Creation PMS Technip-Copier
Creation PMS Technip-Copier
Document Class : CLASS 1 Project N° - Unit Doc Type Serial Number Rev. Page
Azedine DERARDJA
Lemoui Abdelhafid 2012.08.16 10:07:07 Fabien Ruez
2012.08.16 09:51:35
+02'00' 2012.08.16
+01'00' 10:52:11 +01'00'
DOCUMENT REVISIONS
Sections changed in last revision are identified by a vertical line in the margin
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REHABILITATION AND ADAPTATION PROJECT
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CONTENTS
4. RESPONSIBILITIES ............................................................................................................................................4
8. ATTACHMENTS ..................................................................................................................................................7
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1. PROJECT SCOPE
1.1 General outlines
SONATRACH RAFFINERIE D’ALGER, Algiers Refinery Algeria (OWNER) is presently operating a
2.7 MMTPA petroleum refinery at Algiers, Algeria having various units such as Crude Distillation
Unit, Gas Plant, Catalytic Reformer unit and associated auxiliary units including utility & offsite. The
plant is situated at Sidi-Arcine, located east of Algiers Refinery, and is approximately 10 km from
Algiers Airport and 15 km from the Algiers Port. Algiers Refinery was built in 1964 with a capacity of
1.6 MMTPA for processing of Hassi Messaoud crude oil. Capacity of Algiers Refinery was
increased to 2.7MMTPA in the year of 1970.
As part of “Rehabilitation & Adaptation Project” of Algiers Refinery, OWNER intends to revamp
some of the above units and also add a few new units. Engineers India Ltd. (EIL), New Delhi,
INDIA has been retained as PMC by SONATRACH for Rehabilitation & Adaptation Project of
Algiers Refinery. Under the Rehabilitation Project, the crude processing capacity of the Refinery
shall be increased by 35%. The revamp of existing units in the refinery and associated Utilities and
Offsite facilities shall be enhanced / modified under Rehabilitation part.
OWNER has also planned to produce fuels conforming to the Euro-2009 specifications.
Accordingly, OWNER has planned to implement a project under Rehabilitation part to increase the
capacity from the complex including modernization of existing utilities and offsite facilities. Electrical
modernization and Instrument modernization including new DCS and central control room are also
part of Revamp plan.
Under the Adaptation project SONATRACH intends to maximize diesel and minimize fuel oils. For
this matching new Utilities, Offsite facilities and an Effluent Treatment Plant (ETP) with Biological
treatment plant to cater to the requirement of the refinery have been planned. New Residual
Fluidized Catalytic Cracking Unit (RFCCU), Sulfur Block containing Sulfur Recovery unit (SRU),
Amine treatment Unit (ARU), Sour water stripper unit (SWS), Fuel Gas treating unit (FGATU) and a
new MS Block containing Naphtha Hydrotreater unit (NHTU), Light Naphtha Isomerisation Unit
(LNISOM),Continuous Catalytic regeneration Unit(CCRU) have also been planned under the
Adaptation Project.
Under instrumentation modernization work, all existing pneumatic instruments in existing plants,
revamped or otherwise, shall be replaced with electronic instruments with all associated
accessories. A central control room (blast resistant) shall be replaced with a new DCS control
system which will control, monitor the Refinery. Both Rehabilitation and Adaptation area plants,
Utilities and Offsite have been planned along with a number of Satellite rack rooms. Fire and gas
detection and monitoring system of the refinery is also part of Project.
Under electrical modernization work, a new 63 kV grid power reception and distribution terminal
along with a number of new and revamp of substations have been envisaged. This will also include
addition and replacement of existing transformers, switchgears etc. New plant communication, Fire
alarm, telephone systems in plant and few of non plant buildings are also part of the Project.
As part of Fire water system up gradation, a new fire water network along with pump station and
other fire water systems like foam, water monitors have been planned.
1.2 Definitions / Abbreviations
• COMPANY or OWNER: SONATRACH
• EPCC CONTRACTOR: TECHNIP
• SUBCONTRACTOR(S): any party, entity performing site work or causing construction
work to be performed under its own responsibility.
