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PHASE 1B PSR-1 REJUVENATION PROJECT PROVISION OF TECHNICAL WORK SCOPING AND ENGINEERING SERVICES
PHASE 1B PSR-1 REJUVENATION PROJECT SCOPE OF WORK FOR PROVISION OF REPLACEMENT OF DISPLACER LEVEL TRANSMITTERS TO GUIDED WAVE RADAR LEVELTRANSMITERS PSR1RJV-IN-SOW-0004 31
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PROJECT NAME DOCUMENT TITLE
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Contract No. PTSSB/TC1/TSA/003 Work Order No. PMES-WO-009
DOCUMENT NO. PACKAGE NO.
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TPC REV CODE
ISSUE DATE
DOC STATUS
PTSSB ACCEPTANCE
AUTHOR
CHECKER
APPROVER
NAME
NAME
NAME
NAME
A
20-Jan-2014
IFR 1
KF Ng
Art Enciso / YS Cheaw
Uni Krishnan Kannan
Nor Azlan
B
7-Feb-2014
IFR 2
KF Ng
Art Enciso / YS Cheaw
Uni Krishnan Kannan
Nor Azlan
0
17-Feb-2014
AFD
Natasha
Art Enciso / YS Cheaw
Uni Krishnan Kannan
Nor Azlan
Document Class : B - Confidential ( Should only be shared with staff or contractors who have a need-to-know)
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TABLE OF CONTENT
EXHIBIT II PART A 1.0 2.0 3.0 PART B 1.0 2.0 3.0
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GENERAL PROJECT INFORMATION INTRODUCTION DEFINITIONS & ABBREVIATIONS GENERAL SCOPE OF WORK GENERAL SCOPE DETAIL SCOPE OF WORK HEALTH SAFETY & ENVIRONMENT RULES AND REGULATIONS SCHEDULE AND DURATION LIAISON WITH OTHER CONTRACTORS DESIGN AND ENGINEERING PROCUREMENT FABRICATION AND CONSTRUCTION QUALITY CONTROL AND ASSURANCE INSPECTION, TESTING AND COMMISSIONING DOCUMENTATION WORK COMPLETION AND START-UP SPARE PARTS AND SPECIAL TOOLS WARRANTY AND DEFECT LIABILITY NOTICE COMPANY’S SCOPE ATTACHMENTS
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PART A 1.0 2.0 3.0 PART B 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0
SCOPE OF WORK
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EXHIBIT I
SPECIFICATIONS
PROCEDURES AND REQUIREMENTS GENERAL PROCEDURES CONTRACTOR’S OBLIGATION INSPECTION OF SITE STANDARD AND SPECIFICATIONS APPLICABLE CODES AND STANDARDS EQUIPMENT SPECIFICATIONS AND DATASHEETS ENGINEERING SPECIFICATIONS
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GENERAL PROJECT INFORMATION
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PART A:
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EXHIBIT I - SCOPE OF WORK
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1.0
INTRODUCTION
PETRONAS Penapisan (Melaka) Sdn. Bhd, is a wholly owned subsidiary of PETRONAS [hereinafter to as PP(M)SB] which operates a refinery complex to produce high quality refined petroleum products which include LPG, Petrochemical Naphtha, Motor Gasoline, Dual Purpose Kerosene, Diesel, Low Sulphur Waxy Residue, Fuel Oil, Lubricant Base Stocks.
PSR-1 was commissioned in 1994 and would reach its design lifetime by 2014 after twenty (20) years in operation. PP(M)SB has undertaken Asset Life Study (ALS) to assess the current
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condition of the PSR-1 plant and to identify necessary actions to maintain the assets for continued operation for another 20-25 years.
A Detailed Technical Work Scoping and Engineering Study was conducted to prioritize and
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strategically plan in detail all the recommended actions proposed by PSR-1 Asset Life Study.
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PSR-1 Rejuvenation Project will be implemented under the following phases:
Phase 1A: FY 2012 – FY 2013 (COMPLETED)
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Phase 1B: FY 2014 – FY 2020
The Scope of Work detailed in this ITB is for the execution for PSR-1 Phase 1B.
The execution will be carried out in plant normal operation i.e. Outside Turn-Around (OSTA) based on the available window.
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2.0
DEFINITIONS AND ABBREVIATIONS
2.1
Definitions The following terms and definitions shall apply throughout the document: • The word ‘shall’ indicates mandatory requirement • The word ‘should’ indicates preference The definitions described herein provide further clarification that will be implemented in this project to ensure compliance with requirements of this Scope of Work. Words appearing in capital letters shall have the meaning assigned to them in this Scope of Work.
Definitions Means PETRONAS Penapisan (Melaka) Sdn. Bhd. i.e. PP(M)SB (Company No: 164522-V), a wholly owned subsidiary company of PETRONAS, which owns and/or operates the Melaka Refinery Complex located in Mukim Sungai Udang, Tangga Batu, Melaka comprising of amongst others the PSR-1, the PSR-2 and the MG3 Plant, and shall include its successors in title and permitted assigns, and shall, where the context so admits and requires, also include its employees, agents or designated representatives. Means the contract entered into between the COMPANY and CONTRACT the CONTRACTOR for the WORKS in accordance with the terms and conditions contained herein including all articles, exhibits and any other documents attached hereto or incorporated by reference including any subsequent amendments to them. CONTRACTOR Means Party(ies) entering into this CONTRACT with the COMPANY for the performance of the WORKS as set forth in this CONTRACT and includes the CONTRACTOR’s personnel, representatives, successors and authorized parties. Means [dd/mm/yyyy i.e the date as specified in the Letter of EFFECTIVE Award], as further specified in SECTION II, PART A, DATE ARTICLE 5 – CONTRACT DURATION. Shall have the similar meaning as per the CONTRACT PROJECT Preambles. Means the areas or places as designated by the COMPANY SITE(S) where the WORKS is to be performed or delivered, as further specified in EXHIBIT I – SCOPE OF WORKS. Means Party(ies) including but not limited to supplier, vendor SUBCONTRACTOR and/or companies performing construction work(s) that has or have entered into a contract, directly or indirectly with the CONTRACTOR, for the performance of any part of the WORKS.
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No. Terms 1 COMPANY
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WORKS
Means the work to be performed and rendered by the CONTRACTOR or its SUB-CONTRACTOR, as expressly set forth in this CONTRACT, which is more particularly described in EXHIBIT I – SCOPE OF WORKS and all of CONTRACTOR’s and/or its SUB-CONTRACTOR’s activities that are reasonably inferable from the description of the said scope of WORKS, including any other activity which is not specified in this CONTRACT but which in the course of the WORKS becomes necessary for completion to be effected.
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2.2
Abbreviations
2.2.1
General Authorized Entrant and Standby Person Approved for Construction Approved for Design Asset Life Study American Petroleum Institute Bank Guarantee Jabatan Bomba dan Penyelamat
BS CAD CCC CEP DCS DOE DOSH
British Standard Computer-Aided Design Contract Closure Certificate Construction Execution Plan Distributed Control System Department of Environment Department of Occupational Safety and Health
EPCC ESD FAT FOB GWR HSES IEC
Engineering, Procurement, Construction & Commissioning Emergency Shutdown System Factory Acceptance Test Free On Board Guided Wave Radar Health, Safety, Environment and Security International Electrotechnical Commission
I.S. ITP JB JKDM JMS JSA
Intrinsic Safety Inspection and Test Plan Junction Box Jabatan Kastam Diraja Malaysia Job Method Statement Job Safety Analysis
MBMB MCB MWCC MIDA NDT NIOSH
Majlis Bandaraya Melaka Bersejarah Main Control Building Mechanical Work Completion Certificate Malaysian Investment Development Authority Non-Destructive Test
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AESP AFC AFD ALS API BG BOMBA
OSTA
National Institute Occupational Safety and Health Outside Turn Around
P&ID PLC PPE
Piping and Instrumentation Diagram Programmable Logic Controller Personal Protective Equipment
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PETRONAS Technical Standards Quality Assurance Quality Control Ready For Start-Up Site Acceptance Test Shutdown Safety & Health Officer
SPD SPIR ST TA TPIA VDRL WCC
Surge Protection Device Spare Parts and Interchangeability Record Suruhanjaya Tenaga Turn Around Third Party Inspection Agency Vendor Data Requirement List Work Completion Certificate
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PTS QA QC RFSU SAT SD SHO
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GENERAL
3.1
This Contract calls for Lump Sum basis for the provision of design, engineering, manufacturing, material procurement, fabrication, documentation, inspection, delivery, decommissioning, demolition, disposal, installation, termination, testing and commissioning for replacement of Displacer Level Transmitters to Guided Wave Radar Level Transmitters for PSR-1 Rejuvenation Project Phase 1B.
3.2
CONTRACTOR shall be required to execute the rejuvenation works on the above items 3.1 in order to meet COMPANY’s target objectives i.e. to maintain the assets for continued operation for another 20-25 years.
3.3
This document along with all attachments, codes, standards, etc. is for PSR-1 Rejuvenation Project Phase 1B. The WORKS are to be performed during plant Outside Turn-Around (OSTA) period in year 2015 and 2016.
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3.0
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EXHIBIT I - SCOPE OF WORK
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PART B: SCOPE OF WORK
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1.0
GENERAL SCOPE CONTRACTOR’s general scope of works shall include but not limited to the following: CONTRACTOR shall perform the WORKS in accordance to the applicable PTS, International codes, the governing codes, industry best practices and in compliance with the Malaysian regulations in force.
1.2
CONTRACTOR shall provide all safety items for his workers and follow the safety rules of COMPANY.
1.3
CONTRACTOR shall provide management, supervision, manpower, materials, machinery, equipment, tools, consumables, transportation and all necessary resources for satisfactory completion of the WORKS.
1.4
CONTRACTOR shall submit project history record of similar nature in Oil and Gas industry.
1.5
The CONTRACTOR shall develop the project organization chart for the purpose of this contract.
1.6
CONTRACTOR shall maintain strict quality procedures in accordance to PTS to ensure compliance to codes, specifications, drawings and instruction issued by COMPANY during installation process.
1.7
CONTRACTOR shall practice good housekeeping at all times during the execution of the WORKS.
1.8
CONTRACTOR shall procure all materials required for the completion of the WORKS. The procurement function shall include issuing of purchase orders, expediting delivery, performing the necessary inspection and test to ensure quality and quantity, shipping, unloading, custom clearance and transportation to the work SITE.
1.9
CONTRACTOR shall familiarize themselves thoroughly with all the reference drawings and documents for assessment of all works that need to be carried out in this project.
1.10
CONTRACTOR shall perform site visits and thoroughly inspect the SITE with COMPANY’s engineer to discuss and decide upon the modification works and other requirements before submission of their quote.
1.11
CONTRACTOR shall submit site visit checklist to COMPANY for information/review before visit. During site visit, CONTRACTOR shall identify the detail modifications required for the replacement work.
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1.1
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CONTRACTOR shall check and ensure that the material is suitable and adequate for the WORKS. CONTRACTOR shall notify COMPANY of any discrepancy found in package and to obtain interpretation and/or description from COMPANY on discrepancies prior to commencement of WORKS.
1.13
CONTRACTOR shall confirm the feasibility of implementation include the availability of spaces and areas for the purpose of the WORKS. Any space constraint, discrepancy, error and omission in the WORKS details shall be notified to COMPANY for resolution prior to commencement of WORKS.
1.14
CONTRACTOR shall perform site verification to the existing facilities and installation prior to commencement of WORKS. In no case shall the WORKS be subjected to any future variation, resulting from failure of CONTRACTOR to verify the services.
1.15
CONTRACTOR shall be responsible for vendor drawing submission, installation procedures, QA/QC program, detail work plan/schedule, monitoring, progress reporting, manpower loading and all other necessary procedures and documents which shall include project co-ordination procedure as stipulated in this Scope of Work.
1.16
CONTRACTOR shall coordinate, expedite and resolve any problem that arises in providing materials and services in compliance to COMPANY requirement.
1.17
CONTRACTOR shall furnish all documents for COMPANY approval prior to executing emergent work for verification purpose.
1.18
CONTRACTOR shall update all the related drawings to SITE As-Built drawings.
1.19
CONTRACTOR shall conduct site verification to confirm the constructability of the proposed facilities and to identify any form of obstruction that may be encountered during construction. Any space constraint, discrepancies, error or omission between the drawings and actual SITE condition shall be brought to the attention of COMPANY for resolution prior to pre-fabrication and installation works. All additional work due to overlooked discrepancies shall be borne by the CONTRACTOR.
1.20
CONTRACTOR shall supply complete materials, labour, tools, equipment, etc. and all necessary items required to carry out surveying, fabrication, inspection, transportation, construction and installation of the WORKS.
1.21
All works shall strictly follow the AFD / AFC drawings supplied by COMPANY. Any deviations from the AFD / AFC drawings shall be notified to COMPANY at least three (3) days prior to executing the WORKS. CONTRACTOR shall obtain COMPANY’s approval prior to execution of the deviations.
1.22
CONTRACTOR shall perform the WORKS as specified in this document and also in accordance with the mark-up drawings specifically marked in ATTACHMENT-4.
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CONTRACTOR shall ensure all waste inclusive but not limiting to scrapped material, tools etc. were completely removed upon completion of the installation works.
1.24
CONTRACTOR shall perform all site installation works as required and as shown in the relevant drawings. To minimize fieldworks, all materials are pre-fabricated at factory.
1.25
Where scaffolding is required for the installation work at SITE, only tubular scaffolding (complying with BS standard) shall be allowed to be used inside COMPANY plant. Only qualified and DOSH certified scaffolding supervisor is allowed to supervise the scaffolding installation. All scaffolding shall be in accordance with COMPANY requirements and must be inspected and approved by COMPANY scaffolding inspector. All scaffolding workers and helpers shall attend a scaffolding induction session in COMPANY.
1.26
The use of safety harness shall be mandatory for working at elevated position, including during erection of scaffolding. Safety Belt shall not be used.
1.27
CONTRACTOR shall provide sufficient vehicle to ensure efficient worker mobilization to site location. The vehicles provided shall meet the COMPANY requirements.
1.28
CONTRACTOR shall bear any cost of temporary removal and re-installation of any structure foreseen obstruction during execution of the WORKS.
1.29
CONTRACTOR shall repair, reconstruct, reinstate and make good any damaged facilities due to execution of the WORKS to the satisfaction of COMPANY.
1.30
All materials supplied shall be original and unused, accompanied by relevant manufacturer document such as mill certificate, test certificate, etc. Without those documents, COMPANY has all the right to reject such materials.
1.31
CONTRACTOR shall submit a weekly work progress report to COMPANY indicating the percentage of work completed, portion of work currently in progress and highlighting any constraints that may exist with mitigation plan.
1.32
The replacement work shall be carried out during OSTA in year 2015 and 2016.
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2.0
DETAIL SCOPE OF WORK
2.1
CONTRACTOR shall be responsible, but not limited to, the design, material, engineering, procurement, manufacture, supply, fabrication, installation, supervision, inspection, testing, commissioning, decommissioning, demolition, disposal, project management and documentation for the replacement of existing Displacer level transmitters to Guided Wave Radar level transmitters. The WORKS shall be in strict accordance with this specifications, attachments, PTS and applicable codes and standards.
2.2
CONTRACTOR’s scope shall include but not limited to the following:CONTRACTOR shall supply, design, engineer, install, deliver, test and commission sixty six (66) sets of Guided Wave Radar level transmitters to replace existing Displacer level transmitters at PSR-1 complete with all required accessories, pipe or tubing & fittings associated with the transmitters. Refer to ATTACHMENT- 5 for Tag Number List.
ii)
CONTRACTOR shall dismantle existing Displacer Level transmitters and install the Guided Wave Radar level transmitters complete with associated accessories i.e. Chamber, vent/drain connections, termination cables etc. up to commissioning.
iii)
CONTRACTOR shall return the transmitter’s electronic together with the displacer to COMPANY for safe keeping. However, for the chamber shall be disposed to designated area defined by COMPANY.
iv)
CONTRACTOR shall perform site visit to confirm the existing cable length sufficiency for the connection of Guided Wave Radar level transmitters. CONTRACTOR shall supply and install intermediate junction box and cable (refer to PTS 32.37.20.10 Section 3.5) if existing cable lengths are found not adequate during detailed engineering design. Cable splicing is prohibited.
vi)
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CONTRACTOR shall ensure all materials and equipment shall meet the process design and environmental conditions as per the existing requirement and shall be new, free of defects and of the quality as specified herein.
CONTRACTOR shall verify the existing SPD and barrier suitability to drive the required power to the transmitters. CONTRACTOR shall propose and supply new suitable barrier if the existing barriers deemed not suitable. CONTRACTOR shall obtain COMPANY’s approval on the barrier’s model and make prior to supply. COMPANY only accepts MTL or P&F make for barriers.
vii)
CONTRACTOR shall provide a transmitter remote mounted local indicator for area where no accessible platform for operation and maintenance personnel is available.
viii)
CONTRACTOR shall ensure the new chamber provided with level measurement reference marking. The marking shall permanently show 0%, 25%, 50%, 75% and 100% of level measurement. CONTRACTOR is to propose the marking material for COMPANY’s approval.
ix)
CONTRACTOR shall submit the required Bill of Materials for the replacement WORKS.
