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10100.
PO Nº- 10100-2410.
CLIENT PO Nº 10100.
RAPCO GROUP-EPC
UNIT / EQUIP. No: …….
CONTRACTOR review comments do not indicate either responsibility or liability for accuracy and completeness of this Document or alter any
contractual terms and conditions.
Date;-29.10.2017.
This document is property of UTE TR Naphtha RT and TR Saudia for Services and Contracting Co Ltd.
Its reproduction without previous permission in writing is strictly forbidden .
.
10100-00-082-PD-0002-tmp02
RAS TANURA REFINERY
CLEAN FUEL PROJECT
INDEX
Description
I. Introduction
1. Mobilization
2. Procurement Phase
3. Construction Plan
3.1 Organizational Chart
3.2 Construction Schedule
3.3 Drawing Control
3.4 Change Order Process
3.5 As built Drawing and Project Record Book documentation
3.6 Project Control Reporting System
3.7 Cost Control and Billing
3.8 Transportation Plan
3.9 Especial Construction Method
3.10 Procurement Spare Parts
3.11 Format for Inspection Log Books
4. Document Control Procedure
4.1 Control of Document
4.2 Document Registering
4.3 Revision Control
4.4 Numbering System and Formatting
4.5 Document Control Log
4.6 Security procedure for Protection of Information
4.7 Preliminary Acceptance, Project Handover and Demobilization
III. References
b. Construction Schedule
c. Manpower Schedule
d. Equipment Schedule
I. INTRODUCTION
The project is the Construction of Temporary Facilities for the Contractor (TR-SA) to support
the Ras Tanura Refinery Clean Fuels Project.
Due to compressed time schedule of completion of the project, RAPCO has made this project
execution plan in o r d e r to d e t e r m i n e the m o s t applicable way to be adopted
in the project implementation in compliance to the technical specifications, drawings,
scope of work and contract documents. RAPCO is looking forward to complete the project
on time in a safe manner with high level of quality acceptable to the client.
The Scope of Works includes, but not limited to the construction and procurement of materials
and supplies for the Contractor Accommodation Camp, Contractor and Client Main
Offices, Laydown Area and the Offices complete with all associated works and all supporting
infrastructures including storm water drainage, sanitary sewer network, sewage tank and its
appurtenances, potable water supply and network, fire line network, electrical power, roads
and open parking areas, sunshades for parking areas. However, the work shall be divided
into phases. The first phase is determined and agreed and the succeeding phases shall be
implemented according to the needs that may arise.
RAPCO shall also supply adequate and competent manpower, equipment and tools,
materials needed for the implementation of the project. Provide and supply consumable
materials, testing devices. Provide temporary pioneer office both for the RAPCO and the
Contractor with complete facilities needed for the implementation of the project.
The above items shall be properly addressed in order to ease the pace and make the
construction as easy as possible.
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The PEP is viewed with an objective to meet the project completion date in four (4months.)
months’ time subject to the following conditions;
a. Award of Contract
b. Approval IFC Drawings
c. Complete Site Handover
This PEP shall be followed as a guideline for the sequence of construction activities subject
to change as the situation dictates.
The Project Execution Plan shall be divided into the following stages;
1. Mobilization
2. Procurement Phase
3. Construction Plan and Sequence
4. Document Control Procedure
5. Preliminary Acceptance, Project Handover and Demobilization
1. Mobilization
RAPCO Camp
RAPCO have an existing camp at Ras Tanura. The Camp has a total building area of 900
m2. The area of t h e Camp is approximately 1700 m2. It has RCC framed structures with
all facilities. The expansion of the camp is also underway. All the RAPCO workers for the
project are accommodated in this Camp. All the manpower to be assigned to the project shall
be attending a safety orientation.
RAPCO will construct a Site Office with other amenities. This location is subject for the approval
of the Contractor (TRSA)
Equipment/Vehicles
The equipment to be utilized in the project shall be brought to site for inspection prior to use.
Operators shall be TUV Certified.
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Prepare and submit all the required materials for the project including the MSDS for approval
of the Contractor.
prepare and submit all the proposed Subcontractors pre-qualification documents for
approval of the Contractor.
Prepare the material submittal log indicating the date of approvals, purchase orders
and deliveries.
