Rapid P0022 Punj Con Man 0001 0001 - A PDF

Document Number
Project Package Originator Discipline Doc. Type Unit n° Serial n° Rev. Page
RAPID P0022 PUNJ CON MAN 0001 0001 A 2/56
CONSTRUCTION EXECUTION PLAN
REFINERY TANK FARM
HOLD’s
HOLD n° REF. § DESCRIPTION ACTIONS
Electronic File Name: RAPID-P0022-PUNJ-CON-MAN-0001-0001 REV-A

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TABLE OF CONTENTS
1.0 INTRODUCTION...............................................................................................................................5
2.0 OBJECTIVE......................................................................................................................................5
3.0 DEFINITIONS...................................................................................................................................6
4.0 SCOPE OF WORK...........................................................................................................................7
4.1 Brief Scope Of Work..........................................................................................................................7
5.0 CONSTRUCTION MANAGEMENT..................................................................................................12
6.0 SEQUENCE OF CONSTRUCTION ACTIVITIES.............................................................................15
7.0 CONSTRUCTION ORGANISATION CHART...................................................................................16
8.0 CONSTRUCTION EXECUTION STRATEGY..................................................................................17
8.1 Construction Manpower ................................................................................................................. 18
8.2 Manpower and man-hour histogram .............................................................................................. 19
8.3 Construction Activities.................................................................................................................... 21
9.0 LIST OF PROCEDURES/ METHOD STATEMENTS.....................................................................23
10.0 SUB-CONTRACTING......................................................................................................................28
11 CAMP MANAGEMENT....................................................................................................................30
11.1 Camp Facilities............................................................................................................................. ..30
11.2 Camp Common Facilities............................................................................................................... 32
11.3 Temporary Facilities Areas............................................................................................................. 32
12.0 CONSTRUCTION PLANNING, SCHEDULING, MONITORING & REPORTING...........................34
13.0 QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC).......................................................35
14.0 WAREHOUSE MANAGEMENT & MATERIAL CONTROL..............................................................36
15.0 SITE INSPECTION AND TESTING.................................................................................................43
16.0 FIELD ENGINEERING.....................................................................................................................44
17.0 FIELD TENDERING.........................................................................................................................45

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18.0 FIELD PURCHASE.........................................................................................................................45
19.0 HEALTH, SAFETY, SECURITY AND ENVIRONMENT (HSSE) MANAGEMENT..........................45
20.0 INDUSTRIAL LABOUR RELATIONS..............................................................................................47
21.0 CONSTRUCTION EQUIPMENTS...................................................................................................48
22.0 CONSUMABLES CONSTRUCTION MATERIAL AND BULK MATERIAL......................................51
23.0 CONSTRUCTION SITE PREPARATION AND ACCESS................................................................51
24.0 COMMUNICATION SYSTEM DURING CONSTRUCTION.............................................................52
25.0 UTILITES FOR CONTRACTOR OWN CAMP, OFFICE BUILDING AND OTHER FACILITIES ....52
26.0 CONSTRUCTABILITY REVIEWS...................................................................................................53
27.0 SITE MANAGEMENT.......................................................................................................................54
28.0 MECHANICAL COMPLETION.........................................................................................................54
29.0 SITE CLOSURE..............................................................................................................................55
30.0 ATTACHMENT 1................................................................................................................. ............56

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1.0 INTRODUCTION
Petroliam Nasional Berhad is building a grass root integrated Refinery and Petrochemicals
Complex to meet both domestic and Asia’s energy and chemicals demand. The RAPID PROJECT
consists of refining and petrochemical activities as detailed below: Refinery with a deep conversion
scheme; 300 000 barrels per day capacity,
 Naphtha Steam Cracker; 1.28 million tons of ethylene per year capacity,
 Petrochemical Derivative Units (polyethylene, ethylene oxide, ethylene glycol,

polypropylene, propylene oxide, propylene glycol, rubbers, etc.) and
 Utilities, off site and jetty installations.
The RAPID PROJECT is located at Pengerang, Mukim of Pengerang, Kota Tinggi District, Johor
and is in close proximity to the international shipping lane connecting the Straits of Malacca,
Singapore and the South China Sea.
2.0 OBJECTIVE
The objective of the Construction Execution Plan is to describe the methodology planned &
conceived by the CONTRACTOR for executing the WORK and develop Construction Procedures
for all site activities in-line with the requirements of the Contract, submitted to OWNER for
review. After OWNER’s review of each of the Procedures, and after incorporation of all
comments made by OWNER, the Procedures shall be issued for OWNER’s formal approval,
put into effect, and incorporated into the Construction Execution Plan. The Construction
Execution Plan shall be continuously followed and up-dated by CONTRACTOR throughout the
whole Construction up to FACILITY MECHANICAL COMPLETION.
The prime objective is to ensure that the Project shall be completed in a safe and reliable
manner with the minimum impact on the environment while maintaining all safety, quality and
schedule requirements of the OWNER.
This will ensure that the WORK will be safe, reliable and suitable for their intended purpose in
accordance with the CONTRACT. During execution of the WORK, CONTRACTOR shall supervise
all construction activities, ensure availability of requisite EQUIPMENT and MATERIALS, perform

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all the QA/QC and HSSE activities during construction, control, assess and monitor the progress of
the WORK and report daily, weekly and monthly to OWNER (as per ITB).
CONTRACTOR has acquired full knowledge of the conditions of labour (legal, contractual and
market conditions for labour employment), the conditions of the WORKSITE, and environmental
aspects.
CONTRACTOR shall mobilize at the early stage of the Design process in order to organize
construction activities in a systematic and sequential manner to ensure that the WORK is carried
out safely in accordance with the CONTRACT. Construction Management shall be carried out by
CONTRACTOR and shall not be subcontracted.
3.0 DEFINITIONS
The following definitions shall mean as explained below:
OWNER : PRPC REFINERY AND CRACKER SDN. BHD.
CONTRACTOR : Punj Lloyd Ltd – Punj Lloyd Sdn. Bhd (PLL -PLSB)
PMC : Project Management Consultant - RAPID
PMT : Project Management Team
HOME OFFICE : Punj Lloyd Ltd. Gurgaon Office, India
PD : Project Director
PM : Project Manager
DPM : Deputy Project Manager
CCM : Chief Construction Manager
CM : Construction Manager
EM : Engineering Manager
PM [P] : Procurement Manager
PCT : Project Control Team
TCF : Temporary Construction Facilities

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CPM : Critical Path Method
PMS : Project Master Schedule
RFSU : Ready for Start up
CW : Construction Work Package
4.0 SCOPE OF WORK
The broad scope of work shall comprise of the following activities:
1. Civil foundations
2. Structural Steel works
3. Tankages
4. Fabrication and Erection of Piping
5. Erection of pumps & vessels.
6. Electrical & Instrumentation works.
7. Painting & Fireproofing works.
8. Insulation works
9. Pre commissioning ,Commissioning & Performance Test
10. Handing over of facilities.
4.1 Brief Scope of Work
Scope of work includes provision of all works (permanent or temporary) necessary to execute
and complete the work under the Contract. It includes Project Management, Design,
Engineering, Procurement, Interface with other contractors and third parties, acquiring permits,
Construction, inspection and testing, Pre- Commissioning, Commissioning, handing over of
facilities, providing necessary technical direction and assistance to OWNER for overall
performance tests and rectification of defects during warranty period as per contract
requirement. Above mentioned scope of works are related to the following:

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a. UNIT 5100: Refinery Storage (Common Part)
 Atmospheric Flashed Steam Condenser
 Atmospheric Steam Condensate flush drum
 Atmospheric Steam Condensate pump
b. UNIT 5110: Refinery Feedstock
 Four Crude Storage Tanks,
 Three Crude Oil Feed Pumps
 Automatic Crude Sampling Package
c. UNIT 5150: Refinery Intermediate Products
 Twenty Eight Storage Tanks to store Intermediate products rundown from The Process
Units,
 Six LPG Intermediate Storage Vessels (Mounded Bullets),
 Two Storage Vessels (Spheres) for Light Cracked Naphtha,
 Thirty nine Transfer pumps,
 Three antioxidants for cracked products and one LPG final product additive
d. UNIT 5170: Refinery Finished Products
 Twelve Finished products check tanks,
 Eight Finished products transfer pumps,
 One Gasoline Blender
 One Fuel Oil Blender
 Four Additive Injection Packages
 One Kerosene / Pygasoil Heater

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e. UNIT 5190: Refinery Slop
 One Light Slop Storage Tank and Two Light Slops Transfer pumps
 One Heavy Slops Storage Tank and Two Heavy Slops Transfer pump
 One LPG Off-spec Storage Vessel and Two LPG Off-spec Recycle pumps
 One LPG Blow-down Drum
 Two Light Slop drain Drum
 One Heavy Slop Drain drum
 Two Light Slop Drain Pump (HC)
 Two Light Slop Drain pump (Water)
 One Heavy Slop drain Pump
f. UNIT 4600: Flushing Oil
 One Flushing Oil Storage Tank
 Two Flushing Oil Pumps
 Major Start-up/ Shut down Flushing Oil Pump
g. UNIT 6440: Pressurized Storage Flare System
 One Pressurized Storage Flare Package
 Two Flare KO Drum Pumps
 One Flare KO Drum
h. UNIT 5900: Tank Farm Interconnecting
 Process and utility interconnecting lines
 On/Off Valves

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It is also supported with the utility system, which are:
i. UNIT 4800: Potable water system for RAPID Tank Farm
 Four Potable Water Loops
j. UNIT 6300: Common Effluent Treatment Plant for RAPID Tank Farm
 Two Accidently Oily Contaminated system
 Continuous Oily Contaminated Pits
k. UNIT 4300: Instrument Air Buffer Vessel (4300 – V – 501)
The plot plan of the PRPC Refinery showing the RAPID TANK FARM AREA is attached herewith.
Refer document no. as RAPID-P0022 -PUNJ-CVS-DWG-5000-0003.
Following buildings are also associated to these UNITS and part of facilities scope:-
 Field Auxiliary Rooms
 Electrical Substations
 Pump Shelters
 Operator Shelter Building
 Analyser House
As specified in the contract, details of major facilities such as tanks, mounded bullet and spheres
(in CONTRACTOR scope) are as under :

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List of Tanks
Sr. Dia Height