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CONTRACTOR shall provide experienced Project Engineer for the WORKS who shall be responsible for providing technical guidance, direction and installation during execution of the PROJECT.
xi)
CONTRACTOR shall provide sufficient manpower during site execution to ensure that the WORKS can be completed within specified windows in year 2015 and 2016.
xii)
CONTRACTOR shall provide Factory Acceptance Test (FAT) and Site Acceptance Test (SAT) procedure for COMPANY’s approval.
xiii)
CONTRACTOR shall provide a GWR specialist to be part of the commissioning team.
xiv)
Any conflicts or differences arising from any omission, error, or misinterpretation by CONTRACTOR shall be rectified by CONTRACTOR in a timely manner, at no cost to COMPANY.
xv)
CONTRACTOR shall provide the final and As-Built detailed drawings/documents, calculations, operating manual and maintenance manual approved by COMPANY for information and records as per the VDRL.
xvi)
CONTRACTOR shall ensure the maintainability criteria, maintenance philosophy and spares requirements are fully considered in the development of the detailed design.
xvii)
CONTRACTOR shall conduct physical and technical surveys to verify all connections to existing facilities are correct.
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xviii) CONTRACTOR shall comply with latest revision of PTS and all the existing Project Specification, as applicable. CONTRACTOR shall be responsible to ensure that all instrumentations are working properly. CONTRACTOR shall prepare detail design WORKS package which consist of but not limited to:
Main specification for design, fabrication, supply, installation testing and
commissioning
Instrument Index with Tagging Numbers.
Wiring Termination Details
Loop Drawing
Hook-up drawings
General Arrangement Drawing
Specification for Guided Wave Radar level transmitters and accessories.
Test Certification And Material with Inspection (i.e. Mill, NDT, etc.)
Inspection and Test Plan (ITP)
FAT / SAT Procedure / Report
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Grounding / Nameplate / Tagging Details
Installation, Modification and Demolition Drawings/Documents
Consolidated Bill of Materials
Other Associated Document/Drawings (Warranty, Certification and etc.)
Master Deliverable List
xxi)
CONTRACTOR shall be responsible for the cabling (if any) and termination for Guided Wave Radar level transmitters.
xxii)
CONTRACTOR shall prepare all installation and demolition drawings required for installation and removal work respectively.
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xxiii) CONTRACTOR shall prepare detail schedule for pre-installation, installation and postinstallation activities and submit to COMPANY for approval. xxiv) CONTRACTOR shall be responsible to provide new documentation or update related AsBuilt drawings and documents for the WORKS. CONTRACTOR shall be responsible to set up a proper project organization consisting of all necessary manpower and shall be approved by COMPANY.
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xxvi) A work progress report shall be submitted to COMPANY on monthly basis during the engineering stage and on daily basis during execution stage, indicating the percentage of work completed, portion of work currently in progress and highlighting any constraints that may exist. xxvii) The CONTRACTOR project management responsibilities shall include but not limited to:
Interfacing with COMPANY and COMPANY’s other contractors working at SITE.
Co-ordination of the design, engineering, manufacturing, assembly, testing and
delivery of the equipment.
Progress control, including co-ordination of progress control meetings, progress
reporting, catch-up plan (if required) and critical path monitoring.
Quality Control.
2.3
Specific Equipment Requirement:
2.3.1
The Guided Radar level transmitters and its associate components shall be off-the-shelve with proven track records. CONTRACTOR shall submit project history record of supply and installation in PETRONAS subsidiaries and other Oil and Gas industries.
2.3.2
The transmitters features and functions shall include but not limited to the following :
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viii) ix) x) xi) xii)
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All transmitters shall be SIL2 certified per IEC 61508, as minimum. All transmitters shall be equipped with integral LCD with user configurable engineering units The transmitter shall be 2-wire with 4-20 mA signals with HART and shall be capable to interface with HART Handheld Communicator. Cable entry to each transmitter shall be provided with Ex certified conduit suitable for bottom entry. All transmitters shall be provided with weather shield. The housing material for the transmitter shall be aluminum (standard). The transmitter shall be painted and coated as per manufacturer standard. However, for safeguarding transmitters housing shall be Red in colour. Accuracy of the overall level instrument shall be +/-10mm or better. Ingress Protection of the transmitter shall be to IP65 of IEC 60529 as a minimum. The power supply for the transmitter shall be loop powered from 4-20mA signal. Tubing and fittings supplied shall be suitable for the process design conditions and shall be 316 Stainless Steel as minimum of Swagelok make, with imperial size. The chamber material, process connection and rating shall be as per existing Displacer level transmitter specification. CONTRACTOR to verify GWR suitability for new chamber for COMPANY approval. Transmitter shall not be affected by radio frequency interference such as Walkie-Talkie, wireless paging system and other power and communication equipment. Transmitters should have built-in filters for immunity to RFI / EMI (as per IEC 61000 and PTS 33.64.10.33). Transmitter shall be equipped with SPD.
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2.3.3
The preferred manufacturer for Guided Radar Level Transmitter is Emerson or Endress + Hauser.
2.3.4
CONTRACTOR shall re-design new chamber process connection, if necessary. The re-design process connection shall be submitted to the COMPANY for approval.
2.3.5
CONTRACTOR shall ensure internal surface of the chamber is smooth during manufacturing to ensure no signal interruption. CONTRACTOR to provide technical data to prove the smoothness of the chamber for COMPANY’s review.
2.3.6
CONTRACTOR shall modify (if required) existing connections and drain point in order for successful installation and commission of the transmitters.
2.3.7
The Guided Wave Radar level transmitter shall be labelled with the following information:
2.3.8
Name and address of manufacturer
Manufactured date
Model and serial number
As a minimum, the Guided Wave Radar level transmitter assembly shall be EEx’ib’ certified,
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suitable for hazardous area classification for respective level instrument location, by an authorized certifying authority (ATEX or equal). Permanent nameplates or labels shall be provided to identify the individual equipment assemblies. In addition, labels should be provided as appropriate to convey operating instructions, warning plates, rating data and other general information.
2.3.10
Name, identification, instruction and warning plates and their fixing materials shall be of durable, corrosion resistant material (stainless steel). They shall be provided with indelible inscriptions in English language. Plates mounted on the outside of the equipment shall be fixed by means of durable self-threading screw or pop rivets.
2.3.11
CONTRACTOR shall provide name plate with engraved equipment tag number on a 316SS plate with 1mm stainless steel wire.
2.3.12
Chamber surface preparation and painting shall be in accordance to PTS 30.48.00.31. The paint system applied shall provide adequate protection against the adverse effects of the climate specified.
2.3.13
Provision of commissioning spares and special tools, if required.
2.3.14
All other additional accessories as required shall be under CONTRACTOR scope of supply. (i.e. steam tracing, insulation, etc.)
2.3.15
CONTRACTOR shall propose detailed WORKS execution plan and numbers of days required together with manpower loading plan in order to perform the execution, as followings;
2.3.16
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2.3.9
Removal, demolition and disposal of existing instrument Installation of new level instrument Wiring and termination Loop check from field instrument up to Control System
CONTRACTOR shall include three (3) training session namely; operation and maintenance training consist of classroom and site training. The number of the participants for the training per session shall be 15 personnel. The training shall be conducted in Malaysia by specialist(s) who must be fully conversant with the offered equipment. Training shall cover basic theory, equipment construction, operating procedures, maintenance and troubleshooting procedures. Training material shall be suitable for maintenance personnel.
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2.4
Preservation, Storage & Transportation
2.4.1
CONTRACTOR shall be responsible for the correct coordination before delivering to SITE. Any cost related to Preservation, Storage and Transportation until site installation shall be borne by the CONTRACTOR.
2.4.2
It shall be ensured that during transport, storage, and installation, cable ends are suitably sealed to avoid ingress of water.
2.4.3
All Handling / Shipping & Delivery to SITE including All Risk Transit Insurance shall be included under CONTRACTOR’s scope of supply.
2.5
Exception to Requirements
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CONTRACTOR is responsible for meeting all the requirements described in this document. Only exceptions specifically agreed and authorized by COMPANY in writing shall be considered accepted and valid.
HEALTH SAFETY & ENVIRONMENT RULES AND REGULATIONS
3.1
General
3.1.1
CONTRACTOR shall provide comprehensive HSES Plan to perform the WORKS in accordance to the requirement of COMPANY’s HSEMS and HSES Plan which is detailed in Section II Exhibit V. The HSES Plan is to be submitted to COMPANY for review and approval prior to commencement of WORKS at site. As a minimum, the HSES Plan shall include the following:
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Organizational structure for HSE management showing clear reporting, communication and interfacing with COMPANY HSES Representative.
Identify required supervisory positions according to the job risk; for site HSES surveillance A schedule of regular meetings to discuss HSE interface matters
iv.
Criteria for selection of SUB‐CONTRACTOR(S) including HSES performance
v.
Strategies/plan to ensure SUB‐CONTRACTORS to meet COMPANY’s HSES standard
vi.
Implementation of PPE program, HSE program (including audit) for this contract scope (including spot checks, inventory)
vii.
Environmental Management Plan which include but not limited to environmental management system, resources (organization), waste, wastewater and hazardous waste management plan.
viii.
Environmental hazards associated with operations including system(s) to be applied to control these hazards
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ix.
All equipment, tools and materials for the contract scope activity are correctly certified, registered, controlled and maintained in a safe working condition.
Requirement for Safety Officer shall be identified based on Scope of Work and if there is a requirement to have a Safety Officer, Safety Officer shall have a valid registration with DOSH.
3.1.3
All CONTRACTOR activities shall be supervised by dedicated Safety Supervisors at SITE throughout the duration of the WORKS.
3.1.4
CONTRACTOR shall comply and prepare Mandatory Control Frame (MCF) checklist and submit to COMPANY for approval. Sample of MCF checklist as per Section II Exhibit V.
3.1.5
All manpower involved in the WORKS shall be required to undergo baseline Medical Examination and urine test prior to and after completion of the job and records shall be submitted to COMPANY doctor for approval. Medical Examination shall be conducted by qualified COMPANY panel doctors.
3.1.6
CONTRACTOR shall adhere to COMPANY HSES Rules and Regulations at all times as per Section II Exhibit V. Non-compliance to the rules and regulation will cause the Contractor’s personnel and the COMPANY to be subjected to disciplinary action.
3.1.7
In addition to safety, CONTRACTOR personnel shall abide to any security rules and other special /in- house rules which may be implemented and issued by COMPANY from time to time.
3.1.8
All CONTRACTOR personnel shall pass OGSP training by NIOSH before attending mandatory HSE briefing/training to be organized by COMPANY HSES Department before being allowed to enter or work inside the Plant premises. CONTRACTOR shall be required to observe the briefing schedule closely. Request for such briefing shall be forwarded via proper request form to the COMPANY Representative and HSE Department three (3) working days in advance. Only personnel who attend HSE Briefing will be provided with Safety Visa to allow entrance inside the Plant.
3.1.9
All CONTRACTOR personnel who are involved to work inside the confined space area shall undergo and pass medical examination to ensure their fitness for work. CONTRACTOR shall provide a copy of the medical certificate as proof for each applicable person prior to Execution period. Only personnel with NIOSH Certificate of Confined Space (AESP Level 1) will be allowed to work inside the area. In addition, those working in confined space entry shall also be familiar and fully trained in handling and using Breathing Apparatus (BA) verified by COMPANY HSES Department. All cost of NIOSH Certification shall be borne by the CONTRACTOR.
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CONTRACTOR shall provide the basic Personal Protective Equipment (PPE) for all personnel which not limited to:
Fire Retardant (NOMEX – IIIA) coveralls
ii.
TYVEX or chemical suits
iii.
Safety helmet (hard-hat)
iv.
Working gloves
v.
Safety shoes (steel toe required)
vi.
Eye protection (safety glasses or goggles suitable for job)
vii.
Full body safety harnesses for working at height with double layard
viii.
Breathing apparatus (include back-up units) – if require based on job requirement
ix.
Full face/half face respirator come with approved type of cartridge for working in confine space.
x.
Dust mask
xi.
Escape respirators (to be approved by COMPANY prior to use)
xii.
Portable (10 minutes) emergency escape set for blasting job.
xiii.
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3.1.10
Vests for standby person and fire watcher
3.1.11
All PPE supplied shall meet standard for use in the refinery as defined and approved by the COMPANY HSE Department.
3.1.12
CONTRACTOR shall to equip its personnel with H2S Escape Respirators to be used during the execution of WORKS at plant SITE. CONTRACTOR shall equip its Safety Officer and Work Supervisor with H2S Gas Badges. CONTRACTOR’s Safety Officer shall be the focal person for weekly calibration of the gas badges and report to COMPANY’s Safety Representative.
3.1.13
CONTRACTOR shall ensure that all the machinery working at COMPANY premises shall be in good working condition complete with safety devices such as spark arrester, reverse alarm, fire extinguisher, etc.
3.1.14
CONTRACTOR shall provide detail work schedule and work procedure complete with Job Safety Analysis (JSA) to COMPANY for review and approval during planning stage. The details of work procedure complete with JSA for each item mentioned in the Scope of Work shall be submitted 4 weeks prior to start of work. CONTRACTOR shall comply all with JSA findings at no additional cost to COMPANY.
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CONTRACTOR shall ensure that all electrical equipment and vehicles have been inspected and approved by COMPANY prior to use for the work. CONTRACTOR shall comply with COMPANY Portable Electrical Equipment and Temporary Electrical Installation (PETI) Standard.
3.1.16
CONTRACTOR shall comply with all PTW requirements and shall commence work after authorization from COMPANY via Permit to Work (PTW) system.
3.1.17
CONTRACTOR shall produce a Safety Performance Report which consists of Contractor Safety Management Program, Weekly Contractor Performance Report and Contractor Safety Performance Report. The safety performance report shall be submitted together with the Execution Report at the conclusion of the WORKS.
3.1.18
CONTRACTOR shall provide standby boat (including qualified and valid helmsman) as per
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3.1.15
safety requirement for working at Jetty (above water level).
Requirement of Scaffolding are as follows:
3.2.1
All works not accessible more than 2 meter from ground level or from elevator platform require proper scaffolding.
3.2.2
Scaffolding shall be provided with safe means of access and it shall be provided with hoist arms or block/tackle for hoisting material or tools when necessary.
3.2.3
Frame type scaffolding are not allowed to be used in COMPANY. All scaffolding material shall be confirmed to BS 1139 and approved by DOSH. Wooden platform are not allowed to be used unless with approval from Area Manager.
3.2.4
All scaffolding shall be inspected and tagged with an approved scaffold tag by competent person before used and re-inspected at weekly intervals during use.
3.2.5
All scaffolds shall be tagged with approved scaffold tag to indicate that they are safe for use. Scaffolding without scaffold tag will not be allowed to be used.
3.2.6
Any scaffold which is modified due to removal of equipment shall be re-inspected and tagged with scaffold tag before reuse.
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3.2.7
Any scaffold not safe for use shall be labelled with a “Not Safe To Use” or they are INCOMPLETE AND NOT SAFE TO USE. Effluent and Emissions
3.3.1
CONTRACTOR shall comply with requirement of local regulations on disposal of all waste during construction.
3.3.2
CONTRACTOR shall control and minimize dust emissions during construction using damping down, wind barriers and other measures as appropriate.
3.3.3
CONTRACTOR shall ensure that the use of asbestos in any form, including gaskets, insulation and fireproofing materials is not permitted in the project.
3.4
Noise
3.4.1
CONTRACTOR shall exercise noise reduction rather than noise control policy to meet the noise emissions criteria in the project equipment and construction machinery selection. Noise control shall only be considered to ensure compliance of noise emissions criteria after all effort on noise reduction had been exercised.
3.4.2
CONTRACTOR shall note the particular requirement for limiting the noise contribution from the project. CONTRACTOR shall ensure current noise level in the plant and at the perimeter fence will not be increased. CONTRACTOR shall note the requirement to specify proposed Hearing Protection Area.
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3.5
Environmental Protection
3.5.1
CONTRACTOR shall protect all existing vegetation surrounding the WORKS, from the effects of its own and its SUB-CONTRACTOR’s construction operations.
3.5.2
CONTRACTOR shall follow all Malaysian Environmental Regulation to abate and avoid noise production and air, water and soil pollution during the execution of the construction WORKS.
3.5.3
CONTRACTOR shall not use asbestos products or product containing asbestos.
3.5.4
CONTRACTOR shall make necessary arrangements for disposal of waste material during construction. The arrangement shall meet the requirements of the local authorities.
3.5.5
CONTRACTOR shall comply with the latest DOSH requirement for any blasting activities using
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GMA Garnet blasting media. All blasting works shall be performed by DOSH approved CONTRACTOR.
Disposal of Construction Waste
3.6.1
CONTRACTOR shall adhere to all Authorities laws and regulations in performing the disposal activities.
3.6.2
CONTRACTOR shall monitor and record all movement of the Disposal activities and shall submit the record to COMPANY upon request.
3.6.3
CONTRACTOR shall segregate and dispose metal and non-metal waste into two separate containers with proper labelling.
3.6.4
CONTRACTOR shall segregate the Scheduled-Waste and Non-Scheduled Waste and to transport the waste to a designated area in plant which to be identified by COMPANY.
