AMAL HRSG 1

PROJECT
C311/333

Kick Off Meeting

( Wednesday 4th April 12, Muscat )

AMAL HRSG 1 PROJECT

KOM Agenda : TIME

TOPIC

13.30 to
Assembly
13.40
13.41
Welcome Address
13.50
13.51- 14.10 Introduction of PDO & AHEC
delegates
14.11
Project Introduction
14.20
14.21
15.00
15.01
15.20
15.21
15.30

Kick-off Presentation

SPEAKER

PROJECT
MANAGER

AHEC
AHEC & PDO

Discussions
Close Out

AHEC

AMAL HRSG 1 PROJECT

Project

AMAL HEAT RECOVERY STEAM GENERATOR -1

Owner

Petroleum Development Oman (PDO)

EPC Contractor

Location
:
South of Oman and approximately 1 KM to the
Existing Amal Sub station

Scope

Contract Value

Duration

660 Days

Start Date

21-Mar-12

Completion

10-Jan-14

Al Hassan Engineering Co. S.A.O.G.

EPC of Heat Recovery Steam Generator project.

6.93 Million RO

South west of

AMAL HRSG 1 PROJECT

PROJECT OBJECTIVES

To meet the future steam demand in AMAL West field, the Company
plans to install a Heat Recovery Steam Generator unit at AMAL Power
Plant. The HRSG shall be installed at the back end of an existing GE
Frame 9E Gas Turbine with a target net average calendar day per year
steam production of 6,000 tonnes per day at a delivery pressure of
100 barg and 80% quality.

AMAL HRSG 1 PROJECT

SCOPE OF WORK

Install and commissioning a new HRSG at the back of Amal

Power station gas turbine. The HRSG will have capability of
producing 6000 tons of steam per day. (The HRSG, Pumps and
DCS will be procured and free issued by PDO)

Install high pressure feed water pumps, instrument air

compressors and associated electrical switchgears systems.

Design and Construction of Utility building to house the

electrical switchgears and controls systems (DCS, IPS, etc.)

Design, supply and installation of Switchgears, UPS, Instrument

Air compressors & piping works.

Civil and mechanical work associated with the above.

AMAL HRSG 1 PROJECT

Supply and Installation of overflow interconnection piping from HRSG to

HRSG blow down Pit to Existing Amal steam blow down pit.

Design and construction of HRSG blow down pit.

HVAC System.

Design, supply and installation of balance of plant Piping works

Fire detection and alarm system.

Scope includes interfacing with HRSG OEM supplier/ Vendor.

Pre commissioning and Commissioning.

AMAL HRSG 1 PROJECT

AMAL HRSG 1 PROJECT

Organisation Chart

AMAL HRSG 1 PROJECT

Staffing of Contract and Project Management

*

Project Manager : Shall be overall responsible for the complete project and
focal point for PDO for execution of the project. His responsibility includes
Engineering, Procurement, Project Management, Construction, Safety,
Contract
Management and Quality till successful completion of the
project. All other
personnel w.r.t. project execution will be under his guidance as per the project
organization chart.
*

Construction Manager: He shall be the site in charge for the construction

activity and full responsible for keeping the Project Manager updated of the
proceedings of the construction on regular basis as per reporting procedure,
including safety & Quality.
*

Engineering Manager: Shall be responsible for the proper interfacing and

co-ordination between the design consultant, PDO, PDOs PMC, AHEC Project
procurement & Construction team. He shall optimize the engineering activities in
such a manner that the project objectives w.r.t engineering shall meet the Companys
expectations with respect to schedule, quality of materials and service.

AMAL HRSG 1 PROJECT

Project Management:
The project management primarily be a Head Office based activity involving
project controls, Engineering coordination, Procurement, Cost control, Contracts
administration and construction activity monitoring include safety & quality
administration.
Change control and monitoring shall fall under the purview of Project Manager

10

AMAL HRSG 1 PROJECT

Key personnel CVs

* Key personnel inline with Contract requirement are already identified for the
project
Project Manager/ Contracts Manager
Engineering Manager
Construction Manager
Interface Manager
Construction Engineers (CME&I)
Procurement Manager
Commissioning Manager
Planning Manager
Lead Site QA/QC Engineer
HSE Manager
QC Inspector (CME&I)
*

Krishnaraj G B
Murali Krishna
M N Tamodharan
Karthikeyan
Girish
Arun Roshan DSouza
Kopula Sudakhar
Binil Mohan

Their respective CVs shall be Submitted to PDO focal point.