Tank Tag No. Description Nos.
No. (m) (m)
1 4600-T-001 Flush Oil Storage Tank 1 30 16
2 5110-T-001 A/B/C/D Crude Storage Tank 4 92 21.8
3 5150-T-001 A/B/C/D/E AR / HDT AR Storage Vessel 5 77.5 21.3
4 5150-T-002 A/B SR Naptha Storage Tank 2 66.5 15
5 5150-T-003 A/B SR Kerosene Storage Tank 2 43 15
6 5150-T-004 AG Storage Tank 1 73 15
7 5150-T-005 ARDS Gasoline Storage Tank 1 73 15
8 5150-T-006 HDT LN Storage Tank 1 40.5 15
9 5150-T-007 HDT HN Storage Tank 1 34 15
10 5150-T-008 A/B Reformate Storage Tank 2 26.5 15
11 5150-T-009 A/B Cracked Naptha Storage Tank 2 68 15
12 5150-T-010 Pyoil Storage Tank 1 15 15.9
13 5150-T-011 A/B MCN Storage Tank 2 42.5 15
14 5150-T-012 A/B HCN Storage Tank 2 35.5 15
15 5150-T-013 A/B LCO / Pygasoil Storage Tank 2 38.5 15
16 5150-T-014 A/B Slurry Storage Tank 2 23 15.6
17 5150-T-015 A/B C7+ Storage Tank 2 18 15
18 5170-T-001 A/B/C Gasoline Check Tank 3 37.5 15
19 5170-T-002 A/B/C Jet Fuel / DPK Check Tank 3 23.5 15
20 5170-T-003 A/B/C Diesel Check Tank 3 41 15
21 5170-T-004 A/B/C Slurry / FO Check Tank 3 17 16.2
22 5190-T-001 Light Slops Storage Tank 1 33 15
23 5190-T-002 Heavy Slops Storage Tank 1 40 15.7

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List of Mounded Bullet / Sphere
Sr. Dia Height /

Tank Tag No. Description Nos.
No. (m) Length (m)
1 5150-V-001A LPG Intermediate Storage Vessels 1 8.5 61
2 5150-V-001B LPG Intermediate Storage Vessels 1 8.5 61
3 5150-V-001C LPG Intermediate Storage Vessels 1 8.5 61
4 5150-V-001D LPG Intermediate Storage Vessels 1 8.5 61
5 5150-V-001E LPG Intermediate Storage Vessels 1 8.5 61
6 5150-V-001F LPG Intermediate Storage Vessels 1 8.5 61
7 5190-V-003 LPG Off-spec. Storage Vessel 1 6 60
Light Cracked Naphtha Storage
8 5150-V-002A 1 32.8 --
Vessel
Light Cracked Naphtha Storage
9 5150-V-002B 1 32.8 --
Vessel
The CONTRACT results in staged delivery of the facilities in two (02) sections as described
below so as to satisfy the OWNER’s requirements and Performance Guarantees.
UNIT NO. 5110 (CRUDE STORAGE),

UNIT NO. 4600 (FLUSH OIL SYSTEM) PROVISIONAL
SECTION - I UNIT NO. 4800 (WATER SYSTEM) ACCEPTANCE BY
UNIT NO. 6300 (EFFLUENT TREATMENT) 31.08.2018
CONDENSATE RECOVERY SYSTEM
UNIT NO. 5150 (REFINERY INTERMEDIATE UNIT)
UNIT NO. 5170 (REFINERY FINISHED PRODUCT)
UNIT NO. 5190 (REFINERY SLOP UNIT) PROVISIONAL
SECTION - II UNIT NO. 6440 (REFINERY FLARE UNIT) ACCEPTANCE BY
UNIT NO. 5100 (CONDENSATE RECOVERY 21.10.2018
SYSTEM).
UNIT NO. 5900
5.0 CONSTRUCTION MANAGEMENT
The Project will be organized under overall management of the Project Director and Project
Manager fully assisted by the Key personnel of the project. Project Director will act as
CONTRACTOR REPRESENTATIVE who will be responsible for operation and performance of
the whole Project and overall project management. The engineering activities will be executed
under the direction of the Engineering Manager functionally reporting to the Project Director.

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Engineering shall be organized into traditional disciplines, each headed by a Discipline Lead
Engineer. The deliverables of engineering disciplines shall be passed on to the Procurement
Manager for Procurement and to Chief Construction Manager at site for site construction and
erection jobs.
CONTRACTOR’s Chief Construction Manager will be responsible for overall construction
management, coordination and timely execution of entire Construction activities. Chief
Construction Manager will report to Deputy Project Manager, who in turn will report to Project
Manager. Construction teams will be deployed considering wide work spreads of the project.
Accordingly, dedicated Construction Managers are proposed for the various disciplines like
Civil, Tankages, Piping, Equipment, Electrical & Instrumentation etc. who will report to Chief
Construction Manager, based at site.
Construction Manager of each work area will have dedicated team of discipline
engineers/supervisors, safety supervisors, QC Inspectors for completion of work in their
respective areas. A proposed Construction Team (Refer Page No. 16) is covered under
CONTRACTOR Organization Chart (Construction).
CONTRACTOR shall ensure delegation of adequate and sufficient power to his Chief
Construction Manager / Construction Managers for effective and smooth functioning of the
construction management. CONTRACTOR’s PMT support shall provide support to the Chief
Construction Manager/Construction Manager at site during construction on all matters of Project
execution including the following:
 Field engineering
 Mobilizing Vendor specialists required during construction / commissioning.
 Rectification/ replacement of defective supplies, if any, noticed during construction and
commissioning.
 Inspection / expediting of replacement orders / field purchase orders for items ordered
by Field Purchase Cell.
 Expediting replacement of imported / indigenous items found short / damaged.
 Incoming Material Inspection at site and the required documentation for the same.
 Complying all statutory requirements and the required documentation, coordination with
OWNER.
 HSSE
 QA/QC

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During construction phase, Project Manager will provide above-mentioned support to construction
team. Having full knowledge of the applicable laws and regulations, conditions of labour, local
conditions, the site conditions and environmental aspects CONTRACTOR will comply with the
requirements thereof including applicable codes and standards.
The Construction Execution Plan shall be continuously followed and up-dated by CONTRACTOR
throughout the whole Construction up to MECHANICAL COMPLETION.
The Construction supervision, co-ordination and management activities shall be carried out by
CONTRACTOR in accordance with the Construction Procedures developed and submitted by
CONTRACTOR and approved by OWNER/PMC. CONTRACTOR shall prepare construction
driven schedule/Level IV within the framework of overall CONTRACT schedule and submit to
OWNER for approval. CONTRACTOR shall plan, execute, monitor and control construction
activities as per the approved construction schedule/Level IV.
The “Construction-Driven” approach recognizes that the achievement of shorter schedules and
optimum costs during the Construction Phase is dependent on supportive drawing and material
deliveries to the JOBSITE on or before actual need arises.
To accomplish this, the needs of Construction has been identified, given proper attention and
priority, and used to drive the Engineering and Procurement efforts of the job. "Float Preservation"
is one of the prime goals in using this WORK process.
Construction Management Functions
The Construction management functions to be performed by CONTRACTOR will include the

following as key functions for effective timely and safe execution, monitoring and control.
 Planning, scheduling, monitoring and reporting

 Construction supervision, discipline wise.
 Quality assurance and quality control discipline wise.
 Inspection on receipt of materials at Site
 Shipping, custom clearances, inland transportation
 Warehouse management and material control
 Field engineering / Purchase
 Health, Safety, Security and Environment (HSSE ) Management

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 Statutory clearances and enforcement of statutory rules / regulations and labour

laws.
 Personnel/Administration/Industrial Relations
 Billing and Invoicing
 Finance and Accounts
 Work Permit system
6.0 SEQUENCE OF CONSTRUCTION ACTIVITIES
Detailed project schedule is under preparation and is being submitted separately to OWNER for
their review and approval covering all aspects of Construction activities.
However, construction sequence by work disciplines will be as per the following order, as
commonly applied to general plant construction. This general sequence will be implemented for
main process and utility systems.
 Development of Temporary construction facilities such as offices/warehouses and

camps including soil investigation, power supply, water, material storage etc.
 Civil and building works
 Piling works
 Civil Foundation of Tanks, pumps etc.
 Fabrication, preassembly and erection of steel structures.
 Fabrication and erection of tankages and equipments like pumps etc.
 Fabrication and erection of mounded bullet and spheres
 Fabrication, erection and testing of Pipes (including blasting / painting).
 Electrical and Instrumentation & Control system.
 Telecommunication
 Painting and Insulation works.
 Interface compliances
 NDT works.
 Energization of Substations and Electrical / Instrumentation panels.
 LOOP TEST
 Attending Punch Points and Pre Start-up Safety Review.
 Pre-commissioning and commissioning.
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7.0 CONSTRUCTION ORGANISATION CHART
PROJECT
DIRECTOR
L K SHARMA
PROJECT
MANAGER
TBA
DEPUTY PROJECT
MANAGER
UMA MAGASH
CHIEF
CONSTRUCTION
MANAGER
SUPRIYO MITRA
CONSTRUCTION CONSTRUCTION
CONSTRUCTION CONSTRUCTION PLANT &
MANAGER MANAGER
MANAGER MANAGER EQUIPMENT
(PIPING &
(CIVIL) (TANKS) (E & I) MANAGER
EQUIPMENT)
PIPING & EQPT.

CIVIL TEAM TANK TEAM E & I TEAM P & E TEAM
TEAM
AREA IN- AREA IN- AREA IN- AREA IN- AREA IN-
CHARGES CHARGES CHARGES CHARGES CHARGES
(CIVIL) (PIPING & EQPT.) (TANK) (E & I) (P & E)
PIPING
CIVIL ENGINEERS TANK ENGINEERS E & I ENGINEERS P & E ENGINEERS
ENGINEERS
SUPERVISORS SUPERVISORS SUPERVISORS SUPERVISORS SUPERVISORS

(CIVIL) (PIPING) (TANKS) (E & I) (P & E)

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8.0 CONSTRUCTION EXECUTION STRATEGY
Initially, Project Management Team (PMT) will be stationed at Home Office in Gurgaon, India,
headed by CONTRACTOR REPRESENTATIVE.
Some of the main functions from this office are as under:
 Mobilization of PMT Team

 Establishment of Office Facilities for OWNER/PMC and CONTRACTOR at Home Office.
 Preparation and Submission of all procedures as identified in contract document
 Managing Engineering Team
 Managing Subcontract Services starting from RFQs’ till placement of WO
 Managing Procurement Services starting from RFQs’ till placement of PO
 Correspondence and Communication with OWNER/PMC
 Attend Meetings with OWNER/PMC, Vendors and Subcontractors
 Arrangement of Indirect and Direct Staff for the Project
 Arrangement of Insurance and Performance Bond
 Arrangement of manpower clearance from labour ministry in India
 Arrangement of Construction Equipment for the Project from its pool in India
PMT will work from this Home Office till substantial Engineering progress is achieved and order for
all major Procurement packages has been placed. Engineering and Procurement Team of PMT
will remain at Home Office to complete balance Engineering and Procurement works till order
placement.
Site office will be constructed at the area provided by OWNER and the Construction
Management Team will be accommodated at the site office.
Initially, during engineering phase, Chief Construction Manager will be based at Home Office.
Deputy Project Manager will be based at Kuala Lumpur/ Site for timely development of Camp/
Temporary Construction Facility and executing geo-tech investigation etc. CONTRACTOR shall
be working from Kuala Lumpur Office initially for 6-8 months after which it shall be shifted to
Temporary Site Office to be set-up within RAPID PROJECT boundary.

