CONSTRUCTABILITY PROGRAM

CONSTRUCTABILITY PROGRAM
TABLE OF CONTENTS
1.0 SCOPE 3
2.0 PURPOSE 3
3.0 DEFINITIONS 3
4.0 RESPONSIBILITIES 4
5.0 INSTRUCTIONS 5
6.0 REFERENCES 6
7.0 ATTACHMENTS 6
1. SCOPE
This project specification defines the requirements for Constructability for all process units, offsites and utilities on the CNOOC and Shell Petrochemicals Complex (CSPC) Project. The specification is applicable to the Implementation phase.
2. PURPOSE
The purpose of this specification is to describe the extent of Constructability reviews that will be undertaken for the Implementation phase of this project. The specification also advises the involved parties and their responsibility.
3. DEFINITIONS
3.1 Constructability, as defined by the USA Construction Industry Institut e (Cll), is “the optimum use of construction knowledge and experience in planning, design, procurement and field operations to achieve overall project objectives”.
Constructability is the ongoing process of integrating construction knowledge and experience into conceptual design, procurement, detailed engineering and field construction operations which provides the opportunity to reduce costs and improve project schedules.
The ability to influence project costs and to incorporate construction experience and methods into a project plan and design is greatest during the early stages of the project. Therefore, the greatest benefit of the Constructability process will be derived with the earliest establishment and implementation of a Constructability plan on a project.
3.2 Constructability review refers to the process whereby experts from every discipline gather together to consider and question a design in order to explore the possibility that design improvements may allow reduced construction costs or improve convenience for the end user. The Constructability review will be attended by experienced construction and operations personnel, some experienced personnel who were not involved in the original design, together with the design team.
The Constructability design review process generally leads to suggestions
for design improvements which:-
will ensure build-ability
will allow easier and hence lower cost construction
will improve safety during construction by reducing risk
will improve accessibility during both the construction and operating phase
• • • •
4. RESPONSIBILITIES
4.1 EP or EPC CONTRACTOR shall submit his Constructability Program for PMC approval. This shall address as a minimum all areas identified in this specification.
4.2 PMC will nominate a Construction Coordinator who will monitor compliance by the CONTRACTOR to his Constructability Program.
4.3 CONTRACTOR shall appoint a Constructability Engineer to lead and co-ordinate all his constructability activities throughout the engineering/procurement phase of the project.
4.4 EP or EPC Project Manager
4.4.1 Shall ensure a schedule of Constructability reviews is prepared to suit the schedule of design document production.
4.4.2 Shall chair the formal Constructability reviews and ensure that, the
correct expertise participates, and that the findings of the team are properly documented and allocated to actionees and that completion is followed up.
4.4.3 Shall review relevant previous experience (e.g. operation alerts) prior to Constructability meetings.
4.4.4 Shall prepare an agenda for the Constructability review.
4.5 EP or EPC Constructability Engineer
The EP or EPC Constructability Engineer shall provide construction knowledge, experience and engineering input into the project throughout all phases of the project.
The Constructability Engineer shall arrange for other construction specialists, as required by the project. His responsibilities include:
• Arrange for the production of the Contractor project site HSE plans • Arrange for Hazards to Construction risk assessments/HEMP compliance
• Develop the construction execution plan (as applicable).
• Arrange for constructability and design reviews.
• Input to the construction schedule/construction area breakdown/detailed work breakdown structure (WBS) and construction sequencing.
• Arrange transportation and lifting studies (for major equipment).
• Arrange and coordinate all specialist construction personnel
• Coordinate with material control and shipping.
• Ensure site surveys ar e conducted
• Provide construction input into pre-qualification of sub contractors. • Develop the temporary facilities (as applicable).
• Ensure the appropriate lessons learnt from previous projects are taken into consideration.
• Develop and arrange f or the timely production of all construction deliverables.
• Carry forward constructability issues identified in Definition Phase (PMC will provide).
• Prepare and implement Constructability Awareness Workshops.
5 INSTRUCTIONS
5.1 Programme
CONTRACTOR shall develop a programme of project specific construction deliverables and formal reviews, which will define responsibilities and due dates compatible with the project schedule.
