OLAN DEEMS

Underground Piping Installation Procedure

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This procedure is intended to provide general application guidance and establish controls during preparation and installation. To ensure that installation of underground cooling water line 60”diameter and smaller is carried out safely, efficiently and in accordance with good working practice, as per OWNER Job Specifications.</div>
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<b><span style="font-size: large;">A. Required Tools and Equipment:</span></b></div>
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<ul>
<li>40-Ton Crane</li>
<li>Welding machine</li>
<li>Non-metallic ropes, tag lines </li>
<li>Shackles</li>
<li>Welding gloves</li>
<li>Welding mask</li>
<li>Face shields</li>
<li>Grinding machines / disc</li>
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<b style="font-size: x-large;">B. Pre-Installation Activities:</b></div>
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• Ensure that all relevant documents have been approved by OWNER prior to commencing installation, and that the latest revisions of IFC drawings, specifications including approved procedures are disseminated to concerned personnel who will carry out the work.</div>
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• Ensure that all piping materials to be transported from warehouse / laydown area to the work area complies with the project specifications. Site handling and identification of all piping materials and components shall be in accordance with SUBCON Standard Project Instruction.</div>
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• Check and verify spool and random pipe installation location and co-ordinate with rigging section. Check pipes and spools materials if damaged or if end cover is in place before transporting to the work area. All materials of doubtful condition or quality shall be immediately segregated from the job site, an NCR raised and the material shall not be used.</div>
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• During transportation, spools shall be adequately secured with soft lines to prevent damage. Where practicable, end cap/protectors shall be installed to prevent ingress of any foreign objects and damage to weld preps.</div>
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• Over hanging from the trailer / truck body of any piping materials is not allowed. Ensure that they are properly and adequately secured.</div>
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• To prevent damages on coated pipe spools, handling shall be carried out with non-metallic slings. Chains or wire ropes shall not be used. Coated spools shall be stored on soft standing wood dunnage or sandbags. Attach soft tag lines, where necessary, to prevent swinging and possible damage during loading and handling of coated pipe spools.</div>
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• Check and verify the location and orientation of spools to plant North on IFC isometrics / plan drawings. Establish good reference points for proper alignment and commence installation in progressive manner.</div>
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• Starting from the North toward South of the plant, excavation using Dozer shall be carried out in accordance with SUBCON Standard Operating Instructions, ensuring that trench construction conforms to OWNER project requirements and specifications. Once the trench has been prepared and sand bedding brought to required grade and compacted, pipe installation may commence. Sand bedding shall be free of rocks, stones and other objects, which could cause damage to the pipe coating.</div>
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• Prior to setting the pipe on sandbags into the ditch, the underside of the cooling water line shall be holiday tested. Following coating of the welds and coating repair areas, the coating all around the pipe shall be tested to ensure there are no holidays. Holiday testing should occur just prior to authorizing the backfill activity. Backfill should begin within the next 8 to 24 hours. </div>
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<span style="font-size: large;"><b>C. Installation Activities:</b></span></div>
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• Use a 40-ton Crane for installing the underground cooling water line. Non- metallic ropes and tag lines shall be attached to the pipe for controlling and to prevent swaying and damage to coating during lifting and installation. The pipe will be lifted and positioned horizontally (see attached drawing) and will be lowered into the trench in accordance with SUBCON Standard Operating Instructions.</div>
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• The pipe spool will be placed on a pile of sandbags in the trench with adequate access around the full section of the joint to be welded by excavating enough depth from the graded bottom at the weld area location. Provide sufficient support to the pipe section in the trench to prevent movement / misalignment.</div>
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• Conduct dimensional check, verify the squareness of the pipe end at the weld bevel and grind if required, to ensure the joint can be accurately fitted and aligned to obtain good weld quality.</div>