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Main functions from this office shall be as follows:
 Arrangement of CIDB License, DOSH registration, Labor Department approval, work

permits approval and all other regulatory approvals
o Regulating liaisioning service provider, who will be very much conversant or is
having past experience working with statutory bodies of Malaysian government, are
being appointed as facilitator in securing above-mentioned approvals.
o Immigration agent is being appointed for processing and maintaining records of all
expatriates. KL office will work in close co-ordination with these agents.
 Arrangement of tax clearance for imported items
 Arrangement of meetings with Local Vendors, Subcontractors and suppliers
 Set-Up temporary site office near RAPID Project to monitor
 Monitoring and Supervision of Camp/Temporary Construction Facilities for
OWNER/PMC and CONTRACTOR.
 Coordinating with OWNER/PMC to ensure availability of WORK SITE as per ITB.
 Coordinate with Geotechnical Subcontractor, CAMP Facility Subcontractor and other
Subcontractors
 Arrangement of Construction Equipment required for the Project in and around Malaysia
Followings are the main objectives considered while formulating Construction work execution
strategy. The Strategy shall include:
8.1 Construction Manpower

CONTRACTOR shall organize and mobilize construction staff/manpower in a Sequential manner
to ensure that the project works are carried out in accordance with the construction schedule as
per project scope. Mobilization of construction staff should be such that the progress achieved in
phased manner should match with the overall project schedule.
CONTRACTOR shall exercise its best efforts to maximize local manpower. Nevertheless it is
estimated that, to meet project requirement, CONTRCTOR may have to mobilize foreign work
force which may be in the range of 70% to 80% of total requirement due to the non-availability of
local labour force in the adequate numbers for all contractors in the RAPID Project. The countries
identified for obtaining foreign manpower are mainly from Indonesia, India, Nepal and
Bangladesh. The Labour mix, in particular percentage and origin on the total labour force will be

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of the high qualified personnel for field management and floor management (general foremen and
working foremen). By high qualified field and floor management it is meant personnel mainly with
proven long experiences with the subcontractors, with high cost incidence but essential to
guarantee a good productivity. In the total labour working craft force the qualification of the skilled
pipe fitters, welders, masons, carpenters, etc, will be specifically surveyed.
For facilitating smooth operation towards deployment of expatriates, dedicated immigration/visa
agent is being appointed. Main responsibility of this agent will be:
 Checking of all antecedents of persons deployed by CONTRACTOR or Sub-Contractor.
 Processing the application towards issuance of visa.
 Maintenance of records
The works of all Sub-Contractor’s will be managed by the Chief Construction Manager and
discipline Construction Manager of the CONTRACTOR who shall perform the duties of
construction management, coordinate and monitor the works of the Sub-Contractor(s) and be
responsible for timely completion of the respective works. The CONTRACTOR will establish the
pre-requisites for successful completion of Sub-Contractor(s) work. However, by deploying the
Sub-Contractor(s), as approved by OWNER for any discipline, CONTRACTOR does not get
exonerated from his total responsibility under the subject contract and CONTRACTOR will take
necessary action to meet the target. CONTRACTOR will ensure that execution of works will be
done as per standards/ approved specifications/drawings. CONTRACTOR will prepare
construction schedules based on the overall project schedule of the WORKSITE and submit the
same to OWNER / PMC for approval. Monitoring and control of the construction activities will be
carried out as per the approved construction schedule and procedures.
CONTRACTOR will submit Daily construction manpower deployment report to OWNER in
approved format. In case of urgency or meeting dates as laid down in schedule, CONTRACTOR
will arrange.
8.2 Manpower and man-hour histogram

Manpower and man-hour histogram by major section and discipline and their manpower
deployment schedule on monthly basis.

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MANPOWER HISTOGRAM
Shall be submitted after approval of Level III Schedule
MANHOUR HSITOGRAM

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INDIRECT MANPOWER TRADE WISE
8.3 Construction Activities
 Site Activities will be started by soil investigation, expected to be done by Feb’15 and
report is expected on or before May’15.
 This shall be followed by Camp and Temporary Camp Facilities construction.
 On completion of the above site construction activities shall be started as per the
Schedules agreed.
 As per ITB, CONTRACTOR has to hand over the facilities in two sections
o SECTION 1 – Unit No.5110, 4600, 4800, 6300 & Condensate Recovery system.
o SECTION 2 – Unit No.5150, 5170, 5190, 6440, 5100, 5900 etc.
 TANKAGE WORK
o Total scope of work for tankages is estimated at 44378MT inclusive of tanks, tank
structures and appurtenances.
o Based on the RFSU dates, Excavation work for Tanks of unit no.5110 will be
started from Jan’16.
o Prefabrication of tank plates will be started by Jan’16.
o Erection of tanks will be started by Apr’16.

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 EQUIPMENT ERECTION
o Total scope of work for Pumps, Package units, Mixers, condenser is estimated at
1498MT
o Excavation for pump stations will be started by Jun’16.
o The package units and particular equipment will be delivered in fully assembled
module or partial assembled parts.
o For the installation of the package units, the installation manual issued from the
vendor will be precisely observed, and the supervision for installation and the Pre-
commissioning will be made.
 HEAVY LIFTS
o Heavy lifting work will have a proper rigging plan and duly certified lifting
accessories like spreader beams, tools and tackles, slings, etc. for their heavy lift
operation. The rigging plan will be submitted for approval to the OWNER/PMC
prior to start of the job.
o The lifting study will have the details mentioned below as lifting study and plan :
 Confirmation checks of the weight and dimensions of the load to be lifted.
 Crane model.
 Crane configuration.
 Crane capacity at working radius and required boom length .
 Required sizes and capacities of slings, shackles, rigging beams.
 Verification of lifting points on the load to be lifted.
 Structural calculations if lifting frames are to be used.
 Crane accessibility for the lift and placement and possible interference with other items
erected.
 Bearing capacity of the ground at lifting position and for the access route.
 Any known subsurface conditions, such as underground piping or drainage systems,

liable to affect the lift.

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 Piping Work
o Total scope of piping fabrication and erection work is estimated at 470245 id and
1832548 inchM.
o Pre-Assembly Methodology will based on assembling two or more spool pieces in
the Pre-Assembly yard and then shifting to WORKSITE for erection.
o CONTRACTOR will develop and implement construction methodology which will
include material control, piping status monitoring, spool management, Test
Package etc. will be applied for piping work to control the material and construction
status properly from material receiving through to system hand over to OWNER.
o Prefabrication of piping will be started once 70% of tank plate fabrication is
completed.
o Erection of fabricated spools will be done initially on the bulk mode and later at a
criteria based on test pack and system completion.
o Small bore fabrication will be partially done at field and necessary NDE will be also
done at the project location itself.
o CONTRACTOR plans to start Supporting of the erected piping as soon as the
support for the line specific is fabricated in their workshops.
9.0 LIST OF PROCEDURES/ METHOD STATEMENTS

Prior to start of each activity/ work, CONTRACTOR will submit METHOD STATEMENT with JSA to
the OWNER for their review and approval. On getting approval, job will be carried out. All
construction activities will be as per approved drawing and specifications. Prior to start of each
activity, method statements need to get approved at least one month prior to start. Some of the
method statements & procedures are as under:
1. List of Method Statements -
a. Method Statement for Survey Works (Refer document RAPID-P0022-PUNJ-CON-

PRC-0001-0011).
b. Method Statement for Grading Works (Refer document RAPID-P0022-PUNJ-CON-
PRC-0001-0016).
c. Method Statement for Earth Works (Refer document RAPID-P0022-PUNJ-CON-
PRC-0001-0017).

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d. Method Statement for Random Rubble Masonry (Refer document RAPID-P0022-

PUNJ-CON-PRC-0001-0018).
e. Method Statement for Brick Works (Refer document RAPID-P0022-PUNJ-CON-
PRC-0001-0019).
f. Method Statement for Concrete Pavement (Refer document RAPID-P0022-PUNJ-
CON-PRC-0001-0023).
g. Method Statement for IBM Roads (Refer document RAPID-P0022-PUNJ-CON-
PRC-0001-0020).
h. Method Statement for Bituminous Course (Refer document RAPID-P0022-PUNJ-
CON-PRC-0001-0022).
i. Method Statement for Liquid Retaining Structures (Refer document RAPID-P0022-
j. Method Statement for Tank Pads (Refer document RAPID-P0022-PUNJ-CON-
PRC-0001-0021).
k. Method Statement for Underground Piping Works (RCC/CI) (Refer document
RAPID-P0022-PUNJ-CON-PRC-0001-0025).
l. Method Statement for Underground Piping Works (Steel /GI) (Refer document
m. Method Statement for ERC&IRC Road Crossing (Refer document RAPID-P0022-
n. Method Statement for Antitermite (Refer document RAPID-P0022-PUNJ-CON-
PRC-0001-0028).
o. Method Statement for Plastering & Pointing (Refer document RAPID-P0022-
p. Method Statement for Painting (Refer document RAPID-P0022-PUNJ-CON-PRC-
0001-0030).
q. Method Statement for False Flooring & False Ceiling Work (Refer document
r. Method Statement for Water Proofing (Roof) (Refer document RAPID-P0022-
s. Method Statement for Door, Windows & Ventilators (Refer document RAPID-
P0022-PUNJ-CON-PRC-0001-0033).

