Installation Of Storage Tanks Construction Essay

Installation Of Storage Tanks Construction Essay The proposal contains the detailed scope of works on various discipline of the tender, procedures developed for execution of Storage tank construction of the project Construction of Oil Terminal, the purpose of this technical proposal is to provide clear direction in the form of procedures, controls and administration practices in order that the services provided by contractor are in accordance with the tender and contractual requirements and in accordance with CGL internal quality systems and procedures. The intent of this document is also to communicate the execution strategy to all concerned. Proposal Purpose : This proposal sets out the scope, programme and terms to provide a single window service, with all the expertise and technical competence for the entire work related to the storage tank construction as given below. Design and engineering Procurement of materials for the tanks Fabrication Field erection , welding and testing Surface preparation , painting Assistance during Pre commissioning, commissioning and training All the works shall be carried out as for the completeness of the project. This proposal is in accordance with the engineering specifications, drawings, all the statutory regulations and international codes and standards have been considered in our proposal for this Job. Basis of offer Proposal is based on tender enquiry, data sheets, specifications, drawings issued as the tender documents. Validity This proposal will be valid for acceptance within 60 days from the date of commercial tender submission any further extension on proposal validity shall be subject to mutual agreement between the client and contractor. B. Detailed Scope of Works 1 Proposed List of Tanks Sr. No Tank Tag no Product Type Qty (Nos.) Capacity m3 Size in Meter Diameter Height 1 T-2011/2012 Gas oil / UGL EFR (single deck ) 2 750 11.5 8.5 2 V-4011 Jet A1 Horizontal 1 10 2 3 3 TF-T-2005 ULG 98 EFR (single deck ) 1 5000 22.5 15 4 V-2011 ULG 91/95/98 Horizontal 1 10 2 3 5 T-7001/T-7002 Firewater CS Dome 2 6500 22.5 19 6 TF-T-2003/2004 ULG 95 EFR (single deck ) 2 20000 36 22 7 V-1011 Gas oil Horizontal 1 10 2 3 8 TF-T-1001/1002/1003 Gas oil EFR (single deck ) 3 20000 36 22 9 TF-T-2001/2002 ULG 91 EFR (single deck) 2 20000 36 22 10 T-5001/5002/5003/5004 Jet A1 CS Dome 4 24000 41 22 2. Scope of Supply and Works 2.1 Scope of Supply All permanent material for tanks such as Plate Materials, nozzles manholes, wind girder and stiffener etc. required for the tanks. Internal External floating roof, Floating roof Seal, all the permanent accessories of the Floating roof. Internal and external accessories indicated on data sheet Clips for platform/ladder/pipe support directly welded on tank body. Bolts/nuts, clamps, gaskets for internal Blind flanges together with bolts/nuts and gaskets for blinded nozzles and manholes Davits and/or hinge for manholes. Vortex breaker (if required). Platforms, spiral stairway with handrails, roof handrail. Internal pipe with support Breather valves/ emergency drain / Rim vents and gauge hatch (if required). Name plates with bracket Earth bosses or lugs Settlement check lugs Support clip for firewater and Foam system piping connected to the tank. Surface preparation and Painting material for equipment Test plate for PQT and WPQT Spare parts of gasket and B/N for construction and pre-commissioning. Construction Equipments Electricity for construction.(fabrication and erection ) Heavy equipment, all machineries and other facilities for construction Welding rods, grinding wheels, cutting gases and other Miscellaneous Consumables for construction All the NDT equipments for testing and inspection Hydraulic Jacks Power Pack for the tank erection Pumps temporary pipes and fittings for hydro testing Tools and jigs including scaffolding for construction Consumable material for erection Blind flanges together with bolts/nuts and proper gaskets for hydrostatic test Corrosion inhibitor for hydrostatic test (if required) Direct and Indirect Manpower Dedicated design and drafting item for the project. Dedicated Construction management team at site Dedicated project management at