11

AMAL HRSG 1 PROJECT

Design Verification
FEED Documentation Review & Verification to ensure

Completeness, Correctness and compliance to the design intent.

Suitability of the FEED Package for Detailed Engineering.
Verification Scope change management.
Document Numbering & Equipment numbering philosophy.
Drawing and Document format.

To achieve above objective, following Key FEED documents will be reviewed.

*
*
*
*

Plot Plan / Layouts

General Arrangement Drawings
PEFS
Equipment / Material Selection and Sizing
Individual Discipline deliverables as necessary

Design Review
HAZOP Review
SAFOP Review
IPF Review

12

AMAL HRSG 1 PROJECT

Mobilization Plan

Engineering
* Mott Macdonald / TR Engineering to be finalised as a Design consultant
* All Engineering will carried out at Design consultant office at Muscat for the entire
project

Procurement
*

Procurement shall be handled by a dedicated team consisting of discipline wise

procurement engineers already identified. The team will be headed by
Procurement manager

13

AMAL HRSG 1 PROJECT

Scheduling and Execution of the work

We have prepared Level 3 schedule in consultation with all proposed discipline

Engineers and the same shall be circulated to the respective personnel for the
timely, safe & efficient execution of the project

Project controls under the guidance of Project Manager shall closely be

monitored by all Discipline Heads / Planning Engineers and keep comparing the
actual deliverables to the baseline schedule and take corrective action as and
when required to enable proper aligning of the project schedule to client
requirement and contract.

Planning will be monitored since start of the project to the end of the project. The
monitoring of the project is the continuous process.

Reporting shall be done and submitted to PDO as per contract documents C8

Procedure for Contractors.

14

AMAL HRSG 1 PROJECT

Testing, Commissioning & Training

* All testing of equipment will be carried out by PDO approved testing
engineer.
*

Approved commissioning Engineer will be mobilized 120 days prior to start of

pre commissioning activities.

* The commissioning plan will be prepared as per PR 1159 detailing all

aspects of the pre commissioning and commissioning.
* Commissioning plan will be prepared 3 months in advance including
activity checklist and approval will obtained before start of commissioning
activities.
*

Acceptance test will be carried out in accordance with the requirement of C6- 21
and ISO 2314. During this acceptance test the plant will be operated by
company staff.
15

AMAL HRSG 1 PROJECT

Final Documentation
*

As Built Drawings.

Operating and Maintenance manual.

Vendor bulletins and operating instructions.

* Design reference manual as per SP 1132.

*

Plant data book.

Complete drawing register as per the requirement of SP1003.

Commissioning Reports.

* A Documentary video (DVD Format) on project history from award to

commissioning

16

AMAL HRSG 1 PROJECT

Histogram of resource levels.

17

AMAL HRSG 1 PROJECT

Site Establishment

Office & Camp Facilities: Existing Facilities of Amal power project shall be used
for Amal HRSG project. All office and camp facilities to the company personnel
will be provided as specified in C6-29.

On-site Fabrication Facilities: Existing fabrication workshop will be constructed

as part of Industrial Facilities. This facility shall be used for complete fabrication
of pipes, spools, structural, Painting works etc. In Addition to this AHEC is
planning to use Ghala work shop for fabrication of Structural / Piping.

Site office: Existing office facility will be used for this project.

18

AMAL HRSG 1 PROJECT

Equipment Storage Yard

* The equipments supplied by vendor either through free issue or our own
procurement shall be safely stored as per the procedure furnished by vendor.
*

Material lay down area shall be used for storing of materials in identified areas
for different class of materials.

* Storage of rejected materials: A separate area shall be identified as quarantine

area for storage and subsequent disposal of rejected items.

19

AMAL HRSG 1 PROJECT

Living Accommodation:

Existing camp to be used for the accommodation of the construction personnel

and site workmen. The camp shall be in accordance with PDO norms.

All Facilities for company personnel will be provided as specified in C6 -29

Camp will be equipped with all facilities required.

Camp Boss will be the supervisor

Camp security will be provided.

20

AMAL HRSG 1 PROJECT

Camp Layout

21

AMAL HRSG 1 PROJECT

Site Office Facility

22

AMAL HRSG 1 PROJECT

Industrial/ Storage Facilities

23

AMAL HRSG 1 PROJECT

Communication To and From site:

1.