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t. Method Statement for Sanitary Fittings & Fixtures (Refer document RAPID-P0022-
u. Method Statement for Floor Finishing (Refer document RAPID-P0022-PUNJ-CON-
PRC-0001-0035).
v. Method Statement for Wooden Works (Refer document RAPID-P0022-PUNJ-
CON-PRC-0001-0036).
w. Method Statement for erection of Tanks ( using JACK LIFT method).( Refer
document RAPID-P0022-PUNJ-CON-MAN-0001-0037).
2. PERMITS and timing of approval will be maintained as per document RAPID-P0022-
PUNJ-CON-MAN-0001-0007.
3. Detail of facilities for Construction site office for both OWNER and CONTRACTOR will
be maintained as per document RAPID-P0022-PUNJ-CON-MAN-0001-0002.
4. Construction strategy related to pre-fabrication, modularization, access route to the
WORKSITE, sequence of activities, contingency plans to address bad weather,
late delivery, etc will be maintained as per document RAPID-P0022-PUNJ-CON-MAN-
0001-0003.
5. Sequencing of work, manpower forecasts, etc will be maintained as per document
RAPID-P0022-PUNJ-CON-MAN-0001-0004.
6. Description of major CONTRACTOR’s EQUIPMENT, numbers, source of equipment,
mobilization dates and duration at WORKSITE. Refer document RAPID-P0022-PUNJ-
CON-MAN-0001-0005.
7. Master list of all procedures to be used for construction, installation, inspection and
testing activities of the PROJECT will be maintained as given in document RAPID-
P0022-PUNJ-CON-MAN-0001-0006.
8. Procedure for liaising with the OWNER, Authorities and related parties. Refer document
RAPID-P0022-PUNJ-CON-PRC-0001-0004.
9. Procedure for WORKSITE document control and co-ordination, red line revision control
will be maintained as given in document RAPID-P0022-PUNJ-CON-PRC-0001-0005.
10. Construction progress will be reported as per document RAPID-P0022-PUNJ-CON-
PRC-0001-0006.

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11. Procedure for VENDOR(s) and SUB-Contractor’s qualification, approval, surveillance

and auditing will be maintained as per document RAPID-P0022-PUNJ-PUR-PRC-0001-
0016.
12. Inspection Test Plans (ITPs) For Site Works will be maintained as per document RAPID-
P0022-PUNJ-QAC-QAA-0001-0002.
13. Welding Procedure Specification (WPS) and Procedure Qualification Records (PQR) will
be done as per document RAPID-P0022-PUNJ-QAC-PRC-0001-0024.
14. Procedure for backfill material and compaction control, dumping of spoil or excess
material will be given in document RAPID-P0022-PUNJ-CON-PRC-0001-0007.
15. Welder Qualification Test will be carried out as per document RAPID-P0022-PUNJ-
QAC-PRC-0001-0025.
16. Formwork installation and removal will be carried out as per document RAPID-P0022-
PUNJ-CON-PRC-0001-0013.
17. Installation and checking of scaffolding will be carried out as per procedure laid down in
the document RAPID-P0022-PUNJ-CON-PRC-0001-0009.
18. Installation, cutting, inspection and testing activities related to rebar will be done as per
document RAPID-P0022-PUNJ-CON-PRC-0001-0012.
19. Concrete work including repair of cracks and damages (spalled / damaged edges),
inspection and testing activities will be carried out as per document RAPID-P0022-
20. Procedure for structural steel fabrication and erection will be maintained as per
document RAPID-P0022-PUNJ-QAC-PRC-0001-0003.
21. Coating, painting including field applied joint coating and inspection & repairing will be
carried out as per document RAPID-P0022-PUNJ-QAC-PRC-0001-0006.
22. Procedure for piping installation. Refer document RAPID-P0022-PUNJ-QAC-PRC-0001-
0004.
23. Procedure for hot tapping. Refer document RAPID-P0022-PUNJ-QAC-PRC-0001-0005.
24. WORKSITE security will be followed and maintained as per document RAPID-P0022-
PUNJ-HSE-MAN-0001-0003.
25. Non-destructive testing and inspection (including radiography and handling of
radiographic materials) will be carried our as per document RAPID-P0022-PUNJ-QAC-
PRC-0001-0008.

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26. Procedure for insulation and cladding. Refer document RAPID-P0022-PUNJ-QAC-PRC-

0001-0007.
27. Procedure for cleanup, drainage and erosion control. Refer document RAPID-P0022-
28. Repair of damages (including coating and other repairs on existing facilities) will be done
as per document RAPID-P0022-PUNJ-CON-PRC-0001-0014.
29. Nonconformities and other quality problems will be reported as per document RAPID-
P0022-PUNJ-QAC-PRC-0001-0020.
30. Procedure for Electrical, earthing installation and testing. Refer document RAPID-
P0022-PUNJ-QAC-PRC-0001-0019.
31. Hydro test procedure including source of hydro test water, test packs, and its disposal
will be carried out as per document RAPID-P0022-PUNJ-QAC-PRC-0001-0013.
32. Flushing, blowing and chemical cleaning will be done as per document RAPID-P0022-
PUNJ-QAC-PRC-0001-0015.
33. Pneumatic testing will be done as per document RAPID-P0022-PUNJ-QAC-PRC-0001-
0014.
34. Environmental management practices, monitoring frequency and reporting during
Construction phase.
35. Mechanical completion will be governed by System Completion Plan vide document
RAPID-P0022-PUNJ-CMM-MAN-0001-0015.
36. Commissioning procedure will be done as per document RAPID-P0022-PUNJ-CMM-
PRC-0001-0008.
37. Procedure for Cathodic Protection. (Refer document no. RAPID-P0022-PUNJ-QAC-
PRC-0001-0018).
38. Procedure for Die Penetration test. (Refer document no. RAPID-P0022-PUNJ-QAC-
PRC-0001-0011).
39. Procedure for erection and alignment of Rotary Equipments. (Refer document no.
RAPID-P0022-PUNJ-QAC-PRC-0001-0016).

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10.0 SUB-CONTRACTING
To adhere to the schedule, CONTRACTOR has planned to subcontract some specialized activities
and construction alongside departmental works. CONTRACTOR is responsible for all the activities
undertaken/ performed by the Sub-Contractor in line with the terms and conditions of the contract
between OWNER and CONTRACTOR. The subcontracting plan in line with the CONTRACT and
approved by OWNER shall be complied to during the execution stage.
The scope of work to be subcontracted will be identified, evaluated by Project Manager, who will
work in coordination with Engineering Manager, Procurement Manager, Subcontracting Manager,
HSSE, QA/QC and construction managers. Sub-Contracting Manager is responsible for organizing
and performing necessary activities to enable availability of specified, recommended, technically
compliant and approved sub-contractors who can deliver the works within specified dates as per
approved project schedule, with required HSSE, QA/QC standards and in full compliance with the
prime contract along with necessary documentation, guarantee/warranty and insurance cover.
The qualification of Sub-Contractor will be evaluated on the following parameters:
 Previous experience & performance with CONTRACTOR in similar service / equipment /
materials.
 Reference & previous track records related to specific service/ equipment/material
requisition.
 ISO/OHSAS certification or anyother credible evidence of ability to meet the international

standard.
 Capability in Engineering, Manufacturing and after sales services.
After internal assessment, if bidders are found suitable, proposal will be submitted to PMC for their
review and approval. Based on the approval by PMC, Sub-Contractors will be empanelled as
approved subcontractor for the subject work.
Sub-Contract Manager will update the list of Sub-Contractors on regular basis. The Project
Manager shall approve all Sub-Contractors.
Alongside the departmental work, following packages (in full/ part) has been considered for
subcontracting:
 Geotechnical Investigation
 Camp and Temporary facilities construction works
 Civil and Building works

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 Piling works
 Spherical storage tanks
 Mounded Bullet
 Tank calibration works
 NDT works
 Painting and Insulation works
 Cathodic protection works
 Third party Inspection
 Transportation works
 Services for housekeeping, catering etc.
 Services for Regulatory works
 Piping work
 Structural Work
 Electrical and Instrumentation work
10.1 Sub-Contracting Process

CONTRACTOR will issue approved REQUEST FOR PROPOSAL to the qualified bidders,
appearing on the sub-contractor list, along with Scope of Work, applicable specifications,
drawings and documents for the project along with GCC and SCC. All communications with
bidders/ Sub-Contractors (pre and post order) will be routed through Subcontract Manager with
necessary inputs from all concerned departments.
Sub-contractor’s schedule shall be in line with the overall project schedule.
10.2 Bid Evaluation

Subcontract Manager will ensure that replies to all technical queries have been done after due
diligence from Engineering Manager. Technical and quality evaluations will be done in
accordance with Project Specifications, standards and project QA/QC requirements. Technical
Bid evaluation will reflect the sub-contractor’s confirmation for
 Project specification,
 Scope of Work
 Documentation requirement in line with OWNER/PMC requirement.

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Technical Bid evaluation shall be done as per the requirement of individual packages as
mentioned in the ITB.
10.3 Award Recommendation

After completing technical, QA and commercial evaluations, the Subcontract Manager will finalize
the Award Recommendation and obtain necessary internal approvals. The Commercial bid shall
be considered only when vendor is qualified in technical bid evaluation.
Sub-Contracting Plan bearing document number RAPID-P0022-PUNJ-PUR-MAN-0001-0002 has
already been submitted for PMC review and approval.
11 CAMP MANAGEMENT
For project implementation, CONTRACTOR has planned to construct accommodation camp in

client designated area. The camp will be the main accommodation facility which will house and
attend all personnel working on the Project site. Camp will be designed by specifically meeting
OWNER requirements as well as CONTRACTOR HSSE policy and specifications. The facilities
will be sized to support the peak of activities.
CONTRACTOR shall submit the Camp Schedule bearing document number RAPID-P0022-PUNJ-
PCN-PLN-0001-0013 for OWNER review and approval.
11.1 Camp Facilities

CONTRACTOR shall provide accommodation Camp for temporary living facilities to contribute to
the smooth, timely and safe implementation of the project. Operate and maintain its own
Accommodation Camp as well as to use the Camp Common facilities during the Project execution
for ensuring the good living conditions, motivation, health and safety of all personnel.
CONTRACTOR shall establish PIONEER camp prior to start any construction work in camp and
TCF.
 Dormitories/Workers building
 Supervisor’s accommodation building
 Manager’s accommodation building
 Mess for Workers, Supervisors & Managers
 Gym with equipment for Workers and Supervisors
 Club house with gym for Managers

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 Laundry with equipment

 Maintenance & Storage area
 Dojo
 Sports facilities as per contract
 Other facilities as per contract also but not limited to above
General
Since the volume of the work is huge, CONTRACTOR will build a camp which can house
approximate 4000 manuals and Non-manual staffs/workers in an integrated and a developed
camp which will house all modern amenities.
 The Camp shall be equipped by Telephone/Radio systems : Boss Camp, First Aid and
Fire station.
 The camp shall be equipped with a Fire station to house a Fire Tanker with a
centrifugal pump and 250m supply delivery hose.
 Fire hose reel next to kitchen, laundry and several areas will be used alongside Fire
Hydrants.
 The Camp shall be equipped with a First Aid Post with a standby Ambulance.
 The Camp shall be equipped with Recreation areas for TV and social meetings.
Separate Recreation area shall be for Engineers and Managers.
 The Camp shall be equipped with a playground.
 The Camp shall be equipped with a big room for Recreation gathering.
 A special location shall be allowed for at least 2 to 3 Bank ATM machines.
 Camp area shall be in accordance to the number of Workers. 60m² needs to be
allocated for each worker.
 Once the land is allocated, a study need to be concluded to check if water well can be
used with its filtration systems.
 Once the land is allocated, solid waste disposal strategy shall be implemented.
 The Camp shall be equipped with a Prayer Room.
 In addition to our yard recreation, provision of internet facilities is also being envisaged
in the camp recreation centre.