3.6.5
Any waste contaminated with chemical, oil, etc. (scheduled waste) such as filter elements, containers, etc., shall be disposed-off as Scheduled waste.
3.6.6
CONTRACTOR shall bear all costs, including royalties, imposed by local authorities for dumping
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of domestic waste. 3.7
House Keeping and Site Cleaning
3.7.1
CONTRACTOR shall ensure its personnel maintain a high standard of safety and hygiene while working at the work SITE. Rest shelters, and site cabins shall always be kept tidy and comfortable for the workers.
3.7.2
At the conclusion of the Execution of work, COMPANY will arrange for a series of joint housekeeping exercise between all CONTRACTOR to perform the overall housekeeping. This housekeeping exercise shall be repeated until COMPANY is satisfied with the condition of the plant.
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3.7.3
CONTRACTOR shall maintain good housekeeping throughout the duration of the WORKS. COMPANY shall stop all on-going work if necessary to facilitate the total housekeeping work.
3.7.4
CONTRACTOR shall ensure that all machinery including cables for welding machines, power tools, lighting etc. are grouped and laid out in a neat and orderly arrangement throughout the WORKS.
3.7.5
CONTRACTOR shall dismantle and remove all temporary wiring, plumbing, etc. and shall dispose-off all waste and scrapped to locations agreed by COMPANY, leaving the SITE in a clean and orderly condition to the satisfaction of COMPANY and local authorities, if applicable. SCHEDULE AND DURATION
4.1
The WORKS is scheduled to be completed within nine (9) months from EFFECTIVE DATE which is the Contract Award Date.
4.2
All WORKS shall be executed on 12-Hour basis during OSTA window.
4.3
CONTRACTOR shall conduct an Interactive Planning Workshop for the Critical Path activities. CONTRACTOR is to make provision for COMPANY to attend this workshop.
4.4
CONTRACTOR shall submit Level 2 Project Schedule within thirty (30) days after the EFFECTIVE DATE and Level 3 Project Schedule with forty-five (45) days of EFFECTIVE DATE with Critical Path Method (CPM). The Project Schedule submitted by CONTRACTOR shall comply with CONTRACTOR’s Proposal Bid Submission and / or as agreed during the TechnoCommercial Meeting.
4.5
Primavera P6, MS Project or equivalent as deemed acceptable to COMPANY during the CONTRACTOR’s bid submission shall be used for the Schedule.
4.6
The schedule minimum shall include all activities and assigned resources (all the phases e.g. planning and execution) as follow: i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii.
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4.0
Kick off Meeting Level 3 Schedule & MDR for AFC Engineering Detail Design Activities for AFC Procurement Activities FAT Equipment Delivered On-Site All Site Preparation Activities Installation / Construction Activities including mobilization and demobilization WCC SAT Pre-Commissioning & Commissioning Ready for Start-up / Handover Project Closure
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CONTRACTOR is required to provide man-power and machinery histogram for all phases of the WORKS.
4.8
CONTRACTOR shall submit Progress Report on weekly basis to update COMPANY on progress of WORKS. CONTRACTOR shall develop catch up plan if there is any delay of WORKS.
4.9
CONTRACTOR shall also provide a two (2) weeks look ahead plan as part of the Progress Report.
4.10
CONTRACTOR shall provide a dedicated full time Project Planner/Project Control during the execution of WORKS. The work progress shall be update routinely minimum on 12-hour basis.
4.11
WORKS shall be completed at the earliest time possible. CONTRACTOR is expected to work during outside normal working hours, weekends and public holidays to meet the limited windows allocated by COMPANY.
4.12
CONTRACTOR shall obtain COMPANY Operation Schedule which to be used for the weekly construction planning.
4.13
Work permit shall be submitted before 4 pm one day before the plan execution day.
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LIAISON WITH OTHER CONTRACTORS
5.1
CONTRACTOR may encounter other contractors assigned by COMPANY engaged for other project working in same location(s)/ area(s). CONTRACTOR shall cooperate fully with the other contractors employed by COMPANY and shall afford reasonable access and facility for the execution of their work.
5.2
CONTRACTOR shall identify the interfacing activities during the planning and execution phase among themselves and define and agree the sequence of activities prior to the execution e.g. crane, scaffolding, integration testing, staging area, and other activities which to be developed during the OSTA communication planning.
5.3
CONTRACTOR shall attend all integrated planning activity conducted by COMPANY as to ensure smooth planning and minimize interfacing between various other contractors.
5.4
CONTRACTOR shall ensure that any part of the SITE which is to be shared with other contractors/Projects is cleaned up and left in reasonable conditions for use by others.
6.0
DESIGN AND ENGINEERING
6.1
General
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5.0
i. ii. iii. iv.
6.1.1
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CONTRACTOR's engineering work shall cover all disciplines and includes, but not limited to the preparation of all necessary documents and drawings, such as data/requisition sheets, Project Specifications, requisitions, instruction and detailed drawings, reports, calculations, within the Scope of Work as required: To ensure a smooth and uninterrupted execution of the project phases, i.e. procurement of materials and equipment, construction, start-up and operation. To fulfill the requirements of the WORKS and COMPANY's instructions. To fulfill the requirements of local law and statutory authorities for granting of permits, inspection and safety. To provide COMPANY's with sufficiently detailed instructions and records of the new facilities to allow safe and efficient operation and maintenance of the WORKS.
CONTRACTOR shall produce and submit Detailed Engineering drawings and Bill of Material for review and approval by COMPANY.
6.1.2
CONTRACTOR engineering works shall include but not limited to: i.
Perform engineering analysis and review for verification of existing installation.
ii.
Produce engineering and documentation inclusive but not limited to engineering calculation, specification and datasheet, layout and schematic drawings, isometrics, and detailed drawings.
iii.
Where applicable, constructability review, drawing content review and clash checking shall be conducted. CONTRACTOR's procedures and planning shall allow for field
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verification of COMPANY issued as-built drawings/mark-up drawings and all activities required for incorporating revised information throughout the CONTRACT period. iv.
CONTRACTOR shall provide inputs to support any modification in accordance to COMPANY Procedures and shall also include review of any Execution Strategy developed for the WORKS.
v.
CONTRACTOR shall produce final as-built drawings incorporating all the changes as part of the Project Close Out.
vi.
Lifting, accessibility and rigging studies as required by the WORKS and/or as directed by COMPANY. Fabrication, demolition & installation drawings.
viii.
Tie in methods.
ix.
Temporary power supply for pre-commissioning and commission activities.
x.
Review electrical and instrumentation support design, electrical and instrumentation cable
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vii.
and tubing tray routing design, review relevant drawings and recommend adjustment due
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to space limitations, review system compatibility in meeting the design and operational intent.
Final design check and revalidation of engineering data provided herein so that the
or
xi.
completeness of WORKS specified shall comply with its functional requirement and its
xii.
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intended purposes.
Temporary work; including special purpose spreader beams and supports during
constructions
xiii.
All necessary corrective measures during fit up and all engineering required for site- run
installation clash checks.
xiv.
6.2
Testing procedures and documentation.
Preparation of Design and Engineering Documents Drafting (2-Dimensional) CONTRACTOR shall confirm the actual condition at SITE prior to drafting works. All 2D drafting, shall be executed on Micro station / AutoCAD.
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6.2.1
Standard Forms In general, CONTRACTOR shall use the latest PSR-1 Rejuvenation Phase1B standard forms, template sheets and title blocks for all documents and drawings prepared for the PROJECT. In a situation where the use of COMPANY's standard procedures and standard forms is not applicable, CONTRACTOR may use its own procedures and forms, subject to prior written agreement from COMPANY.
6.2.2
Symbols on Drawings and Schemes The symbols and identifications to be used on drawings and flow sheets shall be in accordance
6.2.3
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with PSR-1 Rejuvenation Phase1B standards.
Document Numbering & Revisions
Documents and transmittal shall be identified and coded in accordance with PSR-1
6.2.4
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Rejuvenation Phase1B Job Procedure for Numbering System for Technical Documents.
Use of Computer Systems and Electronic Data Handover
or
CONTRACTOR shall use the following COMPANY standards for electronic data: Microsoft Access
Spreadsheet Files
Microsoft Excel
Text Files
Microsoft Word
Drawing
AutoCAD /Microsoft Access Database
Others
To be agreed with COMPANY
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Database Files
In all cases the version of software shall be approved by COMPANY before use, and shall preferably be the latest proven release of software. The software version shall not be changed during project execution unless prior approval has been obtained from COMPANY.
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Review and Approval of Design & Engineering Documents
6.3.1
CONTRACTOR shall submit relevant documents for COMPANY review and approval. This includes statutory authorization, and to satisfy specific requirements as prescribed in the PROJECT.
6.3.2
Approval by COMPANY shall not relieve CONTRACTOR of any of its responsibilities under the CONTRACT to provide safe, operable, reliable and efficient system suitable to meet the design intent and in full compliance with the Project Specification.
6.3.3
CONTRACTOR shall arrange and provide for all engineering approvals, of equipment within the Scope of Work, and must obtain all necessary authority certificates and approvals of documents in time.
6.3.4
The fact that a document may or may not have been commented upon, in no way relieves CONTRACTOR of its liabilities and obligations for the full compliance with the WORKS under the CONTRACT.
6.4
Issue of Release Documents
6.4.1
CONTRACTOR's documents which are ready for subsequent action (i.e. for procurement and for construction) and in which all comments have been incorporated shall be issued marked Approved for Construction (AFC)'.
6.4.2
In cases where significant modifications and/or revisions have to be made on released AFC documents, these documents shall then be re-issued for comments, clearly marked 'Re-Issued for Construction'.
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7.0 7.1
PROCUREMENT General CONTRACTOR shall be responsible for the procurement of materials, equipment and services in order to complete the WORKS unless specified otherwise. All materials, equipment and services supplied by CONTRACTOR shall comply with the relevant specifications and standards.
7.1.2
CONTRACTOR shall perform all procurement and related activities as necessary to complete the WORKS. The procurement function shall inclusive of procurement of material and/or services, packaging and shipping, permitting and licensing, handling and warehousing and all kinds associated with procurement of the material and/or services.
7.1.3
CONTRACTOR shall warrant that all material and/or services supplied shall be new, un-used, fit for the intended purposes and shall conform to the project requirements.
7.1.4
CONTRACTOR shall:
7.1.5
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Comply with applicable laws, and sound business practices. Search the material and/or service sources from trusted financial organizations with proven performance suitable to the requirements of the WORKS. Communicate effectively with Suppliers, the COMPANY, and other Contractors. Ensure that COMPANY’s rights and CONTRACTOR’S obligations shall not be affected by acceptance of bid application letter, subcontracts, or by other bidding activities carried out by CONTRACTOR. Manage procurement processes and deliver goods to meet PROJECT schedule requirements. Develop procurement documents that accurately describe the materials to be bid or the services to be subcontracted and the terms under which such materials or services shall be procured. CONTRACTOR shall provide a copy of Purchase Order format with terms and conditions to COMPANY as reference (upon request only). The Purchase Order structure should cover, at a minimum: 1. Project Supplier identification data. 2. Description of the scope of work and schedule. 3. Technical and Quality requirements. 4. COMPANY has rights to make plant/shop visits for testing, witnessing, and general process verification. 5. Expediting, delivery (logistics and transportation) processes. 6. Reporting requirements.
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CONTRACTOR shall provide a detailed Procurement Plan included in Project Implementation Plan.
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7.2
Sub- Contracting CONTRACTOR shall submit the list of potential subcontract(s) for the WORKS for COMPANY’s approval.
7.2.2
CONTRACTOR shall maximize Malaysian participation and resources a SUB-CONTRACTOR in the execution of the WORKS.
7.2.3
CONTRACTOR shall identify COMPANY from and against any claims from SUBCONTRACTOR arising in connection with CONTRACTOR’s inquiry and/or selection of SUBCONTRACTOR.
7.2.4
COMPANY shall have the right to approve or to reject any proposed SUB-CONTRACTOR by the CONTRACTOR without assigning any reason for the rejection. Any rejection by COMPANY shall not have impact on overall PROJECT schedule.
7.2.5
Sub-Contracting of scope of work that includes engineering, and/or supply of materials, shall be contracted in full recognition of COMPANY’s procedures and requirements. Engineering and Procurement documents shall be distributed accordingly.
7.2.6
CONTRACTOR remains responsible for the quality, capability and performance of the SUBCONTRACTOR. CONTRACTOR shall be responsible for obtaining the best possible guarantees and warranties from all SUB-CONTRACTOR.
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Purchase Orders
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7.3
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7.2.1
CONTRACTOR shall update ‘enquiry’ requisitions to ‘order’ status to include all details agreed with supplier and COMPANY prior to order commitment. If a change in design or specification is made after issue of the Purchase Order, CONTRACTOR shall issue a revised requisition, together with appropriate revised drawings and documents. The revised requisition shall clearly indicate the scope of the revision.
7.3.2
COMPANY shall be shown as consignee for all procurement from outside Malaysia, in order for COMPANY to qualify for tax or import duty exemption from Malaysian Investment Development Authority (MIDA). All material procured by CONTRACTOR shall not include the import duty and tax in the cost.
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7.3.1
COMPANY will be responsible to apply tax exemption. The Purchase Order for all item procured from outside Malaysia shall be placed based on Delivery At Place (DAP). 7.3.3
CONTRACTOR is required to extend one copy of un-priced Purchase Order for every procurement package complete with all attachments and any variations thereto for COMPANY’s review and approval.
7.3.4
The Purchased Order shall include, where appropriate, a statement that the material and services concerned is subjected to inspection by COMPANY or their nominee and that they shall have full access to Vendor shop/ works during all stages of manufacturing and testing.
7.3.5
Purchase Order shall state, by means of the requisition for engineering document, drawings, cross sectional drawings, fabrication drawings, calculation, certificates, data instruction book, operating/ maintenance manual, spare parts list and other documents requirements and submission schedule.
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7.3.6 7.4
CONTRACTOR shall prepare a documented query for any proposal of deviation for COMPANY’s review and approval prior to approval is granted. Sub-Contractor Documents
CONTRACTOR shall be responsible to secure, assemble and distribute to COMPANY the Sub-Contractor documents. CONTRACTOR shall obtain manufacturing drawings and data in sufficient quantities as per project requirement. CONTRACTOR shall include in Procurement Plan, a procedure for control, handling and processing of SUB-CONTRACTOR’s documents.
7.4.2
The Purchase Order or Purchase Requisition shall specify requirement of drawings, calculations, fabrication, inspection and test plans, test procedure, spare parts lists (SPIR) and other documents from the Supplier.
7.4.3
CONTRACTOR shall be responsible for the timely receipt, logging and issuance of all documents for internal review, recording of the approval status and transferal of these documents to and from SUB-CONTRACTOR, CONTRACTOR and COMPANY.
7.4.4
CONTRACTOR shall be responsible for ensuring the drawings received from Supplier in a certified ‘as fabricated’ status and the drawings are revised to ‘As Built’ status after installation stage.
7.4.5
CONTRACTOR shall be responsible to review, comment and correct the Supplier drawings, calculations, quality plan, fabrication, inspection and test plans, and other documents. Markedup copies shall be sent to COMPANY for information/ review. CONTRACTOR shall demonstrate that COMPANY’s comments have been incorporated by the Suppliers.
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7.5.1
CONTRACTOR shall submit a detailed expediting plan as part of the Procurement Plan. The expediting plan shall provide a systematic method of ensuring that material and services are delivered and received. The procedure shall include a procurement tracking system and list of expediting activities with schedule to meet the required delivery.
7.5.2
CONTRACTOR shall provide COMPANY with a copy of Expediting Status Reports on material and services on weekly and monthly basis or as requested by COMPANY. Any deviation from the schedule on any procured items must be reported immediately to COMPANY with explanation for each deviation and proposed remedial action plan.
7.5.3
CONTRACTOR is responsible for the expediting of the above mentioned documents and tracking their status via the Supplier Document Register.
7.5.4
CONTRACTOR shall keep up-to-date records on all visits or contacts with the SUBCONTRACTOR and shall file the same with the appropriate Purchase Order.
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7.6
Inspection and Surveillance CONTRACTOR shall be responsible to provide an inspection and quality assurance program/ procedure to ensure that COMPANY is provided with products that meet the requirements of the project.
7.6.2
CONTRACTOR shall provide Vendor verification program/ procedure for quality of material and services to ensure that COMPANY is provided with product that meet the project requirement. The Vendor verification program/ procedure shall inclusive but not limited to identification of quality surveillance requirements, quality surveillance planning, and processes for surveillance implementation and procedure for controlling of non- conformance.
7.6.3
CONTRACTOR shall carry out a receiving inspection on all procurement item.
7.6.4
CONTRACTOR shall notify COMPANY on the arrival of procured items at CONTRACTOR’s receiving designated point prior to CONTRACTOR’s Material Receiving Inspection. COMPANY shall have the right to carry out inspection on all procured items.
7.6.5
CONTRACTOR shall confirm in writing the material and services conform to the acceptance and testing criteria as per project specification. COMPANY may also carry out an inspection at CONTRACTOR’s Vendor and Sub-Vendor manufacturing facilities and at the time of receiving of the procured items.