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2. PURPOSE
This procedure covers the overall Progress Measurement System implemented for measuring the
physical work progress during the Construction execution of the PROJECT, including specific
weight factors to be used for a given level.
The reporting progress during the construction execution shall serve two important purposes:
• To position the construction activity with respect to the planned progress at the PROJECT
level and trades activities. This is an essential parameter that assists the CONTRACTOR
assessing its performance and the adequacy of its resources and organization to deliver
the plant with the agreed program.
• To prepare CONTRACTOR monthly payment as defined in the CONTRACT Agreement
3. REFERENCE DOCUMENTS
Construction Execution Plan: 9952T-0000-PP-0801
Progress Measurement Procedure: 9952T-0000-PP-0304 Rev A
Construction Work Breakdown structure: 9952T-0000-PP-0306 Rev 0
4. RESPONSIBILITIES
It is the responsibility of the Site Project Control Manager to ensure that a physical progress
measurement system is in place and is fully implemented so that the reporting is correct and
auditable and that the consolidation of SUBCONTRACTORS reporting rests with the
CONTRACTOR Project Control Manager at Site.
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6. ADDITIONAL REPORTS
In addition to the progress calculation and reporting, SMC gets the possibility to calculate the
current contractor productivity by comparison with the information incorporated in SMC.The report
displays the work productivity curve for instantaneous and cumulative productivity. The productivity
is calculated based on the following formula for week or month:
Instantaneous (or cumulative) planned hours for week or month/ instantaneous (or cumulative)
planned progress for week or month x instantaneous (or cumulative) actual progress for week or
month/ instantaneous (or cumulative) actual hours for week or month x 100.
8. ATTACHMENTS
Attachment 1: Work Classes Definitions and Weights(To referee to Construction work breakdown
procedure 9952T-0000-PP-0306-0 annexure 4.
Attachment 2: Typical Jobsite Breakdown Structure
Attachment 3: SMC Software Functionalities
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ATTACHMENT 1:
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Progressive Weight
MEASURE UNIT
WORK CLASS
DISCIPLINE
Step Weight
CODE
13 PIPING
13100 PREFABRICATION
13110 PIPING >= 2 INCH PREFABRICATION
13110 PIPING >= 2 INCH PREFABRICATION (By MATERIAL: CS, SS, AS)
KG
SPOOLING 2 2
MATERIAL RELASED AND CONSERVATION STATUS 3 5
PIPES SECTIONING 20 25
ASSEMBLY AND TACK WELDS 20 45
WELDING 30 75
NDE/PWHT/PAMI EXECUTION AND TRACEABILITY 20 95
SPOOLS IDENTIFICATION AND SHIPPING RELEASE 4 99
FINAL CHECK 1 100
13200 ERECTION
13210 PIPING >=2 INCH ON SITE A.E.
13210 PIPING >=2 INCH ON SITE A.E. (By MATERIAL: CS, SS, AS)
KG
DELIVERED MATERIAL READY AT SITE 5 5
ERECTION AND ALIGNMENT 25 30
WELDING 30 60
NDE, PWHT, PAMI EXECUTION AND TRACEABILTY 10 70
PIPING SUPPORT DIMENSIONAL CHECK 13 83
PUNCH LIST BEFORE PRESSURE TEST 5 88
PRESSURE TEST 10 98
PUNCH LIST AFTER PRESSURE TEST 1 99