LOCATION NO OF PERSION
CONTRACTOR OFFICE TR - 2
CONTRACTOR OFFICE TR - 3
a. Site Preparation
b. Civil W orks 6
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CLEAN FUEL PROJECT
LOCATION NO OF PERSION
CONTRACTOR OFFICE TR - 1
WAREHOUSE (WH)
a. Site Preparation
b. Civil W orks
c. Fencing, access point and gate
d. Roads and Parking Area
e. Urbanization
f. Buildings
g. Electrical Network
h. Grounding and Lightning network
i. Water Network
j. Sewage System
k. Rain W ater Network (OPTIONAL)
l. HVAC System
m. IT Network
n. Fire Fighting and Fire Protection System
o. CCTV System
p. Furniture
The proposed Organization Structure shows the lines of authority or flow of command from
the Project Manager down to the Foreman. Responsibilities shall be determined both
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from the RAPCO Construction side as RAPCO Quality Team throughout the construction
period. Below are the personnel who will constitute the Project Management Team.
Project Manager
Site Engineer
Secure all relevant work permits to execute the job and ensures that a copy of the permit
is displayed in the work area
Supervise the execution of the work and ensure that it is being done as per project drawings,
standards and procedures
Arrange for the required equipment and materials required to execute the job
Prepare and submit the daily report in coordination with the site foremen.
To ensure that all field operatives including Subcontractor personnel directly involved with
the performance of the works have been briefed with this method statement and what is
expected of their works performance.
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Ensures that any and all corrective works is promptly performed following in-house
inspections Shall maintain a monitoring drawing showing the stages of Concreting works until
completion
The Site Engineer reports directly to the Project Engineer
Interface Coordinator
The Interface coordinator could be the Project Manager and he shall be responsible also
for the MEP Works.
He shall coordinate with other Contractors in the Project site for all the utilities such as
Mechanical, Electrical and Plumbing works, it also include Communication and
Instrumentation works.
He shall be technically competent and have a good aptitude in all fields of construction
related activities including safety requirement.
Quantity Surveyor
Arrange specification for the procurement of major equipment and minor materials,
Obtain the technical quotations such as specifications of equipment materials and to give
clarifications for questions raised by vendors supplying the materials,
Obtain commercial quotations and carry out negotiations with vendors,
Arrange for placing purchase orders,
Materials storage and delivery according to manufacturer and site requirements respectively,
Planning Engineer/Scheduler
obtains and reviews all categories of different discipline planning,
maintain the overall project planning,
obtain feedback from site for progress measurement,
milestone verification,
sets up and maintains the quality control plan for the project,
performs regular inspections,
inspect all materials delivered to site/ and prior to installations,
make factory visits for the vendors for inspections of the fabrications stages,
assure that the materials are as per specification prior to shipment,
reports all project QA aspects to the project manager,
Submit design drawing and shop drawings as per the schedule of the project,
Submit the Final as built drawing after mechanical completion,
Project Planning, scheduling and control of the project will be done using Primavera Project
Management Software (P6). RAPCO project manager will closely supervise and guide
the planning and scheduling team in coordination with other key personnel in the project.
Critical milestone dates will be established to meet the project completion in time and monitor
the progress effectively.
The summarized proposed work schedule for the execution of the work is attached. The
schedule shown reflects the planned time period required for completing various activities
in the project within the scheduled duration requirements of owner.
The overall project schedule will be updated based on the accomplishments on a monthly
basis. The monthly report will contain activities executed in that month and activities
planned for the consecutive month by each discipline. The monthly progress report will be
submitted at the end of every Gregorian Month. The report will contain the progress of activities
executed in the previous month, activities planned for the consecutive month and pending
items to be resolved. The report and graphics will display variances of the actual progress
in comparison to the scheduled plans. The monthly report will include activities in detail
that are executed in the month, progress of engineering, procurement (shipment of materials),
construction and an overall summary of man-hours and s-curves.
All planning and scheduling updates will be executed using computers coupled with
project management system located on RAPCO planning department at the head office.
Field construction schedule will be prepared and issued to the construction crew in the field
for better control, monthly program mark-up and end of month reporting. The project
manager and construction crew will give the feedback on a monthly basis to RAPCO's
planning department for assessment and updating of the schedule. The monthly report shall
state the work performed over the period of reporting, the current position of the work, and
comparisons with the original contract schedule. Problems encountered (if any) will be
highlighted too in the report, together with solutions for those problems.
