PREQUALIFICATION DOCUMENT

Sample Construction Execution Plan

Site Construction

The execution strategies for different projects are unique for the respective scope. The type
of equipment to be mobilized, the sequence of mobilization and methodology for execution
are dictated by the contract scope. However, the basic procedures governing site
construction, construction Quality control, safety procedures etc. for all the projects are
governed by ISO 9001 procedures and established systems.

A kick-off meeting shall be organised upon receipt of Letter of Acceptance from the Client,
when the scope and schedule shall be finalised and the related project activities set in
motion. Immediately after the kick off meeting, the subcontractor methodology shall be
prepared which is explained below.

The following describes in brief constructability procedure and the main activities to be
undertaken to ensure a smooth phasing-in of personnel, equipment and other resources
required for works related to the construction works of this project.

Project Mobilization:

Task Force Mobilization

Project organization at Head office, Area Office and site will be form a task force team
dedicated to this specific project. The task force will be responsible for the following:

 Review the contract scope & finalize a definitive work execution plan.
 Appoint project staff who will be involved in the mobilization and execution
of the project.
 Prepare and submit work procedures for Client approvals.
 Review manpower & equipment requirements.
 Brief the project staff on project requirements and work plans.
 Initiate recruitment notifications.
 Establish schedules for regular meetings with project staff and Client.
 Establish effective interface process between Construction contractor’s
activities.
 Initiate and establish networking between vendors / sub contractors /
specialized agencies.
 Evaluation of vendors and constantly monitoring their performance.

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Sample Construction Execution Plan

 All Technical expertise and international project management skills will be

brought in by the parent company O&G.
Temporary facilities and lay down area
 Construction of utilities like construction water and power will be first
established from the nearest point available at the site.
 The lay down area will have proper access roads to approach different
facilities within the lay down area for movement of trailer and cranes
expected for storage and fabrication of equipments, piping materials and
structural materials.
 Temporary site facilities like Site office, covered storage for special items,
open air storage pipes & structural, Stress reliving facility, instrument testing
facility, QA/QC labs, P&M Shop, etc. will be established on top priority within
the area earmarked by the Client.
 Setting up of a time office at site which will be responsible for industrial
relations & labor welfare affairs. Also an experienced Industrial relation
officer will be appointed to screen the labors prior to putting them on job and
proper records will be maintained.
 Fabrication yard & Labor camp facilities will be established in a very
geographically situated location.
 All the temporary facilities and lay-down area will be executed through
present capability of O&G and Sub-Contractor.

Manpower mobilization
O&G currently have about 352 Staff & 2138 workmen.

Following would be the manpower mobilization strategy:

Mobilization of personnel for any project is dynamic. The build up of the numbers is
seldom a single occurrence. The intake is normally designed over time with particular
detail to the composition of discipline crafts that are deemed necessary. For this reason
several stages of the enterprise have been identified as trigger points which can
reasonably explain the commencement of intake for a particular need or for general use.
The stages comprise and are developed into four major phase like Pre – construction,
Camp, Infrastructure and Temporary Facilities, Construction Works & Commissioning.

 The first phase of pre-construction activities will commence upon contract

award predominantly concerned with office staff and construction
engineering groups, who would be responsible for developing the
framework of schedules, procedures, qualifications, and certifications that

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Sample Construction Execution Plan

will ensure satisfactory quality and management controls during the

subsequent execution of all project works. These are readily available in
Kuwait.
 Within days of the award an all-purpose crew of experienced manpower
will undertake the work of establishing the site offices. A mix of crafts will
be necessary to set up the initial crew for the site offices, lay-down yard and
site fabrication shops. The personnel selected will be chosen from an
available pool of labor with due consideration for the time required in
accomplishing this task. These are also available through present resources
of O&G and Sub-Contractor.
 Facilities construction introduces the major requirement for labor that will
be needed to implement the multi-discipline craft activities essential in
executing and completing the program of works. The camp accommodation
and facilities will precede the manpower growth that is expected to provide
the required range of available housing units in line with staff and
manpower levels. The mobilization of pre-commissioning personnel will
herald the final phase of the project focused on the completion of distinct
elements of the work that are to be finalized prior to mechanical
completion. This phase will be supervised and managed by experienced
engineering staff that will control the technical and specialist crafts
involved in testing and pre-commissioning checks.

In the above strategy, O&G Engineering W.L.L assures to identify key personnel of the
project from contract award to final completion. All the Technical expertise, Project
Management, experienced supervisors and skilled workmen from India and other
multinationals, also all on ground support by form of logistics, lay down area, site setup,
facility setup the resources available in Kuwait through O&G. This methodology will ensure
that the staff and manpower mix will be properly arranged and available to meet each
phase of the project, as defined by the project schedule to achieve the contracted milestone
dates.

Equipment Mobilization
Mobilization of equipment for the project will be subject to similar influences in build up
of manpower. The number and type of equipment will be identified based on the
commencement of each project phase.