CONTRACTOR shall be responsible for coordinating and arranging the forwarding and shipping of procured items both inside and outside Malaysia. CONTRACTOR shall appoint COMPANY’s approved agency for freight forwarding services and inland transportation.
7.7.2
CONTRACTOR shall obtain all necessary insurances from reputable and financially secure companies licensed or incorporated in Malaysia and approved by COMPANY.
7.7.3
CONTRACTOR shall become familiar with the importing and exporting laws of Malaysia.
7.7.4
CONTRACTOR shall become familiar with the requirements of the transportation of procured items to the job site.
7.7.5
CONTRACTOR shall receive, transport and warehouse all procured items in a manner as to prevent damage and to ensure that only new materials are supplied for the project.
7.7.6
CONTRACTOR shall provide, prepare, maintain and re-store all sites and facilities necessary for storage and handling of procured items during shipping and transportation.
7.7.7
CONTRACTOR shall advise COMPANY with a reasonable notification period for all import shipment being planned to enter Malaysia under COMPANY consignee. CONTRACTOR shall also provide COMPANY with all documentation required for materials imported into Malaysia. CONTRACTOR shall inform COMPANY on any changes in shipping program
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7.7.1
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Shipping and Transportation
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7.7.8
CONTRACTOR shall give COMPANY a special notice for the shipping and transportation of engineered materials involving critical lifting.
7.7.9
CONTRACTOR shall submit COMPANY for information a copy of the shipping and transportation procedure.
7.8
Packing and Marking CONTRACTOR shall provide appropriate shipping protection for all procured items to prevent damage and contamination.
7.8.2
All material shall be marked or have tags attached indicating details of the material such as equipment name and quantity, purchase order number, project details, dimensions, gross and net weight, special handling, lifting and storage instruction, country of origin and any other relevant information.
7.8.3
CONTRACTOR shall ensure that each purchase inquiry and Purchase Order and all correspondence, specification, drawings, spare parts information, data on special tools, or other papers pertaining to procurement shall bear specific identification system.
7.8.4
All tags and marking shall be fade resistant and able to withstand extended periods of storage in bright sunlight and other atmospheric conditions prevalent at the job-site.
7.8.5
Any assembly drawings, operating manuals, packing slips, import documents, etc. shall be sealed and securely attached or enclosed with the shipment.
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7.8.1
Custom Clearance and Government Tax Exemption CONTRACTOR shall acquire the necessary licenses from the Government of Malaysia for the import of the procured items into Malaysia.
7.9.2
Custom clearance in Malaysia shall be performed by CONTRACTOR who shall have all the appropriate and necessary permits and approvals from the relevant authorities.
7.9.3
CONTRACTOR shall source all material and equipment locally. If the material and equipment is not available locally, CONTRACTOR may source the material from outside Malaysia and COMPANY will bare all the impose taxes. However, if the tax exemption rejected by MIDA due to the item and equipment is available in Malaysia, CONTRACTOR shall bare all the cost related to import and sale taxes.
7.9.4
CONTRACTOR shall arrange for all import and/ or customs formalities at Port of Entry. The most appropriate/ lowest tariff rate shall be applied and COMPANY reserves the right to check the rates applied.
7.9.5
CONTRACTOR shall also maintain an inventory listing on the status of all imported materials and shall advice COMPANY of any access and of any disposal to be made.
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In order to qualify for tax exemption of import duties and sale tax, COMPANY shall at its own expenses apply for the tax exemption of import duties and taxes to the Malaysia Federal Government Treasury Department on the material to be imported into Malaysia. All credit from import duties and taxes will belong to COMPANY.
7.9.7
CONTRACTOR shall ensure the information contained in the shipping documents and the Custom Declaration Forms and Import Duty Exemption Form are matching.
7.9.8
CONTRACTOR shall be responsible to ensure that the procured items imported under Government Tax Exemption shall be used and stored at job-site only. CONTRACTOR shall not sell, transfer ownership, export or move from job-site the said materials approved by the Malaysia Federal Government Treasury Department through COMPANY.
7.9.9
The importation of material under the Government Tax Exemption shall be made on the required quantity and shall be used for the project only. CONTRACTOR shall advise COMPANY of any surplus and cost of duties and taxes for the surplus shall be the responsibilities of CONTRACTOR.
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7.9.6
7.9.10 CONTRACTOR shall prepare tax exemption documentation and submit to COMPANY within one (1) week after date of Purchase Order to supplier.
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7.9.11 CONTRACTOR shall bear the cost of tax and duty to Customs should the application of tax exemption be rejected by MIDA due to failure of CONTRACTOR to provide correct and complete information as required by MIDA; e.g. wrong declaration of quantity, specification, fail to provide photo and drawing etc.
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7.9.12 In the event of tax exemption yet to be approved, CONTRACTOR shall forward a request to COMPANY for Bank Guarantee (BG) two (2) weeks before the arrival of material/equipment at port. 7.9.13 CONTRACTOR shall be responsible for BG redemption from customs on behalf COMPANY. CONTRACTOR shall update BG status to COMPANY every two (2) weeks.
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7.9.14 CONTRACTOR shall be responsible to hand over all original documents related to customs clearance, tax exemption, MITI, SIRIM and etc.to COMPANY. 7.9.15 CONTRACTOR shall inform COMPANY two (2) weeks in advance for all movement of tax exempted materials / equipment outside COMPANY premises; e.g. movement to fabrication yard etc. 7.9.16 CONTRACTOR shall appoint COMPANY panel forwarding agent i.e. MISC or Kontena Nasional for customs clearance and transportation to COMPANY premise. 7.9.17 CONTRACTOR shall prepare accountability report for Jabatan Kastam Diraja Malaysia (Melaka) to COMPANY progressively. 7.9.18 In the event of COMPANY has to pay tax and duty in advance of MIDA tax exemption approval, CONTRACTOR shall be responsible to liaise with Jabatan Kastam Diraja Malaysia (JKDM) for tax and duty reimbursement claim on behalf of COMPANY, upon approval of tax exemption from MIDA.
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7.9.19 CONTRACTOR shall be responsible to arrange for material inspection by SIRIM or authorized third party as part of JKDM requirement for imported material (e.g. pipe, steel plate etc.). All cost related to the requirement shall be borne by CONTRACTOR. 7.10
Procurement Status Report
7.10.1 CONTRACTOR shall issue a copy of Procurement Status Report periodically to COMPANY which include for each Purchase Order. 7.11
Material Control
7.11.1 CONTRACTOR shall be responsible for the control of procured items,
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7.11.2 CONTRACTOR shall submit to COMPANY a copy of Material Control Procedure to describe in detail control functions which shall inclusive but not limited to receiving of shipment, inventory control, issuing of material, return of surplus, warehousing, etc. 7.11.3 CONTRACTOR shall at all-time maintain records detailing the material that have been received, stored, or issued for construction and shall make such records available to COMPANY upon request by COMPANY. Procurement Close Out
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7.12
Purchase Order and any amendments thereto Purchase Requisition Import, Packing and Shipping Documents Catalogues and specification Manufacturer Routine Test Report Type Test Certificate for equipment & associate components. Final Acceptance Testing Reports/ Mill Certificates, and Any other specific procurement documentation as requested by COMPANY.
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1. 2. 3. 4. 5. 6. 7. 8.
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7.12.1 CONTRACTOR shall transfer to COMPANY copy of all files relating to procurement of each item upon completion of procurement activities. The file shall contain, but not limited to:
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FABRICATION AND CONSTRUCTION
8.1
General
8.1.1
CONTRACTOR shall be responsible for all works related to the Construction of the PROJECT as described in the Scope of Work, Project Specification, PTS and proven accepted practices and procedures. The construction work shall be performed in safely manner, reliable and suitable for their intended purpose.
8.1.2
CONTRACTOR shall strictly comply with the HSE requirement as stipulated by COMPANY. CONTRACTOR shall take utmost precautions on all safety aspects in coordinating, performing and completing the construction work within and adjacent to live Plant(s).
8.1.3
CONTRACTOR shall provide all supervision, labour, construction equipment, tools and tackles, materials and consumable, temporary facilities, construction utilities such as power, nitrogen, air, water, etc., and render all support services necessary for the Construction activities.
8.1.4
CONTRACTOR is deemed to have full knowledge of all applicable laws and regulation, conditions of labour, local condition, site conditions and environmental aspects and shall comply with the requirements thereof.
8.2
Construction Execution Plan
8.2.1
CONTRACTOR shall produce a Construction Execution Plan (CEP) prior to commence the construction and submit to COMPANY for approval. The CEP shall identify the key critical construction strategies and key issues that will require detailed risk assessment and constructability review.
8.2.2
Construction Execution Plan shall include but not limited to the following: i) ii) iii)
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8.0
CONTRACTOR's manpower and man-hours histogram by major section and by discipline. Major Construction Equipment mobilization plan on monthly basis with short description CONTRACTOR’s plan and procedures to be submitted prior to start of the activities (Job Method Statement etc.). The plan and procedures shall inclusive but limited to heavy transport and lifting, prefabrication plan, tie-in plan, work plan during shutdown, regulatory and local agencies permitting procedure and approval plan etc.
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CONTRACTOR shall establish a site management organization with sufficient responsibility and authority for all activities up to Work Completion.
8.2.4
CONTRACTOR shall appoint one full time Construction Manager responsible for all its Construction activities. The Construction Manager shall always be contactable at all times.
8.2.5
CONTRACTOR’s site Management Organization shall be established with reference to COMPANY’s site Organization to facilitate communication and work arrangement as best as reasonably practical. CONTRACTOR shall provide and submit to COMPANY for approval, a detailed Organization chart of its proposed site Organization, including names, roles and responsibilities, terms of reference for the various job functions and their respective reporting relationships.
8.2.6
CONTRACTOR shall ensure that the numbers of its skilled Construction Supervisory Personnel are adequate to ensure effective direct control and coordination of all construction activities of both its and its SUB-CONTRACTOR, and are present on SITE at all times throughout the PROJECT. COMPANY reserves the right to instruct CONTRACTOR to increase the levels of its and/ or its SUB-CONTRACTOR’s Supervisory Personnel, at CONTRACTOR’s cost, in the event that safety, quality or progress of the WORKS warrants such action to be taken.
8.2.7
CONTRACTOR shall ensure its site management team is available on SITE at all times including adequate and experienced engineering personnel from each discipline for a prompt response in resolving all engineering issues arising on SITE during the Construction period up to Work Completion.
8.2.8
CONTRACTOR shall be responsible for the direct management of all its SUB-CONTRACTOR activities at SITE, in particular for ensuring their construction progress and the quality of the work performed by them as per Project Specification. CONTRACTOR shall follow operational constraints, which may arise from time to time due to actual conditions in the plant. COMPANY reserves the right to attend any meetings held between CONTRACTOR and its SUBCONTRACTOR.
8.3
Construction Schedule
8.3.1
CONTRACTOR shall prepare a detailed Construction Schedule. CONTRACTOR shall control the schedule of the construction work at SITE. CONTRACTOR shall ensure that the Project Execution Schedule and other Project Planning and Control Tools are sufficient to control the activities and resources during the Construction.
8.3.2
CONTRACTOR shall consider preparing a detailed Construction schedule in order to meet the given OSTA window.
8.3.3
CONTRACTOR shall monitor the progress and delayed area, analyzed the reason of the delay and forecast the influence of such delay. CONTRACTOR shall be responsible to take effective counter measure immediately to recover the time delay, upon endorsement by COMPANY.
8.3.4
CONTRACTOR shall obtain COMPANY’s approval to work any hours outside normal working hour and shall identify safety and supervisory personnel required to control such work.
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8.2.3
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CONTRACTOR shall also identify any requirements for COMPANY personnel to support and inspect / witness the work during such working hours. Construction Personnel
8.4.1
CONTRACTOR shall provide all necessary management personnel, labour and SUBCONTRACTOR in adequate numbers in order to execute the WORKS in accordance with this ITB. CONTRACTOR shall submit list of name of its and its SUB-CONTRACTOR’s personnel including workers/labour to COMPANY at least two (2) months in advance prior to SITE entry for screening purpose.
8.4.2
COMPANY shall have the right to assess and accept any CONTRACTOR’s personnel/workers and its SUB-CONTRACTOR’s personnel/workers before engagement for works, and to refuse without explanation, any particular person permission to enter or to perform work on SITE. COMPANY shall have the right to exclude from SITE any person(s) who infringe Malaysian laws or the regulations in forced.
8.4.3
Persons failing qualifications of conduct and/or ability in the opinion of COMPANY shall be immediately removed from the PROJECT and repatriated (if expatriates). CONTRACTOR is not entitled to COMPANY’s reasons in this instance. CONTRACTOR shall make provision for the timely and adequate replacement of all such personnel.
8.4.4
CONTRACTOR’s and its SUB-CONTRACTOR’s personnel, both technical and direct labour, shall have all the required technical skills and qualifications required for the performance of the work to which they are assigned and shall have in their possession all needed licenses and certificates needed to substantiate this. COMPANY reserves the right to conduct technical interviews with any personnel presented to COMPANY for their acceptance.
8.4.5
Once CONTRACTOR personnel and its SUB-CONTRACTOR’s key personnel have been accepted by COMPANY, they shall not be removed / replaced unless alternative persons, accepted by COMPANY, are made available on SITE, allowing at least one (1) week overlapping for both personnel for task handing-over process.
8.4.6
CONTRACTOR’s and SUB-CONTRACTOR’s supervisory personnel and Supplier Representatives shall be fully conversant with Bahasa Melayu and/or English language, both written and spoken.
8.4.7
CONTRACTOR and its SUB-CONTRACTOR shall maintain complete personnel records on all persons employed on SITE.
8.4.8
Visas, Work Permits, Rules, Licenses and Notices.
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8.4
a)
CONTRACTOR shall make timely arrangements, and be responsible for the necessary passports, Malaysian visas and work permits for any expatriates personnel and labour to be employed by it and its SUB-CONTRACTOR. CONTRACTOR shall keep accurate and updated personnel registration and administration and keep COMPANY informed of any new intake or whenever requested.
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b)
CONTRACTOR shall ensure that all expatriate person(s) to be employed on SITE are registered with relevant government agencies prior work on SITE.
c)
CONTRACTOR shall obtain all permits and licenses and bear all fees necessary as required by law for the proper execution of WORKS. A copy of each permit or license shall be submitted to COMPANY for acknowledgement and record keeping.
8.4.11
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CONTRACTOR shall ensure that all expatriate person(s) to be employed on SITE are registered with relevant government agencies prior work on SITE.
CONTRACTOR shall obtain all permits and licenses and bear all fees necessary as required by law for the proper execution of the WORKS. A copy of each permit or license shall be submitted to COMPANY for acknowledgement and record keeping.
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CONTRACTOR shall arrange all relevant site induction, training of labour to perform the WORKS in accordance with applicable codes, supervision of trade qualification tests, and maintenance of test records. Personnel Transportation
CONTRACTOR shall provide all the necessary transport for its and its SUBCONTRACTOR’s personnel to/from and within SITE at all times.
Access for CONTRACTOR’s vehicles to the SITE shall be strictly limited and shall require an Entry Permit issued by COMPANY’s security department. Private vehicles shall not be permitted in the Plant. CONTRACTOR shall designate its vehicles, subject to COMPANY’s approval, necessary for transportation and construction purposes for Plant entry. Prior to Plant entry, all vehicles shall be fitted with a spark arrestor and be subjected to inspection by COMPANY.
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8.4.10
CONTRACTOR shall make timely arrangements, and be responsible for the necessary passports, Malaysian visas and work permits for any expatriates personnel and labour to be employed by it and its SUB-CONTRACTOR. CONTRACTOR shall keep accurate and updated personnel registration and administration and keep COMPANY informed of any new intake or whenever requested.
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Construction Tool and Machinery/ Equipment
8.5.1
All CONTRACTORS’s tools and equipment shall be fit for purpose, and maintained in a safe working condition. Guards and electrical trip switches must work effectively and must not be removed or bypassed. Any substandard tools are strictly prohibited.
8.5.2
CONTRACTOR shall provide all tools and machinery necessary for the effective execution of the WORKS. All construction equipment intended for use on SITE shall conform to COMPANY’s requirements.
8.5.3
CONTRACTOR shall carry out scheduled inspection and testing of construction machinery in accordance with relevant local authority’s safety regulation or manufacturer requirements, as a minimum. CONTRACTOR shall keep records of these inspections and make available to COMPANY whenever requested.
8.5.4
CONTRACTOR shall not allow the use of any machinery, which is unsafe or unsuitable for any specific task. COMPANY shall have the right to stop any work if found using any machinery deemed unsafe or incapable of performing the work to the required standard. Such machinery shall be replaced immediately by CONTRACTOR and no schedule or cost impact can be claimed by CONTRACTOR.
8.5.5
CONTRACTOR shall provide machinery servicing and repair facilities and a stock of spare parts and consumables at SITE, to minimize down-time in case of any machinery breakdown.
8.6
Risk Assessment and Method of Statement
8.6.1
CONTRACTOR shall carry out a full Risk Assessments with regards to all its Construction activities on SITE. This activity is expected to be at least one (1) month before site execution activities are expected to begin.
