The objective of this document is to provide an overall view of how the Contractor shall plan, execute and manage the Project to get it completed efficiently, timely and economically with the highest quality and in accordance to the requirements of the Company. The Attachments to this document are issued for reference or information only and revisions to them shall be issued as individual documents on an asrequired basis, but it is not the intent to reissue this PEP to incorporate any of the abovementioned revisions. In addition to this document, Contractor shall issue individual execution plans and procedures for key phases of the project, these documents shall include but not be limited to the following: Engineering Execution Plan Procurement Plan Fabrication Onshore Precommissioning Loadout and seafastening
PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [2] of [38] Date: 07 Nov 2014 REVISION RECORD SHEET No Rev No A Content of revision Issued for Qualification Date of Revision 07 Nov 2014 PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [3] of [38] Date: 07 Nov 2014 TABLE OF CONTENT INTRODUCTION 1.1 PROJECT DESCRIPTIONS 1.2 BRIEF SCOPE OF WORK 1.3 OBJECTIVE OF THIS DOCUMENT 1.4 DEFINITIONS/ ABBREVIATIONS 1.5 REFERENCE DOCUMENTS PROJECT SCHEDULE PROJECT MANAGEMENT 12 3.1 OVERALL PROJECT MANAGEMENT 12 3.2 DETAIL ENGINEERING MANAGEMENT 14 3.2.1 ENGINEERING ACTIVITIES 17 3.2.2 PROJECT ENGINEERING 17 3.2.3 PROCESS ENGINEERING 17 3.2.4 STRUCTURAL ENGINEERING 18 3.2.5 PIPING ENGINEERING 18 3.2.6 MECHANICAL ENGINEERING 19 3.2.7 ELECTRICAL ENGINEERING 19 3.2.8 INSTRUMENT ENGINEERING 20 3.2.9 SAFETY ENGINEERING 20 3.2.10 INTERFACE AND COMMUNICATION 20 3.3 CONSTRUCTION ENGINEERING MANAGEMENT .21 3.4 PROCUREMENT MANAGEMENT 22 3.4.1 PROCUREMENT PLAN 22 3.4.2 PROCUREMENT SYSTEM 23 VENDORS LIST/ SUPPLY CHAIN MANAGEMENT: 23 PROCEDURES: 23 SUPPLIER SELECTION METHODOLOGY: 23 EXPEDITING AND TRACKING: 24 INSPECTION AND TESTING: 24 LOGISTIC AND INTERFACE/MANAGEMENT OF FREIGHT FORWARDER(S): 25 PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [4] of [38] Date: 07 Nov 2014 3.5 FABRICATION/CONSTRUCTION MANAGEMENT .28 3.6 ONSHORE TESTING AND PRE-COMMISSIONING .39 3.7 LOAD-OUT AND SEAFASTENING .40 3.8 TRANSPORTATION 41 3.9 QUALITY MANAGEMENT (QAQC) 41 3.10 HSE MANAGEMENT 45 PROJECT OBJECTIVES 46 ATTACHMENTS 46 PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [5] of [38] Date: 07 Nov 2014 INTRODUCTION 1.1 Project Descriptions The COMPANY, formed by Eni Ghana E&P Limited, Vitol Upstream Ghana Limited and Ghana National Petroleum Corporation (GNPC), is undertaking Ghana OCTP Development Project, FPSO The OCTP (Offshore Cape Three Points) block is located in the Offshore Ghana in 600-900 meters of water depth and about 60 km from the coast Facilities within FPSO Contract Package include the installation of a FPSO conversion unit and tie-in to facilities belong to other project packages (P1, P3, P4) via pipeline and submarine cable system PTSC M&C Co Ltd received the ITB for Supply of Topside Process Modules (M04, M05, M10, M12 and M13) for the project (hereinafter referred to as the "EQUIPMENTS" and “SERVICE”) The design basis for the Modules was conducted by Eni S.p.A Exploration & Production Division and Global Process Systems Pte Ltd The Modules comprise the following key components/sub-packages: - MEG Regeneration Package - Produced Water Treatment Unit - Sand Separation and Cleaning Package - Seawater Treatment Unit - Cooling Medium System - Displacement/Centrifugal Pumps - PIG Launchers & Receivers - Manual valves, Barred Tee, 3D Bends - Instrument valves (SDV, BDV, Choke valves, PSV, MOV) - Field instruments (transmitters, gauges, etc.) - Spare parts, lifting gears (if any), etc This Procedure demonstrates a general plan for engineering, procurement, fabrication and execution of the EQUIPMENTS and SERVICE and shall be read in conjunction with other Project Procedures and Specifications PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A 1.2 OVERAL PROJECT EXECUTION PLAN Page [6] of [38] Date: 07 Nov 2014 Brief Scope of Work The Scope of Work to be performed by Contractor under this Contract is Detail Engineering, Procurement, Construction/ Fabrication, Onshore testing/ pre-commissioning, Load-out & Seafastening and Transportation of these modules to Singapore nominated port (EPC) of 05 FPSO Process Modules M04, M05, M10, M12 and M13, Details Scope of Works are in accordance to Company’s latest ITB (Instruction to Bid) and up to date Company’s provided documents 1.3 Objective of this Document The objective of this document is to provide an overall view of how the Contractor shall plan, execute and manage the Project to get it completed efficiently, timely and economically with the highest quality and in accordance to the requirements of the Company The Attachments to this document are issued for reference or information only and revisions to them shall be issued as individual documents on an as-required basis, but it is not the intent to reissue this PEP to incorporate any of the above-mentioned revisions In addition to this document, Contractor shall issue individual execution plans and procedures for key phases of the project, these documents shall include but not be limited to the following: Engineering Execution Plan Procurement Plan PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: OVERAL PROJECT EXECUTION PLAN TBA Revision No.: A Fabrication Onshore Pre-commissioning Load-out and seafastening Page [7] of [38] Date: 07 Nov 2014 Such individual execution plan shall be issued in sufficient time to allow review and approval by Company prior to commencement of the particular work component 1.4 Definitions/ Abbreviations Following definitions/abbreviations will be referred to in this document: Project EPC FOR FPSO PROCESS MODULES Company Yinson Production PTe/FPSO Owner/Operator Client ENI Ghana or its Affiliates Contractor PTSC M&C PTSC M&C PTSC Mechanical and Construction Co Ltd FEED Front-End Engineering Design DE Detailed Engineering EPC Engineering, Procurement, Construction PEP Project Execution Plan TBA To be Advised PMT Project Management Team QA.QC Quality Assurance/Quality Control MTO Material Take Off TR Technical Requisition RFQ Request for Quotation TBC Technical Bid Clarification TBE Technical Bid Evaluation CBC Commercial Bid Clarification CBE Commercial Bid Evaluation LLI Long Lead Item PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: OVERAL PROJECT EXECUTION PLAN TBA Revision No.: A AR Award Recommendation MR Material Requisition PO Purchase Order OS&D Overage, Shortage and Damage LTI Lost Time Injury ISO International Organization for Standardization OHSAS Occupational Health and Safety Management Page [8] of [38] Date: 07 Nov 2014 System 1.5 HSE Healthy, Safety, Environment MDR Master Document Register MWS Marine Warranty Surveyor KPI Key Performance Indicator PMT Project Management Team FPSO Floating Production Storage and Offloading NDT/NDE Non-destructive Testing/Examination CTR Cost and Time Resources Reference documents The following, documents have been referenced when compiling this PEP document: ISO 9001-2008 Quality Management System Requirements ISO 14001-2004 Environmental Management System OHSAS 18001-1999 Occupational Health and Safety Management System Environment Quality Act and Regulations PROJECT SCHEDULE Some proposed preliminary key milestones of the Project are as follows PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [9] of [38] Date: 07 Nov 2014 KEY MILESTONES ID Milestone Key Date Project Team Mobilization Completed 01 Nov 14 Start Engineering 10 Nov 14 Start Construction 02 May 15 Mechanical Completion (MCD) for Modules M04, M05 06 Dec 15 Loadout and Sea-fastening Modules M04, M05 Completed 10 Dec 15 Mechanical Completion (MCD) for Module M10, M12, M13 27 Jan 16 Loadout and Sea-fastening Module M10, M12, M13 Completed 30 Jan 16 Deliver M04, M05 to Singapore at nominated port 14 days after ID Deliver M10, M12, M13 to Singapore at nominated port 14 days after ID Note: The above key milestones will be updated as per the approved project schedule Because of the scale of the Project, the Project Engineer will mainly work with Level and Level of planning, i.e Contract Control Schedule and Contract Detailed Schedule Level defines critical path activities on day to day basis while Level includes and identifies all deliverable elements, e.g CTRs, drawings/documents, each piece of equipment, each spool, etc To start with Project Planning, the work activities shall be developed following a Work Breakdown Structure (WBS) with three levels: Level – Phases Level – Disciplines Level – Activities/Sub-Activities WBS Level – Phases comprises the following components: P – Preparation E – Engineering P – Procurement C – Fabrication / Construction FAT – Factory Acceptance Test (FAT) TR – Transportation WBS Level – Disciplines In terms of detailed engineering, the following components will be employed: PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [10] of [38] Date: 07 Nov 2014 01 – Process 02 – Mechanical & Piping 03 – Structure 04 – E & I 05 – General For the WBS Level – Activities/Sub-Activities, work activities within each discipline shall be identified according to Level of Planning, such as activities required to execute the work can be monitored on daily basis Then, the Level schedule shall clearly identify all the detailed activities along with all the milestones given in the Contract Activities concerned to project management, supervision, planning administration and quality assurance shall be shown as separate “hammock” activities without specified duration Each activity in the network shall be attached with the following information: - Activity number - Activity description - Planned activity duration excluding holidays - Early/Late Start & Finish dates - Total Float - Actual start, actual finish dates - Percent Complete Progress Measurement In summarizing the overall progress, the weighing of each Phase is assigned basing upon PTSC preliminary judgment for the EQUIPMENTS and SERVICE Below is the Preliminary Level weighting for Progress Measurement: Phase ID Description Assigned Weightage E Engineering 10% P Procurement 30% C Construction 50% FAT Factory Acceptance Test (FAT) 5% TR Transportation 5% The WBS Level weighted factors allocated to each discipline are assigned basing upon total manhour allocated (applied for Engineering and Technical activities) as follows: Discipline ID Description Assigned Weightage 01 02 03 04 05 Process Mechanical & Piping Structure E&I General Total 15% 40% 20% 15% 10% 100% PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: OVERAL PROJECT EXECUTION PLAN TBA Revision No.: A Page [11] of [38] Date: 07 Nov 2014 Progress for Engineering and Technical deliverables is counted basing upon typical milestones as follows: Milestone ID Description Earned Progress 01 02 03 04 Started (S) Inter-Discipline Check (IDC) Issued for Review