FINAL CHECK 1 100
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WELDING 22 69
NDE, PWHT, PAMI EXECUTION AND TRACEABILTY 7 76
PIPING SUPPORT DIMENSIONAL CHECK 9 85
PUNCH LIST BEFORE PRESSURE TEST 5 90
PRESSURE TEST 8 98
PUNCH LIST AFTER PRESSURE TEST 1 99
FINAL CHECK 1 100
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14300 PILING
14320 CAST IN SITU CONCRETE PILES
14321 VIBRATED CAST IN PLACE PILES
LM
FINAL PILE LENGTH 10 10
CASING INSTALLATION (IF ANY) 5 15
REINFORCEMENT CAGE INSTALLATION 45 60
CONCRETING 30 90
CASING RECOVERY (IF ANY) 5 95
FINAL CHECK 5 100
14400 EARTHWORKS
14420 GENERAL EXCAVATION
14420 GENERAL EXCAVATION
CUM
EXCAVATION 60 60
MATERIAL TRANSPORT 35 95
FINAL GRADING 4 99
FINAL CHECK 1 100
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14820 CROSSINGS
14900 DEMOLITIONS
14910 DEMOLITIONS
14910 DEMOLITIONS
U
SAFE CONDITION PRIOR DEMOLITION / DISMANTLING 5 5
DEMOLITION / DISMANTLING 65 70
TRANSPORT TO DISPOSAL AREA 29 99
FINAL CHECK 1 100
14920 DISMANTLING U
SAFE CONDITION PRIOR DEMOLITION / DISMANTLING 5 5
DEMOLITION / DISMANTLING 65 70
TRANSPORT TO DISPOSAL AREA 29 99
FINAL CHECK 1 100
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INSTALLATION 45 94
TEST 7 98
INSPECTION / CHECK POINT 1 99
FINAL CHECK 1 100
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FINAL INSPECTION 1 98
INSPECTION / CHECK POINT 1 99
FINAL CHECK 1 100
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INSTALLATION OF INSTRUMENT 74 94
FINAL INSPECTION 5 99
FINAL CHECK 1 100
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FINAL INSPECTION 3 69
INSTALLATION 25 94
TEST 7 99
FINAL CHECK 1 100
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INSTALLATION 15 98
TEST 1 99
FINAL CHECK 1 100
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INSTALLATION OF INSTRUMENT 40 60
INSTALLATION 30 95
TEST 2 97
FINAL INSPECTION 5 98
INSPECTION / CHECK POINT 1 99
FINAL CHECK 1 100
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PNEUMATIC CONNECTION 7 66
INSTALLATION 28 95
TEST 2 97
FINAL INSPECTION 2 98
INSPECTION / CHECK POINT 1 99
FINAL CHECK 1 100
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16 ELECTRICAL INSTALLTION
16100 GROUNDING AND LIGHTNING SYSTEM
16100 GROUNDING AND LIGHTNING SYSTEM
16101 UNDERGROUND GROUNDING CONDUCTOR
LM
CONDUCTOR LAYING 65 65
CONDUCTOR JOINTS AND DERIVATIONS 25 90
TESTS 7 97
FINAL INSPECTION 2 99
FINAL CHECK 1 100
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TESTS 7 97
FINAL INSPECTION 2 99
FINAL CHECK 1 100
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TESTING 10 95
FINAL INSPECTION 4 99
FINAL CHECK 1 100
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16213 DC CHARGERS
U
MECHANICAL INSTALLATION 70 70
ELECTRICAL INSTALLATION 15 85
TESTING 10 95
FINAL INSPECTION 4 99
FINAL CHECK 1 100
16214 BATTERIES
U
RACK AND BATTERIES INSTALLATION 60 60
BATTERY CONNECTION AND FILLING 35 95
FINAL INSPECTION 4 99
FINAL CHECK 1 100
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GROUNDING OF CONDUIT 8 98
FINAL INSPECTION 1 99
FINAL CHECK 1 100
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FINAL INSPECTION 9 99
FINAL CHECK 1 100
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16706 CABLES