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• Proceed to lower the 2nd pipe spool into the trench and maneuver into a position level with the pipe string already in place. Do not force fit any pipe joint during fit-up, this will minimise stress exerted on the pipe. External clamps and other similar devices shall be used to retain/maintain the pipe position and alignment during tack welding.</div>
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• Only a qualified welder shall carry out tack welding in accordance with Procedure No. QCD-####. Submit “Fit-up” request (WIR) for each pipe joint and on acceptance of fit-up assign a welder. Only approved welding electrodes / filler rods shall be used and controlled in accordance with SUBCON Q.C. Procedure No. QCD-#### and the approved Welding Procedure Specifications (WPS).</div>
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• Once fit-up is accepted, ensure that weld area is clean, free of dirt, scale, rust paint, or any foreign objects and ensure adequate protection from wind, dust, rain, and wind blown sand before full welding shall be carried out.</div>
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• Welding shall not be done when the ambient temperature is lower than 0ºF (-18ºC) or when surfaces are wet, exposed to rain, sleet, or high wind.</div>
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• Accomplish welding in one complete heating cycle (where possible), balancing the deposition of the weld metal to minimise distortion resulting from the effects of heat input. No weld joint should be left until, Root, Hot pass and one substantial filler has been completed.</div>
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• Prior to welding inspection, clean all welds using grinder and or wire brush. All welding inspection shall be in accordance with OWNER Specifications No. W01-F01 and SUBCON Standard Operating Instructions respectively. Non-destructive examination shall be carried out in accordance with Specification No. 00-W-0003. Any repair on welding shall be done in accordance with SUBCON Q.C. Procedure No. QCD-####.</div>
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• If flange joints are to be connected, all bolting requirements shall be carried out in accordance with OWNER Specification and SUBCON Work Instruction No. PRJ-####.</div>
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• At the end of each workshift, the open ends of the installed pipe shall be secured / covered using frame supported polyethylene / tarpaulin sheets to prevent ingress of any foreign objects or living organisms.</div>
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• The same methodology shall be applied for the installation of the next succeeding pipe until the last pipe spool is fully installed to complete the system.</div>
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<b><span style="font-size: large;">D. Post-Installation Activities:</span></b></div>
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• Upon completion of welding inspection and acceptance of OWNER, repair for any damaged coating shall be carried out in accordance with coating material manufacturer’s recommendation, SUBCON Standard Operating Instructions and project Specification No. 00-N-0031.</div>
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• After obtaining NDT clearance from quality control, all field joints shall be coated with coal tar epoxy coating in accordance with SUBCON work instruction / method statement.</div>
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• Prior to backfilling and compaction works, all waste materials and sharp objects shall be removed from the trench. Extreme care shall be observed when placing backfill materials to avoid damage to pipe coating. Backfilling and compaction shall be carried out in accordance with SUBCON Standard Operating Instructions.</div>
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• The sand bedding material shall be dune sand meeting the requirements of Procedure No. 81-C-0001, Rev. 1 “Method Statement Procedure of Backfill for Cooling Water Pipes”.</div>
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• Structural fill material shall meet the requirements of 00-C-0010, “Specification for Excavation and Backfill”. </div>
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• For final backfill, compaction of the dune sand surrounding the pipe may be achieved by using water flooding. Dune sand to be compacted by water flooding should be placed in lifts not exceeding 200mm. Mechanical compaction in the area directly above the pipe should not begin until there is a minimum cover of 300mm (loose lift thickness) of dune sand above the pipe.</div>
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• Conduct housekeeping properly.</div>
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<b>V. Work Sequence & Procedue {as described above}</b><br />
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Underground Piping Installation Procedure

This procedure is intended to provide general application guidance and establish controls during preparation and installation. To ensure th...