The pre-construction phase will start with that initial planning of types and number of
equipments, more importantly this phase will also deal with the certification of equipment
and the qualification of operators prior to use.

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Sample Construction Execution Plan

The first set of equipment required at the site location will be to undertake the work of
establishing the infrastructure, site facilities & civil works. The mix will include earth
moving equipment, generators, cranes, forklifts, trailers, tractors and general purpose
vehicles which are available in with O&G’s present establishment in Kuwait. To augment
the equipment resource available at Kuwait.

A temporary setup of fuel and water services with continual backup maintenance facilities
will be made available at site to meet the demand of equipments working continuous.

With the start of pre-commissioning most major construction equipment will be surplus
per requirements and will be demobilized in an orderly manner with Client. This phase of
the work will require a more specialized package necessary for completion system
checks, system flushing, hydro-test, and reinstatement and pre-
commissioning/commissioning.

With the systematic approach as outlined above, in terms of maintenance support and
contingency replacement plans together with the awareness of required numbers and
timing, the program for equipment mobilization/demobilization will cope with the
realities of the location and minimize congestion on the project work site.

O&G has gained valuable experience in similar refinery projects, where the provision of
adequate and reliably maintained construction equipment was of major importance to the
successful conduct of the works. This project will also benefit from that experience, and
will be undertaken in a professional and organized manner.

General Constructability Concepts

Civil Works
 Civil works will primarily commence with the earth works followed by
foundations for equipments, pipe racks, structure’s, buildings,
infrastructure and general facilities, etc.
 Majority of the civil works will be done in-house with special agency
works like piling, fire proofing to be sub contracted.
 For main civil works item “Concerting “ , as per our previous experience
we would source the same by procuring Ready Mix Concrete from
approved RMC plants. This is to avoid installation of batching plant inside
the project premises which shall lead to movement of more number of
vehicles carrying raw materials for concrete and concrete transit mixers
inside the running refinery and to avoid possible environmental pollution
inside the plant premises.

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 The Filling material will be supplied thro’ the local suppliers and the
source confirming to the specification is available in the neighborhood
area. All the tests required towards the Quality controls will be carried out
before selection of the source.
 Aggregate and sand confirming to the specification will be supplied thro’
the local suppliers available in the area. All tests required for the Quality
controls will be carried out before selection of the source.
 Storm water drainage system shall be developed early in order to
facilitate construction and expedite site development work. Permanent
road bases shall be used as the construction roads with topping added at
the end of the job completion. The access road shall be developed for
movement of major equipments during and after construction.
 As far as possible, mechanized way of excavation shall be carried out
after taking on necessary precautions with respect to under ground
utilities.
 For any demolishing works prior approval from Client will be taken and
work will be carried out in a safe manner.

Mechanical Works
Piping
 Receipt and storage of material.
 Color coding (longitudinal stripping) shall be used for bulk piping for
identifying material type. Standard coding system will be adopted.
 Maximize pre-assembly of piping spools at grade level in an offsite area.
 Before erection of pipe ensure pipe internal are clean.
 Ensure socket weld joint gaps are maintained within tolerance.
 Plan piping installation in such a way that support and piping installation
are being done parallel.
 Ensure all in line equipment is available for erection.
 Prefabrication shall be performed at shop located in or at an area near to
the project site.
 All welding to be performed by qualified welders.
 Provide a line forecast what lines go to the fabrication shop in accordance
with erection sequencing.
 Minimize cut long/field to fit situations with alloy and large bore pipe.
 Flag for field joint will be indicated in the shop drawings.
 Priorities for off-site fabricated piping shall be established by
construction within the restraints of vendor information.

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 Install as much as possible piping attachments in shop (e.g. lugs, shoes,

etc.).
 Construction shall review field weld locations on shop fabricated piping.
 Special cradles or stiffeners on fabricated pipe shall be fabricator's
responsibility.
 Hydro tests as much as shop fabricated piping as possible prior to
delivery to site.
 Welding of dissimilar metals in pipe runs should be shop fabricated.
 All areas requiring welding of dissimilar materials will be identified
beforehand for welding procedure selection and welder qualification
accordingly.
 Prepare and obtain Client approval for hydro testing scheme.
Equipments
 Unloading of equipments and safely moving to the erection location.
 The cranes shall also be equipped with luffing jib attachments to avoid
interference of other equipments with crane boom.
 Erection equipments will be deployed at site based on the delivery
schedule provided by the client.
 For movement of heavy cranes ground load studies shall be carried
and adequate safety measure will be taken to ensure safe movement
of such heavy duty cranes.
 Wherever required ground hard standing will be done by using
boulders and WBM as per the requirements.
 A detailed erection methodology indicating location of cranes, lay
down position of equipments, location of tailing crane, operating
radius of cranes, boom configuration, direction of slew, boom to
equipment and head room clearances and details of lifting gears to be
used shall be submitted to Client well in advance for approval.