Existing Landline communication will be used for this project.

2.

E-mail and Fax Facilities shall be provided by AHEC at office Premises.

3.

All office automation to the company will be provided as specified in the C6

documents C6-29

24

AMAL HRSG 1 PROJECT

Construction services and utilities:

Local Community Contractor : We shall actively engage LCC services

wherever possible on various construction services, based on their
resources and potential ( Mainly Earth works)

Drinking Water : PDO RO plants will be used for drinking water.

Catering : Reputed catering contractor for this project has already been
identified.

Sewage Disposal :Sewage Disposal will be done at existing STP.

25

AMAL HRSG 1 PROJECT

Material Control Facilities:

* The following are the detailed material control procedure :

All equipment & materials including spare parts at the project site shall be
received by AHECs authorised personnel. Upon receipt, materials will be
inspected for specification, quantity, quality, shipping damage, certification of
approval and conformity to purchase order. Reporting on damages, if any, for
possible insurance claim / corrective action.

Material shall be handled with great care and protected from the impact of
throwing, dropping, dragging, bumping and hitting which may damage the
material or coating.

Materials shall be lifted by suitable equipment with non-abrasive wide nylon pipe
slings or special lifting hooks.

26

AMAL HRSG 1 PROJECT

Security:
Site security shall be arranged by AHEC. we shall appoint Security staff for the entire
duration of the project. The sources of Local Security will be done through Local
Wali / PDO authorities,

27

AMAL HRSG 1 PROJECT

HSE

Managing HSE Workshop.

Hazard Sheets & HEMP Register.

Toolbox Talks & Use of Prompt Card

STOP Implementation

Job Safety Plan & PTW application

Road Transport mentorship programme and drivers Forum.

Journey Management System/Journey Transit Point at Haima & AHEC IZZ Yard
with rest room facilities including for PDO.

HSE Audit and Review

28

AMAL HRSG 1 PROJECT

HSE

OPAL certified HSE Management System is in place

AHEC QHSE Management System & Sustainable development Management

System endorsed by PDO.

AHEC is ISO 14001 and OHSAS 18001 certified company.

Addresses all issues including Legal and other requirements in HSE Plan.

Provides frame work for Continual improvement

Visible demonstration of Companys Corporate Commitment.

Amal HRSG project addressed life saving rules for site implementation.

Sub Contactor Letter of Assurance Verification.

CEOs Letter of Assurance to P.D.O.

All incidents and RTA reporting through Project Manager responsibility.

29

AMAL HRSG 1 PROJECT

Subcontracting:
Identified subcontract areas are as follows:

NDT

Insulation.

Earth Works

HVAC Works

Design & Engineering

Catering Services

Road Works

30

AMAL HRSG 1 PROJECT

Detailed Design Activities and assurance

Engineering Contract Quality Plan will be prepared in compliance with ISO 9001-2000
Document & Drawing control register.
Preparation of Engineering documents & drawings.
Single Discipline Checks (SDC) and Inter discipline check
Incorporation comments of SDC/ IDC.
Internal Quality Audits.
External Quality Audits.
SAP Coding.

31

AMAL HRSG 1 PROJECT

Procurement Activities & Assurance

Material Tracking Sheet on regular basis.

All project material shall be procured from approved vendor list.

Floating enquiries to company approved suppliers with all relevant technical

specification.

Communication on changes, if any to an order during production by change control.

Expediting

Inspection by company approved third party/AHEC/Company.

Kick off/Inspection meeting between company, suppliers & contractors prior to start
of manufacturing activities.

32

AMAL HRSG 1 PROJECT

QA/QC activities and assurance

Contract Quality plan of SP 1171 will be prepared and approval from the client
shall be obtained.
ISO-9001:2008 Quality system shall be implemented.
AHEC is accredits certificate for U stamp (Pressure vessel), S Stamp
(Pressure boilers) and R Stamp (Repair works)
All the relevant QCPs (ITPs) shall be prepared initially with the project scope of
work and approval shall be obtained from client.
The approval for site key QA/QC Personnel shall be obtained from client and will
be mobilized to site on need basis.
The audit shall be conducted as per the audit plan. (In the CQP).

33

AMAL HRSG 1 PROJECT

34

AMAL HRSG 1 PROJECT

35