Office Supervisory staff for Fabrication and erection QA/ QC personnel for testing and inspection Safety and EHS officers a site Skilled, semi skilled and unskilled man power for the fabrication and erection and testing at site 2.2 Scope of Work Mechanical design (strength calculation and detail design) Loading data for tank foundation design. Manufacturing drawings Documentations (procedure fabrication construction, ITP and others) Submission of as-built documents and drawings Material procurement Shop fabrication Packing list (packing volume, size weight, etc) Packing and inland transportation of shop fabricated components. Unloading of materials at site PWHT for 1st course shell with nozzles as per code requirement. Hydro-test and water drainage as broom clean condition after hydro-test and drying Settlement checking during hydrostatic test Temporary work of utility for construction and test Site construction Inter connecting walkway between tanks. Inspection test at shop and test. Surface preparation and painting for exterior surface as per specification. Internal Coating as per spec Hot dip galvanizing of tank handrails and staircase Project management and control Third party inspection agency review Attending the meeting with client and consultant Over all construction management of storage tank package Documentation for government approvals if any Mechanical guarantee Other activities to meet requirements of inquiry 2.3 Out of Scope of Supply Work Tank foundation and civil works Oil Pass required for the site crew and staff. Electrical, Instrumentation accessories Process Piping, Plant piping, inter connecting pipes between tanks. Cabling (including earth cable) and wiring materials. Supply of anchor bolts (if required)/ Grouting for tank bottom All kinds of valves including shut-off valves for draw-off sumps and external piping. Companion flanges and bolts/nuts Pumps , Heaters , Hearting coils if any Insulation material and work (if required) Fire protection material and work Customs clearance and taxes duties if any Government permit and approval (for local regulation) Tank Gauge (Radar Type) Level instruments (High Low) and transmitters All kind of instrumentation and Electrical works Lightning protection if any , Earthing 2.4 Facilities to be provided by Client Oil passes for our crew and staff. Adequate space for the Lay down area in the vicinity of site Adequate space for the fabrication and painting yard in the vicinity of site(if space is not provided we will fabricate Prime the tank plates at our fabrication shop in Dubai and transport it to sites for erection ) Site office for our staff Rest room facilities for our crew C. Project Execution Design and detail engineering : Contractor In house Fabrication and shop priming: At site(if fabrication area is available) If no area is available at site, then fabrication will be done at our fabrication shop Erection at site: Contractor In house team Surface preparation and painting through reputed sub contractors. Typical Project Execution Plan Project execution plan organization Contractor formal role in the project implementation will commence from the signing of the Agreement between the Client and Contractor. However, the effective participation of the contractor will start from the date of receipt of letter of intent (LOI) and the project kick off meeting, where project scope and basis will be formally agreed. Contractors Organization Charts The Contractor will appoint a Project Manager to take total charges of scope of work for which they are responsible. The structure is shown in the organization charts. 1.2 Overall Project Execution The Project Manager and his team are the primary interface point between the Contractor and Client. It is via this interface that all the day-to-day correspondence passes and project report are issued. The Project Manager with his team oversees the contractors scope of work. The projects coordinator is responsible for the coordination between Client, Engineering, Procurement, Fabrication and the Site Operation. As soon as LOI is issued internal Kick-off meeting will be held to firm up the project procedures. In order the successfully achieve its objective the Project Manager issues the Project Dossier detailing the interface between Contractor and the Client. It sets out the detailed working method to be employed by them though all phases of the job. With the co-ordination procedure the project schedule and methods of measuring progress and controlling the work are also issued. Inventory Procedure Quality Control Shipping Procedure and Forecast Field Project Control Procedure Field Safety Procedure Change Order Procedure. 