8.6.2
Risk Assessment methodology shall be used to identify and assess Health, Safety and Environmental hazards during Construction and pre-commissioning and commissioning phases. These hazards may be identified at any stage of the project; e.g. COMPANY data, existing drawings, site survey investigations, design and Constructability reviews, or information that may emerge during the work execution.
8.6.3
The risk assessment shall characterize the risk in terms of severity and probability. The risk assessment shall be the platform for development of method statement and shall be guideline for eliminating or minimized the risk to an acceptable level.
8.6.4
CONTRACTOR shall prepare detailed Method of Statements for all works which has risks to HSE as determined by Risk Assessment. The method of statement shall describe the work procedures, sequence of operation and the controls necessary to achieve effective management of risk, and efficient execution of WORKS. Detailed Method Statements shall be prepared for all critical tasks.
8.6.5
Method statements shall be submitted to COMPANY at least one (1) week prior to the anticipated commencement of the work. The method statement shall be reviewed by COMPANY.
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8.5
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Audits of method statements shall be carried out by the CONTRACTOR’s Safety Management Team. Tie-In and Shutdown Works
8.7.1
CONTRACTOR scope shall include tie-in works which need to be undertaken during normal operation as well as during plant shutdown. CONTRACTOR shall develop Tie-in Plans and Method Statement for all tie-in work.
8.7.2
CONTRACTOR shall ensure that the tie-in work are thoroughly planned well ahead of the construction phase and shall, discuss and plan with COMPANY the necessary tie-in activities to the existing plants. CONTRACTOR shall maximize installation of tie-ins during normal operation to minimize the shutdown workload.
8.7.3
CONTRACTOR shall plan and identify all works requiring shutdown especially the tie-in work. CONTRACTOR shall ensure that the tie-in work are thoroughly planned well ahead of the construction phase and shall, discuss and plan with COMPANY the necessary tie-in activities to the existing plants.
8.7.4
CONTRACTOR shall complete the tie-in work timely as planned. The plan shall identify the tie-in category with a time schedule. CONTRACTOR shall ensure minimum interference with the existing plant and operating facilities.
8.7.5
CONTRACTOR shall discuss with COMPANY on isolation plan etc. prior to execution of the WORKS.
8.7.6
CONTRACTOR shall submit the energization procedure to COMPANY at least three (3) weeks prior to the replacement scope.
8.7.7
CONTRACTOR shall be responsible to supply and provide all necessary materials, consumable, manpower and tools etc. to execute all tie-in activities. CONTRACTOR shall report directly to and working under the directive of COMPANY’s Plant Operation Personnel during tie-in activities until the completion and normalizing of the affected systems.
8.7.8
CONTRACTOR shall consider maximize pre-assembly of items, as practicable. The split of the work scope between the shop and work SITE shall be fully detailed in the method statements provided in the CONTRACTOR’s Execution Plan.
8.7.9
CONTRACTOR shall take note that COMPANY may not be able to shutdown the process unit for installation and tie in works. In the event COMPANY is not able to shutdown the process, CONTRACTOR shall execute the tie-in work(s) via “hot-tapping/live-tapping” method. For such case CONTRACTOR shall be responsible to prepare Job Safety Analysis (JSA) and obtained the approval from COMPANY’s designated approver.
8.7.10
All tie-In work shall be performed in accordance with relevant codes and standards and Project Specification.
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8.7
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Scaffolding
8.8.1
CONTRACTOR shall ensure that all personnel associated with erection, alteration, modification, dismantling and supervision activities must have attended the appropriate training skill and accreditation by approved body.
8.8.2
CONTRACTOR inspection personnel shall conduct all necessary inspection prior to commencement of any scaffolding erection. Proper signage shall be displayed prominently and affected areas shall be barricaded.
8.8.3
All scaffolding erection shall only be used upon authorization by responsible personnel the erected scaffolding shall be green tagged.
8.9
Protection of Plant Facilities
8.9.1
CONTRACTOR is responsible to ensure no damage to existing equipment and plant facilities during WORKS execution. CONTRACTOR shall employ all suitable means of protection to avoid any damage to the existing plant asset.
8.9.2
CONTRACTOR shall report to COMPANY any property damage or near misses.
8.9.3
CONTRACTOR shall repair and/ or replace all damaged asset at no cost to COMPANY within stipulated time, unless otherwise specified.
8.10
De-Commissioning
8.10.1
CONTRACTOR shall be responsible for the equipment isolation, de-isolation in preparation for the decommissioning work.
8.10.2
CONTRACTOR shall conduct risk assessment to assist with hazard identification and risk control identification prior to the decommissioning work.
8.10.3
CONTRACTOR shall perform site audit to identify/anticipate potential hazards during decommissioning operation. CONTRACTOR shall be responsible to develop hazardous material removal plan before commissioning from the activities.
8.10.4
CONTRACTOR shall conduct the demolition phase with supervisory by COMPANY representative.
8.10.5
CONTRACTOR shall be responsible to dismantle the equipment into its component parts. The parts has to be secured and with proper packaging for transportation to the storage area.
8.10.6
CONTRACTOR shall discuss with COMPANY on the dismantling and disposal/storage requirement of the de-commissioned equipment.
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9.0
QUALITY CONTROL AND ASSURANCE
9.1
General
9.1.1
CONTRACTOR shall develop and implement relevant QA program for all activities involved in the project to ensure quality planning and the quality control throughout the project implementation. The QA activities shall be incorporated into Scope of Works of the project and are scheduled and monitored through the Project Quality Plan. The applicable QA programmes all inclusive but not limited to: Quality Assurance Program for Project Management
b.
Quality Assurance Program for Engineering and Design
c.
Quality Assurance Program for Procurement
d.
Quality Assurance Program for Construction
e.
Quality Assurance Program for Commissioning
f.
Quality Assurance Program for Project Closed Out and Turnover
a.
Quality Assurance for Project Management
A project control plan that serve as an overall project implementation document that describe the organisation, define specific roles and responsibilities, prescribe delegation of technical and commercial authorities, provide a schedule for reviews and specify participation in such activities.
The procedure shall covers as a minimum the establishment of Project Quality Plan, Design Contractor Quality Plan, Supplier Quality Plan, and Construction Contractor Quality Plan.
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b.
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a.
Quality Assurance for Engineering and Design The QA program for development of engineering and design specifications shall provide guideline for implementation of quality assurance activities such that the development are being properly monitored and controlled and the adequacy of the design is verified before being implemented.
The program shall be inclusive but not limited to specification control, interface control, engineering/design change controls, design reviews including constructability reviews, design verification and approval, reliability, operability and maintainability engineering.
c.
Quality Assurance for Procurement
The QA program for Procurement function shall provide guideline for implementation of quality assurance activities during the performance of procurement of equipment, materials and/ or services to ensure compliance with project standards and specification.
The QA activities shall be inclusive but not limited to development of specification, selection of Supplier or Contractor, quality plan, COMPANY’s involvement, vendor’s performance monitoring, quality audits and reviews, control of deviations and
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concessions, control of standard and document verification and approval, materials control, quality control, inspection requirements and shipment/delivery requirements. The program shall applicable to procurement of new equipment and replacement equipment and materials and it activities covers design, fabrication and shipment and delivery of the equipment and/or materials to the work SITE.
d.
Quality Assurance for Construction
The QA program for construction stages shall provide guideline for implementation of quality assurance activities during the construction and installation to ensure compliance with design specifications and the equipment are installed in accordance with manufacturer’s instructions.
The QA activities shall inclusive but limited selection of Construction Contractor, Construction equipment and material control, Document control, Pre-Fabrication and construction control, Handover control of completed works
The program shall applicable for all construction stages inclusive pre-fabrication, erection and installation of new facilities, installation of new equipment removal and re-installation of existing equipment and any other construction or installation works implemented for the project.
e.
Quality Assurance for Commissioning and Decommissioning
The QA program for Commissioning and De-Commissioning shall provide guideline to assure the facilities and/or equipment are commissioned or de-commissioned properly, without risk to the safety of personnel or environment and minimal disruption to the operation of existing facilities with any necessary changes having been suitably authorized and recorded, and the facilities or equipment are safely handed over to COMPANY
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De-commissioning of process equipment applies to physically and permanently taken the process equipment out of service, removed from the facility and will not be returned to service. Quality Assurance for Project Close Out and Turnover The QA program for Project Close-Out and Turnover shall provide guideline for a proper project close out and turnover after the completion of the project. The QA activities shall inclusive but limited to development of lessons learned, contract close-out, document and records turnover, post-implementation review and close-out report.
9.1.2
CONTRACTOR shall operate a quality system satisfying the applicable provision of ISO 9000 or BS 5750 (series), or agreed equivalent, commensurate with the goods and services provided.
9.1.3
COMPANY reserves the right to carry out Quality and Technical Review at CONTRACTOR’s works including review of quality documentation.
9.1.4
CONTRACTOR shall be responsible at all times provide dedicated competent and qualified personnel approved by COMPANY.
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9.1.5
Where CONTRACTOR subcontracts the whole or main parts of the WORKS or materials, then these requirements shall be applied in full to SUB-CONTRACTOR.
9.1.6
Control of CONTRACTOR and SUB-CONTRACTOR shall encompass measures to verify that progress and quality requirements are met. Surveillance/audit of SUB-CONTRACTOR shall be performed by CONTRACTOR as necessary.
9.2
Quality Surveillance
9.3
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COMPANY may perform quality audits, technical reviews, test witnesses and inspections at source in order to verify compliance with the CONTRACT requirements. CONTRACTOR shall provide free access to COMPANY and co-operate with COMPANY in the performance of all testing, witnessing and audits.
Audits/Reviews
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COMPANY reserves the right to audit at source at any time during the duration of the CONTRACT and will give two (2) weeks’ notice. CONTRACTOR shall undertake to close out any findings raised as part of such an audit.
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CONTRACTOR shall co-operate in the provision of information and the supply of all necessary CONTRACTOR personnel to allow COMPANY or their delegated authority to perform a meaningful audit/review.
9.4
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The results of any internal audits/reviews conducted by CONTRACTOR shall be documented and made available to COMPANY within one (1) week after completion of CONTRACTOR audit/review.
Non-conformity and Corrective Action
CONTRACTOR shall notify COMPANY immediately when a non-conforming WORKS is identified which requires repair, rework, replacement or a concession. COMPANY will review the non-conformance and either agrees with CONTRACTOR's proposed repair procedure or agree with a concession or reject the WORKS. Non-conformities and proposed corrective actions shall be properly and systematically documented for COMPANY's appraisal/approval. CONTRACTOR shall implement corrective action plans as soon as possible.
9.5
Preventing Action Preventing action/mitigation action shall be proactively initiated against for all non-conformities shall be detected from various sources of works execution.
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INSPECTION, TESTING AND COMMISSIONING
10.1
General
10.1.1
CONTRACTOR shall develop detailed Inspection and Testing Plan for all activities, which includes acceptance criteria for each activities and submit for COMPANY’s approval prior to procurement. This Inspection and Testing Plan shall be in accordance to PTS 63.10.08.11.
10.1.2
CONTRACTOR shall conduct FAT & SAT for all relevant equipment. CONTRACTOR shall notify COMPANY at least two (2) weeks before the test for COMPANY to assign the relevant personnel. COMPANY has the right to witness the test.
10.1.3
CONTRACTOR shall prepare proper documentation such as datasheets, specifications and forms to be used during testing. Copies of the documents shall be made available to COMPANY.
10.1.4
CONTRACTOR shall provide reports of all necessary inspection/tests in accordance with statutory requirements, insurance party and the project requirements. These reports shall be in a form meeting the requirements of such other parties or government agencies, as applicable.
10.1.5
COMPANY may appoint a Third Party Inspection Agency (TPIA) services for the equipment inspection. TPIA/COMPANY shall have free access to the CONTRACTOR’s and his SUBCONTRACTOR’s work SITE during execution of the WORKS. CONTRACTOR shall extend the Inspector in all the possible assistance to witness the tests and to satisfy himself that the materials furnished in accordance with specification and relevant documents and that workmanship is satisfactory in every aspect. Inspection by COMPANY or his Inspector will in no way relieve CONTRACTOR of any of his responsibilities for ensuring that the system supplied meets all the requirements of this document and its attachments.
10.1.6
CONTRACTOR shall maintain acceptance/rejection forms for all types of inspection and testing, as specified. These documents shall contain all details as required by the code including details such as item number, quantity, specification, date of inspection, type of inspection, result, third party inspection, certificate etc.
10.1.7
All inspection and acceptance tests shall be carried out on the equipment at CONTRACTOR’s works and may be witnessed by COMPANY. Inspection by COMPANY or his representatives shall in no way relieve CONTRACTOR of any of his responsibilities for ensuring that the system / equipment meets all the requirements and conforms in full to the contents of Scope of Work.
10.1.8
CONTRACTOR shall give COMPANY or his representatives, without charge, all facilities and access evidences for satisfying himself that the equipment is being manufactured in accordance with the relevant datasheets, sketches, codes and standards.
10.1.9
Any manufactured part, which does not comply with the requirements, or material which shows defects during inspection will be rejected. When a part of the unit is rejected, CONTRACTOR shall be notified in writing. If any rectification work is required to be done, it shall be carried out by CONTRACTOR at his own expense and without delay to the WORKS.
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10.0
10.1.10 CONTRACTOR shall prepare complete inspection and report within one (1) week after the event for COMPANY’s review. PHASE 1B PSR-1 REJUVENATION PROJECT
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10.1.11 The required inspections are shown in the following table as minimum: NO.
DESCRIPTION
COMPANY
Manufacturing Progress Inspection as per request
Yes
2
Factory Acceptance Test Procedure Review
Yes
3
Factory Acceptance Test
Yes
4
Factory Acceptance Test - Punch List Inspection
Yes
5
Site Delivery Inspection
6
Site Acceptance Test Procedure Review
Yes
7
Site Acceptance Test
Yes
8
Site Acceptance Test - Punch List Inspection
9
System Performance Test and Reliability Test
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Commissioning
Yes
Yes Yes Yes
10.2
Factory Acceptance Test (FAT)
10.2.1
CONTRACTOR shall ensure the equipment’s are ready for testing complete with tools, temporary facilities and consumables necessary for the tests.
10.2.2
CONTRACTOR shall ensure the personnel responsible to conduct testing is competent readily available and able to brief all relevant personnel before commencement of the tests.
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For FAT that to be conducted outside of Malaysia, CONTRACTOR shall assign its relevant personnel and allocate minimum two (2) seats for attendance by COMPANY’s personnel. Travelling and lodging cost for COMPANY’s personnel shall be borne by COMPANY. The notification of the test shall be done at least three (3) weeks before the test.
10.2.4
Apart from visual and mechanical testing, functional testing shall include the simulation of each input and output to verify proper system response for analogue and digital signals as a minimum.
10.3
Site Acceptance Test (SAT)
10.3.1
CONTRACTOR shall carry out all site inspections and tests necessary to comply with Project Specification and to satisfy the requirements to achieve Ready For Start-Up (RFSU).
10.3.2
CONTRACTOR shall inform COMPANY at least two (2) working days in advance before any site testing and inspection due to commence. CONTRACTOR shall provide the necessary testing, measuring and calibration facilities and tools prior to any inspection and testing.
10.3.3
CONTRACTOR shall provide proof of proper Construction, with routine checks on the quality of the WORKS, is in accordance with the Project Specification. If during testing the WORKS is deemed to be unsatisfactory, CONTRACTOR shall remedy the defects immediately at its own cost. COMPANY will consider no schedule impact.
10.3.4
COMPANY reserves the right to request, at no cost, any additional tests/inspections during construction by giving notice in writing to CONTRACTOR, who shall carry out the test/inspections including the preparatory/restoring works, to prove the WORKS has been satisfactorily executed.
10.3.5
COMPANY shall be allowed access to inspect all underground WORKS installations prior to backfill. Any backfills performed prior to such inspection, CONTRACTOR shall re-excavate to allow inspection to be carried out.
10.3.6
CONTRACTOR shall provide CONTRACTOR specialist to supervise final adjustments and to inspect and advise during testing, starting-up and running-in, of the equipment installed.
10.3.7
In addition CONTRACTOR’s representatives shall be present during installation, final adjustments, testing, running-in, starting-up and initial operation of equipment, in accordance with purchase agreement.
10.3.8
CONTRACTOR’s site inspections shall take in account of any local authorities (e.g. DOSH, DOE), insurance or third party inspection requirements.
10.4
Testing Certificates
10.4.1
Records of all calibrations, testing and conformity checks shall be provided by the CONTRACTOR. The testing certificates shall be made available by the CONTRACTOR and approved by COMPANY prior to commissioning. The procedure for site testing and witnessing shall be agreed in writing by the COMPANY prior to commencement of WORKS.
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10.2.3
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Site Inspection of Electrical & Instrument Works
10.5.1
Site Installation, Inspection and Testing of Instruments shall be in strict accordance with the PSR-1 Project Specification and relevant Instrument Standards and Codes.
10.5.2
All test and calibration equipment shall be certified and tested by Standard Industrial Research Institute of Malaysia (SIRIM) or any third party accredited by SIRIM and shall be approved by COMPANY.
10.5.3
CONTRACTOR shall supply all necessary calibrated testing equipment and instruments.