Approved for Construction/Approved for Bid/Approved for Purchase Total 10% 40% 30% 20% 100% Earned progress for Procurement activities is counted basing upon typical milestones as follows: Milestone ID Description Progress 01 02 03 04 05 06 Issued RFQ to Bidders 10% TBE & CBE 10% PO cut 30% Receipt of Material 20% Testing 10% Issued for Construction 20% Total 100% Stage from PO cut until Receipt of Material is called VDI/VDR/expediting period Earned progress for Vendor document packages is calculated as follows: Milestone ID Description Progress 01 02 03 04 Received vendor data Returned comments on vendor data Received amended vendor data Received final vendor document Total 15% 25% 30% 30% 100% Progress for production activities is calculated as follows: Work Package ID 01 02 03 04 Description Mark & Cut Fit-up Welding Accepted (NDT) Steel Erection Pipe E&I 25% 25% 50% 25% 80% 40% 40% 40% 10% 10% 10% 20% 25% PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [33] of [38] Date: 07 Nov 2014 Materials which have been damaged or found to have defects will not be used except where there are only minor surface marks, in which case PTSC M&C will obtain approval from Company The materials shall be dressed provided the wall thickness is not reduced and the manufacturing tolerances defined in the appropriate material or purchasing specification are complied with Radial grooves or scratches on gasket faces are not allowed Re-facing/ machining will require Company’s approval Any re-facing that reduces the flange thickness to less than the minimum thickness allowed by the relevant code or standard is rejected Edge thickness of flange will be checked after re-facing Piping Fabrication Sequence The spool fabrication will be implemented with the sequence of marking, cutting, fit-up, Welding, NDT and painting Marking: All materials shall be marked for identification and traceability purposes Items marked to facilitate traceability shall maintain the marking throughout manufacturing and fabrication stages Markings which will be covered in the final assembly and coating, shall be first transferred to the as-built traceability quality records The transfer of marking to traceability quality records shall be subject to Company verification Cutting: Carbon steel shall be cut by methodology of flame cutters, high speed cutters, grinders or band saw machines Stainless steel, duplex stainless steel and CuNi shall be cut by high speed cutters, grinders, plasma cutting or band saw machine All cutting tools shall be compatible materials for Duplex Stainless Steel to avoid any contamination All materials cut by a flame or arc shall have the edge ground back to clear the affected zone The grinding wheel is marked by an impregnated red dye in the make-up of the disc which denotes chloride and surplus free material when used for stainless steel and high alloys Wire brushes with stainless steel bristles will be used, dedicated to stainless steel and high alloy materials Files for use on stainless steels and non ferrous alloys shall be new and dedicated to a particular alloy only All edges shall be accurately maintained as per design requirement with a smooth even surface with all slag removed Beveling will be performed with a beveling machine Separate machines will be used for carbon steel and stainless steel Preparation will be in accordance with the approved WPS Edge Preparation for Welds The preparation of edge for welding shall be done by machining or grinding PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [34] of [38] Date: 07 Nov 2014 Edge preparation shall be performed in accordance with the approved WPS & ANSI B 31.3 The surfaces of the edge preparation shall be free from tears, grease, oil slag, scale or internal burrs Stainless steel and high alloy pipe shall be beveled by a grinding or beveling/ machine only Separate machines will be used for carbon steel and stainless steel Fit – up piping spools: Alignment for the fit-up of the piping components shall be executed on a steel floor or steel jack stand for carbon steel spools For stainless steel and high alloy spool fabrication the floor will be covered with wooden planks or rubber All stands will be insulated with clean rubber sheeting to prevent contamination of the spools Under no circumstances shall stainless steel, high alloy & non ferrous materials be allowed to come into contact with carbon steel Pipe shall be properly supported at least meter off the ground and aligned by jigs or clamps in order to eliminate strains prior to tack welding Where jigs or clamps are used for stainless steel and high alloy fabrication, these items will be lined with clean rubber or stainless steel material to eliminate the possibility of contamination with other project material Welding All welds shall be performed in accordance with the approved WPS which shall be displayed on a notice board close to the work The welding grooves shall conform to the ANSI B 31.3 and ANSI B 16.25 and approved WPS All edges of surfaces to be welded shall be cleaned to a bright metal finish, in a manner suitable to remove any oxides, scale, grease, oil, or contamination due to flame cutting or machining Oil paint and dirt shall be removed from the pipe surface For at least one (1) inches from the bevel before welding is started Cleaning must be carried out just prior to tacking and repeated just prior to welding Stainless steel wire brushes shall be used for all other materials except carbon steel and low alloy