Other works like structural fabrication and erection, painting, insulation, refractory, etc will
be done with best available construction methodology for similar projects executed.

Electrical & Instrumentation Works

 Receipt and storage of equipments as per the sequence of utilization.
 Ensure electrical and piping are in agreement with location and
installation of heat tracing.
 Liaise with piping team to eliminate clashing between piping and
electrical equipment, cable trays, etc.

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 Installation details shall include approved gaskets and thread

lubricants, type of service (vapor, liquid), slope of lines, etc.
 Assist in testing and calibration of E&I equipments as required for the
project.
 Lead instrument engineer shall keep book with all cut sheet
information to be turned over to the field prior to start of construction.
 Use non-welding type of supports and brackets where ever possible.
 Procurement of consumables and temporary materials from Client
approved vendors.

Project Planning, Scheduling and Monitoring

Project planning will be done using latest Primavera Project planner or MS Project planner.
This software will be used to develop, plan & monitor the entire project, which includes
various phases e.g.: site mobilization, fabrication, transportation, erection, testing and
commissioning. A tentative project execution schedule will be submitted during the
bidding stage. Complete project control monitoring will be done by (PCD) Project Control
Department.

Procurement Strategy

O&G has its own Global procurement network managed through EIP software and
procurement departments which are set up in different parts of the country.
O&G has got area for proper storage and handling of material and equipment that are
received from other countries in mina-Abdullah yard and skilled personnel man this
operation.

Materials Management
In house software “Site Materials System” will be used for all site related material
management functions. This will comprise of proper/ systematic information of storage/
retrievable systems for raw materials, components, spares & equipment. This software will
also track for the materials issued, utilized and balance enabling for better planning of
material requirement, prevent sudden storages and for faster material reconciliation.

Consumables, materials under supply by constructor contractor and temporary

construction materials will be procured from approved vendors.

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Quality Assurance & Quality Control

A full-fledged Quality Assurance and inspection department will be responsible for the
following activities.
 Welding & related processes
 NDT including Radiography, Ultrasonic, Dye-Penetrant & Magnetic Particle
Inspection Techniques.
 Inspection of civil, Electrical & Instrumentation items

Based on the approved quality assurance and inspection plan, materials / equipments shall
be subject to inspection. In addition to our own QA/QC staff, we would engage the services
of qualified agencies for inspection of specialized/critical items and also depending upon
the project requirement we may engage Client approved third party inspection agencies.

Logistic Management
Logistic will be accorded high priority & experienced personnel will be assigned the
responsibility for total logistics for the smooth progress of the project execution. Logistics
department will also work in co-ordination with shipping agents and customs department.

Sub-Contracting
O&G Engineering W.L.L shall source the materials, equipment and services required for the
project. Approved vendors to meet quality, delivery, reliability and other specific
requirement of the project.

Construction Contractor will review and study capacities, capabilities and previous
experience of the sub-contractor prior to award of the contract. Construction contractor will
follow a standard ISO vendor evaluation process to select a competent sub-contractor.
Specialized agency works like painting, insulation and refractory will be sub-contracted to
Client approved vendors.
All the sub-contractor workmen and equipments will be screened before putting them on
job.

A dedicated department with experienced staff will be responsible for the sub-contracting
works.

Pre- commissioning

The power and utility requirements for Pre-commissioning and Start-up shall be
communicated to the Client. The power requirement during commissioning and sustained
operation of the plant shall be drawn from the grid, as per project requirement.

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System flushing, blowing and drying

Removal of instruments, box up spool pieces and carry out Water flushing/ air flushing (for
cryogenic pipes) of pipe lines to get rid of dirt, weld spatter etc from the system as per the
pre commissioning procedure.

Box up
Leak test of the system keeping the instruments locally isolated. QC engineer to witness
and certify leak test.

Instruments testing
Instruments connections hook up to DCS and loop testing of all DCS loops. DCS test and
clearance by QC engineer.

Statutory clearances
All Statutory Approvals shall be ensured to be in place, to charge the system and get it
ready for commissioning.

Trial run of rotary equipment

As per the Equipment supplier’s instructions and guidance.

Utilities charging
Utilities like Instrument air, Process air, process water, Steam, Cooling system, are
established. Fire fighting system commissioned.

Trial of other equipment

All the package and bought out equipment are tested as per the Supplier’s
recommendations under their guidance.

Start-up and Commissioning

After the Mechanical completion and respective pre-commissioning activities of the plant,
O&G will provide the resources necessary to complete the start-up and commissioning
process in an efficient and timely manner.

Representatives from the Process Licensor and critical equipment suppliers shall be
available at site to supervise their respective scopes to ensure smooth commissioning of the
Unit.

O&G Engineering W.L.L will take care of the above activities and the required manpower
assistance shall be supplied as per the contract.

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