10.5.4
All test results shall be recorded in an agreed format with the COMPANY’s Construction Team. Certified copies (signed by a competent person approved by COMPANY’s Construction Team) of the record shall be forwarded to the COMPANY’s.
10.5.5
COMPANY’s Construction Team shall witness all instrument loop functional tests.
11.0
DOCUMENTATION
11.1
General
11.1.1
CONTRACTOR’s responsibilities for documentation required as minimum, are outlined in this section. The documents listed are intended to inform CONTRACTOR as to the level of documentation submittal required. Specific document requirements shall be as specified by COMPANY and these requirements will evolve over the course of the project. CONTRACTOR shall submit Master Document List (MDL) for COMPANY review and approval.
11.1.2
All documentation shall be in English language hardcopy and electronic media.
11.1.3
CONTRACTOR shall furnish documents in native file where applicable upon request by COMPANY.
11.1.4
CONTRACTOR shall be responsible to update and supersede existing documents from the original plant design book. This activity shall be clearly supervised by COMPANY personnel.
11.1.5
CONTRACTOR shall furnish documents/drawings that are of suitable first generation quality. Drawings that are not, in COMPANY's opinion, of suitable quality will be returned to CONTRACTOR for re-submission or at COMPANY's option may be redrafted by COMPANY or his representatives to CONTRACTOR's account.
11.1.6
CONTRACTOR will be held liable for all COMPANY costs resulting from errors in CONTRACTOR's certified prints. CONTRACTOR is cautioned against submitting certified drawings and data, which have not been checked.
11.1.7
CONTRACTOR’s responsibilities for documentation required as minimum, are outline in this section.
11.1.8
Approval by COMPANY shall not relieve CONTRACTOR of any of its responsibilities under the CONTRACT to provide safe, operable, reliable and efficient system suitable to meet the design intent and in full compliance with the Project Specification.
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10.5
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11.2
Design Books CONTRACTOR shall provide Design Books which shall contain reference information for the design and engineering of project and all other parts of the WORKS. The Design Books shall reflect the WORKS ‘As-Built’ and contain equipment information ‘As-Built’.
11.3
Operating Manual CONTRACTOR shall provide Operating Manuals, which shall contain the necessary data and information to operate the equipment.
11.4
QA/QC Manuals
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CONTRACTOR shall provide QA/QC Manuals, which shall contain the necessary data and information of quality control, inspection test plan (ITP), etc. .
11.5
Supplier Data Books / Manufacturing Data Records
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CONTRACTOR shall provide Supplier’s Data Books / Manufacturing Data Records for all purchased equipment and bulk materials including, but not limited to, Supplier Installation, Operation a nd Maintenance Manual, Vendor Drawings, Bill of Material, Mill Certificate, NDT Certificate, Performance and Test Data, Factory Acceptance Test Report (FAT), Type Test Certificate, Explosion Proof Certificate, any International Body Certification, Local Authorities/Statutory Approval, etc. Construction Data Report
11.6.1
CONTRACTOR shall provide record of Job Method Statement (JMS), Job Safety Analysis (JSA), test procedure, inspection test record, SAT, calibration records, progress reports, construction drawings, shop drawings, etc.
11.6.2
CONTRACTOR shall submit Work Completion report upon completion of WORKS for COMPANY’s approval.
11.6.3
After completion of the works, all drawings and specifications related to the WORKS shall be updated and ‘As-Built’ according to the actual WORKS done at SITE.
11.6.4
COMPANY has made a diligent effort to ensure the accuracy of drawings and documents. However, it shall be the responsibility of the CONTRACTOR to verify and confirm the accuracy of the drawings and documents to ensure satisfactory execution of the WORKS.
11.7
Commissioning Manuals
11.7.1
CONTRACTOR shall provide a Commissioning Manual for all equipment, which shall contain the schedules and procedures for all Commissioning activities.
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Commissioning Data Report
11.8.1
CONTRACTOR shall provide a Commissioning Data Report for all equipment, which shall contain Commissioning Record and Performance Test Record for all Commissioning activities.
11.9
Spare Parts and Interchangeability Record (SPIR)
11.9.1
CONTRACTOR submission of spare parts list shall be in two (2) copies of the completed SPIR form in accordance with PTS 70.10.90.11, Appendix 1, Guide to Completion of the Spare Parts List and interchangeability Record – SPIR.
11.9.2
CONTRACTOR shall complete all the relevant records as required, such as material specification, dimension, sizes etc. Completed SPIR forms shall be submitted to COMPANY three (3) months after the issuance of purchase order of the respective equipment and material.
11.10
Two (2) Years Operational Spare Parts List
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Final Electronic Record
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11.10.1 CONTRACTOR shall submit a list of spare parts (optional) for the equipment and material, which are adequate for two (2) years operation and maintenance of the project by COMPANY. The recommended list complete with schedule of prices shall be submitted along with bid proposal for review by COMPANY.
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11.11.1 CONTRACTOR shall provide a Final Electronic Record for all the documents and drawings included in the Design Books, Supplier Data Books, Operating Manuals, QA/QC Manuals, Construction Data Report, Commissioning Manuals, Commissioning Data Report, Spare parts and Interchangeability Record (SPIR) and Two (2) Years Operational Spare Parts List. 11.11.2 CONTRACTOR shall ensure the production of all drawings and documents are compatible with COMPANY electronic format. 11.11.3 All final drawings and documents shall be supplied in CD-ROM in native as well as pdf format. 11.11.4 CONTRACTOR shall provide all documentations in format of one (1) original copy, two (2) hardcopies and five (5) electronic copies. 11.12
Miscellaneous
11.12.1 All files not formally handed over to COMPANY shall be kept by CONTRACTOR for ten (10) years after Work Completion, together with supporting software, with provision for reasonable access by COMPANY. After that time, CONTRACTOR shall consult COMPANY concerning the disposal of such archived documents.
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11.13
Document Numbering CONTRACTOR shall refer to COMPANY’s document numbering PMPMS – 20114 – Technical Document Numbering System Procedure in ATTACHMENT-1.
11.14
Document Rights All information/calculation, datasheets/deliverables produced by CONTRACTOR shall be accessible and belongs to COMPANY and be able to retained by COMPANY in its native format.
11.15
Punch Listing
CONTRACTOR shall categorize all the Punch Listing in Category A, B, C and D in line with Punch Listing Procedure in Attachment 2 and 3.
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11.15.2
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11.15.1 CONTRACTOR and COMPANY shall jointly perform Punch listing activities before the scheduled Work Completion date. The Punch Lists shall cover all items, which have not yet been fully completed or deviated from the requirements of the project.
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12.0 12.1
WORK COMPLETION AND START UP Requirements for Pre-Commissioning and Commissioning CONTRACTOR shall develop a Work Completion, pre commissioning and commissioning/start up database with check sheets and procedures including punch lists categorization each system at each stage to ensure that the plant is not attempted to be pre-commissioned, energized or commissioned/started up with any detrimental defect in the individual systems. Each of the above stages are to be fully documented and witnessed by the COMPANY and Third Party inspectorate where required. Pre-Commissioning
12.2.1
Pre-Commissioning activities include the preparation of the project for equipment Ready for Start-Up (RFSU).
12.2.2
Pre-Commissioning refers to activities before Work Completion of the project, to ensure the project is ready for commissioning. Pre-Commissioning activities shall be performed according to system priority and system–wise completion.
12.2.3
CONTRACTOR shall notify COMPANY of any planning for Pre-Commissioning activities at least one or two days in advance. CONTRACTOR shall provide evidence that all appropriate procedures safety plans/permit to work/safety procedures are in place, and are approved by COMPANY. Activities which have operational implications shall be conducted under COMPANY supervision and control.
12.2.4
CONTRACTOR shall prepare detailed procedures for all Pre-Commissioning activities. The procedure shall be submitted to COMPANY for approval at least three (3) weeks prior to commencement date of that activity.
12.2.5
The Pre-Commissioning activities on each system/ unit between Work Completion and RFSU shall be recorded in the system/ unit Completion Manual for each system/ unit.
12.2.6
CONTRACTOR shall ensure the availability of CONTRACTOR specialist at SITE to supervise activities during pre-commissioning and commissioning activities.
12.2.7
CONTRACTOR shall provide evidence that the system/ unit dossier records are up to date.
12.2.8
COMPANY shall review and sign the report three (3) days after completion of each PreCommissioning activities. CONTRACTOR shall keep complete and accurate records of all PreCommissioning activities and submitted for issuance of MWCC by COMPANY. Issuance of MWCC is mandatory to ensure that the equipment is ready for smooth startup.
12.2.9
Issuance of MWCC for an equipment/system shall occur when it has been erected, tested and inspected in accordance with the project requirement, together with complete QA/QC support documentation as required and the equipment/system is ready for commissioning.
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12.2
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Commissioning
12.3.1
Commissioning of a unit, or section, or an individual system of the PROJECT will occur as soon as it has been pre-commissioned i.e. upon issuance MWCC. Commissioning shall mean those activities performed by CONTRACTOR after RFSU which include any operating adjustments, satisfactory completion of which is required to achieve Work Completion in accordance with the provisions of the conditions of CONTRACT.
12.3.2
CONTRACTOR shall ensure the availability of key personnel at SITE to supervise activities during pre-commissioning and commissioning activities which include technical support i.e. manpower, specialist, tools & equipment for initial start-up and commissioning of each system/ equipment following RFSU until the unit has achieved smooth startup with stable operation of minimum 72 hours.
12.3.3
Commissioning shall be part of CONTRACTOR’s Scope of Work, which may include simulation, running, and preparation activities required which is not limited to, e.g.
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No load running of mechanical equipment’s, if applicable, with corresponding adjustments Simulation of circuits using water, if applicable, with corresponding adjustments Tests of alarms and interlocks
CONTRACTOR shall provide to COMPANY a detailed commissioning schedule and status monitoring method.
12.4
Work Completion
12.4.1
Work Completion for all equipment/system is considered to be achieved, after acceptance by COMPANY and issuance of approval by relevant Local Authority, where applicable.
12.4.2
All documents, forms and procedures required for Work Completion shall be submitted and approved by COMPANY prior to the application for WCC.
12.4.3
CONTRACTOR shall provide and maintain a single Work Completion Dossier for each system/ equipment, which shall encompass all the requirements from Construction phase up to Work Completion. The Work Completion Dossier shall include but not limited to the following:
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Work Completion Checklist
Equipment List, Factory and Site Acceptance Test Report
Certificates (e.g. MWCC, QA/QC Declaration, etc.)
Punch Listing
Inspection Test Plan records (Summary)
Drawings (e.g. Wiring diagrams, etc.)
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CONTRACTOR shall inform COMPANY in writing by means of “Notice of Work Completion” upon completion of all Punch List items for issuance of WCC.
12.4.5
CONTRACTOR shall complete all the housekeeping in accordance to COMPANY’s satisfaction.
12.5
Equipment Performance Test(s)
12.5.1
CONTRACTOR shall perform Performance Test(s) to demonstrate that the project is capable to meet performance guarantee. All Performance Test(s) shall be conducted by CONTRACTOR based upon criteria defined by the CONTRACTOR and approved by COMPANY. CONTRACTOR shall meet the PSR-1 specifications, PTS and/or recognized international standard for testing requirement and criteria. COMPANY reserves the right to request additional test deemed necessary for the project at no cost to COMPANY.
12.5.2
The Performance Test(s) shall be lead, coordinated and managed by CONTRACTOR and assisted by COMPANY. The Performance Test(s) shall be conducted in the presence of COMPANY.
12.5.3
The Performance Test(s) shall be conducted only after the completion of commissioning works.
12.5.4
CONTRACTOR shall produce Performance Test(s) procedures and submitted to COMPANY for approval one (1) month before the proposed start date of the test(s). CONTRACTOR shall liaise closely with COMPANY in developing this procedure to ensure that the test(s) can be carried out safely within live plant.
12.5.5
CONTRACTOR shall ensure that all instrumentations and ancillary equipment, permanent and or temporary, required to perform and monitor the Performance Test(s) are ready for prior to the test(s).
12.5.6
CONTRACTOR shall submit the Performance Test(s) report within one (1) week after the completion date of the test. COMPANY shall review the report and revert to CONTRACTOR no later than two (2) weeks from the date of receipt. COMPANY shall officially issue the WCC backdated to the date of testing upon acceptance and approval of the report. Should there be defects or deficiencies in the project identified during Performance Test(s), those defects/ deficiencies shall be remedied by CONTRACTOR. The system/ unit shall not be considered to have passed the Performance Test(s) until the defects/ deficiencies are remedied to the satisfaction of the COMPANY. CONTRACTOR shall re-conduct the performance test after the remedial work is completed.
12.5.7
CONTRACTOR shall consolidate and compile all related documents at the end of the WORKS in a form of a Manufacturing Data Report (MDR) Book and submit to COMPANY for approval.
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13.0
SPARE PARTS AND SPECIAL TOOLS
13.1
General
13.2
CONTRACTOR’s responsibilities with regard to provision of spare parts, special tools and associated services shall inclusive but not limited to the following; Construction and Pre-Commissioning Spare Parts
ii)
Commissioning Spare Parts
iii)
Spare Part Interchangeability Records
iv)
Special Tools
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i)
Construction and Pre-Commissioning Spare Parts
Commissioning Spare Parts i)
ii)
13.5
CONTRACTOR shall provide commissioning spare parts during the commissioning period.
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13.4
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Construction and Pre-Commissioning spare p arts covers all spare parts, consumable, catalysts, chemical and lubricants etc. required for the construction, pre-commissioning, and commissioning of the project. CONTRACTOR shall include the necessary construction and pre-commissioning spare parts as part of the WORKS.
CONTRACTOR shall provide all consumable required for the pre-commissioning and commissioning of the project as part of the WORKS.
Special Tools i)
CONTRACTOR shall supply to COMPANY all special tools (i.e. HART Handheld communicator 475) required for operation and maintenance of the project; minimum of one set of special tool shall be supplied for the WORKS package. The special tools shall be supplied in a proper enclosure i.e. small box/container with engrave tagging. All special tools supplied by CONTRACTOR shall be identified by a number system in accordance standard coding procedure.
ii)
All Special Tools shall be handed over to COMPANY prior to the issuance of the WCC.
iii)
In the event of CONTRACTOR may need to use the special tools during WORKS execution, COMPANY may authorize CONTRACTOR for the usage with the understanding that the CONTRACTOR shall promptly replace the tools if damaged.
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WARRANTY AND DEFECT LIABILITY NOTICE
14.1
The Warranty period is twelve (12) months upon issuance of WCC by COMPANY.
14.2
CONTRACTOR shall warrant and guarantee that the WORKS will be performed in a professional manner, in accordance with good industrial practices, executed to the highest quality of workmanship, free from defect, fault and fully comply with the requirements stipulated in the Contract.
14.3
Upon detecting of any defects or fault COMPANY will issue the defect notification and CONTRACTOR shall expeditiously make good such defect or fault at its own expenses at the acceptable duration agreed by COMPANY.
14.4
Should CONTRACTOR fail to take expeditious measures to make good such defect or fault, COMPANY may its discretion make good the defect by itself or employ a third party. CONTRACTOR shall reimburse all the costs incurred thereby.
15.0
COMPANY’S SCOPE
15.1
COMPANY will assign focal person to assist the CONTRACTOR to comply with related permits and documents required.
15.2
COMPANY will provide limited First Aid medical treatment to CONTRACTOR personnel when required.
15.3
COMPANY may provide utilities and facilities listed in the followings:
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15.4
Limited supply of water and steam.
Electricity and assistance for any work requiring electricity. CONTRACTOR shall notify relevant COMPANY Representative at least one day in advance should CONTRACTOR require assistance. Laydown area for the CONTRACTOR’s usage for their storage area, office area (Cabin/Field office), etc. Limited assistance of any form provided the CONTRACTOR notify COMPANY at least one day in advance.
COMPANY will conduct final inspection and clearance upon completion of SITE work before box-up.
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16.0 Item
ATTACHMENTS Document No.
Description
1
Technical Document System Procedure
2
Punch List Procedure for PSR-1 Rejuvenation Project
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Punch List Form
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Work List 15 - MARK-UP Drawings for Replacement of Displacer Level Transmitter to Guided Wave Radar Level Transmitter
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Guided Wave Radar Transmitters Tag List
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PROJECT MANAGEMENT & DELIVERY Author ABS
Approved By NAH
Date Approved 23 Jan 2014
Title PUNCH LIST PROCEDURE FOR PSR-1 REJUVENATION PROJECT
Classification Internal Use Only Version 1
TABLE OF CONTENTS OBJECTIVE
2
2.0
DEFINITIONS
2
3.0
PUNCH LIST STRUCTURE
3
4.0
PROCEDURE
4
4.1
Walkdowns
4
4.2
Punch List
4
4.3
Categories
5
4.4
Punch List Coordinator(s)
5
4.5
Punch List Clearance
7
PUNCH LIST NUMBERING
6.0
ATTACHMENTS
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Phase 1B PSR1 Rejuvenation Project Punch List Procedure.doc
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PROJECT MANAGEMENT & DELIVERY Author ABS
Approved By NAH
Date Approved 23 Jan 2014
Title PUNCH LIST PROCEDURE FOR PSR-1 REJUVENATION PROJECT
1.0
Classification Internal Use Only Version 1
OBJECTIVE The purpose of this procedure is to lay out the method for identification, registration and clearance of Punch List items for Phase 1B PSR-1 Rejuvenation Project in order to achieve Mechanical Completion.