steel Any cracks, blowholes, cold laps, unusual irregularities, slag, flux, or other impurities that appear on the surface of any welding bead shall be removed by grinding or chipping before depositing the next successive bead The requirement of the finished weld reinforcement for all materials should comply to ANSI B 31.3 specification for piping Two welders may be required on pipe Ф400mm and above, if necessary, pipe to be marked with welder’s ID No for area welded If arc strike occurs, this shall be removed by grinding followed by MT or dye penetration test For new piping, the acceptable wall thickness is the thickness as calculated inclusive manufacturing PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [35] of [38] Date: 07 Nov 2014 tolerances, corrosion and erosion allowances If pipe is ground severely to repair, the damaged part of the pipe shall be removed Internal purge of argon shall be used for the GTAW process root pass on stainless steels as specified by WPS Purging will be carried out by using the best method for the particular application during welding NDE and Repair of defects Extent of welding test shall be examined in accordance with drawing indicated All final examinations shall be performed after any required post weld heat treatment NDE and visual inspection should be performed in accordance to ANSI B 31.3 for piping The surface of repair welding will be cleaned thoroughly before welding in accordance with applicable W.P.S All repairs shall meet the inspection requirements and acceptance standards for the original material Major repairs shall be inspected by Company who shall be notified at least one day in advance of starting the repair Installation Method for pipe work: All piping work shall be completed in accordance with approved piping drawing such as plot plans, sections, general arrangements, isometrics drawing, piping material classes, pipe support schedules, standard, special support details, spools drawings and relevant vendor drawings as applicable The pipe spools will be lifted onto the module utilizing tower cranes and soft slings to minimize handling damage Any modifications of pipe routing due to interference will be immediately notified to Company and reflected on “as – built” drawings Field copy to be provided at earliest opportunity in case rerouting configuration may be undesirable to Company for any reason Final painting of all field butt welded joints shall be applied only after successful completion of hydrostatic test Pipe work shall be erected on permanent supports designated for the line Temporary supports shall be kept to an absolute minimum, but to an extent sufficient to protect nozzles and adjacent piping from excessive loads during the erection Pipe work shall be fitted in place without springing or forcing to avoid undue stressing of the line or strain being placed on a vessel or item of equipment, etc All temporary pipe spools and supports that are aids to erection, testing/flushing, sea-fastening, etc are to be specially marked for removal identification PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [36] of [38] Date: 07 Nov 2014 Field modification of prefabricated piping shall be performed in strict accordance with this specification and the applicable code, standard or recommended practice All weld slag, burrs and all foreign matter shall be removed from the piping prior to closure All lines shall be installed true and plumb except where specifically noted on the drawings Installation of piping shall be scheduled so that no undue strain will be inflicted on equipment due to lack of support, dead weight or misalignment Electrical & Instrument installation: E&I installation is part of the construction works and it plays an important role in completing fabrication of the project as per schedule Following section will give an overview of how PTSC M&C will execute the E&I installation works in Project General requirements All electrical materials and equipments shall be installed and connected in a complete and workmanlike manner in accordance with the Specifications, Drawings, and Manufacturer’s instructions The electrical materials and equipments shall be prepared, installed, loaded out and ready to operate with a minimum of offshore work The electrical safety shall be achieved by means of insulation, shrouding, earthing and bonding of equipments, warning labels and due diligence in the selection of equipments and materials Equipments that may deteriorate with direct exposure to sunlight shall be fitted with sunshields Points or drainage are to be provided for all locations that may accumulate rain or wash down water Where possible, all sandblasting and painting of the surrounding structures and pipes shall be done before any electrical equipment is installed No sandblasting shall be done around the equipment after it is installed without suitable protection and Company’s approval All electrical equipments shall be covered with fire resistant tapes or wrapped with plastic during the painting of the surrounding structures, pipes, vessels, tanks and other equipments Special care shall be taken to prevent damage of any electrical equipment due to welding or other fabrication or installation operations Stainless steel shall not be worked with tools containing ferrous material and all stainless steel equipments shall be protected against ferric contamination caused by welding, grinding, or cutting in the vicinity All worked stainless steel material shall