For site activities progress report shall be submitted covering work accomplished during the
past week and work planned for the next week. This report will be submitted every Thursday.
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3.3.1 The Document Controller to the discipline head and other staff in accordance
with the drawing distribution list, voiding the old revisions shall distribute new drawing
or revisions, after being logged.
3.3.2 He will ensure that the QA/QC Department has the drawings/documents for
checking and approval and keeping a copy for the quality control file.
3.3.3 The Engineering Department Head shall review and / or revise and sign the distribution
list.
3.4.1 The new change drawing shall be submitted and approved by the client or
contractor construction manager prior to the changes in structural detail that will
constitute cost impact to the project which found in the site that protrude or
obstruct the construction activities.
3.4.2 Computation in terms regarding the cost impact shall be presented and approved to
the client or contractor construction manager, together with the attached approved
standard form used for process of the change order.
3.5.1 RAPCO Project Engineering department shall be responsible for the updating
marinating, preparing and marking “red line” prints of IFC drawing to produce “as –
built” mark-ups for the work executed
3.5.2 The RAPCO Project Engineering department shall prepare and transmit to original
marked-up “red –line” prints indicating the “as –built” condition of the work. Copies of
marked-up “red – line” prints will not be acceptable. “As-built” drawing shall be formally
transmitted to the client’s representative. The transmittal document shall list drawing
number, Revision and Drawing title. Each “As-built” drawing shall be stamped as follows:
3.5.3 Prior to transmittal to client, RAPCO Projecting Engineering department shall check that
all necessary “as – built” dimensions are given, are correct and represent the true “as
built” condition of work. Dimensions shall be sufficient so as to produce the adding or
subtraction of dimensions to arrive at required dimensions. Material specifications shall
be marked on the drawing; especially those materials provided, furnished and installed
the by RAPCO. The QA/QC Department shall check for consistency between “as-
built” drawing and all cross-referenced drawing. Deletions, omissions and errors shall be
corrected accordingly. RAPCO shall add any explanatory notes required on the “as-
built” drawing.
3.5.4 All work either “field designed” or field-routed” by RAPCO shall be presented as clearly
as possible on the existing Project drawings in the manner described herein. If such
presentations are insufficient to properly depict the “as-built” condition. RAPCO Project
Engineering department shall prepare dimensioned field “sketches” which will correctly
and accurately indicate the field “as-built” condition.
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a. Field sketches may be presented in the form of isometrics orthographic plans and
elevations or both. Each of these forms shall be supplemented with details and
explanatory notes where necessary.
b. Field sketches shall be presented in a neat and legible manner. Free hand drawing
and sketches are not acceptable. Field sketches may be given on
8-½ X 11(E-Size), 11X17 (D Size), 20 X28 (B Size) or 28X40 (A Size) paper sizes.
c. Each field sketch shall carry a unique sketch number assigned by the RAPCO to
maintain a consistent drawing number pattern for field sketches throughout the
entire job.
d. Field sketches shall list all reference drawing, the system of which it is a part, line
number (where applicable), and any pertinent information required to clearly indicate
and define the work done.
Prepare and submit Daily, Weekly and Monthly Reports for all phases of the Project as
required by Company.
All reports shall be structured by major discipline and shall be summarized for the total of the
Services. All reports shall be based upon the current agreed Schedule and shall include
statistics and activities found from the approved schedule.
These instructions shall include the minimum requirements of the Company but Contractor is
free to propose additional items that will enhance the value of the report.
The following procedure demonstrates the process used for cost control and billing using
a well-organized and systematic approach. This system will be created in order to ensure
accuracy as well as certainty in what is claimed in requests for payment, so that both the
Contractor and the Sub- Contractor may be able to easily recognize any contradictions
between the actual cumulative completion of the project and what is reported as completed.
PROCEDURE REQUIREMENTS
The following items are the main criteria required in order to produce a payment request, as
well as to revise and verify the accuracy within the corresponding request/invoice:
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The PMS will be created after the Construction Schedule is agreed upon by the Contractor.
The percentages breakdown will be based on the following (Schedule C):
Requests for payment will be produced by using a Microsoft Excel file that allows the input of
basic raw data and then calculates and derives the final invoice amount along with the
necessary deductions.