TERMS AND DEFINITIONS Means PETRONAS Penapisan (Melaka) Sdn. Bhd. (PP(M)SB) (Company No: 164522-v), a wholly owned subsidiary company of PETRONAS, which owns and/or operates the Melaka Refinery Complex located in Mukim Sungai Udang, Tangga Batu, Melaka comprising of amongst others the PSR-1, the PSR-2 and the MG3 Plant, and shall include its successors in title and permitted assigns, and shall, where the context so admits and requires, also include its employees, agents or designated representatives.
CONTRACT
Means the contract entered into between the COMPANY and the CONTRACTOR for the WORKS in accordance with the terms and conditions contained herein including all articles, exhibits and any other documents attached hereto or incorporated by reference including any subsequent amendments to them.
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COMPANY
CONTRACTOR
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MWCC, WCC
Means Party(ies) entering into this CONTRACT with the COMPANY for the performance of the WORKS as set forth in this CONTRACT and includes the CONTRACTOR’s personnel, representatives, successors and authorized parties. MWCC is Mechanical Work Completion Certificate. It is a hand over document to Plant Operation to safely commission the equipment. WCC is Work Completion Certificate where the warranty shall commence from the date stipulated on the certificate.
PROJECT
Shall have the similar meaning as per the CONTRACT Preambles.
Punch List Item
Is an item which has not been installed and / or erected according to the approved specifications and / or erection documents or that is required to be modified as a result of safety or operability requirements.
Punch Identification
Means identification and registration of Punch List items.
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PROJECT MANAGEMENT & DELIVERY Author ABS
Approved By NAH
Date Approved 23 Jan 2014
Title PUNCH LIST PROCEDURE FOR PSR-1 REJUVENATION PROJECT
Classification Internal Use Only Version 1
Is physical completion, correction or rectification of the identified Punch List items.
SIGN-OFF
Is the process of obtaining signatures confirming the completion of a Punch item and verification for its closure.
SITE(S)
Means the areas or places as designated by the COMPANY where the WORKS is to be performed or delivered, as further specified in EXHIBIT I – SCOPE OF WORKS.
SUB-CONTRACTOR
Means Party(ies) including but not limited to supplier, vendor and/or companies performing construction work(s) that has or have entered into a contract, directly or indirectly with the CONTRACTOR, for the performance of any part of the WORKS.
WORKS
Means the work to be performed and rendered by the CONTRACTOR or its SUB-CONTRACTOR, as expressly set forth in this CONTRACT, which is more particularly described in EXHIBIT I – SCOPE OF WORKS and all of CONTRACTOR’s and/or its SUB-CONTRACTOR’s activities that are reasonably inferable from the description of the said scope of WORKS, including any other activity which is not specified in this CONTRACT but which in the course of the WORKS becomes necessary for completion to be effected.
PUNCH LIST STRUCTURE
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Punch Clearance
There shall only be one Punch List for a particular System. Any Punch List item identified on any walkdown by any party shall be registered into the Punch List of that particular System. A Punch List for a System shall exist from the first walkdown onwards, (e.g. Walkdown No. 1, Walkdown No. 2, and so on) until Provisional Acceptance or until such time as all items have been cleared, resolved or re-assigned. It is a condition that all Punch List items shall be cleared prior to the issuance of WCC, unless deemed otherwise by COMPANY. Attachment 1 indicates the Punch List form.
Phase 1B PSR1 Rejuvenation Project Punch List Procedure.doc
Page 3 of 8
PROJECT MANAGEMENT & DELIVERY Author ABS
Approved By NAH
Date Approved 23 Jan 2014
Title PUNCH LIST PROCEDURE FOR PSR-1 REJUVENATION PROJECT
PROCEDURE 4.1
Walkdown In order to verify the installation of a System has been accomplished according to Approved For Construction (AFC) drawings, Technical Specifications and relevant documentation, a number of walkdowns shall be conducted as follows: Walkdown No. 1 – A Construction walkdown involving CONTRACTOR’s construction personnel. Among the purposes of the walkdown is to verify that lines, motor vessels, tanks, etc. are ready to be tested and that all the necessary work has been completed to allow the subsequent test to be safely executed. Any Punch List items identified during this walkdown shall be categorized as Category “A”, which indicates that the Punch List items need to be resolved and verified, prior to inviting COMPANY representative to execute Walkdown No. 2.
ii.
Pre-Walkdown No. 2 – CONTRACTOR shall issue the Inspection Request (IR) with Punch List identified for all disciplines including after Commissioning after completing the Pre-Commissioning system flushing / blowing, reinstatements and loop checking of the particular System. This Pre-Walkdown No. 2 shall capture as early as possible category “A” items prior to Notice of MWCC. With this approach, the Walkdown No. 2 is only for COMPANY’s verification of category “A” items cleared, thus expediting the COMPANY’s approval in MWCC Notification.
iii.
Walkdown No. 2 – Following issuance of Notice of MWCC of a System, COMPANY’s representative shall attend a walkdown in Contractor’s presence to satisfy itself that the System is mechanically complete to verify category “A” items are cleared.
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4.0
Classification Internal Use Only Version 1
iv.
Walkdown No. 3 - Following issuance of Notice of MWCC, COMPANY’s representative shall attend a walkdown in to satisfy itself that the System is Ready For Start Up. CONTRACTOR’s Commissioning Manager shall attend the walkdown with COMPANY’s personnel.
COMPANY’s personnel shall only attend the scheduled walkdown(s) through the IR procedure, after receiving the fully signed-off Punch List items generated by CONTRACTOR for a particular System. 4.2
Punch Parties Individual Punch parties consist of the followings: a) A CONTRACTOR Construction Walkdown (Walkdown No. 1) which will include: CONTRACTOR’s Punch List Coordinator, Area Manager, Discipline Manager, Engineering Discipline representative, SUBCONTRACTOR personnel.
Phase 1B PSR1 Rejuvenation Project Punch List Procedure.doc
Page 4 of 8
PROJECT MANAGEMENT & DELIVERY Author ABS
Approved By NAH
Date Approved 23 Jan 2014
Title PUNCH LIST PROCEDURE FOR PSR-1 REJUVENATION PROJECT
Classification Internal Use Only Version 1
b) A joint COMPANY and CONTRACTOR Walkdown (Walkdown No. 2) will include: COMPANY personnel, Punch List Coordinators, Construction Managers, Area Manager, Discipline Manager, Commissioning Managers, Engineering Discipline representative, Supervisors or Operators from COMPANY. c) A joint COMPANY and CONTRACTOR Walkdown (Walkdown No. 3) will include: COMPANY personnel, Punch List Coordinators, Construction Managers, Area Manager, Discipline Manager, Commissioning Managers, Engineering Discipline representative, Supervisors or Operators from COMPANY. 4.3
Punch List
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A Punch List item shall be generated if, during any of the walkdown, any item of outstanding work or error or omission, or if the System has not been built in accordance with the AFC Engineering drawings, Technical Specifications and relevant Documentation.
or m
Each Punch List item in a System shall be uniquely numbered and entered into database for tracking of the clearance process. From the database, CONTRACTOR shall be able to produce Punch Lists by System. The list shall constitute a “work to go list” prior to a System being ready to be taken to the next phase of the Project.
4.4
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The Originator of the Punch List items and the date on which the originator identified the defect will be identified against the Punch List item and shall be responsible to ensure that the identified Punch List item is cleared or resolved. Categorization of Punch List Items
Fo
All Punch List items shall be categorized in accordance to the time when the item shall be cleared. Only when all the items identified by category have been cleared for a particular System, the next phase of the PROJECT can commence. The Punch List categories are: i.
Category “A” Punch List items for a System shall be cleared and verified, by CONTRACTOR prior to COMPANY’s Acceptance of MWCC.
ii. Category “B” Punch List items for a System shall be cleared and verified, by CONTRACTOR prior to Commissioning. iii. Category “C” Punch List items for a System shall be cleared and verified, by CONTRACTOR prior to COMPANY’s issuance of WCC. iv. Category “X” items that are disputed. A Punch List Resolution Form is attached in which the scheduled meeting between COMPANY & CONTRACTOR shall be conducted to determine the agreement before approval of the MWCC Notification. Phase 1B PSR1 Rejuvenation Project Punch List Procedure.doc
Page 5 of 8
PROJECT MANAGEMENT & DELIVERY Author ABS
Approved By NAH
Date Approved 23 Jan 2014
Title PUNCH LIST PROCEDURE FOR PSR-1 REJUVENATION PROJECT
Classification Internal Use Only Version 1
Following a walkdown, CONTRACTOR’s Punch List Coordinator shall issue to CONTRACTOR’s Construction Manager or Commissioning Manager all Punch List items that resulted from the walkdown. For CONTRACTOR Construction Walkdown, the Punch List Coordinator, the Commissioning Manager and the Construction Manager shall sit and obtain consensus on the categories of all Punch List items. In the event of a disagreement, the matter shall be referred to CONTRACTOR’s Project Director / Deputy Project Director for resolution, which their decision will be final.
io
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For Walkdown that includes COMPANY’s personnel, the COMPANY’s Punch List Coordinator shall provide CONTRACTOR’s Punch List Coordinator with the Punch List items duly categorized for distribution to CONTRACTOR’s Construction Manager or Commissioning Manager.
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Should any disagreement arise with COMPANY’s Punch List or categorization of items in COMPANY’s Punch List, CONTRACTOR’s Punch List Coordinator, Construction Manager and / or Commissioning Manager shall meet with COMPANY’s designated personnel to resolve the issue.
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In the event that an agreement failed to be obtained, the matter shall be referred to CONTRACTOR’s Project Director / Deputy Project Director, PMT Project Director and PMC Project Manager for resolution, which their decision will be final. Failure to resolve the issue shall constitute a “Dispute” under the CONTRACT. 4.5
Punch List Coordinator(s)
Fo
Both the CONTRACTOR and COMPANY shall nominate a Punch List Coordinator who shall liaise with each other on all matters related to Punch List items and shall be responsible to ensure that:
Walkdown are to be scheduled and set up
Punch List items are properly recorded
Any duplications are deleted
Parties who shall be attending the walkdown are duly notified
Punch List items are cleared and signed off by the Originator of the item
Hardcopy and electronic copy of each Punch List item is being maintained
Identify and record all signatures
Each Punch List item is correctly categorized
Reports are issued as required by COMPANY
Note: CONTRACTOR’s Punch List Coordinator shall be responsible for Contractor Punch List on all of the above. COMPANY’s nominated Punch List Phase 1B PSR1 Rejuvenation Project Punch List Procedure.doc
Page 6 of 8
PROJECT MANAGEMENT & DELIVERY Author ABS
Approved By NAH
Date Approved 23 Jan 2014
Title PUNCH LIST PROCEDURE FOR PSR-1 REJUVENATION PROJECT
Classification Internal Use Only Version 1
Coordinator shall be responsible for COMPANY’s generated Punch List on all of the above. 4.6
Punch List Clearance Copies of the discipline Punch List items for each System shall be issued to CONTRACTOR’s Discipline Managers who shall be responsible for clearance of the Punch List items. Once a Punch List item has been resolved, CONTRACTOR’s Discipline Manager shall sign and date the Punch List to confirm that the particular item has been cleared. It shall be the responsibility of the Originator of a Punch List item to ensure that the item is cleared, resolved or re-assigned.
io
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Contractor’s Discipline Manager will then give the original Punch List to CONTRACTOR’s Punch List Coordinator who shall register the details into the database and file the signed off hardcopy Punch List for future reference.
or m
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For CONTRACTOR generated Punch List items, CONTRACTOR’s Punch List Coordinator shall advise the Originator of the Punch List item that the item has been cleared. For COMPANY generated Punch List, the responsibility shall be upon COMPANY’s Punch List Coordinator.
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If the Originator is satisfied that the Punch List item has been cleared, the Punch List shall be signed and returned to the Punch List Coordinator who shall register the details into the database and file the hardcopy Punch List for future reference.
Fo
In the event that the Originator does not agree that the Punch List Item has been cleared, the issue needs to be resolved with CONTRACTOR’s Discipline Manager.
Phase 1B PSR1 Rejuvenation Project Punch List Procedure.doc
Page 7 of 8
PROJECT MANAGEMENT & DELIVERY Author ABS
Approved By NAH
Date Approved 23 Jan 2014
Title PUNCH LIST PROCEDURE FOR PSR-1 REJUVENATION PROJECT
5.0
Classification Internal Use Only Version 1
PUNCH LIST NUMBERING Predefined and numbered punch lists shall be utilized to record all punch items. This will ensure that all items, packages and systems are punched and to minimize duplication. Punch Lists shall commence with Walkdown No. 1, the same list shall be forwarded to Pre-Commissioning / Commissioning / Licensor and finally forwarded to the Joint Inspection Team for the final punch out in Walkdown No.3. This Punch List shall be the Master Punch List and shall be utilized to control the punching activity. - All punch lists shall be predefined and uniquely numbered.
Discipline
Unique Number
Description
Item
19
Mechanical
K1901
Rotating equipment
Compressor
19
Mechanical
C1901
Static equipment
Column
XX
SCR 8
Common item
SCR No.8
Piping
19PA01
Piping system
Plant air
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PROJECT
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Unit No
19
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Numbering examples:
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- The unit number, to which the punch list refers, followed by a Discipline Code and then by a unique number, shall predefine each assigned punch list. As certain items are not uniquely assignable to a specific unit, PROJECT shall prefix them instead of the unit number.
ATTACHMENTS
Attachment 1 – Punch List Form
End of Document
Phase 1B PSR1 Rejuvenation Project Punch List Procedure.doc
Page 8 of 8
Petronas Penapisan (Melaka) Sdn. Bhd. Phase 1B PSR-1 Rejuvenation Project
INSERT CONTRACTOR'S
PUNCH LIST FORM
LOGO
EQUIPMENT/TAG NO: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AREA/TESTPACK/ISO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PUNCH LIST NO:
REV:
CONTRACT NO:
DRAWING NO:
REV:
CONTRACTOR:
Initiator
DISCIPLINE:
CATEGORY
REMEDIAL WORKS
A B C X
COMPLETION CONTRACTOR INITIATOR DATE SIGN DATE SIGN
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Item
"A" - Before acceptance of Mechanical Work Completion Certificate "B" - Before Commissioning "C" - Before issuance of Work Completion Certificate "X" - Disputed Items
Page:
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F. Code
Discipline Code
Doc Type
Doc No.
PSR1RJV
IN
TSK
0152
Doc. Class : B – Confidential Page 2 of 2
TABLE OF CONTENT
DOC / DWG NOS.
NO. OF SHTS
1
Drawing and Specifications
V-2173-P31-A-001
185
2
Project Specification for Displacement Type Level Instrument
S-00-1373-032
n
DESCRIPTION
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PHASE 1B PSR-1 REJUVENATION PROJECT
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Guided Wave Radar Level Transmitters List 025 053 015 002 010 017 057 018 021 027 005 503 506 507 001 004 005 007 057 008 058 009 059 011 013 004 014 002 001 003 006 008 007 437 002 007 010 014 001 013 003 004 008 009 011 012 005 003 004 001 002 002 005 006 002 003 004 501 006 005 003 004 001 002 005 016
Service Description C‐1110 Tank Level V‐1101 Tank Level V‐1102 Tank Level V‐1103 Tank Level V‐1104 Tank Level V‐1107 Tank Level V‐1107 Tank Level V‐1108 Tank Level V‐1109 Tank Level V‐1113 Tank Level V‐1115 Tank Level V‐1151 Tank Level V‐1152 Tank Level V‐1152 Tank Level V‐1201 Tank Level V‐1202 Tank Level V‐1202 Tank Level V‐1203 Tank Level V‐1203 Tank Level V‐1204 Tank Level V‐1204 Tank Level V‐1205 Tank Level V‐1205 Tank Level V‐1206 Tank Level V‐1208 Tank Level C‐1301 Tank Level C‐1301 Tank Level E‐1307 Tank Level V‐1301 Tank Level V‐1302 Tank Level V‐1304 Tank Level V‐1311 Tank Level V‐1312 Tank Level V‐1334 Tank Level A‐1401 Tank Level C‐1401 Tank Level C‐1402 Tank Level C‐1402 Tank Level V‐1401 Tank Level V‐1401 Tank Level V‐1402 Tank Level V‐1402 Tank Level V‐1406 Tank Level V‐1406 Tank Level V‐1408 Tank Level V‐1408 Tank Level V‐1409 Tank Level C‐1501 Tank Level C‐1501 Tank Level V‐1501 Tank Level V‐1501 Tank Level A‐1603 Tank Level V‐1609 Tank Level V‐1609 Tank Level V‐5101 Tank Level V‐5101 Tank Level V‐5102 Tank Level V‐5104 Tank Level V‐5105 Tank Level V‐5106 Tank Level E‐5804 Tank Level V‐5801 Tank Level A‐6401 Tank Level V‐6401 Tank Level V‐6402 Tank Level V‐6663 Tank Level
Inst. Type
I/O Type
IS / Non IS
PID No.