be passive after working All stainless steel panels and tubing shall be sprayed or coated with VCI (Vapour Corrosion Inhibitors) solution to prevent and protect against weld sputter prior to installation All electrical material and equipments shall be substantially aligned with surrounding structural members and installed in such a manner as to present a finished installation PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: OVERAL PROJECT EXECUTION PLAN TBA Revision No.: A Page [37] of [38] Date: 07 Nov 2014 All electrical material and equipments shall be installed in a manner, which provide ease of access for operation, service and maintenance of all equipments, piping and valves All electrical material and equipments shall be substantially secured in order to prevent damage due to weather or handling during load out, open sea transport, and offshore installation Installation procedure for electrical: Prepare shop drawings for the following items: Supports layouts for cable ladder/ tray routings, Support details for cable ladders/ trays, Support details for single equipments Check what types of steels are available Compare with AFC MTO and raise the request of deficient items to authorized personnel/parties Prepare necessary steel material as taken off from shop drawings Fabricate and paint the supports as per AFC shop drawings with reference to AFC typical installation detail drawings and Project Specifications Mark the supports with their appropriate tag numbers, ensure they can be easily identified by inspectors from normal locations For supports which may be installed, install these supports on the site following the typical installation detail drawings, layout drawings and Project Specifications Touch up support’s welding damaged areas Invite Company Representative for inspection of the support installed prior to the installation of equipment (if required) Mark the drawings for the completed support Update the installation for Redline Markup dossier Installation procedure for instrument/equipment: Upon receipt at warehouse, equipment shall be inspected about technical and quality status All abnormal conditions shall be recorded into OS&D reports and reported to authorize personnel immediately Equipment which pass inspection shall be preserved in the warehouse or other appropriate location and strictly following Project Specifications, common regulations, and agreement between Company and PTSC M&C Appropriate tests shall be carried out for equipment which require quality and function testing These requirements are included in and documented into the Mechanical Completion Dossier - PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [38] of [38] Date: 07 Nov 2014 Electrical and Instrumentation Test Records which shall be submitted for Company approval Some equipment systems require such calibration/ function tests are Fire & Gas detectors, lighting fixtures, circuit breakers, batteries, instruments, etc The equipment shall be installed in accordance with the Manufacturer’s instructions with particular respect to tolerances for flatness, straightness, verticality, alignment, stress and loadings For more equipment illustrations, see products’ literatures Location of equipment: All equipment shall be positioned in accordance with the design drawings The location of equipment and devices which are not dimensioned on the drawings are approximate, and the exact location of equipment and devices will be established by Company and approved by the Company Representative All equipment shall be located to provide easy access by personnel for inspection, in-situ maintenance and removal and replacement of components Where reasonably possible, equipments shall be located such that access for maintenance does not require the use of a ladder or similar maintenance access platform Equipment requiring operation, replacement or inspection shall not be located higher than 1800mm or lower than 60mm above floor level except with Company permission As far as possible, electrical equipment shall be located outside wet areas and those areas prone to spillage Where necessary, special detectors and guards shall be provided to protect equipments against damage due to spillage, build up and cleaning with water hoses Easy access shall be provided to all devices and terminals in panels, cubicles marshalling boxes and junction boxes Access space of 600mm (minimum) plus clearance for door opening or equipment withdrawal shall be provided for all equipment All equipment including field and motor terminal boxes shall be arranged so that cabling is bottom entry, unless approved by the Company Equipment such as light switches and power outlets shall be mounted at a minimum of 1.2m above the operating platform level or grade as applicable, unless otherwise specified Equipment and components shall not be mounted on cladding, handrails, machinery or unapproved locations unless specific directions are given by the Company Where equipment is mounted along or in access ways, it shall be positioned, modified or protected such that it does not present a hazard to pedestrians or equipment traffic using the access way, nor be subject to accidental operation or possible damage Equipment shall not be relocated without Company approval Cables, cable ladders, brackets, poles and fittings shall be kept clear of and supported independently from stair and platform handrails and ladders Light stanchions shall not be braced PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [39] of [38] Date: 07 Nov 2014 on top of handrails, except as directed, and shall be spaced off so as to leave the handrails clear of obstruction For detail information on how PTSC M&C will carry out the fabrication and installation of the E&I in Project, PTSC M&C will develop a detail Electrical & Instrumentation Installation Procedure and will submit to Company for approval Material receiving control Material receiving will follow the internal material control procedure of PTSC M&C Generally, the material will be received under the control and supervision of the logistic personnel and the warehouse keeper At the time of receipt the material, all related personnel (Engineering, construction, QAQC, logistic and warehouse keeper) will be invited to attend the material receiving inspection A material receiving inspection report comes with OS&D report will be made and issued to all relevant parties to record the actual quantity, quality, specifications, spare parts, accessories… comes as per the signed off purchase order During the fabrication, surplus material as well as scrap material will be quarantined for the reconciliation purpose after the project completed A procedure will be developed and getting approval from Company for control of the material including scrap and surplus material Fabrication Dossiers: Following basic fabrication dossiers will be developed for the fabrication works: 3.6 Doc No Document Name TBA Structural Fabrication & Erection Procedure TBA Piping Fabrication & Erection Procedure TBA Electrical & Instrumentation Installation Procedure TBA Mechanical Equipment Installation Procedure TBA Preservation and protection Procedure ONSHORE TESTING AND PRE-COMMISSIONING Pre-commissioning/Commissioning representatives will be appointed on the commencement of the design phase so as: to define Pre-commissioning/Commissioning package limits; to advise designers; to review the developing design with a view to effective onshore Precommissioning/Commissioning; and, to prepare onshore Pre-commissioning/Commissioning procedure The following principles will be adopted as part of the overall Pre-commissioning/Commissioning strategy: PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [40] of [38] Date: 07 Nov 2014 Early involvement of Pre-com/Commissioning personnel to assist in the detail design and procurement phases; Maximization of Pre-commissioning/commissioning at the vendor’s work-site through factory acceptance tests and system integration tests; Planning of fabrication and Pre-commissioning/Commissioning activities so that overlap, as far as practical, can be achieved to facilitate the Precommissioning/Commissioning process; Maximizing onshore pre-commissioning and commissioning of systems; Accessing vendor expertise by including the vendor representatives on the Precommissioning/Commissioning team; Operating onshore Pre-commissioning/Commissioning work-packs to ensure the safe and controlled handover to Company, via the project completion systems - Finally, members of the commissioning team will be assigned to construction sites to familiarize themselves with the plant and undertake pre-commissioning activities The Onshore pre-commissioning work shall be the basis of maximum extent feasible; the precommissioning normally takes place at the sub-system level, which includes three main types of field activities: Conformity checks: carried out on each item of equipment or component, such as instrument, packages, motors, cables, vessels, etc, to verify visually the condition of the equipment, the quality of the installation, the compliance with Project drawings and specifications, Vendor’s instructions, safety rules, codes, standards and good practice Static/de-energized tests: carried out on equipment to ensure the quality of critical components This “cold” testing concern all disciplines, e.g calibration of instruments, machinery alignments, setting of safety valves, pressure testing of piping, cables continuities, etc Piping cleaning/ flushing and piping leak test: carried out on pipe work and vessels, using air or water or nitrogen with helium tracer Any further requirements for the pre-commissioning will be detailed in the specific procedure The PTSC Pre-commissioning Management System (PPMS) software is utilized for Mechanical Completion and Pre-commissioning of this project 3.7 Load-out and Seafastening Load-out The loadout of the modules from the fabrication position onto transportation barge will be performed by means of multi axle trailers Basically, load-out of the objects in Project will be carried out by sub-contractors which will be selected at the later stage PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [41] of [38] Date: 07 Nov 2014 Some potential subcontractors for load-out as follows: PTSC Supply Base: Normally, PTSC M&C will sign the subcontract with this company for the load-out service If any change, PTSC M&C will make notification to Company ALE company SARENS Company Mammoet Company Load-out procedure shall be prepared by the subcontractor and submitted to PTSC M&C for review before it will be submitted to Company for approval This procedure is not available at this early stage; however it will be prepared upon completion of the subcontractor selection 3.8 TRANSPORTATION Transportation all modules shall be provided by PTSC M&C’s Subcontractor Summary of execution as below: 3.9 Modules M04 M05 Weight (MT) 1303.24 1265.93 M10 587 M12 765 M13 818.07 Description