This file will include five main sheets, of which half of them allow for the input of raw data,
and the rest are used to derive or display results, and they are as follows:
1. Invoice Sheet
2. Overall Progress Summary
3. Construction Breakdown – Schedule C (Contract)
4. Construction Breakdown – Man-hours
5. SAUDIZATION Summary Report
Items 3 and 5 will allow for the input of raw data, while the rest will be “leave-alone” sheets.
The flow chart and invoice sheet example depicts this process.
Therefore, this system requires a basic understanding of the Contract breakdown prices, and
the construction schedule for this project. It is a smooth merge between cost engineering
and planning, so that any concerned person may easily use this process and produce
invoices with ease.
a. Accommodation Buildings
b. Recreation Buildings
c. Gymnasium
d. Kitchen and Mess-hall
e. Support Buildings
f. Roads and Parking Areas
g. Covered Parking Areas
h. Roofing Materials
i. Sports Facilities
Like any other project, RAPCO prefers to be ready in every aspect of construction. The
management team of the company will do its effort to make use of the vast experience
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gained from the previous projects which were successfully implemented. RAPCO is
committed to complete the construction of the TCF without delay and to achieve the target
date of completion.
It involves the collection of information such as the requisition of materials needed for the
project, the delivery of materials, inventory, warehousing, material handling, packaging,
security of the goods and services that they are safely delivered to their proper destination.
The required equipment at every stage of the project progress shall be delivered in a timely
manner.
Proper handling and storage of materials plays an important role in the construction work.
Careful planning will reduce effort and time and help in meeting the project completion
schedule. It also helps in the overall safety performance of the project.
Proper manual lifting positions should be made before any lifting operations. Only light
materials enough for manual lifting should be lifted. The capacity may differ per person.
Provide enough workers for heavy lifting operations.
Drivers must be properly trained, authorized and must have a valid Saudi Arabian government
driver’s/operator’s license. Safety chains between tractors and trailers should be properly
secured, loads should not exceed its rated capacity, warning lights/flags should be provided
when loads are extended out of the drop line. Use of appropriate equipment for each type
loads i.e., when the materials is in a pallet, use forklift, if it is a big container van and portables
then use a crane and so on.
TRSA requires all equipment operators to be third party certified by agencies, approved by the
company. All operators should not operate any equipment when their certificate is expired.
Operators should have with them their valid certificate during operating their equipment. Lifting
plan shall be submitted for review and approval prior to work. In any case, there is no lifting
operation without the corresponding approved lifting plan.
a. Steel reinforcement
b. Portables
c. Masonry Blocks
d. Formworks
e. False-works
f. Piping Materials and fittings
g. Plumbing fixtures
h. Equipment
i. Generators
j. HVAC Materials
Etc.
Material Storage should be provided in a Containers and Store Rooms to contain all indoor
materials, if needed air conditioned or/ otherwise/ covered shade on site. Other materials
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shall be in the open secured area called LAYDOWN AREA. The area should be bigger enough
to accommodate the expected materials to be stored.
Materials storage shall be segregated according to groups. Each type should properly be
stored in each place. Pipes should be stored according to supplier’s manual and TRSA
requirement. Fluids should be provided with a drip tray and handled according to MSDS
requirements. All storage shall be provided with proper arrangement and access.
Observe precautions stated on label and also industrial safety regulations. All safety measures
shall be observed to ensure the well-being of the workers. These are found in the safety
plan.
Material delivery should be coordinated among Suppliers in order to avoid site congestion.
Each subcontractor shall submit his schedule of delivery. This in turn will help the contractor
to properly organize and reschedule the delivery if it affects the construction schedule. The
requirement of heavy trucks route ordinance by the traffic department shall be complied.
Hence, the drivers should be informed as to the schedules or timings that they can travel
and a vicinity map showing the project location and access routes.
The Project Manager and RAPCO key personnel shall control the flow of the above resources.
It is their prime duty to ensure that all the resources needed to start and to complete the
project shall be available on or before the schedules. The team shall constantly monitor
and follow up all site requirements from time to time for proper delivery at site without
delay. They must ensure that the temporary site office is taken cared properly such as office
supplies, IT connections and other miscellaneous site office requirements. They shall see to
it that all medical requirements for the clinic are delivered promptly. They shall be
responsible for the operation and maintenance of the site office. The site office shall meet
the requirement of TRSA standard for temporary facility.