5.2 Constructability
The Constructability Engineer will arrange for the Constructability review team, which will be drawn from key members of the project team and other required specialists. These key personnel will conduct formal reviews as determined by the schedule and project requirements. The key
personnel will normally be drawn from the following:
PMC Construction Co-ordinator
Company Representative
From Contractor
Project Manager
Engineering Manager
Chief Engineers
Construction Manager
Planning Engineer
HSE Manager
Quality Assurance Manager
Project Commissioning Engineer
Materials Manager
Other specialists may be required to participate in the constructability reviews depending on the subject being reviewed. It is anticipated that most constructability activities will involve only a small number of the above at any one time.
The agenda for each Constructability review will define which personnel are required to attend.
5.3 Constructability Awareness Workshops
Contractor shall submit his proposals for PMC approval for Constructability Awareness at all levels in his organisation.
5.4 Constructability Ideas Log
Contractor shall include his proposals for operating a Constructability Ideas Log to raise and close out good practices and innovative ideas. • • • • • • • • • • • •
5.5 Lessons Learned
Previous experiences on similar projects and locations including from PMC shall be considered together with applicable items from the “lessons learned” database and corporate alerts.
Prior to above referenced Constructability reviews, attendees shall provide references to previous experience/lessons learned to the Constructability Engineer to collate.
5.6 Basis of Reviews
The reviews shall use the checklists provided in section 7 attachments. 5.7 Documentation for Reviews
The Contractor Engineering Manager shall ensure documents required under section 7 attachment lists are available at the Constructability review.
5.8 Maintenance of Constructability Records
The Contractor Constructability Engineer shall maintain records of constructability activities/outcomes.
5.9 PMC Constructability Forums
PMC will lead a maximum of three one day Constructability Forums to be attended by Contractor Constructability Engineers. Additional attendees will be drawn from Constructability review attendees listed in 5.2. The first will take place within six months of contract award.
The purpose of these forums will be to share progress and lessons learnt and agree action plans where appropriate.
6 REFERENCES
6.1 HSE Plan: Management Systems Overview SP-8560-0000-0003
6.2 HSE Plan: Site Management SP-8560-0000-0006
6.3 Construction Environmental Control Plan PR8560-000-1503
7. ATTACHMENTS
7.1 Check List for Constructability reviews.
7.2 Engineering documents to be reviewed.
ATTACHMENT 7.1
CONSTRUCTABILITY CHECK LIST
CONTRACTOR shall note that in the Definition Phase Plot Plan and Constructability reviews were carried out. PMC will provide copies of the
minutes to CONTRACTOR for Definition Phase status on following items:
1. Are there any existing buildings/structures on the site where the new plant is due to be built?
2. Is there any contaminated land on the new site? If so have the problems associated with this been quantified?
3. Are there any existing overhead or underground services?
4. Will construction involve workers coming into contact with lead, asbestos, PCBs or radioactive substances?
5. Is the proposed construction site adjacent to any other industrial, commercial, domestic activity or existing operating plant? How will construction be managed to ensure that there will be no adverse interactions or can these be engineered out?
6. Are there any very large, heavy, special or complex items of equipment requiring special attention?
7. Are items in (6) being designed for transport and lift?
8. How will such items get to the site?
9. What is the strategy for dressing of vessels and modularisation?
10. Are there any special requirements for on-site construction?
11. How are the lines to be tested?
12. To what extent is chemical cleaning required?
13. Are there any special safety requirements?
14. What is the design strategy to minimise the level of risk during construction and commissioning?
15. Where are the laydown areas and construction offices?
16. Are there adequate areas for lifting operations?
17. Which are the routes for the movement of large loads on plot?
18. Are roads wide enough for cranes to get in and out again?
19. Will fired heaters arrive on site in one piece? Will they need to be erected on site?
20. Are any vessels or tanks being erected from pieces on site? Is space available?
21. Are compressors being erected on site? Is space available?
22. Is there a strategy for unit(s) becoming operational whilst other units are being constructed?
23. Review drawings for Temporary Facilities, laydown areas and fabrication
24. What actions should be taken in response to the Soils Report?
25 How will temporary electrical supplies be provided?
26 At what depth is the water table?
27 What existing underground services are there?
28 When will permits be required for excavation?
29 Will piling operations impact on adjacent plant and buildings?
30 Are there any overhead power cables or pipe racks?
31 Where will cranes be located?
32 What laydown areas are required?
33 Will the installation of some equipment need to be delayed until after major lifting operations are complete?
34 Is there any need to lift over live plant?
35 Is there risk from transport near live plant.
36 What first aid arrangements will be available on the site?
37 Is there an emergency plan for evacuation of the site?
38 Are there climatic problems due to heat, cold, wind, snow or darkness?
39 How will liquid and solid waste be disposed of during the construction phase?
40 Is there a problem with either noise or vibration during construction phase?
41 How will Control of Substances Hazardous to Health <COSHH> be handled during construction? Is there a list of substances for which COSHH Assessments are required?
