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