The site expenses are used for purchasing small quantity of materials which are not included
in the procurement plan. It is also used for the day to day expenses for the operation and
maintenance of the site office and lay down area. The site budget shall be allocated to the
project manager for the speedy solutions of the site expenditures. The amount is determined
depending on site requirements. The budget shall be released to site on time as per request.
These are the methods used for the construction, as guidelines to follow in order to
eliminate and to minimize construction safety hazards.
Use for permit issuance prior to start the work, and as one of the requirement for permit
approval.
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The purpose of this document is to provide the updated Spare Parts and Interchangeability
Record (SPIR Form) template, a set of instructions for completing the template, and a Generic
Spare Parts Work Flow diagram to understand the Spares data and procurement process. This
document will also define the term Spare Parts Data Package (SPDP) which is referenced in the
Non-Material Requirements (NMR) document and in other areas of the Contract documents.
The Spare Parts Data Package (SPDP) is a collective term used to denote, but not limited
to the detailed data required on the SPIR Form (included in this document) and the
complete equipment Bill of Materials with drawing references for all tagged equipment, as
referenced in the NMR.
These documents will refer to the approved signed “Quality Compliance and Equivalency
form” with transmittal , As agreed to use and follow the TRSA (Site Quality Manual). The
following are the TRSA form to be used under the SQM to be included in the inspection log book,
as follows; F01301, F01302, F01401, F01402, F01501, F02201 and F02202
The procedure establishes the methods used to exchange information, register, distribute
and file documents between TRSA and RAPCO. This will:
Provide instruction for the means by which documentation, drawings and data are
controlled in the project.
Define the means by which documentation is transmitted.
stipulate document and drawing version/revision control.
All i n c o m i n g and o u t g o i n g project documents including correspondence.
Project generated technical documents and drawings (deliverables).
Project generated non-technical documents (non- deliverables)
The document control department will register all project deliverables. Each document has
unique document number, be controlled by revision and carry the appropriate signature.
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The originator will modify an existing document and assign a revision number. This will be done
by the document controller for logging, revision validation and transmittal.
All document produce shall be generated in accordance with the project document
numbering system.
RAPCO will comply with the security for the protection of information and technology and
all document supplied by TRSA
Preliminary acceptance of the project will be achieved only when all new works and
installations is commissioned and put into service to the satisfaction of TR-SA representative.
RAPCO will also remove all the debris and temporary facilities from site gradually. Further,
the site of temporary facilities shall be returned to their original or better condition.
RAPCO shall notify the client when the project is mechanically completed by providing the
following information:
Description of the work completed by RAPCO and ready for handing over and
mechanical completion acceptance.
Marked up red line as built drawings showing any changes from the latest design drawings.
List of rectified exception items.
Inspection, pre-commissioning and commissioning records for those systems offered for
acceptance.
Following issuance of any mechanical completion notice, RAPCO shall complete all remaining
work as agreed by owner.
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III- REFERENCES
1. Construction Organizational Chart
2. Construction Schedule
3. Manpower Schedule
4. Equipment Schedule
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RAPCO GROUP
Trading, Contracting, and Industrial Constructions
EPC CONSTRUCTOR
WEBSITE: www.rapcogroups.com
PROJECT MANAGER
Mr. Bhavanishankar Shetty
Electrical Supervisor
Fabrication Foreman
Asst. for survyor. Civil Foreman Fire Fighting Technician
Mr. Bharath Sharma
Helpers
Plumbing Foreman
Helpers
RAS TANURA REFINERY CLEAN FUEL PROJECT PROJECT: 10100
Rev.: 00
INSPECTION AND TEST PLAN FORM Date : Page 1 of 1
10100-00-090-PD-0002-tmp01 Rev 00
2. DURING EXECUTION
3. AFTER EXECUTION
LEGEND
QUALITY RECORD: C: Certificate V: visual R: Test report
TYPE OF INSPECTION: H: Hold Point W: Witness Point S: R: Review Document
RESPONSIBILITY OF INSPECTION: C: Q: Quality
Surveillance
Construction
RAS TANURA REFINERY CLEAN FUEL PROJECT Contra
ct
REQUEST FOR INSPECTION
10100-00-090-PD-0008-tmp02 Rev00
*Person Responsible for Completion of Quality Work / Test Y=Yes, N=No, F=Failed