Manifold & Pigging Manifold & Pigging MEG Regeneration, Diesel Flushing & Subsea Chemecal Injection Produced Water, Sand Treatment Utility Transportation by 280ft Barge & Tug or Heavy Lift Vessel 330ft Barge & Tug or Heavy Lift Vessel QUALITY MANAGEMENT (QAQC) PTSC M&C’S quality policy statement: PTSC M&C is a leading company specializing in providing technical services, expertise of the oil and gas industry in Vietnam and the region, aiming at producing the services with utmost quality in the fields of construction, fabrication of oil and gas equipments, facilities, oil and gas and related industries The company is committed to achieve quality in every phase of activity to meet customer’s requirements PTSC M&C shall supply quality products and services that are delivered on schedule Our Quality Management System, Safety Management System being of utmost reliance, internationally high standards and shall be base on the requirements of ISO 9001, ISO 14001 and OHSAS 18001 PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [42] of [38] Date: 07 Nov 2014 PTSC M&C shall create corporate culture of continuous improvement towards quality excellence The company’s greatest assets are its people and we shall implement a progressive Human Resources Development Policy to upgrade the knowledge and skill of our personnel to perform their job effectively, productively and cost effectively A comprehensive safety programmed shall be enforced to instill safety awareness among all personnel and ensure a safe and healthy work environment PTSC M&C quality management of the work at all sites shall include all quality related functions such as Quality Control, Quality Assurance and satisfactory implementation of a total quality management philosophy PTSC M&C project quality management organization shall ensure the proper operation of the quality system and ensure that the quality system conforms to the principles of internationally recognized standards such as the ISO 9000 series of standards Generally, the QC team will be acting on each phase of the project as follows At each phase, QC team will be set up properly to assure that the quality of the project will be complied as per requirement and standard The following Quality management procedures will be developed for the purpose of quality management: Doc No Document Name To be advised Project Quality Plan To be advised Internal Quality Audit Procedure To be advised Document & Data Control Procedure To be advised Document Coding Procedure To be advised Final Documentation Procedure To be advised Non-Conformance Control Procedure To be advised Inspection & Test Plan for Blasting and Painting To be advised Inspection & Test Plan for E&I To be advised Inspection & Test Plan for Piping To be advised Vendor Data Control Procedure To be advised Source Inspection Procedure To be advised Inspection & Test Plan for Mechanical PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [43] of [38] Date: 07 Nov 2014 Doc No Document Name To be advised Inspection & Test Plan for Structure To be advised WPS / PQR for Structure To be advised WPS/PQR for Piping To be advised Welding Qualification Test Procedure To be advised Welder Qualification Test Procedure To be advised Weld Repair & Buttering Procedure To be advised Welding Consumable Control Procedure To be advised Welding Control Procedure To be advised NDE- Radiographic Testing Procedure To be advised NDE- Ultrasonic Testing Procedure To be advised NDE- Magnetic Particle Testing Procedure To be advised NDE- Dye Penetrant Testing Procedure To be advised Positive Material Identification Procedure To be advised Post Weld Heat Treatment Procedure To be advised Surface Preparation and Painting Procedure To be advised Coating System Qualification Test Procedure To be advised Leveling & Dimension Control Procedure f To be advised Weld Distortion Control Procedure To be advised Fairing Procedure To be advised Welding Equipment Calibration Procedure To be advised Painting Matrix To be advised Active Welder Qualification Register For Structure To be advised Active Welder Qualification Register For Piping PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [44] of [38] Date: 07 Nov 2014 The quality management of the work for the entire Project shall be governed by the respective existing quality system in place and the approved quality plan developed by the PTSC M&C PTSC M&C shall be governed by this quality plan Doc No: (To be advised) and for the onshore fabrication, testing, pre-commissioning up to load-out and seafastening works The Project Quality Objectives are: Our Quality Management System, HSE Management System being of utmost reliance, internationally high standards shall be based on the requirements of ISO 9001, ISO 14001, and OHSAS 18001 Document relevant project requirements to meet relevant part of ISO 9001 2000 Use qualified and experienced personnel suitably trained to perform their duties Ensure all services and products provided by PTSC M&C pertaining to this project, are in accordance to the Scope of Work of Contract and Company’s Specifications Ensure that all necessary quality activities are specified to PTSC M&C’s SubCont/ Vendor and critical supplier to ensure that the overall level of quality and safety of the project is maintained Comply with applicable Legislation, TCVN & International Codes, Acts and Standards Implement continuous improvements Provide conducive environment and adequate facilities for carrying out work