42 How will access to the site be controlled
43 Are there any innovative design opportunities to aid Construction?
44 Has any disinvestment been adequately designed and planned?
45 Are dimensional survey provisions sufficient to provide adequate dimensional information for design and for accuracy of construction?
46 Is there a need to develop special Method Statements for any activities in the Definition Phase or to highlight as required to be developed in the Implementation Phase.
ATTACHMENT 7.2
REVIEW OF ENGINEERING DOCUMENTS
The following is a typical list of checks to be reviewed against engineering documents.
DOCUMENTS TO
BE REVIEWED PROPOSED CHECKS
1. Plot Plan 1.1 Plant Layout
1.2 Access for construction activities
1.3 Alternative recommendations
1.4 Access for sequential construction
1.5 Area for temporary facilities, warehouse etc.
1.6 Future maintenance
1.7 Heavy lift involvement/available space
1.8 Cranage Access
1.9 Laydown areas and on plot
2. Disinvestment 2.1 Access
2.2 Size and weights
2.3 Safe sequence, procedures
2.4 Any safety hazards, COSHH, etc.
2.5 Disposal laydown areas
2.6 Soil, personnel and equipment decontamination arrangements
3. Underground 3.1 Sufficient depth cable ducts at
drawings road crossings
3.2 Firemain details are clear
3.3 U/G piping to be checked for access, installation, method and testing sequence.
3.4 Earthing review for access, installation method and testing sequence.
3.5 Cable trench routing
3.6 Ensure u/g piping connection to piping layout is constructible, consider flanges rather than difficult field welds
3.7 Consider use of blockwork and proprietary
pre cast items
3.8 Review schedule for design of U/G
facilities and structures to ensure it is early enough to allow installation prior to adjacent foundations
3.9 Ensure final grades are established
prior to installing U/G utilities.
4. Groundworks 4.1 Excavation levels
4.2 Muck out routes
4.3 Backfill access
4.4 Ground bearing pressures
DOCUMENTS TO
BE REVIEWED PROPOSED CHECKS
5. Piling drawings 5.1 Access
5.2 Underground obstructions
5.3 Working sequence
6. Civil/Structural/ 6.1 Interface with other disciplines to avoid
Building/Building clashes Services 6.2 Constructability of reinforcing in major concrete structures
6.3 Cost saving by considering use of proprietary pre-cast units
6.4 Interface platform drawings for inst/elect supports
6.5 Removable structures for major lift access
6.6 Ensure foundation bolts are in correctly (template from vessel fabricators – design check for rigidity)
6.7 Mass concrete rather than many small plinths
6.8 Buildings; ensure cable entries and other penetrations do not foul building steelwork
6.9 Use blockwork where possible in trenches
6.10 Consider pre-fireproofing structures
6.11 Ensure ducts banks are not too deep
6.12 Ensure building internal finish is to specifications
6.13 Ensure HV AC is thoroughly clash detected
6.14 Check interfaces of Services electrical and instrument equipment and cable entries penetrations
6.15 Service ducts in buildings adequate for installation.
6.16 Pouring concrete in extreme climates
6.17 Large concrete pours in preference to multiple small pours
6.18 Permanent access to reduce
scaffolding.
6.19 Provision, location and capacity of permanent lifting beams
6.20 HV AC specification for materials and testing.
6.21 HV AC Plant room layout
6.22 Ensure structure erection contracts contain provisions to reduce requirements for fall protection, ie flooring, handrail and stairways proceed at the same rate as structure erection.