1.3 Design and Engineering The Client has given the basic design. The detailed design for Contractor (in house) will carry out the project 2. Procurement Sub- contracting Contractor will prepare material requisition for all plant, equipment and materials and the Procurement in-charge shall manage the procurement and sub contracting. He will establish the procurement plan, identifying the finite list of requisition to be issued by the engineering groups, to start procurement cycle. Contractor will issue enquiries and obtain offers. Purchase orders will be placed by the contractor on vendors approved by Client, offering best Techno-commercial terms. A list of critical long lead items will be established including long lead item and those critical to programs. Special monitoring of these items will be carried out to ensure timely delivery. Procurement service offered by the contractor will include bid evaluation, arranging vendor coordination meetings, selection, placement of purchase orders, amendment of purchase order and modified if necessary, to reflect any specific requirements of the specific order. 3. Construction Contractors Construction group will supervise the construction to be carried out in a phased manner. It will be responsible for field inspection, material and inventory control and logistics for timely executing of the project. Contractors Project Manager will ensure quality and schedule so that the construction is done as per the detailed design/engineering document prepared by Client and within agreed time frame. 4. Pre-commissioning and commissioning The Commissioning Group headed by the Commissioning Engineer of the contractor will direct and supervise to provide the necessary assistance to the pre-commissioning and commissioning activities of Client. Project in co-ordination with the Commissioning in-charge of Main contractor/consultant. The major activities of this group will include: Check plant units for mechanical completion at size. Prepare pre-commissioning programme to assign priorities during final stage of counteraction work. Planning and scheduling of plant start up activities. Co-ordinate and supervise the start up of the plant. Main contractor/consultant shall conduct process guarantee test turns. 5. Project scheduled, control and reporting Contractors system of project planning scheduling and monitoring is designed to provide comprehensive planning services to the project management team. This system is instrumental in devising realistic schedules establishing checkpoints, keeping overall watch on the progress, deviation from schedules, pinpointing the problem and recommending areas of corrective actions. The details are given below: 6. Planning Scheduling 6.1 Proposed Schedule and overall project schedule The proposed project schedule is submitted along with this proposal. This indicates the project starts date, end date and major milestones of the project the proposed schedule is prepared in the form of bar chart schedule. On award of the control, the proposed schedule is converted into an overall project schedule in the form of squared PERT network on time scale. This network includes overall engineering, procurement and construction duration as well as critical and near critical items for each system. This overall schedule forms the basis for execution of the contract and is used for corporate project review. 6.2 Master Network For project control, master network is prepared for the project, master network is updated internally every month, this is revised if (i) The overall project schedule is revised, (ii) There is a major change in the scope of work, (iii) unforeseen events beyond contractors control. The master network forms the basis for detailed scheduling and project control. 