effectively and efficiently Deviations are controlled and approved Handover documentation is planned, approved and compiled progressively The Project Quality targets for onshore fabrication works are: Repair rate for Structural Welding of less than 0.7% (linear length base) Repair rate for Piping Welding of less than 0.4% (linear length base) Zero construction punch list prior to sail away Meeting all project Scheduled Key Dates PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [45] of [38] Date: 07 Nov 2014 These targets will be included in PTSC M&C’s KPI’s and sub-contractor quality document to ensure that the PTSC M&C’s sub-contractors are aware and committed to achieving the targets The Project Quality targets are set to motivate workers to always focus and have the mind set on quality improvement So that, the Project Quality Plan objectives can be achieved Source Inspection/ Coordination PTSC M&C shall identify project critical materials / packages that require source inspection For overseas Source inspection, PTSC M&C will appoint PTSC M&C’s persons or qualified and Company approved Third Party Inspection Agency (TPI) to carry out required inspection, expediting and monitor manufacturer’s production schedule Determination of levels of inspection will be based on the critical materials / packages Refer to Source Inspection Procedure Positive Material Identification (PMI) PTSC M&C’s QC material inspector and QC piping inspector will perform to positive material identification of SS/DSS piping material and their weldments It shall be implemented effectively to ensure that the chemical composition of alloy materials are as specified in specification Refer to Positive Material Identification Procedure 3.10 HSE Management PTSC M&C and its nominated sub-contractors all have their own documented Health, Safety and Environmental systems that are applicable to all projects they carry out (PTSC M&C has been certified to ISO14001:2004 and OHSAS18001:2007 by DNV) These systems are implemented by supported HSE policies and procedures such as HSE Manual, HSE plan, alcohol & drug policy, emergency response procedure, radiography procedure, scaffolding procedure, lifting procedure, etc PTSC M&C does not intend to merge all the HSE manuals from itself and its nominated subcontractors into a single document However, a specific HSE plan for this project will be developed and it will cover all phases of the project, from engineering, procurement to offshore hook-up and commissioning support PTSC M&C and its sub-contractors are responsible for effectively implementing the plan to achieve the HSE objectives outlined thereof PTSC M&C including its senior management is aware that safety working is the most critical requirement of the scope of work and commits providing a safe working environment to all persons and equipment in the project execution areas For detail information of the HSE works in Project, please refer to the specific Project HSE Plan, doc No (To be advised) Other specific HSE procedures will be developed as follows: Doc No Document Name To be advised Emergency Evacuation Plan (PTSC M&C PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [46] of [38] Date: 07 Nov 2014 Site) To be advised PTSC M&C Project Incident Reporting Procedure To be advised Radiation Safety Procedure To be advised PTSC M&C Scaffolding Procedure To be advised PTSC M&C Permit to Work Procedure To be advised Site Entry Procedure To be advised Inspection and Maintenance of Lifting Equipment Procedure To be advised HSE Manual PROJECT OBJECTIVES PTSC M&C and its nominated subcontractors have set out key objectives for the Project as follows: Contractor will execute and fully complete the work in accordance with the project requirements, international practices and other requirements from Company, Company’s other Contractor Contractor is to maximize onshore works as much as practically possible and minimize offshore works to bring benefits to all parties working on the project Health, Safety and Environment: Total Recordable Incident Rate (TRIR) less than 0.3 Contractor shall try their best to achieve completion of project without LTI Schedule: deliver the Contract Objects on time to meet the schedule Quality: products meet all the project requirements Cost: complete the project within budgets Contractor will use its most capable resources to perform, control and manage the project in order to achieve the agreed targets ATTACHMENTS The following attachments have been referred to for detail information in this Project Execution Plan Attachment Project Organization Chart (Typical) Attachment Yard Layout PTSC MECHANICAL AND CONSTRUCTION GHANA OCTP DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Attachment Fabrication Sequences (Module -Typically) Attachment Yard, Jetty and Quaysides information Attachment PTSC M&C Equipment list Page [47] of [38] Date: 07 Nov 2014 ... 3.1 PROJECT MANAGEMENT OVERALL PROJECT MANAGEMENT PTSC M&C will be responsible for the overall management of the project including development and implementation of overall project procedures, project. .. DEVELOPMENT PROJECT, FPSO Document No.: TBA Revision No.: A OVERAL PROJECT EXECUTION PLAN Page [13] of [38] Date: 07 Nov 2014 Doc No Document name To be advised Overall Project Execution Plan To... individual execution plans and procedures for key phases of the project, these documents shall include but not be limited to the following: Engineering Execution Plan Procurement Plan PTSC