LM
INSTALLATION 90 90
TESTING 9 99
FINAL CHECK 1 100
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17 CIVIL WORKS
17100 CONCRETE WORKS
17110 FOUNDATIONS
17111 CONCRETE FOUNDATIONS FOR EQUIPMENT/STRUCTURES
CUM
DEEP EXCAVATION 5 5
LEAN CONCRETE LEVEL 5 10
FORMWORKS 22 32
REINFORCEMENT 30 62
EMBEDDED ITEMS 10 72
CASTING 17 89
FORMWORKS STRIPPING 5 94
BACKFILLING 5 99
FINAL CHECK 1 100
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CASTING 20 80
FORMWORKS STRIPPING 5 85
PROTECTIVE COATING 5 90
LEAKAGE TEST 5 95
BACKFILLING 4 99
FINAL CHECK 1 100
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18 STEEL STRUCTURES
18100 MAIN STRUCTURAL STEEL ERECTION
18111 TRESTLE STRUCTURES
18111 TRESTLE STRUCTURES
KG
ASSEMBLY 20 20
ERECTION 33 53
ALIGNMENT 16 69
ANCHOR BOLTS TIGHTNESS 26 95
CLEANING 4 99
FINAL CHECK 1 100
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18212 GRATINGS
18212 GRATINGS
KG
GRATINGS SELECTION 15 15
GRATINGS ERECTION 55 70
GRATINGS SECURING 25 95
CLEANING 4 99
FINAL CHECK 1 100
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18320 BUILDINGS
18320 BUILDINGS
KG
ASSEMBLY 19 19
ERECTION 37 56
ALIGNMENT 14 70
ANCHOR BOLTS TIGHTNESS 25 95
CLEANING 4 99
FINAL CHECK 1 100
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18800 CLADDING
18810 SIDING AND ROOFING
18810 SIDING AND ROOFING
SQM
ERECTION 55 55
BOLTING 20 75
CLEANING 24 99
FINAL CHECK 1 100
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20 BUILDINGS
20100 CONCRETE AND MASONRY BUILDINGS (By BUILDING)
20110 CONCRETE FOUNDATIONS
20110 CONCRETE FOUNDATIONS
CUM
EXCAVATION 5 5
LEAN CONCRETE LEVEL 5 10
FORMWORKS 23 33
REINFORCEMENT 28 61
EMBEDDED ITEMS 10 71
CASTING 18 89
FORMWORKS STRIPPING 5 94
BACKFILLING 5 99
FINAL CHECK 1 100
20403 FLOORING
20403 FLOORING
SQM
CHECK OF MATERIAL AT SITE BEFORE INSTALLATIO 20 20
RAISED FLOOR INSTALLATION 40 60
CONCRETE FLOOR FINISHING 30 90
ACCESSORIES INSTALLATION AND FINAL CLEANING 9 99
FINAL CHECK 1 100
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20404 CEILING
20404 CEILING
SQM
CHECK OF MATERIAL AT SITE BEFORE INSTALLATIO 10 10
PLASTERING OR FALSE CEILING 40 50
PAINTING 30 80
FINISHING WORKS AND CLEANING 19 99
FINAL CHECK 1 100
20406 PLUMBING
20406 PLUMBING
U
WATER NETWORK 60 60
FIXTURES INSTALLATION 30 90
FINISHING WORKS/TESTS 9 99
FINAL CHECK 1 100
20430 ELEVATORS
20430 ELEVATORS
U
TEMPLATES SETTING 2 2
BRACKETS INSTALLATION 15 17
GUIDERAILS INSTALLATION 15 32
EXTERNAL LANDING DOOR INSTALLATION 5 37
ELECTRICAL WORKS 20 57
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22 INSULATION
22100 EQUIPMENT INSULATION WORKS
22110 EQUIPMENT HOT INSULATION
22110 EQUIPMENT HOT INSULATION
SQM
JACKETING PREFABRICATION (INCL.STEEL SHEET) 10 10
INSULATING MATERIAL INSTALLATION (INCL. SCAFF 40 50
JACKETING INSTALLATION (INCL.SHEETING) 30 80
MISCELLANEOUS FINISHING WORKS (INCL.SCAFFOL 19 99
FINAL CHECK 1 100
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23 PAINTING
23100 STEEL STRUCTURES PAINTING WORKS
23110 STEEL STRUCT. PAINTING IN FIELD
23110 STEEL STRUCT. PAINTING IN FIELD (2 COATS)
SQM
INTERMEDIATE CHECK 35 35
FINAL COATINGS CHECK 35 70
IDENTIFICATION MARKING 15 85