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11.2 Camp Common Facilities
OWNER shall provide the common facilities like electrical power, waste water treatment, potable
water, fire water, medical services, recreational services, administration, shopping, etc up to
designated battery limit. Including the following;
 Bus station and transportation hub;

 Administrative facilities (bank, post office, shopping complex, etc.);
 Place of Worship;
 Health care facilities (medical clinic, pharmacy, etc.);
 Fire brigade and guard house;
 Recreational facilities.
11.3 Temporary Facilities Areas
OWNER shall provide the area to CONTRACTOR for establishing the following temporary
facilities which are required for execution of work:
 Offices and Buildings for site main office for OWNER as well as CONTRACTOR
 Site office of CONTRACTOR will be responsible for all the support, services and
logistics activities related to the Project Execution of Contract.
 Secondary office buildings for workshop, fabrication yard etc.
 CONTRACTOR will maintain a Equipment Yard for its plant, machinery and
equipments and the location will be near to the fabrication workshops which is
located in the Temporary Facility area which will be allocated to CONTRACTOR
by OWNER. Logistics will be maintained in the location itself and will cater to the
site requirements as per the equipment schedule and requirements from the
Project Site.
 Workshops and fabrication areas including maintenance area for Contractor’s

Equipment.
 Pre-Assembly Shops
Pre-Assembly shops are to aid the site construction by pre-Assembly of Pipe

spools, rack & tank structures and plate bending. The Workshop will also have

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the facility to fabricate pipe supports both bulk, line specific and special pipe
supports.
The Pipe Pre-Assembly involves around 60% of the total inch dia. Total
Fabrication and Erection Inch Dia is 470,245 and Pre-Assembly Inch Dia @60%
of the erection is 282147 id (est.).
A Dedicated Structural Assembly Area will be in force for the assembly of

structures. Fabrication of approx. 5000 MT (incl. Structures & tank structures) will
be carried out here. Bending machines will be installed to fabricate/bend 35000
MT of plates for tankages.
Lay down area of the non-painted pipe spools will be located within the premises
of workshops and will be identified separately. Spools from fabrication and NDE
area will be transported to lay down for further transportation to blasting and
painting yard. Spools which don’t require painting will be kept in the lay down for
further transportation to site. Spools which are blasted and painted will be
transported to lay down again in the allocated area for further transportation to
site.
 NDT Area
Non-destructive testing of Pre-Assembled spools will be done in area allocated

within the premises of the field workshops or in the designated area will have the
facilities like Radiography area/pits, PWHT facilities, film examination room and
any other facilities required for NDT towards checking the authenticity of the
weld.
 Grit blasting and painting shop.
 Blasting and painting yard for the pipe spools and supports will be located near
the fabrication shops and in the area designated. It will have all the required
facilities like compressor house, automatic blasting shop for the blasting and
painting of the pipes, spools and supports.

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Blasting area will consist of open yard blasting and the area will be cordoned off
from the rest of the shop.
Painting will be done in line with the project specification. Painting area will be
cordoned/ separated from blasting area.
 Scaffolding Storage Yard.
 CONTRACTOR will be maintaining Central Scaffolding Storage Yard and the

location of the yard will be inside the material storage area in the temporary area
allocated to CONTRACTOR by OWNER. Logistics will be maintained in the
location itself and will cater to the site requirements.
 Vehicle parking area,
 Field Testing Laboratory,
 First Aid Centre,
 Guard house
 Canteens and washrooms as required
 Security and Safety
12.0 CONSTRUCTION PLANNING, SCHEDULING, MONITORING & REPORTING
CONTRACTOR responsible for construction Planning, Scheduling, Monitoring and Reporting

activities at site in the overall master schedule and details stipulated elsewhere in this document.
Following activities are also to be performed by CONTRACTOR at site. CONTRACTOR has
submitted the construction schedule bearing document number RAPID-P0022-PUNJ-PCN-PLN-
0001-0008 for PMC review and approval.
Construction Master Schedule
Construction Master Schedule shall be prepared and submitted by CONTRACTOR to OWNER for
review and approval.
CONTRACTOR schedule shall:

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 Clearly identify activities in the Master Project Schedule

 Indicate major milestones
 Show critical path and activity float time
 Apply activities conforming to CONTRACTOR work breakdown structure.
 Take monsoon and holiday seasons into consideration.
 Detailed activity schedule shall be required for each activity identified in Master Project
Schedule.
Schedule Control
CONTRACTOR plan shall include,
 Updation of monthly construction schedule.

 Construction progress measurement procedure (document no. RAPID-P0022-PUNJ-
PCN-PRC-0003, which is to be based on physical progress measurement at site as,
approved by OWNER.
 Reference to schedule change procedures
 Catch up plans
 Hold up reports in respect of drawings, materials and front etc.,
 Daily, Weekly and Monthly Progress Report to OWNER / PMC.
13.0 QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC)
The Quality Manager shall responsible for ensuring quality of Construction carried out by the
CONTRACTOR / their approved Sub-Contractor’s in accordance with the requirements given
under quality control Procedures.
CONTRACTOR shall carry out inspection, non-destructive tests and analyzes and certifies
acceptability of all welds, materials and works in accordance with specified OWNER’s technical
standards / international standards and carryout inspection and testing of incoming materials as
per procedures.
All inspections and Test records are to be kept updated by the CONTRACTOR and shall be made
available to OWNER/PMC whenever requested. These documents shall be handed over to

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OWNER/PMC in dossier form on completion of the Commissioning as per Final Documentation

Procedures.
All work/services to be performed by the CONTRACTOR under this contract shall be of specified/
approved quality and CONTRACTOR shall have a Quality Assurance / Quality Control (QA/QC)
system during the performance of various activities such as Engineering, Procurement, Tendering,
Construction, Commissioning etc.
14.0 WAREHOUSE MANAGEMENT & MATERIAL CONTROL
Purpose is to provide appropriate storage facilities for controlling the materials/equipments and to
ensure/maintain proper, up to date records of all incoming materials received and material
issued/consumed for the PROJECT.
Scope of materials handling and storing covers the receiving, identification, control, handling, issue
and documentation of the material required/consumed. CONTRACTOR shall be responsible for
care, custody and control of all in-house material consumptions, Project equipment and for the
permanent installations at site.
Materials handling and storing commences with the receipt of materials at site, and includes the
unloading of materials into the warehouse or open storage area, color coding and the issue of the
materials under the control of CONTRACTOR.
The final operation shall be the disposal of all surplus or residual materials upon completion of the
construction work by CONTRACTOR.
The duties and scope of the persons of CONTRACTOR involved in materials handling and storing
activities are as follows, including mobilization of all labor, equipment, tools and materials required:
 Planning and preparatory works.

 Receiving and unloading of materials - Updating of DRR / DSR.
 Unpacking and inspection (Making GRN in system on getting IMIR signed), which
includes.
 Issuing of Excess, Shortage or Damage Reports.
 Issuing of Request for Urgent Procurement, if any.

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CONTRACTOR shall responsible for carrying out the Warehouse Management and Material
Control in accordance with the warehousing procedure and material control procedure. A
computerized stores management and material control system will be developed. List of salient
activities is as under:
 Transport liaison, both for imported materials as well as materials procured in Malaysia
from the time of dispatch up to receipt at Site.
 Transportation Plan.
o From source to site.
o Site to erection location.
 Receipt, handling, identification, inspection (including confirmation by an alloy analyzer
for alloy steel, stainless steel and other exotic materials) and acceptance, storage and
preservation of materials, codification of all materials.
 Chemicals/Catalyst (if applicable) loading, unloading and transportation, storage and
handling.
 Filings of insurance claim and follow up.
 Documentation for control and accounting of materials.
 Generation and upkeep of traceability records for materials.
 Materials control and issue.
 Inventory checks.
 Field requisition and purchase.
 Spare & tools including handing over of mandatory spares/ tools to the OWNER as per
the terms of the contract.
 Material Appropriation and Handing over as per the terms of CONTRACT.
 Taking up with suppliers on short supplied items and placing replacement orders for
lost/damaged items.
 Intimating to CONTRACTOR’S Home office regarding short/lost/damaged items and
taking up with suppliers and taking replacement action wherever applicable.
 CONTRACTOR shall codify all items of permanent nature which are to be supplied to
OWNER as part of this contractual obligation such as Mandatory spares. This
codification shall confirm to OWNER’s own codes allotted to each item and which shall
be given by OWNER in advance.

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 No material of permanent nature shall be accepted without assigning material code to

each item at the time of handover.
CONTRACTOR shall generate and issue following reports.
 Vendor expediting report fortnightly.

 Fortnightly statement of consignments in transit.
 Daily report of material received.
 Material receipt status and inventory status w.r.t material delivery, schedule.
 Material Inspection Report w.r.t materials received at site.
 Report on Over/Short/Reject/Damage (OSRD) receipts against each consignment on
receipt at warehouse.
 Weekly status of consignments, Material Receipt Report (MRRs).
 Monthly status of field purchase.
 Monthly status of over, short, reject & damage (OSRD) settlement.
 Monthly status of piping material MTO v/s. Actual receipt.
 Log Register of Rotating Equipment’s maintenance.
 Any other report as desired by OWNER.
14.1 Methodology
14.1.1 Material Receipt
Most of the materials imported by ship to nearby Malaysian Port and/or transported in land by
truck / trailor only depending upon the volume of materials.
Immediately upon receipt of materials at site, it shall be flashed to all concerned by Daily
Material Receipt Report. Materials received at site shall be tagged as following:
 Items/Materials which are unloaded but not inspected shall be unloaded at area
marked “UNDER HOLD”.
 Items/Materials which are unloaded and inspected and have some deficiency shall
be unloaded at area marked “QUARANTINE”.
 Items/Materials rejected at “UNDER HOLD” and “QUARANTINE” area due to any
reason shall be shifted to “REJECTED” area.