5:19 AM

Controlling and Reporting Project Progress

<b><span style="font-size: large;">1. Progress Control</span></b><br />
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The Main Contractor's Planning & Scheduling Engineer in the Site Organization is responsible for controlling the Subcontractor's progress and reports with assistance of other required members in the site organization and under the direction of the Site Project Control Manager. The Subcontractor shall inform the Main Contractor of the number of actual man-hours spent for each construction activity at the monthly/weekly progress meeting. </div>
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This information shall be checked utilizing Discipline Supervisors measurements, and the Subcontractor's labor forms.</div>
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The Lead Construction Engineers and Construction Engineers shall be involved to verify that the work has been completed and accepted.</div>
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When the Subcontractor's productivity (percentage of work actually carried out with respect to the total) has been agreed with the Sub-contractor, a narrative and analytical report is issued for each target function, area, discipline and Subcontractor, utilizing the findings of the above meeting.</div>
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The report shall form the basis of the Monthly Progress Report issued to the Main Contractor and utilized for the Subcontractor's payments. </div>
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The Planning & Scheduling Engineer shall utilize the following documents for monitoring and measuring the Subcontractors progress. The typical reporting formats will be provided the Subcontractor after signing of the Subcontract.</div>
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1)<span style="white-space: pre;"> </span>Main Contractor's Overall Detailed Contract CPM Schedule</div>
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2)<span style="white-space: pre;"> </span>Subcontractor's Schedule</div>
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3)<span style="white-space: pre;"> </span>Subcontractor's Cash Flow Chart</div>
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4)<span style="white-space: pre;"> </span>Subcontractor's Progress Measurement System</div>
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5)<span style="white-space: pre;"> </span>Subcontractor's Progress Reports </div>
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<b><span style="font-size: large;">2. Subcontractor's Schedule</span></b><br />
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The Subcontractor shall submit the following schedule to the Main Contractor for review and approval within the time specified.</div>
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<b>1) Overall Bar Chart Schedule</b></div>
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Within ten (10) calendar days from the date of signing the Sub-contract, Subcontractor shall submit the Overall Bar Chart Schedule in three (3) copies. This schedule shall be based on the Overall Bar Chart Schedule provided with the Tender, and any agreed upon modifications thereof, and shall display summarized activities and major milestones of the Subcontract. The schedule will be updated and submitted monthly along with the Monthly Progress Report.</div>
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2) Detailed Critical Path Method (CPM) Schedule</div>
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a) Within twenty (20) calendar days from the date of signing the Subcontract, Subcontractor shall submit to the Main Contractor the overall detailed CPM Schedule in three (3) copies covering the total Scope of Work for review and approval.</div>
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b) This CPM Schedule shall be prepared based on the Contractor's Detailed CPM Schedule for the Construction.</div>
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c) The CPM schedule shall identify critical and sub-critical path activities, constraints, early/late start and finish dates, float times, and shall be cost and resource loaded.</div>
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d) After preparation and the Main Contractor's approval of CPM Schedule as identified above, Subcontractor shall produce and submit three (3) copies of the following document for review : </div>
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<li style="text-align: justify;">Schedule reports, including float reports.</li>
<li style="text-align: justify;">Bar charts and time scaled CPM Logic Diagram for Detailed CPM Schedule.</li>
<li style="text-align: justify;">Cost and resource curves / histograms</li>
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<div style="text-align: justify;">
-  Baseline man-hour/manpower forecasts and progress curves as detailed in Subcontractor Reports hereafter.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
e) Based on approved schedule, the Executive Milestone Summary shall be developed and approved for inclusion in the Monthly Progress Report.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
No amendments shall be made to the approved Detailed CPM <span style="white-space: pre;"> </span>Schedules without prior written approval of the Main Contractor.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
g) Schedule Updates </div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
The Subcontractor will update and issue the Detailed CPM Schedule in bar chart form, as a minimum, once per month. This updated document shall be the basis of work progress compared to the approved schedule. The updated Detailed CPM Schedule shall be submitted with the Monthly Progress Report. The schedule updates shall show the following for each activity.</div>