CLEANING & FINAL TOUCHUPS 14 99
FINAL CHECK 1 100
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25400 SPHERES
25410 SPHERES (By SPHERE)
25410 SPHERES
TONS
ERECTION 30 30
MERIDIAN/VERTICAL WELDS 30 60
EQUATORIAL/CIRCUMFERENT. WELDS 10 70
XRAYS 20 90
CLEANINC, TESTING 10 100
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25600 SILOS
25610 SILOS
25610 SILOS
TONS
STEEL STRUCTURE ERECTION 15 15
SECONDARY STEEL STRUCTURE ERECTION 5 20
FINISHED WELD VISUAL CHECK (SUPPORTING RING A 5 25
FINISHED WELD VISUAL CHECK (ROOF) 5 30
FINISHED WELD VISUAL CHECK (CYLINDER PART) 15 45
FINISHED WELD VISUAL CHECK (ROOF TO CYLINDER 15 60
FINISHED WELD VISUAL INSPECTION (UPPER SECTIO 15 75
PT(10% OF FILLET WELDS) 7 82
RT(10% OF LONG. & CIRC. JOINTS,100% OF T JOINT 7 89
HYDROSTATIC TEST 5 94
ACCESSORIES INSTALLATION 5 99
FINAL CHECK 1 100
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68 MECHANICAL ERECTION
68100 HEAVY LIFTS
68110 ITEMS IN ONE PIECE
68110 ITEMS IN ONE PIECE
TONS
EQUI. ERECTION ON FOUNDATION 60 60
ANCHOR BOLTS THIGHTENING BEFORE GROUTING 30 90
INSIDE VISUAL INSPECTION 9 99
FINAL CHECK 1 100
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68320 BOILERS
68321 PREASSEMBLED BOILERS
TONS
ERECTION ON FOUNDATION 50 50
LEVELLING, PLUMB ADJUSTMENT, BOLT TIGHTENING 30 80
FINAL INSPECTION 20 100
68330 FLARES
68330 FLARES
TONS
MODULE 1 ERECTION 25 25
MODULE 2 ERECTION 25 50
STAIRS ERECTION 4 54
WINCHS ERECTION 3 57
LIFTING SECTION 2 & BOLTING TO SECTION 1 10 67
LIFTING SECTION 4 & BOLTING TO SECTION 3 AND T 20 87
ACCESSORIES ERECTION 7 94
FINAL VISUAL CHECK 5 99
FINAL CHECK 1 100
68340 STACKS
68340 STACKS
TONS
STACK ERECTION 60 60
ALIGNMENT 20 80
ACCESSORIES 10 90
CHECKS 10 100
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REHABILITATION AND ADAPTATION PROJECT
Document Class : CLASS 1 Project N° - Unit Doc Type Serial Number Rev. Page
68811 MISCELLANEOUS
TONS
SKID INSTALLATION ON FOUNDATION 30 30
ELEVATION & ORIENTATION 15 45
ANCHOR BOLTS TIGHTENING 15 60
DISASSEMBLED PARTS ERECTION 20 80
MACHINERY ALIGNMENT 10 90
EQUIPMENT VERTICALITY 9 99
FINAL CHECK 1 100
68812 ELEVATORS
U
TEMPLATES SETTING 2 2
BRACKETS INSTALLATION 15 17
GUIDERAILS INSTALLATION 15 32
EXTERNAL LANDING DOOR INSTALLATION 5 37
ELECTRICAL WORKS 20 57
SHAFT MECHANICAL DEVICES INSTALLATION 10 67
MACHINE ROOM ACCESSORY DEVICES INSTALLATIO 15 82
LIFT CAR ASSEMBLY 12 94
HOISTING CABLES INSTALLATION 5 99
FINAL CHECK 1 100
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90 PRECOMMISSIONING
9000 PRECOMMISIONING
1300 P PRECOMMISSIONING PIPING
PRP1 GENERAL
KG
CIRCUIT PREPARATION 10 10
FLUSHING / BLOWING 35 45
SPRING HANGAR SETTING 10 55
REINSTATEMENT 5 60
DRYING 30 90
TIGHTNESS TEST 9 99
FINAL CHECK 1 100
PRP2 DEGREASING
KG
CIRCUIT PREPARATION 5 5
FLUSHING / BLOWING 30 35
SPRING HANGAR SETTING 5 40
DEGREASING 40 80
REINSTATEMENT 5 85
DRYING 10 95
TIGHTNESS TEST 4 99
FINAL CHECK 1 100
PP 1 - ANG - rev. 2
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REINSTATEMENT 15 80
DRYING 10 90
TIGHTNESS TEST 9 99
FINAL CHECK 1 100
PP 1 - ANG - rev. 2
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REHABILITATION AND ADAPTATION PROJECT