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All the materials received at store shall be recorded in Material Receipt Inspection Report.
 Carry out inspection upon receipt of materials. Any visual discrepancy found during
unloading, stores-in-charge shall record clearly and records will be maintained.
 Verify the availability of test certificates / certificate of conformity/ inspection reports
for the materials to be inspected along with request. No inspection will be carried out
in case of non-availability of test certificates and stores will be asked to provide the
same.
 If the test certificates / certificate of conformity/ inspection reports are available, the
adequacy of the same will be reviewed against the specification, Purchase Order
requirements.
 When the test certificates / certificate of conformity/ inspection reports are found
satisfactory, physical verification of materials of materials will be carried out. When
the test certificates / certificate of conformity/ inspection reports are found to be
unsatisfactory, the same will be referred to purchase department.
During the physical verification of materials, plates, pipes, fittings etc., heat numbers,
serial no.s, grade, manufacturer’s identification etc. corresponds to the details listed
on the test certificates / certificate of conformity/ inspection reports will be
determined. Colour coding will be verified wherever applicable.
 Name details will be verified against test certificates / certificate of conformity/
inspection reports for valves or instrumentation items.
 Visual/ Dimensional inspection shall be done for structural materials like beams,
angles, channels, gratings etc.
 Visual inspection will be carried out during physical verification of welding
consumables. Availability of Batch No., Brand Name, AWS no. etc. will be verified
against test certificates / certificate of conformity/ inspection reports.
 Signed copy of Incoming Material Inspection Register (IMIR) shall be handed over to
stores-in-charge for further action and a copy of the same will be submitted to PMC
for review and acceptance.
 In case of non-conformance, action will be taken as per disposition of non-
conformance and the materials shall be quarantined until an acceptable resolution is
carried out. PMC will be informed and copied on all excess, shortage, damages and

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discrepancy reports. Liaison with other agencies like insurance agency, security
agency will be done by the CONTRACTOR.
 Original MRIR along with the copies of test certificates will be maintained by stores’
department. All the test certificates in original will be handed over to QA/QC
department.
 Contractor will identify the location where the materials are to be stored to avoid
duplication in handling.
 It will be ensured to always unload materials on sleepers, strictly to avoid direct
placement on ground.
 Sufficient numbers of riggers depending upon the type and number of cargos to be
handled shall be arranged.
 If the materials are to be stored in semi-closed / closed premises then it should be
shifted to its location immediately after unloading.
14.1.2 Material Handling

QA/QC engineer will be responsible for inspection of incoming materials and shall ensure that
all the materials received at site conform to the project specification with all supporting
documents in compliance with the report.
 Purchase Order & Test Certificate(s)
 Dimension and visual damage.
 QC stamp or tag etc.
 Lifting equipment, tools & tackles shall be in good condition and of suitable type and
capacity w.r.t the load being handled, shall have valid certification of load.
 Periodic colour coding for lifting equipment shall be implemented and maintained as
per safety procedures. Equipment shall be free from any visible damage and
leakages and shall be maintained in good working condition. Notification of the
current “Colour Coding” shall be clearly posted at the tools & tackles section of
stores.
 Operators/ drivers shall be experienced and shall have security passes relevant to
the WORK SITE and have current valid license for the class of the vehicles to be
driven.

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 All safety practices applicable for material lifting and handling shall be implemented
as per the RISK ASSESSMENT PLAN.
 Pipes and other similar materials will not be allowed to drop or strike objects, which
may damage pipe or coating. Pipes will be lifted, moved or lowered from one
position to others with suitable equipment.
14.1.3 Storage
Storage arrangements, provisions and precautions shall be in accordance with Project
Specification and manufacturer’s recommendations. After physical inspection by QA/QC
engineer, all the materials will be divided into 3 categories.
Fully Closed
Following precaution will be taken for careful storage of the materials:
 Storage room shall be well ventilated and dry floor should be slightly higher than the
surrounding areas.
 Stored goods shall not be overloaded by stacking one above the other.
 Effective care should be taken during handling and transportation so that the
equipment do not get damaged or dented.
 Material shall be handled strictly in line with the recommendations of manufacturer, if
available. Components shall be stacked properly taking into considerations of
handling & preservation. The identification marks shall be rewritten wherever
necessary for easy traceability.
 Steel racks shall preferably be used wherever necessary to make effective use of
space so that smaller components / spares could be stored.
 Lighting fixtures, Receptacles, LB’s etc., shall be kept in racks with identifications.
 Wires, Slings shall be stored in the elevated racks away from rain water.
 For storage of equipments like transformers, HT & LT switchgears, DG Sets,
batteries etc., manufacturer’s instructions for storage shall be followed.
 Drums of paint, or Epoxy components shall be inverted at regular intervals as
specified to minimize the risk of hard settling of pigments.

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Semi Closed
Following precaution will be taken for careful storage of the materials

 Ground on which storage is made shall be firm, reasonably levelled and no
stagnation of water will be there.
 Equipments will be stored on steel/ wooden sleepers or pallets to keep them out of
contact with ground.
 Stored items shall be so positioned that they are accessible for inspection.
 Storage shall provide maximum possible protection against flooding, dirt and
unauthorized access.
 Adequate space shall be left between the stacking for easy handling during storage,
preservation and issue of components.
Open Yard
Following steps shall be taken to store the materials in open yard.
 The open yard shall be levelled considerably and have raised ground with access
roads to facilitate easy handling and stacking of materials.
 Open yard shall be suitably divided into blocks, so that materials shall be kept
according to sizes for locating the materials easily.
 Fire extinguishers shall be provided at strategic locations.
 Separate scrap yard should be identified where all steel scraps could be stored to
avoid mixing.
 The materials/ equipments stored in open yard shall be provided with waterproof
covering.
 Cable drums shall be stored in plain and raised level in a dry cable yard area with
identification tag and oil drums shall be kept horizontally in plain and with screw cap
(or) bung hole at lower side.
 Equipments placed in open yard are to be periodically inspected for the surface
condition to avoid rusting.
 Structural steel shall not be stored in the vicinity of areas where excavation or
grading is being done. This area should be free from water logging.
 Stainless Steel pipes and fittings shall be stored separately from carbon steel.

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 All pipes shall have ends covered with caps or sheet.
15.0 SITE INSPECTION AND TESTING
On receipt of materials at site, physical inspection will be carried out to ensure that the quality and
quantity is as per the specifications and purchase order. The procedure for same will be governed
as mentioned in ITP by the document RAPID-P0022-PUNJ-QAC-QAA-0001-0002.
QA/QC engineer will be responsible for inspection of incoming materials and shall ensure that all
the materials received at site conform to the project specification with all supporting documents in
compliance with the report in relation to the following;
 Purchase Order & Test Certificates

 Dimension and visual damage.
 QC stamp or tag etc.
Site inspection Procedure

 Inspection will be carried out on receipt of materials.
 Availability of test certificates / certificate of conformity/ inspection reports for the
materials to be inspected need to be verified. No inspection will be carried out in case
of non-availability of test certificates and stores will be asked to provide the same.
 If the test certificates / certificate of conformity/ inspection reports are available, the
adequacy of the same will be reviewed against the specification, Purchase Order
requirements.
 When the test certificates / certificate of conformity/ inspection reports are found
satisfactory, physical verification of materials of materials will be carried out. When the
test certificates / certificate of conformity/ inspection reports are found to be
unsatisfactory, the same will be referred to purchase department.
 During the physical verification of materials, plates, pipes, fittings etc., heat numbers,
serial nos., grade, manufacturer’s identification etc. corresponds to the details listed on
the test certificates / certificate of conformity/ inspection reports will be determined.
Colour coding will be verified wherever applicable.
 Name details will be verified against test certificates / certificate of conformity/
inspection reports for valves or instrumentation items.

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 Visual/ Dimensional inspection shall be done for structural materials like beams,
angles, channels, gratings etc.
 Visual inspection will be carried out during physical verification of welding
consumables. Availability of Batch No., Brand Name, AWS no. etc. will be verified
against test certificates / certificate of conformity/ inspection reports.
 Signed copy of Incoming Material Inspection Register (IMIR) shall be handed over to
stores-in-charge for further action and a copy of the same will be submitted to PMC for
review and acceptance.
 In case of non-conformance, action will be taken as per disposition of non-
conformance and the materials shall be quarantined until an acceptable resolution is
carried out. PMC will be informed and copied on all excess, shortage, damages and
discrepancy reports. Liaison with other agencies like insurance agency, security
agency will be done by the CONTRACTOR.
 Original MRIR along with the copies of test certificates will be maintained by stores’
department. All the test certificates in original will be handed over to QA/QC
department.
16.0 FIELD ENGINEERING
During site construction activities, a Field Engineering cell shall be mobilised for resolving any day
to day issues, if any. Field Engineering cell will consist of mainly engineers (across departments as
per requirement) who have worked at the design centre of Home Office. CONTRACTOR will be
responsible for controlling and issue of technical drawings and documents, preparation of field
sketches, field modifications & checking/ preparation of as-built drawings, technical assistance for
field purchase and field tendering etc.
Specialist engineers from CONTRACTOR Home office shall also be deployed at site as per
requirements. Site should have facilities to incorporate field changes.

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17.0 FIELD TENDERING
Procurement Manager and site procurement team will be responsible for carrying out field
tendering activities for sundry local purchases and monitoring of ordered materials and equipments
delivery. Site procurement team will report to procurement manager.
18.0 FIELD PURCHASE
CONTRACTOR will be responsible for carrying out field purchase activities as required. The bulk
of procurement action will be done from CONTRACTOR Home Office. Field Purchase items are
restricted to those required for running and maintenance of the field offices, items required to
expedite construction work and items found short, missing or damaged against the main order
when received at the site. Any material purchased from field for usage in the WORKSITE should
have proper inspection certificate and should be purchased only from OWNER approved vendors.
19.0 HEALTH, SAFETY, SECURITY AND ENVIRONMENT (HSSE) MANAGEMENT
CONTRACTOR shall execute the project in a socially responsible and ethical manner that protects
the Health and Safety of its employees, Sub-Contractors, dependents and the public; and
safeguards the environment. This will enable achieving the Project goal of
“No harm to people, No accident, No damage to the environment
&
No loss of public and/or project’s property”
As an organization we shall comply with all applicable Safety, Health and Environment Laws,
regulations and recognized industry standards prevailing in Malaysia, DOSH regulations 1994 and
other such applicable statuary requirements, code of practices that have been approved.
We shall construct the project following good engineering practices and applying the principles of
Risk management, to provide safe and healthy workplaces by effectively controlling all residual
risks. Discharge of oil and other hazardous substances to the air, land and water shall be
prevented.