6.23 Minimize structural steel field welded connections.
DOCUMENTS TO
BE REVIEWED PROPOSED CHECKS
7. Vessels, PAU's 7.1 Lifting arrangements, frames, spreaders and
vessel/stack lifting lugs
and VPU’s 7.2 Maintenance access
7.3 Calculated weights and centres of gravity
7.4 Setting out, placing and tolerances
7.5 Dressed - check erection access
7.6 Trial fit of platforms etc, if vessel is erected before dressing.
7.7 Physical weight checks, dimensional checks
7.8 Insulation, fireproofing - piping clashes
7.9 Provide at least two anchor bolts slightly higher than the remainder to act as guides during setting of the vessels (slight tapering of the tops to aid location.)
7.10 Check that supports furnished by “others does not interfere with maintenance, nameplates, connections, etc.
8. Piping 8.1 Pipe supports - detail and location availability
8.2 Allowance for insulation and fireproofing - clashes
8.3 Shop/Field fabrication split
8.4 Sequence detailing consistent with construction programme
8.5 Module hook up, optimum fit, hook up butt locations
8.6 Field fit welds - optimum positions
8.7 Clashes; - check
8.8 Vessel branch connections - same specification, tolerance and orientation
8.9 Line lists include pressure test data
8.10 Isos show orientation of vents and drains
8.11 Expansion loop locations - possible better use of bellows
8.12 Ensure basket strainers are supplied to pipe fabricator for trial fitting 8.13 Consider clamp supports adjacent to pumps for 4" lines and below - to assist in pump alignment
8.14 Location of spading points
8.15 Chemically cleaned lines. Possible offsite cleaning and protection 8.16 Ensure pre-commissioning sequences are established early to allow proper scheduling of piping erection.
8.17 Ensure that Lists agrees with th e P&ID’s.
8.18 Ensure vents and drains are engineered for hydrotesting, flushing and start up requirements.
9. Electrical 9.1 Switchboards - access and maintenance
9.2 Earthing - sufficiently detailed philosophy
9.3 Use of standard core multi cables (PMC will establish standards)
9.4 Definition of trench cross sections
9.5 Lighting standards attachment brackets suit handrailing
9.6 Lighting standards Re: capable of being installed without having to
use major cranage
9.7 Cable runs are not underestimated
9.8 Early cable pulling of underground cables. Allowance for spare cables 9.9 Cable tray interfaces
DOCUMENTS TO
BE REVIEWED PROPOSED CHECKS
9.10 Cable entry into buildings is detailed in conjunction with civil drawings
9.11 Supplier package drawings checked and motors tagged correctly
9.12 Lighting and small power for installation
access and method.
9.13 Check that schedule for lighting design is early enough to allow use during construction and
for the dressing out of vessels on the ground
9.14 Size cable trays for additions due to design development during construction
10. Instruments 10.1 Cables - check not too many in confined entry space 10.2 Consider stainless steel piping from inst. air manifolds to instruments - possible cost saving
10.3 Interface CCMS panels
10.4 Full information on loop drawings
10.5 Above ground cable runs not underestimated
10.6 Early cable pulling of underground cables. Allowance for spare cores or cables
10.7 Location of instrument stands and support steel
10.8 Check vendor skid drawings for all aspects of instrumentation. Ensure instruments on skids are in overall instrument list for inspection, precalibration etc.
10.9 Panels - access for maintenances and operation
10.10 Traywork into equipment rooms
10.11 Inter discipline clashes
10.12 Environmental storage conditions to be advised to site
10.13 Cable tray interfaces
10.14 Cable entry into buildings is detailed in conjunction with civil drawings
10.15 Check for correct dimensions of control valves
10.16 Check that drawings show instrument locations and orientations (This should be reviewed by Operations)
10.17 Establish standardized stand details for mass production
10.18 Check routing of “no low point lines”; such as analyser samples, for interferences
11. Suppliers Quality 11.1 Sufficient 'Hold' points to ensure no
Plans clashes that would affect hook up
11.2 Ensure erection documentation is issued to site prior to receipt of the vendor package
11.3 Ensure all Q.C. documentation sent to site on completion of the package
12. Suppliers 12.1 Lifting/handling attachments for Purchase Orders packages are suitable
12.2 Delivery methods compatible with site facilities for receiving
12.3 Weight and dimensional control in place
12.4 Works testing/commissioning optimised
12.5 Delivery dates to match construction schedule.
12.6 Ensure that orders require that anchorage details,
template, etc are scheduled to support foundation
placement .
12.7 Maximize use of driiled in anchors.。