<br />
<ul>
<li style="text-align: justify;">Total Float </li>
<li style="text-align: justify;">Baseline/Target Schedule comparison with current statues schedule.</li>
<li style="text-align: justify;">Percentage complete</li>
<li style="text-align: justify;">Remaining duration</li>
<li style="text-align: justify;">Actual start and finish dates</li>
<li style="text-align: justify;">Forecast start and finish dates</li>
<li style="text-align: justify;">Critical Item Register</li>
</ul>
<br />
<div style="text-align: justify;">
Any changes in logic shall be clearly indicated, together with an accompanying written report briefly summarizing the status of the schedule.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
The update shall also include a separate list of items detailing    activities that are in delay, the extent of the delay, an explanation of the cause, responsibility for clearance and the Subcontractor's proposed recovery plan.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
Periodic joint schedule reviews by the Main Contractor and the Subcontractor shall take place and the conclusions of the reviews shall provide a means of marking and approving changes to the CPM Logic. These changes and approvals shall not constitute a change in the Completion Date and/or the cost of the Facility unless incorporated into a formal, Changes & Subcontract Agreements executed by the Main Contractor and the Subcontractor. (Refer to the Attachment No. 5)</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
<b>3) Bar chart Schedule for Construction Equipment </b></div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
Schedule for the Construction Equipment shall be developed and submitted within twenty (20) calendar days from the date of Subcontract signing. This bar chart schedule shall indicate type and quantity of construction equipment planned for each month.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
<b>4) Shutdowns and Stoppages</b></div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
a) Ninety (90) days prior to any shutdown, the Subcontractor shall submit to the Contractor for approval, a detailed shutdown schedule identifying all activities to be performed during shutdown.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
b) The Subcontractor shall make details of all shutdowns for the Main Contractor and the Owners coordination and approval, and shall clearly provide for and show the numbers and duration thereof. Main Contractor shall give the Owner prior and at least thirty (30) calendar days notice, in writing for any proposed shutdown.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
c) The Subcontractor shall : </div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
Make sequence of its work so that there is a minimum of disruption to production.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
Coordinate his shutdown schedule with any maintenance outages planned by the Owner and the Main Contractor.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
Complete the work to the maximum extent possible with continuous effort, so as to minimize disruption to normal operations.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
The Subcontractor's shutdown schedule will be continuously reviewed and adjusted to reflect actual field progress and any modification required shall be as a result of coordination with the Owner and the Main Contractor.</div>
<div style="text-align: justify;">
<br /></div>
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<br />
<b><span style="font-size: large;">3. Subcontractor's Progress Measurement System (PMS)</span></b><br />
<br />
<div style="text-align: justify;">
The Subcontractor shall prepare Subcontractor's PMS based on the </div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
Main Contractor's PMS and submit it in three (3) copies to the Contractor for review and approval within twenty (20) calendar days from the dates of Subcontract signing. </div>
<br />
<b><span style="font-size: large;">4. Subcontractor's Reports</span></b><br />
<br />
<div style="text-align: justify;">
The Subcontractor shall prepare and submit the following reports to the Main Contractor for review and/or approval within the time specified.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
<b>1) Monthly Progress Report</b></div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
The Subcontractor shall prepare and submit to the Main Contractor, before the last day of each month, comprehensive Progress Reports (both hard and soft copy) as outline below. These Reports shall be presented in concise manner so that the status and actual progress of all significant aspects of the Work up to the twenty fifth (25th) day of the proceeding month shall indicate volume of work done. Within three (3) calendar days of issuing of these reports, the Subcontractor shall make a formal presentation of these at a meeting with the Main Contractor.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
The progress reporting system and the Monthly Progress Report by the Subcontractor shall be consistent in calculation of percentage completed to the values presented in invoices for progress payment.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
The Monthly Progress Report shall include, but not be limited to the following;</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
a) General (Narrative)</div>
<div style="text-align: justify;">
<span style="white-space: pre;"> </span>Performed major work items during this month</div>
<div style="text-align: justify;">
<span style="white-space: pre;"> </span>Scheduled major work items for next month</div>
<div style="text-align: justify;">
<span style="white-space: pre;"> </span>Delayed activities and catch up plan </div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