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CONTRACTOR shall not compromise its focus on HSSE in order to achieve any other business
objectives. It will authorize personal to stop any activity, if found not in compliance with HSSE
requirements.
CONTRACTOR shall comply with the Mandatory Control Framework for RAPID Project and the
values encapsulated in the safety philosophy of OWNER throughout all phases of work.
Employees and subcontractors shall be trained in the policies, procedures, Good Practices and
Law applicable to their assigned duties. Employees will be encouraged to foster a NO BLAME
CULTURE and respond positively to safety observations to achieve a continuous improvement of
safety behaviour.
CONTRACTOR shall ensure conformity with this policy by means of comprehensive training and
compliance program and shall take disciplinary action, including removal from the site, against
those who will not follow, implement and maintain this policy.
Relevant Documents
 RAPID-P0022-PUNJ-HSE-MAN-0001-0001 : HSSE PLAN
 RAPID-P0022-PUNJ-HSE-PRC-0001-0001 : HSSE Policy Statement
 RAPID-P0022-PUNJ-HSE-MAN-0001-0003 : Project Security Plan
 RAPID-P0022-PUNJ-HSE-MAN-0001-0004 : Environment Management Plan
 RAPID-P0022-PUNJ-HSE-MAN-0001-0005 : Waste Management Plan
 RAPID-P0022-PUNJ-HSE-MAN-0001-0006 : Environment Coordination Plan
 RAPID-P0022-PUNJ-HSE-MAN-0001-0008 : Project Health Plan
 RAPID-P0022-PUNJ-HSE-MAN-0001-0009 : Traffic management Plan
 RAPID-P0022-PUNJ-HSE-MAN-0001-0010 : Emergency Response Plan
 RAPID-P0022-PUNJ-HSE-MAN-0001-0011 : HSSE Manual
 RAPID-P0022-PUNJ-HSE-MAN-0001-0013 : Erosion and Soil Control Plan
 RAPID-P0022-PUNJ-HSE-PRC-0001-0001 : Incident Notification, Classification,
Investigation and Reporting Procedure
 RAPID-P0022-PUNJ-HSE-PRC-0001-0002 : Chemical Management Procedure
 RAPID-P0022-PUNJ-HSE-MAN-0001-0007 : HSSE Incentive Scheme
 RAPID-P0022-PUNJ-HSE-MAN-0001-0012 : Environment Quality Management Program
 RAPID-P0022-PUNJ-HSE-PRC-0001-0006 : Permit to Work Procedure

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 RAPID-P0022-PUNJ-HSE-PRC-0001-0008 : HSSE Training Procedure

 RAPID-P0022-PUNJ-HSE-PRC-0001-0007 : HSSE PERFORMANCE MONITORING AND
ACTION TRACKING PROCEDURE (KPIs)
20.0 INDUSTRIAL LABOUR RELATIONS
CONTRACTOR shall be responsible for industrial relation functions and implementation of labour
laws at site. CONTRACTOR staff shall suitably trained and experienced in Labour Relation
functions so as to ensure a good relationship with labour and to prevent the occurrence of
industrial disputes resulting in subsequent delays or work stoppages. In particular, CONTRACTOR
shall maintain close liaison with OWNER and with official union representatives of CONTRACTOR
work force.
CONTRACTOR shall maintain proper liaison with Statutory Authorities and local bodies and shall
be responsible to implement and observe all statutory laws at site.
CONTRACTOR must have on his staff, a well experienced Labour Relation Officer, preferably
from local area. CONTRACTOR confirms that one HR personnel from Kulalampur office will be
deputed at site for this purpose only.
CONTRACTOR shall report immediately to OWNER any problems including labour disputes, fight,
work stoppages. A written report will be submitted to OWNER within 48 hours of the occurrence of
the incident.
CONTRACTOR has separately submitted the Labour Relations Plan bearing document number
RAPID-P0022-PUNJ-PCN-MAN-0001-0001 for PMC review and approval.
CONTRACTOR’s plan shall include;
 A detailed estimate of the number of foreign labour/local labour / labour from other
countries / Malaysia, indirect and direct, sorted by craft. This estimate shall specifically
include the months and durations that potential foreign labour will be required.
 Outline of training plan for local semi skilled labour and respective crafts.
 Outline how the respective Government Agencies will be educated on maximisation of
local workers; Labour welfare plan.
 Outline recruiting plans for all manpower requirements.

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 Identify personnel involved with labour relations and outline procedures to mitigate
disputes, problems should they occur with the labour force.
CONTRACTOR shall hold labour relations meeting in a month with their work force as well as a
separate meeting with OWNER.
21.0 CONSTRUCTION EQUIPMENTS
CONTRACTOR is required to organize and mobilize the construction equipment and other tools /
tackles in a sequential manner to ensure that WORKSITE installation is carried out in a
Mechanized manner and its mechanical completion are achieved within targeted time schedule.
CONTRACTOR shall without prejudice to his responsibility to execute and complete the work,
strictly as per the specifications and other laid down procedures, execute all the work by
mechanizing the construction activities to the maximum extent by deploying all necessary
Construction Equipment / machinery of adequate capacities and numbers.
In order to minimize fabrication at site, major fabricated mounted bullet shall be transported in
single / minimum number of pieces depending upon transportation limitations and erected in single
piece. CONTRACTOR shall carryout the route survey for transportation of over dimensioned
consignments including water ways from source of manufacture / supply to site, well in advance of
placement of order to ensure unhindered transportation of the same to construction site.
CONTRACTOR shall arrange cranes of suitable capacities to match with the erection
requirements and inform the source and ownership of the same.
Crane movement roads required shall be identified by CONTRACTOR and got reviewed /
accepted for availability by OWNER / PMC. However, construction of hard stands for the
positioning of crane in the fabrication yard and at erection site/ locations including approach roads
to the hard stands from the plant roads shall be CONTRACTOR’s responsibility. The hard stands
shall be suitable for the crane loads provided by the crane manufacturer.
For the purpose of equipment erection, CONTRACTOR shall deploy a rigging team headed by a
Rigging Foreman / Engineer reporting to concerned Area Engineer. Area Engineer should be well
conversant with various erection techniques and shall be responsible for preparing erection
schemes in accordance with the approved procedures and based on crane manuals and suiting to
plant layout. Area engineer shall have to foresee various other construction activities in the

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surrounding areas while planning erection schemes including safety aspects of man and
machinery also. CONTRACTOR shall prepare erection schedule in line with the overall project
schedule of the Plant in phased manner with erection schemes of various equipment, vessels and
submit to OWNER for approval. Monitoring and control of erection schedule and erection activities
shall be carried out by CONTRACTOR as per the approved construction procedures.
For efficient working and maintenance of construction aids, CONTRACTOR shall establish and
maintain crane yard / workshop equipped with regular maintenance facilities for various
construction aids for carrying out routine field maintenance during performance of the contract.
Temporary approach road and hard stands wherever required for the movement of the cranes and
other vehicles for equipment erection and transportation of material shall be properly planned and
made by CONTRACTOR. Weekly / fortnightly maintenance’s shall be planned in such a way that
the same does not hamper the erection schedule.
CONTRACTOR shall ensure the timely augmentation of the men, equipment and machinery
depending upon the exigencies of the work to meet the overall project schedule and as per
instructions of OWNER.
Construction equipments are categorized into following sub-categories :
 Major Machineries – Cranes, Excavators, Dozers, Graders, Trailors, Batching Plants etc.
 Minor Machineries – Generators, Welding machines, compressors, piling rigs etc.
 Vehicles – Transport Vehicles.
CONTRACTOR shall prepare and submit the construction equipment deployment schedule
considering the milestones achievement schedule. Daily construction equipment deployment
report will also be submitted by CONTRACTOR to OWNER in the Performa approved by the
OWNER. This report will be a part of DPR. The list of main equipments to be deployed at site is
given on the next page.

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List of Main Equipments to be Deployed at Site

PEAK NUMBERS
S.
EQUIPMENT TYPE CAPACITY INSTRUMENTATION &
NO. CIVIL PIPING TANKS STRUCTURAL BULLETS SPHERES ELECTRICAL TOTAL
TELCOM
1 Tyre Mounted Crane 20/40/75 MT 2 14 15 3 2 2 1 1 40
2 Tyre Mounted Crane 150 MT - 1 1 - 1 2 - - 5
3 Man lift - - - 4 - - - 1 1 6
4 Welding Machine 300 Amps - - 246 11 - 60 17 8 342
5 LT-7 for bottom plate welding - - - 12 - - - - - 12
6 Girth Welding Machine - - - 16 - - - - - 16
7 Air Compressor 300/350 CFM 2 1 4 - - - - - 7
8 Trailer Flat Bed Prime Mover 20/ 40 MT 1 8 14 1 - 2 2 1 29
9 Trailer Low Bed 40 MT - - - - 1 - - - 1
10 Diesel Tanker / Truck 5,000 Lts - - 1 - - - - - 1
11 Power Generator 75/125/ 250 KVA 1 3 23 2 1 6 2 2 40
12 Hydrotesting Pump 280 M3/Hr - - 20 - - 2 - - 22
13 Plate Rolling Machine - - - 2 - - - - - 2
14 Hydrotesting Pump 700 M3/Hr - - 2 - - - - - 2
15 Gantry crane 15T - - 2 - - - - - 2
16 Rectifier (for both Pre-fab and site) 600 AMPS - 49 - - 5 - - - 54
17 Hydrotesting Skid - - 4 - - - - - - 4
18 Excavator & Back hoe loaders - 8 - - - - - - - 8
19 Grader / Dozer - KOMATSU 160 / 180 HP 3 - - - - - - - 3
20 Loader - 8 - - - - - - - 8
21 Dumpers / Trucks/ Telco - 24 - - - - - - - 24
22 Vibratory roller - JCB VM115D - 7 - - - - - - - 7
23 Water Tankers 1,000 G 7 - - - - - - - 7
24 Dewatering pump 10 HP 4 - - - - - - - 4
25 Concrete Pump & Boom Placer - 2 - - - - - - - 2
26 Weigh Batchers - 5 - - - - - - - 5
27 Mixer machines - Diesel - 5 - - - - - - - 5
28 Mechanical broom hydraulic - 1 - - - - - - - 1
29 Bitumen pressure distributor - 1 - - - - - - - 1
30 Pavers - 1 - - - - - - - 1
31 Tandem Roller - 1 - - - - - - - 1
32 Hydraulic Press 300 / 1000 MT - - - - - 3 - - 3
33 Fork Lift - - - - - - - 2 2 4
34 Piling Rig 17 - - - - - - - 17

