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Operation & Maintenance service contract for five years, following after a
Transition period of 6 months.
I have prepared the structure of the document on a Table of content form,
however I need you to develop an intensive methodology, process and
procedures with necessary graphic diagrams, charts, table, etc.
I can provide you the necessary information of the Specific project for you to
observe and generate the document to suite the specific project scope and
requirements.
Contract Objectives
The objectives of the Contract to provide Operations and Maintenance
services for the PHRC on behalf on NNPC, as defined by these Scope of Work
and enclosed annexures.
Document Purpose
NNPC has currently engaged a 3rd party RRC to execute the rehabilitation
process, through to commissioning and start-up of PHRC operational assets.
The purpose of this document is to outline the Operations and Maintenance
Scope of Work and associated activities to be performed by the O&M
Contractor.
High-Level Scope
The high-level Scope of Work for the Contract comprises several key steps
being:
Attendance at the refinery Site during the Transition Period (commences from
the date of handover of the Refinery Areas (1 to 5) up to 72 hours of
uninterrupted running of the plants after startup), Production of all operating
and maintenance processes and procedures during Transition Period;
Handover process with Employer;
Mobilisation of O&M team starting before the first RFSU date and ramping up
to support the RFSU dates for the subsequent production areas;
Operation and Maintenance of the PH Refinery on a phased basis, for five
years from RFSU of Area 5;
Procurement of all consumables and spare parts;
Provision of security and emergency response services;
Provision of medical services;
Provision of training to O&M Contractor employees and subcontractors;
Responsibility for the care custody and control of the units, equipment,
systems identified in B1 Appendix 1 – Scope of Work;
Compliance and achievement of Nigerian content targets; and
Handover process back to Employer and demobilisation of O&M contractor.
There are several redundant units, equipment, systems on the Site identified
in B1 Appendix 1 – Scope of Work that are NOT part of O&M Services for
which the O&M Contractor is NOT responsible for, except for carrying regular
inspections by the O&M Contractor during the Contract period and advising
Employer of any concerns with these units, equipment and systems that
could impact the O&M Contractor.
Note: - It is anticipated that following RFSU the RRC shall remain involved in
the plant operations due to several pre-agreed exceptions such as, but not
limited to:
Fluid Catalytic Cracking Unit (FCCU), where Vacuum Gas Oil (VGO) and Heavy
Diesel Oil (HDO) are cracked to obtain more valuable products, like LPG,
FCCU gasoline used as PMS blend and Light Cycle Oil (LCO) as blend
component for LPFO;
Gas Concentration Unit (GCU);
Gas Treating Unit (GTU); and
Mercaptan Oxidation units.
Area 4 contains three process units namely Dimersol, Butamer Isomerisation
and Alkylation units. The units are designed to produce a high-octane
gasoline blend component.
Area 5, the old refinery, is made up of:
CDU;
CRU; and
LPG unit.
Intermediate products from the CDU are SRN. SRG used for PMS blend,
Liquefied Petroleum Gas (LPG), Straight Run Kerosene (SRK), Light Gasoil
(LGO), Heavy Gasoil (HGO) and Atmospheric Residue (AR), which is further
processed in Area 1 VDU.
The PPU area comprises:
Steam Generation system consisting of four (4) dual fuel fired boilers. These
boilers supply steam to steam turbine generators for power production and
as well as to the refinery to meet process steam demand. These boilers are
fed through four high pressure boiler feed pumps. Two medium pressure
boiler feed pumps are provided to meet the medium pressure feed water
demand of refinery. Two deaerators are provided to ensure heating of
incoming condensate to required pressure before feeding to boiler feed
pumps and remove dissolved oxygen from incoming condensate. Pressure
reducing and de-super heating station is provided to obtain Low Pressure (LP)
steam from High Pressure (HP) steam.
Demineralised water generation system: Raw water is received from a well
water system and then further processed to generate demineralised water as
per process and steam demand. The demineralised water system consists of
an anion exchanger, cation exchanger and mixed bed exchanger. Produced
demineralised water is stored in a tank for further distribution to process and
utility area. Effluent from mixed bed system is treated in a neutralization pit
before being discharged to a wastewater system. Acid and alkali storage with
dosing pumps are provided for regeneration of exchanger columns and mixed
bed column. This system also includes an activated carbon filter and potable
water generation, storage and distribution system.
Cooling water system: Cooling water is supplied to process as well as utility
areas using dedicated pumps. Cooling water system includes an induced
draft cooling tower, cooling water pumps, side stream filter and chemical
dosing systems.
A centralised instrument air and plant air system is provided to meet the
entire refinery and utility area requirement. The instrument air system
consists of three air compressors, one plant air vessel followed by a 2 x 100%
capacity air dryer arrangement and one instrument air vessel.
Inert gas is generated by a cryogenic nitrogen generation system. This
system is designed to meet nitrogen demand from entire refinery complex.
