf

C311 333 - AMAL HEAT RECOVERY STEAM GENERATOR (HRSG)-1 PROJECT

Al Hassan Engineering Co. S.A.O.G.

Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13

Sr. Description M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22

1 Total Manpower 2 8 30 50 75 85 100 105 115 125 135 150 150 165 235 250 250 250 200 130 130 95

Note :-

The above details are only for reference. It may vary during execution of the work

Manpower Histogram

2 8

30

50

7585

100 105115

125135

150 150165

235250 250 250

200

130 130

95

0

50

100

150

200

250

300

M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 M20 M21 M22

Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12 Jan-13 Feb-13 Mar-13 Apr-13 May-13 Jun-13 Jul-13 Aug-13 Sep-13 Oct-13 Nov-13

Total Manpower


*AMAL HRSG 1 PROJECTSite Establishment

Office & Camp Facilities: Existing Facilities of Amal power project shall be used for Amal HRSG project. All office and camp facilities to the company personnel will be provided as specified in C6-29.

On-site Fabrication Facilities: Existing fabrication workshop will be constructed as part of Industrial Facilities. This facility shall be used for complete fabrication of pipes, spools, structural, Painting works etc. In Addition to this AHEC is planning to use Ghala work shop for fabrication of Structural / Piping.

Site office: Existing office facility will be used for this project.


*AMAL HRSG 1 PROJECTEquipment Storage Yard

* The equipments supplied by vendor either through free issue or our own procurement shall be safely stored as per the procedure furnished by vendor.

* Material lay down area shall be used for storing of materials in identified areas for different class of materials.

* Storage of rejected materials: A separate area shall be identified as quarantine area for storage and subsequent disposal of rejected items.


*AMAL HRSG 1 PROJECTLiving Accommodation:

Existing camp to be used for the accommodation of the construction personnel and site workmen. The camp shall be in accordance with PDO norms.

All Facilities for company personnel will be provided as specified in C6 -29

Camp will be equipped with all facilities required.

Camp Boss will be the supervisor

Camp security will be provided.


*AMAL HRSG 1 PROJECTCamp Layout

4.pdf


Site Office Facility

5.pdf



Industrial/ Storage Facilities

6.pdf


*AMAL HRSG 1 PROJECTCommunication To and From site:

Existing Landline communication will be used for this project.

E-mail and Fax Facilities shall be provided by AHEC at office Premises.

All office automation to the company will be provided as specified in the C6 documents C6-29


*AMAL HRSG 1 PROJECTConstruction services and utilities:

Local Community Contractor : We shall actively engage LCC services wherever possible on various construction services, based on their resources and potential ( Mainly Earth works)

Drinking Water : PDO RO plants will be used for drinking water.

Catering : Reputed catering contractor for this project has already been identified.

Sewage Disposal :Sewage Disposal will be done at existing STP.


*AMAL HRSG 1 PROJECTMaterial Control Facilities:

* The following are the detailed material control procedure :

All equipment & materials including spare parts at the project site shall be received by AHECs authorised personnel. Upon receipt, materials will be inspected for specification, quantity, quality, shipping damage, certification of approval and conformity to purchase order. Reporting on damages, if any, for possible insurance claim / corrective action.

Material shall be handled with great care and protected from the impact of throwing, dropping, dragging, bumping and hitting which may damage the material or coating.

Materials shall be lifted by suitable equipment with non-abrasive wide nylon pipe slings or special lifting hooks.


*AMAL HRSG 1 PROJECTSecurity:

Site security shall be arranged by AHEC. we shall appoint Security staff for the entire duration of the project. The sources of Local Security will be done through Local Wali / PDO authorities,



HSE

Managing HSE Workshop.

Hazard Sheets & HEMP Register.

Toolbox Talks & Use of Prompt Card

STOP Implementation

Job Safety Plan & PTW application

Road Transport mentorship programme and drivers Forum.

Journey Management System/Journey Transit Point at Haima & AHEC IZZ Yard with rest room facilities including for PDO.

HSE Audit and Review


*AMAL HRSG 1 PROJECTHSE

OPAL certified HSE Management System is in place

AHEC QHSE Management System & Sustainable development Management System endorsed by PDO.

AHEC is ISO 14001 and OHSAS 18001 certified company.

Addresses all issues including Legal and other requirements in HSE Plan.

Provides frame work for Continual improvement

Visible demonstration of Companys Corporate Commitment.

Amal HRSG project addressed life saving rules for site implementation.

Sub Contactor Letter of Assurance Verification.

CEOs Letter of Assurance to P.D.O.

All incidents and RTA reporting through Project Manager responsibility.