Equipment
System
Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar Guided Wave Radar
AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI AI
IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS IS
11‐1225‐023 11‐1225‐008 11‐1225‐016 11‐1225‐004 11‐1225‐012 11‐1225‐017 11‐1225‐017 11‐1225‐018 11‐1225‐020 11‐1225‐025 11‐1225‐011 11‐1225‐056 11‐1225‐058 11‐1225‐058 12‐1225‐001 12‐1225‐004 12‐1225‐004 12‐1225‐005 12‐1225‐005 12‐1225‐005 12‐1225‐005 12‐1225‐005 12‐1225‐005 12‐1225‐011 12‐1225‐012 13‐1225‐006 13‐1225‐006 13‐1225‐005 13‐1225‐004 13‐1225‐005 13‐1225‐008 13‐1225‐010 13‐1225‐009 13‐1225‐056 14‐1225‐002 14‐1225‐004 14‐1225‐005 14‐1225‐005 14‐1225‐001 14‐1225‐001 14‐1225‐002 14‐1225‐002 14‐1225‐004 14‐1225‐004 14‐1225‐006 14‐1225‐006 14‐1225‐003 15‐1225‐002 15‐1225‐002 15‐1225‐001 15‐1225‐001 16‐1225‐004 16‐1225‐008 16‐1225‐008 51‐1225‐002 51‐1225‐002 51‐1225‐003 51‐1225‐007 51‐1225‐007 51‐1225‐004 58‐1225‐001 58‐1225‐004 64‐1225‐004 64‐1225‐004 64‐1225‐004 66‐1225‐006
C‐1110 V‐1101 V‐1102 V‐1103 V‐1104 V‐1107 V‐1107 V‐1108 V‐1109 V‐1113 V‐1115 V‐1151 V‐1152 V‐1152 V‐1201 V‐1202 V‐1202 V‐1203 V‐1203 V‐1204 V‐1204 V‐1205 V‐1205 V‐1206 V‐1208 C‐1301 C‐1301 E‐1307 V‐1301 V‐1302 V‐1304 V‐1311 V‐1312 V‐1334 A‐1401 C‐1401 C‐1402 C‐1402 V‐1401 V‐1401 V‐1402 V‐1402 V‐1406 V‐1406 V‐1408 V‐1408 V‐1409 C‐1501 C‐1501 V‐1501 V‐1501 A‐1603 V‐1609 V‐1609 V‐5101 V‐5101 V‐5102 V‐5104 V‐5105 V‐5106 E‐5804 V‐5801 A‐6401 V‐6401 V‐6402 V‐6663
DCS ESD DCS DCS DCS DCS ESD DCS DCS DCS DCS DCS DCS DCS DCS DCS DCS DCS ESD DCS ESD DCS ESD DCS DCS DCS ESD DCS DCS DCS DCS DCS DCS DCS DCS DCS DCS ESD DCS ESD DCS DCS DCS DCS DCS DCS DCS DCS DCS DCS DCS DCS ESD ESD DCS DCS DCS DCS DCS DCS DCS DCS DCS DCS DCS DCS
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Tag Type Seq No. LICA LZA LICA LICA LISA LIA LZA LICA LICA LIA LICA LICA LIA LICA LIA LICA LICA LIA LZA LIA LZA LIA LZA LICA LIA LICA LZA LICA LICA LICA LICA LIA LIA LICA LIA LICA LICA LZA LICA LZA LICA LICA LICA LICA LICA LIA LISA LICA LIA LISA LICA LICA LZA LZA LICA LICA LICA LICA LIA LICA LISA LIA LICA LISA LISA LSA
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Unit 11 11 11 11 11 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 12 12 13 13 13 13 13 13 13 13 13 14 14 14 14 14 14 14 14 14 14 14 14 14 15 15 15 15 16 16 16 51 51 51 51 51 51 58 58 64 64 64 66
or
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66
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Remarks
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EXHIBIT II – SPECIFICATIONS PART A: PROCEDURES AND REQUIREMENTS
PHASE 1B PSR-1 REJUVENATION PROJECT
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PART A: PROCEDURES AND REQUIREMENTS 1.0
GENERAL PROCEDURES
1.1
CONTRACTOR is responsible to provide proper design, mechanical reliability and metallurgical fitness of the materials supplied for the WORKS.
1.2
CONTRACTOR is responsible to include any materials, which are not indicated in the drawings but are required to complete the WORKS.
1.3
CONTRACTOR shall submit Vendor’s work application procedure of product (where necessary) to COMPANY’s review and approval. All materials supplied by CONTRACTOR shall be as per existing specifications and PTS selected
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1.4
standards. CONTRACTOR shall highlight and obtain COMPANY’s approval for any deviations from PTS or COMPANY procedures. 1.5
CONTRACTOR shall execute WORKS in compliance with all PTS standards and requirements.
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CONTRACTOR shall highlight and obtain COMPANY’s approval for any deviations from PTS standards and requirements.
CONTRACTOR shall supply Manufacturer’s Test Certificates for all supplied materials.
1.7
In the event of dimensional or quantity differences occur, reduction or addition in prices shall be
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or
1.6
proportionately calculated based on the awarded price. Price variation based on Unit Rates, as listed in the schedule of rates / prices shall be used. 1.8
CONTRACTOR shall engage COMPANY term contractor for scaffolding services. Scaffolding shall be part of the Lump Sum cost.
1.9
All scaffolding shall be constructed as per COMPANY refinery standard for scaffolding according to British Standards BS 1139.
1.10
Scaffold materials and erected scaffolding shall be inspected and approved by COMPANY Representative before being used. Only metal planks shall be used for the erection of Platform.
1.11
CONTRACTOR shall be fully responsible for the co-ordination within his SUB-CONTRACTOR for materials and services provided.
1.12
Prior to installation of any instruments/devices, CONTRACTOR shall perform procedure test to demonstrate its method and equipment will operate in accordance with the design requirements. The test is to assure adequately represent as per manufacturer’s requirements.
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1.13
A successful test qualifies the procedure and workers for installation of the actual instruments/devices. The demonstration and test shall be proposed by CONTRACTOR and witnessed by COMPANY Representative.
1.14
CONTRACTOR shall exert his greatest care not to avoid the cause of damaging any nearby equipment and materials when removing and installing the required instrument/devices eg. to cover with a wooden plate or other means.
1.15
CONTRACTOR shall provide manpower support through-out the commissioning activity for the WORKS. CONTRACTOR shall constantly check updates on the logistic schedule for WORKS provided by
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1.16
the COMPANY on a fortnightly basis. CONTRACTOR shall be required to seek approval from the COMPANY to the jetty berth prior commissioning of WORKS.
CONTRACTOR shall comply to PTS HSE requirements at all times.
1.18
At the end of each working day, CONTRACTOR is responsible to clear the working area and
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1.17
dispose all rubbish and debris in properly tied rubbish containers and transport them to location
1.19
or
(temporary storage) within the designated by COMPANY. At the end of the WORKS, a joint inspection between CONTRACTOR and COMPANY
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representative will be held to determine the completion of the housekeeping activity. 1.20
CONTRACTOR shall comply to Malaysian Laws and applicable regulatory requirements.
1.21
Unless otherwise specified, the CONTRACTOR will be responsible for all contact with governing regulatory agencies for obtaining all required permits. Any clarifications regarding compliance with regulatory requirements or technical information required to obtain permits are to be directed to the CONTRACTOR.
1.22
CONTRACTOR shall submit an Inspection and Test Plan (ITP) for verification and testing of the WORKS.
1.23
CONTRACTOR shall notify COMPANY for inspection or testing three (3) working days prior to the planned inspection or testing dates.
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2.0
CONTRACTOR’S OBLIGATION
2.1
The CONTRACTOR shall – a)
Supply, construct, complete test and commission the WORKS in accordance with the CONTRACT.
b)
Perform the WORKS in a proper manner expected of a CONTRACTOR providing similar WORKS to ensure that the WORKS comply with the requirements of this CONTRACT.
c)
Take all appropriate measures expected of a CONTRACT or providing similar WORKS to ensure that the WORKS comply with the requirements of this CONTRACT. Perform the WORKS and discharge its obligations as contained in this CONTRACT by
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d)
exercising professional judgment and practice, requisite skill, care and diligence. In performing the WORKS, the CONTRACTOR shall provide well-outlined procedures in the form agreed by the COMPANY for reporting and co-ordination purposes. At all times perform the WORKS in such manner as will always safeguard and protect the
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e)
COMPANY’s interest in relation to the WORKS and take all necessary and proper steps
or
to prevent abuse or uneconomical use of facilities, if any, made available by the COMPANY to the CONTRACTOR.
Inform the COMPANY immediately in writing of the occurrence of any factor or event,
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f)
which is likely to affect the WORKS. Such notification shall not be construed as a discharge of any of the CONTRACTOR’s obligation under this CONTRACT.
g)
Provide and maintain throughout the CONTRACT period such number, categories of
qualified and competent personnel necessary to perform the WORKS.
h)
Provide and maintain at its own cost and expense all equipment and materials necessary
for the proper and effective performance of the WORKS. i)
Instruct and supervise its staffs and SUB-CONTRACTOR in carrying out the WORKS’ repairs and other works in relation to the WORKS.
j)
Make good any defect, imperfection, shrinkage or any other fault whatsoever which may appear during the defects liability period.
k)
Carry out any other obligations and responsibilities under this CONTRACT.
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3.0
INSPECTION OF SITE
3.1
The CONTRACTOR shall be deemed to have inspected and examined the SITE and its surroundings and to have satisfied himself before SITE possession as to the following: a)
The nature of the equipment, ground and subsoil.
b)
The form and nature of the SITE.
c)
Verification of the asset items specified in Exhibit I, Part B herein.
d)
The extent and nature of the WORKS, materials and goods necessary for the completion
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of the WORKS. e)
The means of communication with and access to the SITE.
f)
The accommodation may require.
g)
In general to have obtained for himself all necessary information as to risks,
3.2
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contingencies and all circumstances influencing and affecting his WORKS. Any information or document forwarded by the COMPANY to the CONTRACTOR shall not relieve
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the CONTRACTOR of his obligations under the provisions of this clause.
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EXHIBIT II – SPECIFICATIONS PART B: STANDARD AND SPECIFICATIONS
PHASE 1B PSR-1 REJUVENATION PROJECT
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PART B: STANDARD AND SPECIFICATIONS 1.0
APPLICABLE CODES AND STANDARDS
or
e. f. g.
Malaysian Law and Regulation, Local Authorities and By-Laws. Purchase Order / Contract Instructions and requirements contained in the project specification PETRONAS Technical Standard (PTS), including Standard Drawings and Standard Specifications The relevant Group HSE standards PSR-1 Design Specifications Other National and International Codes and Standards
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a. b. c. d.
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As a minimum, all WORKS / equipment supplied as part of this package shall be designed, manufactured and delivered in accordance with the relevant sections of the National / International Codes, Standards and Regulations, whether the equipment or services are supplied by CONTRACTOR directly or by a SUB-CONTRACTOR. All documents referenced herein shall be the latest edition, revision or addendum in effect and form an integral part of this requisition / specification. Equivalent alternatives may be offered and these should be identified and mutually agreed on CONTRACTOR shall meet or exceed the requirements of the latest edition of the following codes, regulations and standards, except as superseded herein. In the event that there are discrepancies or conflicts with items or information contained within the document specified by COMPANY, the following order of precedence shall applied.
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Any resolution of the conflicts or discrepancies shall be brought to COMPANY attention for review and approval prior to commencement of any pertaining issues. In cases of conflict in requirements between documents in the same level of the hierarchy, the most stringent requirement shall apply. CONTRACTOR shall provide its interpretation in writing for COMPANY’s approval. In all such cases of conflict, COMPANY’s decision shall be final. All deviations from the requirements of this specification, its appendices and the referenced codes and standards shall be described in the proposal. In the absence of such a statement, full compliance shall be assumed. Compliance by CONTRACTOR to this specification does not relieve him of the responsibility to furnish equipment of a proper design for the described service conditions and/or to meet the equipment of local government regulations concerning health and safety. 1.1
Disclosure of PETRONAS Technical Standards (PTS) CONTRACTOR is only allowed to divulge PTS publications to its SUB-CONTRACTORs on a “need to know” basis for the WORKS with conditions that the party(ies) has entered into a Secrecy Agreement. In all other cases, CONTRACTOR shall extract relevant information from the PTSs for inclusion in the specifications to be prepared.
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CONTRACTOR is obliged to verified with COMPANY prior to Contract Award that the applicable PTS publications (including amendments covered in PTS circulars), the Standard Drawings, the Standard Specifications are complete and up-to-date. 1.2
Legislative Documents (as applicable) Design of equipment shall comply with the requirements of the following Malaysian legislations: Electrical Supply Act 1990
ii)
Electrical Regulation 1994
iii)
Factories and Machinery Act 1967
iv)
Occupational Safety and Health Act 1994
v)
Petroleum Safety Measures Act 1984
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i)
1.4
Malaysian Codes and Regulation OSHA 1994
ii)
Industry Code Of Practice For Safe Working In A Confined Space 2010 (ICOP)
iii)
Environment Quality Act 1974 (EQA)
iv)
or
i)
Fo rI nf
1.3
Factory and Machinery Act 1967 (FMA)
COMPANY’S PROCEDURES i) ii) iii)
PSR-1 Design Specification S-00-13A0-001: Specification for Painting
HSEMS-20200: Waste Management
Requirements To Perform Works Within Sungai Udang Port Limits
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These shall include subsequent amendments. Areas where specific requirements will apply shall include lifting equipment, identification and handling of hazardous equipment as well as guarding of machinery.
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1.5
Listing of Codes, Standards and Regulations The latest edition of the following codes, standards and regulations shall be followed as applicable. PETRONAS TECHNICAL STANDARDS Welding of Metals
PTS 30.48.00.31
Protective Coatings and Lining
PTS 31.38.01.11
Piping - General Requirements
PTS 32.31.00.10
Instrumentation Engineering Procedure
PTS 32.31.00.32
Instrumentation for Measurement and Control
PTS 32.31.00.34
Instrumentation Documents and Drawings
PTS 32.37.10.11
Installation of Online Instruments
PTS 32.37.20.10
Instrument Signal Lines
PTS 33.64.10.10
Electrical Engineering Guidelines
PTS 33.64.10.11
Lightning Protection System (LPS) (Supplement to IEC 62305)
PTS 33.64.10.33
Electromagnetic Compatibility (EMC) Requirements
or
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PTS 30.10.60.18
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1.5.1
PTS 62.10.08.11
Inspection and Functional Testing of Instruments
PTS 63.10.08.11
PTS 70.10.90.11
Field Commissioning and Maintenance of Electrical Installations and Equipment Spare Parts
PTS 82.00.10.10
Project Quality Assurance
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1.5.2
INTERNATIONAL CODES AND STANDARDS IEC 60079
Electrical Apparatus for Explosive Gas Atmosphere
IEC 60529
Degree of Protection provided by Enclosures
IEC 61000
Electromagnetic Compatibility
IEC 61508
Functional Safety of Electrical/Electronic/Programmable Electronic SafetyRelated System
BS EN ISO 9001 Quality Management Systems
BS 729
Hot Dip Galvanized Coatings on Iron and Steel Articles
BS 4360
Weld able Structural Steel
BS 1139
Metal Scaffolding
BS 4872
Approval Testing of Welding Procedures
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Specification for Degree of Protection Provided by Enclosure
PSR-1 Project Specifications and Drawings
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1.6
BS EN 60529
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or
CONTRACTOR shall review PSR-1 Project Specifications and Drawings related with the WORKS as enclosed in this document. CONTRACTOR shall retrieve the remaining PSR-1 Project Document deem necessary for execution of the WORKS from COMPANY’s Library with supervision by COMPANY’s personnel. In the event of any of the listed document is not available in COMPANY’s Library, CONTRACTOR shall perform site verification and carry out necessary measurement and produce as-built document. The As-Built document shall be submitted to COMPANY as part of the project deliverable.
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1.7
Regulatory Permit and Approval Where required, CONTRACTOR shall liaise with the local authority having jurisdiction and the by-laws to be complied with in order to execute the construction work e.g. Department of Occupational Safety and Health (DOSH), Department of Environment (DoE), Majlis Bandaraya Melaka Bersejarah (MBMB), Jabatan Bomba dan Penyelamat (BOMBA), Suruhanjaya Tenaga (ST) and others third parties having jurisdiction or interest in this PROJECT as necessary throughout the execution of the WORKS.
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CONTRACTOR shall be responsible to apply for all necessary Permits from governmental bodies and local authorities. CONTRACTOR shall provide all information and documents required to enable these permits to be obtained. CONTRACTOR and its SUB-CONTRACTORs shall be registered with the Construction Industries Development Board of Malaysia prior to undertaking any Construction Work. All CONTRACTOR’s and its SUB-CONTRACTOR’s personnel working in the Construction SITE shall possess a valid CIDB Green Card.
EQUIPMENT SPECIFICATIONS AND DATASHEETS
3.0
or
This section is not applicable.
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2.0
ENGINEERING SPECIFICATIONS
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This section is not applicable.
END OF DOCUMENT
PHASE 1B PSR-1 REJUVENATION PROJECT
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