The cryogenic nitrogen generation system is supplemented by Pressure
Swing Absorption (PSA) type system
Wastewater treatment system: Effluent from all over the refinery complex are
collected and treated in common wastewater treatment system. This system
consists of oil treatment section, biological treatment section and sludge
removal section.
Fuel gas system: Fuel gas from the refinery is conditioned to meet
requirements as specified by the boiler package vendor. This system
essentially consists of a heater, pressure reducing valve and knock out drum
and serves the demand for the boiler unit only.
Fuel oil system: Fuel oil is used as fuel in the steam boilers. Oil is stored in
two storage tanks. These tanks are continuously heated with steam. This oil
is filtered and pumped to the boilers based on demand from boiler burner
demand control system.
Caustic storage system: A common storage and distribution system for
caustic soda is provided to cater for demands from the service water unit,
demineralisation unit and refinery. It consists of a storage tank with heater
and forwarding pumps.
Well water system: Raw water demand for the refinery is met through four
water wells. Underground water from bore well is pumped to storage tanks
for further distribution to the demineralised water generation system.
All of the above systems are designed to meet the demand for the new
refinery and utility area. It should be noted that power is supplied by a 3rd
party GEL Utility Limited using three gas turbines external to the complex.
These gas turbines are provided with diesel fuel from the refinery.
The offsite, tank farm, truck loading, fire water network and jetty facilities
are:
Tank farm, pipeline, and jetty: Both the OPHR (Area 5) and NPHR (Areas 1 to
4), have their own Tank Farms for feed stocks, intermediate products and
final products. Oil and liquefied gas movement from the tanks to the process
areas and / or export facilities (pipeline to jetty and to the truck loading
system) is performed through electrical pumps. There is a redundant rail
loading facility.
The refinery complex has its own firewater distribution system. This is mainly
made by firewater tanks, jockey and main pumps and above ground
distribution headers to the users. The jetty facilities have their own fire water
pumps and distribution.
Truck Loading System: Final Products from the refinery are exported outside
the refinery complex through two main routes; jetty (for ship loading) and
roads via the truck loading system.
Storage Tanks Overview: There are various tanks for storage of feeds and
various products with ongoing studies as part of the rehabilitation program to
install new Custody Transfer Metering Systems both on the pipework going
through the truck loading system, and on the pipework of feed / products
going to the Jetty Facilities.
Pipeline from Refinery Complex to Jetty Facilities: The total length of the
pipeline from refinery to the jetty facilities is approximately 5.1 km
comprising 9 pipes of different sizes. It crosses brush land, villages and a
river making it a very critical asset. Up to now, there are no security systems
positioned on the pipeline.
The security of the Pipeline from Refinery Complex to Jetty Facility remains
the responsibility of the Employer.
Unit Capacities
A list of Open Art and Licensed units at PHRC is provided below in Table 2.1.
Table 2.1 - List of Open Art and Licensed Unit
Unit No.
Unit Name
Licensed / Non-Licensed
Original Licensor
Capacity (BPSD)
10
Crude Distillation (CDU)
Open Art
Not Applicable
150,000
11
Naphtha Hydrotreater Unit (NHU)
Licensed
UOP
33,000
12
Catalytic Reformer (CRU)
Licensed
UOP
33,000
13
Kerosene Hydrotreater (KHU)
Licensed
AXENS
14,500
14
FCC Gas Concentration (FCC GCU)
Licensed
UOP
40,000
15
Vacuum Distillation (VDU)
Open Art
Not Applicable
53,765
16
Fluid Catalytic Cracking (FCCU)
Licensed
UOP
40,000
17
Gas Treatment (GTU)
Open Art
Not Applicable
11,500
18
Merox Unit (Mex)
Licensed
UOP
22,720
29
Sour Water and Caustic Treatment
Open Art
Applicable
-
79
Hydrogen Purification (HPU)
Licensed
UOP PSA Unit
-
Area 4 [NOTE 1]
Dimersol
Licensed
IFP
4,580
Area 4 [NOTE 1]
Butamer
Licensed
UOP
3,610
Area 4 [NOTE 1]
Alkylation
Licensed
UOP
7,200
510
Crude Distillation (CDU-II)
Open Art
Not Applicable
60,000
512
Area 5 Catalytic Reformer Unit (CRU-II)
Licensed
UOP
6,000
514
Area 5 LPG Recovery
Open Art
Not Applicable
30,700 kg/hr
517
Area 5 ADIP Unit
Licensed
Shell Global Solution
6,000
Product Evacuation
Final Products from the refinery are exported outside the refinery complex
through two main routes; jetty (for ship loading) and roads via the truck
loading system. There is a redundant train loading facility at the site. The
following products are exported from the refinery via trucks:
The product evacuation bays routings are shown below in Table 2.3
Table 2.3 – Truck Loading Facilities
Product
Bays
Gasoline (Premium Motor Spirit)
8 bays (6 islands)
Kerosene
2 bays (2 islands)
Diesel
4 bays (4 islands)
Fuel Oil
5 bays (3 islands)
LPG
[HOLD 1]
Jetty Loading
Pipeline from Refinery Complex to Jetty Facilities: The total length of the
pipeline from refinery to the jetty facilities is approximately 5.1 km
comprising 13 pipes of different sizes. It crosses bushes, villages and river
making it a critical asset. There are currently no security systems positioned
on the pipeline.