*AMAL HRSG 1 PROJECTSubcontracting:

Identified subcontract areas are as follows:

NDTInsulation.Earth WorksHVAC WorksDesign & EngineeringCatering Services Road Works


*AMAL HRSG 1 PROJECTDetailed Design Activities and assurance

Engineering Contract Quality Plan will be prepared in compliance with ISO 9001-2000Document & Drawing control register.Preparation of Engineering documents & drawings.Single Discipline Checks (SDC) and Inter discipline checkIncorporation comments of SDC/ IDC.Internal Quality Audits.External Quality Audits.SAP Coding.


*AMAL HRSG 1 PROJECTProcurement Activities & Assurance

Material Tracking Sheet on regular basis.

All project material shall be procured from approved vendor list.

Floating enquiries to company approved suppliers with all relevant technical specification.

Communication on changes, if any to an order during production by change control.

Expediting

Inspection by company approved third party/AHEC/Company.

Kick off/Inspection meeting between company, suppliers & contractors prior to start of manufacturing activities.


*AMAL HRSG 1 PROJECTQA/QC activities and assurance

Contract Quality plan of SP 1171 will be prepared and approval from the client shall be obtained.ISO-9001:2008 Quality system shall be implemented. AHEC is accredits certificate for U stamp (Pressure vessel), S Stamp (Pressure boilers) and R Stamp (Repair works) All the relevant QCPs (ITPs) shall be prepared initially with the project scope of work and approval shall be obtained from client.The approval for site key QA/QC Personnel shall be obtained from client and will be mobilized to site on need basis.The audit shall be conducted as per the audit plan. (In the CQP).



7.pdf

Activity ID Activity Name OriginalDuration

Duration % Complete

Start Finish

AMAL HEAT RECOVERY STEAM GENERATOR ( HRSG) - 1AMAL HEAT RECOVERY STEAM GENERATOR ( HRSG) - 1 660 0% 21-Mar-12 09-Jan-14

Start UpStart Up 9 0% 21-Mar-12 30-Mar-12

ST010 Award of Contract / Commencement Date 0 0% 21-Mar-12

ST020 Kick Off Meeting 0 0% 30-Mar-12

Milestone Milestone 618 0% 01-May-12 09-Jan-14

MS01 Mobilization 0 0% 01-May-12*

MS02 Site Establishment 0 0% 19-Jun-12*

MS03 Upon issue of purchase order for 6.6 KV, 415V, IAC, UPS (A/C & D/C) 0 0% 19-Jun-12*

MS04 Engg-Detail Degn,IPF/HAZOP,SAFOP,design calcul'n, CCMS check sheets 0 0% 18-Mar-13

MS05A Upon completion of civil foundations for HRSG and Ancillaries 0 0% 04-Feb-13*

MS05B Civil works Completion - HRSG Control Building, blow down pit and pipe racks0 0% 15-May-13*

MS06 Rcpt Eqpt-Matl for 6.6 KV, 415 V panels, IAC, DC & AC UPS, Bulk piping 0 0% 15-Apr-13*

MS07 Erection completion of HRSG columns, Installation floor, wall casing, roof beam, module and pump package erection0 0% 11-Sep-13

MS08 Construction completion for electrical works, instrument works, Energizing 6.6 KV, 415 V panels and IAC0 0% 21-Sep-13

MS09A Upon Mechanical completion EPC scope of work 0 0% 21-Sep-13*

MS09B Upon completion and precommissioning of HRSG package including including all auxiliaries0 0% 21-Oct-13

MS10 Completion & De-mobil ization 0 0% 09-Jan-14*

Major PDO Inputs (Customer Responsibility)Major PDO Inputs (Customer Responsibility) 424 0% 21-Apr-12 18-Jun-13

Major PDO Obligation Major PDO Obligation 22 0% 21-Apr-12 12-May-12

Free Issue Material- for HRSGFree Issue Material- for HRSG 30 0% 20-May-13 18-Jun-13

Mechanical and PipingMechanical and Piping 30 0% 20-May-13 18-Jun-13

ElectricalElectrical 12 0% 07-Jun-13 18-Jun-13

InstrumentationInstrumentation 30 0% 20-May-13 18-Jun-13

EngineeringEngineering 361 0% 31-Mar-12 26-Mar-13

General Activities and Mi lestonesGeneral Activities and Mi lestones 361 0% 31-Mar-12 26-Mar-13

Process EngineeringProcess Engineering 335 0% 18-Apr-12 18-Mar-13

Civil works EngineeringCivil works Engineering 303 0% 12-May-12 10-Mar-13

Mechanical EngineeringMechanical Engineering 204 0% 06-May-12 25-Nov-12

Electrical EngineeringElectrical Engineering 279 0% 08-May-12 10-Feb-13

Piping EngineeringPiping Engineering 336 0% 25-Apr-12 26-Mar-13

Instrumentation EngineeringInstrumentation Engineering 282 0% 10-Jun-12 19-Mar-13