6.3 Function Schedules At the level of the executing departments, functional schedules are prepared for all functions, viz. process, residual engineering, ordering and delivery. Standard Networks for various functions are used for sequencing various activities in the schedules. These schedules are also used for scheduling projects physical progress and its measurement. 6.4 Key Construction Network This network is delivered from master network. This is made, work area wise, on time scale The number of networks to be prepared depends upon the workload into which the plant is divided. These networks are prepared at a time when engineering and procurement activities have sufficiently advanced and construction activities are about to begin or major milestones such as deliveries of equipments at site, start and completion of civil works, mechanical erection etc., are about to be achieved. 6.5 Reports Basically, three types of reports are produced. First type of report contains activities to be performed in next two months and is known as Activity List. Second type of reports gives the status of drawings, materials, etc. and is named Status Report, which highlights the deviations and exceptions and immediate actions. The Third Type of Reports is the one, which summarize progress report at various time intervals. 6.6 Monthly Progress Report Monthly progress report is basically meant for Client. This report gives a comprehensive coverage of engineering, procurement and construction activities carried out during the month under review. The monthly report apprises the Client of the progress of the project and holds up if an in achieving the progress. The report contains the following information: Overall progress statistics Status of milestones List of problems/hold ups Functional progress curves Quantitative status report for equipment Detailed status of construction D. Work Breakdown Structure E. Bar Chart (Project Schedule) Please Refer Annexure I Project Organization Chart G. Man Power Deployment Schedule H. Construction Equipment Deployment Schedule List of Proposed Vendors and Suppliers Sr No Description Supplier Origin 1 Carbon Steel Plates Corus European(West / East) For tanks Arcelor Mills European(West / East) Posco Korea Dongkuk steel Korea Duffer co Belgium Dillinger Hutte Germany Nippon steel Japan Stemcor South Africa Sumittomo Japan 2 Carbon Steel Pipes Dalmine Spa Italy Manses man Brazil / Germany Nippon steel Japan NKK steel Japan Kawasaki Japan NSC Japan Hyundai pipes Korea Korea pipes Korea 3 Carbon Steel Pipe Benkan corp Korea Fittings Awaji sangayo Corp Japan BKL UK BKL Thailand OMR Italy Techno forge Italy Tect tubi Italy Vanleeuwen Holland 4 Flanges Bebitiz Germany FAD flange Italy Geldbech Germany Korea flange Korea 5 Floating Roof seal Ultra float USA Korea Flot Korea HMT USA CTS Nether land 6 Paint International Paint Jotun Hempel Sigma Responsibility Matrix SR.NO DESCRIPTION Division of Responsibility (subcontractor) (Main Contractor) A ADMINISTRATION 1 Visa/work Permit à ¢Ã‹â€ Ã… ¡ 2 Accommodation à ¢Ã‹â€ Ã… ¡ 3 Food à ¢Ã‹â€ Ã… ¡ 4 Transportation à ¢Ã‹â€ Ã… ¡ 5 Site first Aid Facilities à ¢Ã‹â€ Ã… ¡ B TAXES DUTIES / INSURANCES 1 WCP Insurance à ¢Ã‹â€ Ã… ¡ 2 Automobile Insurance à ¢Ã‹â€ Ã… ¡ 3 Captial machinery insurance à ¢Ã‹â€ Ã… ¡ 4 Contractor All Risk Erection Policy à ¢Ã‹â€ Ã… ¡ C FACILITIES 1 Laydown yard / Fabrication Yard à ¢Ã‹â€ Ã… ¡ 2 Stores à ¢Ã‹â€ Ã… ¡ 3 Site office facilities à ¢Ã‹â€ Ã… ¡ 4 Worker rest room toilets à ¢Ã‹â€ Ã… ¡ 5 Parking Spaces for Vehicles à ¢Ã‹â€ Ã… ¡ 6 Drinking water Portable water à ¢Ã‹â€ Ã… ¡ 7 Electricity for site office and rest room à ¢Ã‹â€ Ã… ¡ 8 Electricity for Fabrication à ¢Ã‹â€ Ã… ¡ 9 Blasting and Painting Facilities à ¢Ã‹â€ Ã… ¡ 10 Carbagge Disposal à ¢Ã‹â€ Ã… ¡ 11 Hazardous Mateial Disposal à ¢Ã‹â€ Ã… ¡ 12 Removal of Construction Debris à ¢Ã‹â€ Ã… ¡ 13 Electricity for Site Construction à ¢Ã‹â€ Ã… ¡ 14 Safety Interface with Client à ¢Ã‹â€ Ã… ¡ 15 Personal Protection Equipments à ¢Ã‹â€ Ã… ¡ D DESIGN ENGINEERING 1 Design à ¢Ã‹â€ Ã… ¡ 2 Engineering à ¢Ã‹â€ Ã… ¡ 3 Detailed drawings à ¢Ã‹â€ Ã… ¡ 4 Support details à ¢Ã‹â€ Ã… ¡ 5 Structural Drawings à ¢Ã‹â€ Ã… ¡ 6 Asbuilt Drawings à ¢Ã‹â€ Ã… ¡ E PROCUREMENT SUPPLY 1 Direct Material (Plates for shell bottom and roof, Structural for stairway, roof handrail and roof structures) à ¢Ã‹â€ Ã… ¡ 2 Consumables à ¢Ã‹â€ Ã… ¡ 3 Gaskets / Bolt / Nuts for hydro testing à ¢Ã‹â€ Ã… ¡ 4 Permanent Gasket/Bolt/Nuts à ¢Ã‹â€ Ã… ¡ 5 All Galvanized items for platform/stairway etc à ¢Ã‹â€ Ã… ¡ 6 All tank mounting appurtenances and Instruments à ¢Ã‹â€ Ã… ¡ 7 Material unloading at site à ¢Ã‹â€ Ã… ¡ F Plant Machinery At Site 1 Crane à ¢Ã‹â€ Ã… ¡ 2 Hydra Crane à ¢Ã‹â€ Ã… ¡ 3 Fork Lift à ¢Ã‹â€ Ã… ¡ 4 Rolling Machine à ¢Ã‹â€ Ã… ¡ 5 Welding Machine à ¢Ã‹â€ Ã… ¡ 6 Generators à ¢Ã‹â€ Ã… ¡ 7 Hydraulic Jacks System (Jacks, power packs, hoses, accessories etc.) à ¢Ã‹â€ Ã… ¡ 8 Tools such Grinding, cutting ,beveling Etc à ¢Ã‹â€ Ã… ¡ G PRE FABRICATION 1 Plate cutting Edge preparation (Shell, Roof, Bottom Annular) à ¢Ã‹â€ Ã… ¡ 2 Sand Blasting and Painting of internal and external surfaces of tank as per client approved Painting procedure. à ¢Ã‹â€ Ã… ¡ 3 Shell plate rolling à ¢Ã‹â€ Ã… ¡ 4 Nozzles Manway Neck Rolling à ¢Ã‹â€ Ã… ¡ 5 Sump Plate Rolling, Welding External painting à ¢Ã‹â€ Ã… ¡ 6 Roof Structure and Floating Deck prefabrication à ¢Ã‹â€ Ã… ¡ H CONSTRUCTION 1 Civil work à ¢Ã‹â€ Ã… ¡ 2 Instrumentation à ¢Ã‹â€ Ã… ¡ 3 Tank Insulation à ¢Ã‹â€ Ã… ¡ 4 Scaffolding for Erection and painting, if any à ¢Ã‹â€ Ã… ¡ 5 Tank Erection -Bottom ,Annular, Shell, Roof, Roof Structure, Floating Deck , shell Roof Nozzles Man way, Sump à ¢Ã‹â€ Ã… ¡ 6 Painting Jobs as per client approved procedure à ¢Ã‹â€ Ã… ¡ 7 Meeting Clients construction Schedule à ¢Ã‹â€ Ã… ¡ I TESTING 1 Liquid Penetrent Testing à ¢Ã‹â€ Ã… ¡ 2 Magnetic Partical Testing à ¢Ã‹â€ Ã… ¡ 3 Radiographic Testing à ¢Ã‹â€ Ã… ¡ 4 Ultrosonic Testing if any à ¢Ã‹â€ Ã… ¡ 5 Post Weld Heat Treatment if any à ¢Ã‹â€ Ã… ¡ 6 Facilities for Hydro-testing à ¢Ã‹â€ Ã… ¡ 7 Water for Hydro Test à ¢Ã‹â€ Ã… ¡ 8 Drain point for hydro-tested water near to tank bottom (Max 250 M) à ¢Ã‹â€ Ã… ¡ 9 Dewatering Drying à ¢Ã‹â€ Ã… ¡ 10 Tank Calibration à ¢Ã‹â€ Ã… ¡ J HANDING OVER 1 Punch list à ¢Ã‹â€ Ã… ¡ 2 RT film Submission à ¢Ã‹â€ Ã… ¡ 3 AS Built Drawing à ¢Ã‹â€ Ã… ¡ 4 Final Dossier submission à ¢Ã‹â€ Ã… ¡ 5 Pre commissioning assistance à ¢Ã‹â€ Ã… ¡ 6 Commissioning assistance à ¢Ã‹â€ Ã… ¡ K GENERAL 1 Third Party Inspection Costs à ¢Ã‹â€ Ã… ¡ 2 All the approvals from Local authorities à ¢Ã‹â€ Ã… ¡ 3 Necessary gate passes / permits to carry-out our works à ¢Ã‹â€ Ã… ¡ 4 Coordination with Client à ¢Ã‹â€ Ã… ¡ Project Estimation Summary Sr.No. DESCRIPTION QTY. Unit Rate Amount I PRELIMINARIES Mobilization of Manpower/Equipment 1 70,000 70,000 Establishment of site facilities 1 200,000 200,000 Insurance 1 200,000 200,000 Demobilization of Manpower/Equipment 1 70,000 70,000 Design/Engineering 1 80,000 80,000 Documentation 1 30,000 30,000 Sub Total AED 650,000 II PROCUREMENT Steel Plates( A 537 Cl.1 ) 3,363 2,931 9,856,953 Steel Plates( A 36 ) 2,258 2,488 5,617,904 Structural 96 2,800 268,800 Pipes Fittings/Flanges 1 510,000 510,000 Fasteners 8 7,000 56,000 Aluminium Dome 1 7,000,000 7,000,000 Hatch / Accessories 1 Jet Mixer + Misc 8 Galvanizing 8 5,000 40,000 Stairway Steps 8 16,500 132,000 Sub Total AED 23,481,657 III CONSTRUCTION Sub-Contract 5,450 1,000 5,450,000 Consumables 1 100,000 100,000 Safety Equipments 1 398,200 398,200 Salary for Staff 1 500,000 500,000 Wages for Fabrication Crew 1 Wages for Erection Crew 1 Equipments ( Hire) 1 1,661,000 1,661,000 Equipments ( Purchase ) 1 600,000 600,000 Mobilization of Pre fabricated material to site 1 320,000 320,000 Scaffolding Erection Tools tackles 1 42,000 42,000 Fuel 1 617,400 617,400 Freight, Visa ,Food Accommodation for Crew 2,663,200 2,663,200 Testing Requirement 1 Site Communication/Stationary/Utilities 1 Office Communication/Stationary 1 Heating Nitrogen Coil 1 3,849,468 3,849,468 Sub Total AED 10,751,268 IV SUB-CONTRACT Civil Foundation Misc. Works 1 8,389,450 8,389,450 Civil Design 1 Soil Improvement 1 Reduce backfilling (1 M) 1 Surface Preparation Painting 1 2,476,700 2,476,700 Belzona application 1 NDT works 1 1,150,000 1,150,000 Third Party Inspection 1 150,000 150,000 Calibration 1 64,000 64,000 Hydro Test 1 200,000 200,000 Sub Total AED 12,430,150 V OTHERS BG Charges 100,000 Finance Charges 150,000 Commission to Agents