The Jetty facilities comprise of an A and a B jetty, both of which have been
upgraded with new loading arms, control room and fire-fighting facilities.
Each jetty has two berths with a stated vessel capability of 35,000 & 5,000
Deadweight Tonnes.
Refinery Business Functions
Refinery Business areas, Core functions and Responsible parties are shown
below in Table 3.1
Table 3.1 – Refinery Business Functions and Responsible Parties
Refinery Business Areas
Refinery Core Functions
Responsible Party
Notes
Strategy
Long Term Strategy
Strategic / business planning (e.g., long term planning)
Employer
Maintenance
and Technical
Services
Operations
Production & Operations Planning / Short Term Planning / Quality Control / lab
Services
O&M Contractor
QC reports need to be shared with PHRC
Production & Operations Execution
O&M Contractor
Maintenance Execution
O&M Contractor
Reliability
O&M Contractor
Inspection
O&M Contractor
Quality Management
O&M Contractor
HSSE
Health & Safety
O&M Contractor
Medical Centre
O&M Contractor
Environmental Management
O&M Contractor
Security - Perimeter
Employer
Security - Internal
O&M Contractor
Fire Service
O&M Contractor
Turnarounds - Execution
Others - TBC
Management Services
Business Support Services
FI, Accounting & Controlling
Employer
Human Resources
Employer
PHRC employees
Human Resources
O&M Contractor
O&M Contractor employees
Training
O&M Contractor
For employees and subcontractors in functions the O&M Contractor is
responsible for
Information Technology
O&M Contractor
Support to functions O&M is responsible for
Information Technology
Employer
Support to functions PHRC is responsible for
Legal / Other Services
O&M Contractor
Support to functions O&M is responsible for
Legal / Other Services
Employer
Support to functions PHRC is responsible for
Groundskeeping
O&M Contractor
Office cleaning
O&M Contractor
Catering
O&M Contractor
Sub-contractor Management
O&M Contractor
Inventory Management
Inventory and Warehouse Management
O&M Contractor
Further to this list such activities shall include, but not be limited to, the
following:
Review and approval of Documents required for the execution of the Scope of
Work. Documents requiring the review and approval of Employer will be as
provided for in the Contract Documents, or if not so provided in the Contract
Documents, then as agreed between Employer and Contractor. Unless
otherwise provided for in the Contract Documents, Employer shall have thirty
(30) calendar days in which to respond to any Documents issued to it by
Contractor for review, comment, approval or otherwise. Approval by
Employer does not release Contractor from his obligations to deliver a safe
complete and operating plant;
Those security elements specifically described as Employer’s responsibility as
set out in Appendix 11 - Security;
Carrying out, or having carried out on its behalf, by other Third-Party
Contractors (but not the Contractor) demolition and site preparation activities
which are necessary to support the Project objectives;
The employer shall be responsible for the management of all refinery
interfaces, with assistance from the Contractor as necessary in the
administration of interfaces;
The provision of the following feeds, utilities or services, to agreed limits.
These are provided at the Employer’s expense:
Crude Oil
Power
Contractor shall be liable for costs incurred for use of utilities and services
above agreed limits;
The provision of the production plan, including long term and future
turnaround plans to the Contractor as per schedule agreed between both
parties;
The offtake of products from the refinery in accordance with the agreed
production plan;
The offtake / disposal of off-grade products and intermediate components as
requested by the Contractor in the event of any shutdown event; and
Wastewater disposal, to agreed limits is available.
Scope of Supply
With the exception of those things identified herein this document as being
provided, supplied, given or operated by Employer, Contractor shall be solely
and entirely responsible for the provision and supply of all things required by
Contractor in the performance of the Scope of Work and the successful
completion of the Project and which shall include, without limitation:
Contractor’s personnel;
Contractor’s offices, work areas, facilities (of every kind), utilities, vehicles,
equipment and all Construction Equipment;
Documents;
Packaged Equipment;
Materials;
Consumables used during Operations;
Catalysts and chemicals as required to facilitate desired operations; and
Spare parts (including as required for operations) and replacement of all
recommended operational spare parts and insurance spare parts used from
stock during routine operations.
INTRODUCTION TO CONTRACTOR’S DETAILED SCOPE OF WORKS
General
This section provides an introduction to certain key aspects of the Scope of
Work for the Project.
Without limitation to whether specifically referenced or not, Contractor’s
Scope of Work includes all requirements, duties, obligations, and
responsibilities set out in the Contract Documents.