M A M J Jul A S O N D J F M A M J Jul A S O N D J F

2012 2013 2014

AMAL HEAT RECOVERY STEAM GENERATOR (HRSG) - 1

(C311333)

AL HASSAN ENGINEERING CO S.A.O.G. OMAN

B- 203

Primary Baseline

Actual Work

Remaining Work

Critical Remaining Work

Milestone

Summary Project Start Date :21-Mar-12

Project End Date :09-Jan-14

Data Date:21-Mar-12

1 of 2

Primavera Systems, Inc.

Date Revision Checked Approved

21-Mar-12 PROJECT ... ARD KGB



8.pdf

Activity ID Activity Name OriginalDuration

Duration % Complete

Start Finish

Procurement (From issue spec to Order Placement)Procurement (From issue spec to Order Placement) 293 0% 12-May-12 01-Mar-13

Procurement - MechanicalProcurement - Mechanical 131 0% 12-May-12 20-Sep-12

Procurement - ElectricalProcurement - Electrical 292 0% 13-May-12 01-Mar-13

Procurement - Instrumentation, ControlProcurement - Instrumentation, Control 189 0% 04-Jul-12 09-Jan-13

ManufacturingManufacturing 336 0% 28-Jun-12 30-May-13

Manufacturing - MechanicalManufacturing - Mechanical 221 0% 04-Jul-12 09-Feb-13

Manufacturing - ElectricalManufacturing - Electrical 336 0% 28-Jun-12 30-May-13

Manufacturing - Instrument & ControlManufacturing - Instrument & Control 219 0% 18-Aug-12 25-Mar-13

Delivery of Material Ex works To siteDelivery of Material Ex works To site 227 0% 15-Nov-12 29-Jun-13

Material Delivery - Mechanical & PipingMaterial Delivery - Mechanical & Piping 142 0% 15-Nov-12 05-Apr-13

Material Delivery - ElectricalMaterial Delivery - Electrical 166 0% 14-Jan-13 29-Jun-13

Material Delivery - InstrumentationMaterial Delivery - Instrumentation 104 0% 05-Jan-13 19-Apr-13

MobilizationMobilization 32 0% 31-Mar-12 01-May-12

ConstructionConstruction 561 0% 31-Mar-12 12-Oct-13

Site EstablishmentSite Establishment 81 0% 31-Mar-12 19-Jun-12

Civil WorkCivil Work 479 0% 20-Jun-12 12-Oct-13

InstallationInstallation 190 0% 21-Mar-13 27-Sep-13

Mechanical Installation HRSGMechanical Installation HRSG 109 0% 26-May-13 11-Sep-13

Mechanical Installation BOPMechanical Installation BOP 130 0% 21-Mar-13 29-Jul-13

Piping Installation HRSG and BOPPiping Installation HRSG and BOP 95 0% 14-Jun-13 17-Sep-13

Electrical InstallationElectrical Installation 165 0% 15-Apr-13 27-Sep-13

Instrumentation InstallationInstrumentation Installation 158 0% 16-Apr-13 21-Sep-13

Pre-commissioningPre-commissioning 64 0% 19-Aug-13 21-Oct-13

CommissioningCommissioning 75 0% 17-Oct-13 30-Dec-13

Completion & DemobilizationCompletion & Demobilization 77 0% 25-Oct-13 09-Jan-14

M A M J Jul A S O N D J F M A M J Jul A S O N D J F

2012 2013 2014

AMAL HEAT RECOVERY STEAM GENERATOR (HRSG) - 1

(C311333)

AL HASSAN ENGINEERING CO S.A.O.G. OMAN

B- 203

Primary Baseline

Actual Work

Remaining Work

Critical Remaining Work

Milestone

Summary Project Start Date :21-Mar-12

Project End Date :09-Jan-14

Data Date:21-Mar-12

2 of 2

Primavera Systems, Inc.

Date Revision Checked Approved

21-Mar-12 PROJECT ... ARD KGB


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South Oman- Marmul field with surrounding RTQ fields (similar reservoir and reservoir fluids)*Marmul Polymer flood project:Hurdles and learningsMany soft issues rather than pure technicalOman - South Oman- Marmul field with surrounding RTQ fields (similar reservoir and reservoir fluids)*Marmul Polymer flood project:Hurdles and learningsMany soft issues rather than pure technicalOman - South Oman- Marmul field with surrounding RTQ fields (similar reservoir and reservoir fluids)

KOM - Amal HRSG Final.ppt

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