Document Class : CLASS 1 Project N° - Unit Doc Type Serial Number Rev. Page
PRE7 UPS
U
UPS FUNCTIONAL TEST 99 99
FINAL CHECK 1 100
PP 1 - ANG - rev. 2
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REHABILITATION AND ADAPTATION PROJECT
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PRE8 DC SYSTEM
U
DC SYSTEM FUNCTIONAL TEST 99 99
FINAL CHECK 1 100
PRM10 FILTERS
TONS
CLEANING 40 40
FILTER ELEMENTS CHECK 59 99
FINAL CHECK 1 100
PRM11 FURNACES
TONS
CLEANING & DRYING OF FURNACE COILS 30 30
CHECK REFRACTORY AND REPAIR IF NEEDED 30 60
CHECK BURNER NOZZLES 10 70
CHECK REGISTER & DAMPERS 10 80
CHECK SOOT BLOWERS 10 90
TIGHTNESS TEST 9 99
FINAL CHECK 1 100
PP 1 - ANG - rev. 2
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REHABILITATION AND ADAPTATION PROJECT
Document Class : CLASS 1 Project N° - Unit Doc Type Serial Number Rev. Page
STROKE ADJUSTEMENT 15 60
CALIBRATION POT AND PSV INSTALLATION 15 75
FINAL SERVICE TEST (H2O) 10 85
BOXIP 14 99
FINAL CHECK 1 100
PRM3 PUMPS
TONS
CLEANING 15 15
AUXILIARIES CONNECTIONS 10 25
OIL FILLING 15 40
SEAL INSTALLATION 10 50
FREE ROTATION BY HAND 5 55
PUMP DRIVER ALIGNMENT 35 90
COUPLING INSTALLATION 9 99
FINAL CHECK 1 100
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PRM9 EJECTORS
TONS
CLEANING 60 60
CLOSE UP 10 70
TIGHTNESS TEST 29 99
FINAL CHECK 1 100
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ATTACHMENT 2:
The following illustrates the typical breakdown structure to be implemented for the follow-up and
monitoring of the physical progress of the works.
JOBSITE BREAKDOWN
SITE JOBSITE WEIGHTING SYSTEM
JOBSITE
LEVEL
= 100% productive manhours
AREA AREA
AREA A
A AREA
AREA B
B = 100% of site productive
45% 55% manhours
= 100% of area
UNIT
UNIT 11 UNIT
UNIT 22 UNIT
UNIT 33 UNIT
UNIT 44 UNIT
UNIT 55 UNIT
UNIT 66
UNIT productive
42% 28% 30% 25% 48% 27% manhours
CIVIL
CIVIL
DISCIPLINE WORKS
PIPING
PIPING MECHANICAL
MECHANICAL ELECTRICAL
ELECTRICAL INSTRUMENT.
INSTRUMENT. PAINTING
PAINTING = 100% of unit
WORKS
28% 38% 7% 5%
productive
14% 8%
manhours
WORK SMALL
SMALL
FOUNDATIONS
FOUNDATIONS FOUND.
STRUCTURE
STRUCTURE DUCTS
DUCTS PITS
PITS PAVING
PAVING = 100% of discipline
CLASSE FOUND.
35% 0% 9% 15% productive
32% 4%
manhours
ITEM C
C 01
01 C
C 02
02 C
C 03
03 B
B 01
01 B
B 02A
02A B
B 02B
02B = 100% of T. o. W.
20% 25% 12% 12%
productive manhours
15% 16%
ANCHOR
ANCHOR CONCRETE
CONCRETE FINISHING
FINISHING
WORKSTEP EXCAVATION
EXCAVATION FORMWORKS
FORMWORKS REINFORCEMENT
REINFORCEMENT BOLTS
BOLTS POURING
POURING WORKS
WORKS
= 100% of the item
15% 15% 30% 10% 20% 10%
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ATTACHMENT 3:
The following illustrates SMC functionalities that are possible for the reporting and monitoring of the
construction progress.
As it is shown in the home page, SMC offers several Modules though which it is
Possible to manage the different information and activities, in order to have a complete
view of the status of the Project.
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Here below in particular, are shown as example, three different charts about Progress
Management:
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PP 1 - ANG - rev. 2