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22.0 CONSUMABLES CONSTRUCTION MATERIAL AND BULK MATERIAL

Raw materials such as concrete, gases, electrodes, paints, insulation material etc. which will be
used for the project, will be in line with the requirement of project specification. Quality of the same
will be governed by the relevant procedure. CONTRACTOR shall ensure that the same is
applicable for consumables and bulk materials too.
Storage of all raw materials and consumables will be as per relevant HSSE documents and
warehousing procedure.
23.0 CONSTRUCTION SITE PREPARATION AND ACCESS
The WORKSITE will be prepared by OWNER and the same will be accepted by the CONTRATOR.
CONTRACTOR will prepare the worksite by providing additional fencing, gates, internal roads,
drains, etc. CONTRACTOR will dispose excess materials in the designated dump area after
backfilling the excavated area (on approval of OWNER).
Preparation of the WORKSITE and transportation of quarried construction materials will be carried
out in environmentally acceptable manner. During excavation, if any cables or obstructions
observed, the same will immediately be informed to the OWNER for taking further necessary
action.
CONTRACTOR will build its own temporary roads and drainage, which will get terminated to the
main network provided by the OWNER.
Site Rules
CONTRACTOR will prepare construction rules in line with the prevailing site rules of the OWNER.
The normal site working hours will be 07:00 am to 07:00 pm from MONDAY to SATURDAY.
CONTRACTOR proposes to work in 2/3 shifts based on the urgency to meet the project schedule.
CONTRACTOR and its sub-contractor will work on Sunday too depending on the asking rate. For
working extra hours beyond normal working hours, necessary information/ permission will be
sought from OWNER. Implementing safety norms will strictly be followed.
Access Control
CONTRACTOR will build fencing along the perimeter of its WORKSITE. ACCESS CONTROL
SYSTEM in line with the same by OWNER will be established/ maintained to monitor and control

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the movement of its staff, workforce and vehicles entering, inside and exiting WORK SITE. Gate
Pass system with identity card will be issued to each individual. No body will be allowed to enter
without having valid gate pass. Gate pass will be issued after verification of his/her documents.
No vehicle will be allowed to enter thru the gate with passenger. Passenger has to get down and
enter through the gate after showing his/her valid gate passes. Vehicle will only be allowed with
driver only. Vehicle will only be allowed / permitted after inspection for compliance by OWNER.
24.0 COMMUNICATION SYSTEM DURING CONSTRUCTION
CONTRACTOR will supply and install hardware in its own facilities (Camp and WORKSITE),
provided by the OWNER, to run its own IT network. The cables will get terminated to the dedicated
pedestals (provided by OWNER), located as close as possible to the WORKSITE/Camp.
LAN for CONTRACTOR Offices

CONTRACTOR shall supply and install the infrastructure components and cables for its dedicated
data/voice LAN at WORKSITE.
WAN Network Access

CONTRACTOR will supply and install active elements necessary to connect to its WAN along with
secure cabinets with interior cooling and UPS. CONTRACOTR shall liaise with Telecom Authority
for design requirement, hardware connectivity, software interface, connection activation for its
WAN.
25.0 UTILITES FOR CONTRACTOR OWN CAMP, OFFICE BUILDING AND OTHER FACILITIES
CONRACTOR shall build its own network for power, water supply such as drainage, sewage,
potable and fire water in its own designated area, provided by the OWNER. All the aforesaid
networks will get terminated to the OWNER’s main network.

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26.0 CONSTRUCTABILITY REVIEWS
Constructability means integrating the design with the construction approach and experience to
optimize (within contract requirements) the project quality, safety, capital cost, and construction
schedule, thus minimizing the overall project cost.
Constructability reviews are coordinated by CONTRACTOR and Client and will be held after 60%
model review to minimize the cost of potential changes. Constructability reviews address issues
such as:
 Determining the order of preparation of engineering documents into work packages and
associated sequencing, so as to avoid site delays.
 Incorporating appropriate advances in construction technology into the design.
 Developing methods to minimize labour intensive operations, including simplification of
work and reduction of hazardous activities.
 Considering plant layout and facility access with respect to construction operations.
 Optimizing construction materials for the project site location and for the skills of
available construction craft.
 Considering impact of procurement and contracting approach on design and
construction.
 Considering system and plant turnover requirements in project planning, and in the
establishment of design deliverable, material, and equipment Required-At-Site dates.
 Third-party (contractor) constructability reviews will address.
 Communication of what is included and what is excluded from construction work
package (CWP) issues.
 Involvement of construction in the design reviews early to better understand the
drawings and scope and for constructability input.
 CWP review by Contractor to identify risk areas where bidders might ask for changes.
 Review and approval of changes to issued CWPs.
 Contractor involvement, if any, in bid conditioning.
 Effect on plans and schedules.
 Schedule for staffing field engineering,

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 Establishing quantity progress reporting to suit the constructor (e.g., large bore pipe by
length, small bore pipe by isometric) and ensure the software can provide the
necessary information.
 Determination if piping to API seal plans for pumps (cooling water, steam down, flare)
can be field routed based on standard schematic details.
 Identification of tie-ins on a location plan.
 Determination of the optimum work process and tools for material control (eg.
AUTOSPOOL, etc).
 Contractor alignment on construction change order cause codes and criteria (eg. design
error or omission, field condition, etc.).
 Understanding of the CM staff size, composition, and roles by CONTRACTOR, e.g. field
material control, document control.
 Verification that steel work is complete and in accordance with design drawings (several
occasions arose where the steel was found to be missing or installed incorrectly).
 Review of any changes to Issue for Construction (IFC) drawings by affected disciplines.
 Identification of when revised deliverables will be available as change orders.
27.0 SITE MANAGEMENT
CONTRACTOR will facilitate and optimize the utilization of the Common Construction Facilities in
order to prevent interference and to smooth their operation.
 To be informed of the Site Rules governing the various activities within the RAPID SITE.
 The management of the various interfaces between the work under the responsibility of
CONTRACTOR and the other work under the responsibility of the other contractors will
require efficient identification, definition, recording, follow-up, monitoring and close-out of
all Interface issues related to the respective scope of works.
28.0 MECHANICAL COMPLETION
All erected equipments and materials will undergo quality inspection as per ITP. Punch Lists will be
prepared accordingly. Subject to compliance of all the points raised in the punch list Mechanical
Completion of the particular system shall be declared.

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29.0 SITE CLOSURE
CONTRACTOR shall submit the FINAL DOCUMENTATION Procedure as per the requirements
and guidelines of the CONTRACT, including Site Closure report for review and approval of PMC.
Procedure for closure of a site shall involve:
 Submission and handing over of all the approved drawings/ documents to the OWNER.
 Accounting of all kinds of equipment’s and machinery received in the project site and
their final redeployment to Home Office or to other Project sites.
 Accounting and reconciliation of surplus materials.
 Settlements of all kinds of payments from the site-office like wages and salaries,
payments against the specialized services used from outside parties, like inspection,
testing, calibration, heat-treatment, etc, payments against the materials, spares,
equipment’s, etc received from the Home Office or any other external agencies.
 Accounting for the actual operating days for the execution of the project, number of
accidents or incidents causing loss of working days and loss of man-days as a result of
the accident/incident, number of Safety violence incidents and any loss of man-days as
a result of such violence.
 Submission of Time extension proposal: Based on the issue of concurrent delays

both on the part of CONTRACTOR as well as OWNER, the request must be submitted
to OWNER / PMC for granting unconditional extension of time without levying any
LD/PD.
 Final ‘completion certificate’ to be received from the OWNER after the necessary tests,
inspections, etc along with handing over all the desired records/documents.
After completion of complete Project, CONTRACTOR shall prepare and submit to OWNER/PMC
a Site Closure report and transfer all the Project As-built and final documentations.

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CONSTRUCTION EXECUTION PLAN

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HOLD n° REF. § DESCRIPTION ACTIONS

Electronic File Name: RAPID-P0022-PUNJ-CON-MAN-0001-0001 REV-A

RAPID P0022 PUNJ CON MAN 0001 0001 A 3/56

CONSTRUCTION EXECUTION PLAN

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4.0 SCOPE OF WORK...........................................................................................................................7

4.1 Brief Scope Of Work..........................................................................................................................7

5.0 CONSTRUCTION MANAGEMENT..................................................................................................12

6.0 SEQUENCE OF CONSTRUCTION ACTIVITIES.............................................................................15

7.0 CONSTRUCTION ORGANISATION CHART...................................................................................16

8.0 CONSTRUCTION EXECUTION STRATEGY..................................................................................17

8.1 Construction Manpower ................................................................................................................. 18

8.2 Manpower and man-hour histogram .............................................................................................. 19

8.3 Construction Activities.................................................................................................................... 21

9.0 LIST OF PROCEDURES/ METHOD STATEMENTS.....................................................................23

11.1 Camp Facilities............................................................................................................................. ..30

11.2 Camp Common Facilities............................................................................................................... 32

11.3 Temporary Facilities Areas............................................................................................................. 32

12.0 CONSTRUCTION PLANNING, SCHEDULING, MONITORING & REPORTING...........................34

13.0 QUALITY ASSURANCE AND QUALITY CONTROL (QA/QC).......................................................35

14.0 WAREHOUSE MANAGEMENT & MATERIAL CONTROL..............................................................36

15.0 SITE INSPECTION AND TESTING.................................................................................................43

16.0 FIELD ENGINEERING.....................................................................................................................44

17.0 FIELD TENDERING.........................................................................................................................45

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18.0 FIELD PURCHASE.........................................................................................................................45

19.0 HEALTH, SAFETY, SECURITY AND ENVIRONMENT (HSSE) MANAGEMENT..........................45

20.0 INDUSTRIAL LABOUR RELATIONS..............................................................................................47

21.0 CONSTRUCTION EQUIPMENTS...................................................................................................48

22.0 CONSUMABLES CONSTRUCTION MATERIAL AND BULK MATERIAL......................................51

23.0 CONSTRUCTION SITE PREPARATION AND ACCESS................................................................51

24.0 COMMUNICATION SYSTEM DURING CONSTRUCTION.............................................................52

26.0 CONSTRUCTABILITY REVIEWS...................................................................................................53

27.0 SITE MANAGEMENT.......................................................................................................................54

28.0 MECHANICAL COMPLETION.........................................................................................................54

29.0 SITE CLOSURE..............................................................................................................................55

30.0 ATTACHMENT 1................................................................................................................. ............56

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 Petrochemical Derivative Units (polyethylene, ethylene oxide, ethylene glycol,

 Utilities, off site and jetty installations.

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The following definitions shall mean as explained below:

OWNER : PRPC REFINERY AND CRACKER SDN. BHD.

PMC : Project Management Consultant - RAPID

PMT : Project Management Team

HOME OFFICE : Punj Lloyd Ltd. Gurgaon Office, India

DPM : Deputy Project Manager

CCM : Chief Construction Manager

PM [P] : Procurement Manager