b) Progress Summary Report</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
c) Detailed Progress Report</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
d) Manpower Histogram </div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
e) Changes and Subcontract Amendment Log</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
f) Summary of HSE activities, problem areas and corrective action taken.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
g) Monthly Invoice Data</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
h) Others</div>
<br />
<ul>
<li style="text-align: justify;">Status of correspondence</li>
<li style="text-align: justify;">Action List for activities related to the Subcontract</li>
<li style="text-align: justify;">Area of Concern / Corrective Reports</li>
<li style="text-align: justify;">Minutes of Meetings which were held during the reporting period</li>
</ul>
<br />
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
<b>2) Weekly Progress Report</b></div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
The "Weekly Progress Report" shall be prepared by the Subcontractor in a format approved by the Main Contractor and submitted to the Main Contractor within one (1) day following the weekly cut-off date as determined by the Main Contractor.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
a) A statement of progress achieved for the week and to-date versus the  approved Schedule of Work (narrative and percentage)</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
b) Progress Curves updated for actual progress.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
c) Area Summary Schedules, where deemed necessary, updated to show <span style="white-space: pre;"> </span>actual progress.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
d) Actual man-hours and average manpower for the week versus planned.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
e) A report on quantities set for the week and to-date versus planned.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
f) For Subcontracts which include engineering and material supply a <span style="white-space: pre;"> </span>statement on drawings and purchase orders issued versus planned.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
g) A report on material received</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
h) A brief statement on achievements, activities to be accomplished during  the following week, critical activities and any other items relevant to the  progress of the Work such as safety, engineering, quality control, etc.</div>
<div style="text-align: justify;">
             </div>
<div style="text-align: justify;">
i) A rolling 3-week schedule updated to reflect, one week history, one <span style="white-space: pre;"> </span>week current and one week forecast status.</div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
<b>3) Daily Job Site Force Report </b></div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
The daily report relates to the number of Subcontractor's staff and manpower present on site, per Subcontract. Subcontractor shall submit this report by [__:00 A.M] each every morning for the current day. The daily job site force report shall be reviewed, verified and signed by the Subcontractor’s construction manager or department disciplined manager.</div>
<div style="text-align: justify;">
<br /></div>
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<br />
<div style="text-align: justify;">
<b>4) Daily Activity Report (DAR) </b></div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
Daily Activity Report (DAR) comprised of the daily construction report and daily manpower/equipment report shall be prepared and   submitted to the Main Contractor for review on and containing the same information as the sample forms supplied in Attachment No. 10. The Subcontractors daily activity report format shall be submitted to the Main Contractor for approval prior to the initial submittal. The daily activity report for each working day shall be submitted by last hours (__:00) on the day. These reports shall include the next day's list of quality field checks required by the Owner's Field Supervisor and other all information as contained in the sample forms including details of idle manpower and equipment and personnel. The daily activity report shall be reviewed, verified and signed by the Subcontractor’s construction manager or department disciplined manager. </div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
<b>5) Safety Reporting (Accidents) </b></div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
Regardless of work site location, accident reporting by the Subcontractor shall be submitted to the Main Contractor as required and detailed in the Owner's Specification and Main Contractor's Safety Plan in a format as approved by the Owner and the Main Contractor.</div>
<div style="text-align: justify;">
       </div>
<div style="text-align: justify;">
<b>6) Additional Systems </b></div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
Where additional systems are used to produce Project Report, data used by the Subcontractor to generate such reports shall be supplied to the Main Contractor on approved media and, as a minimum, be capable of electronic import into Microsoft Excel 2003 Version or Microsoft Access 2003 Version.</div>
<div style="text-align: justify;">
        </div>
<div style="text-align: justify;">
<b>7) Procurement Progress Report/Shop Inspection Status Report</b></div>
<div style="text-align: justify;">
<br /></div>
<div style="text-align: justify;">
This report shall be issued monthly, but separate from the Monthly Progress Report. It shall cover an identical report and shall clearly show all of the information in a tabular format to be provided by the Contractor for all equipment and materials as required for the Works.</div>
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