7000-Extr-N004-Bngl-G00000-Ya-5760 - 00001 - Pep 03R PDF
7000-Extr-N004-Bngl-G00000-Ya-5760 - 00001 - Pep 03R PDF
7000-Extr-N004-Bngl-G00000-Ya-5760 - 00001 - Pep 03R PDF
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Doc. no.: 7000-EXTR-N004-BNGL-G00000-YA-5760-00001
Project Execution Plan Revision: 03R
Revision History
01R 27-May-2018 Issued for review John Gurcam John O’Brien C. VonHaven
02R 24-Jun-2018 Issued for review John Gurcam John O’Brien C. VonHaven
03R 05-Jul-2018 Issued for review John Gurcam John O’Brien C. VonHaven
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Table of Contents
1. INTRODUCTION 4
1.1. Project Overview 4
1.2. Project Scope of Supply 6
1.3. Summary of Exterran Responsibility 10
1.4. Summary of Client’s Responsibility 13
2. PROJECT ENGINEERING AND MANAGEMENT 14
2.1. Project Management 14
2.2. Project Reporting and Meetings 16
2.2.1. Weekly and bi weekly Reporting 16
2.2.2. Monthly reporting 16
2.2.3. Meetings 17
2.3. Project Document Control 19
2.4. Coordination and communications, Correspondence Procedures 20
2.5. Project Controls 22
2.5.1. Scheduling 22
2.5.2. Cost Control 22
2.6. Administrative Support 23
2.7. Engineering Section 23
2.8. Permitting 23
3. PAYMENT INVOICING PROCEDURE 23
3.1. Invoice Format and Content 24
3.2. Invoice Attachments 24
3.3. Payment Milestones 24
4. PROCUREMENT & SUB-CONTRACTING 25
5. MANUFACTURING 26
6. LOGISTICS 28
7. QUALITY MANAGEMENT 29
8. HSE MANAGEMENT 29
9. TRAINING AND COMPETENCE 30
10. CONSTRUCTION SUPERVISION, COMMISSIONING AND START-UP 30
11. OPERATIONS AND MAINTENANCE 31
12. PROJECT CALENDAR 31
13. EXTERRAN ORGANIZATION CHART 31
14. EXTERRAN INTERNAL DOCUMENT DISTRIBUTION MATRIX 31
15. SUMMARY OF PAYMENT MILESTONES AND PENALTY 31
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1. Introduction
1.1. Project Overview
Basra Gas Company has a requirement for Gas Processing Facilities at Ar Ratawi in Iraq. The Basrah
NGL Project covers the installation of Gas Receiving facilities, Acid Gas Removal and Sulphur
Recovery facilities, cryogenic NGL extraction and export facilities with a total capacity of 400 MMScfd
of feed gas, split between two identical processing trains.
The Project is based on the use of replicated, standard, pre-engineered gas treating and NGL extraction
designs, modularized to a high degree, as widely used in the NGL industry and adjusted where needed
to process the feed gas composition specified. A notional 200 MMSCFD capacity per train is requested.
Exterran Execution Plan is to design and manufacture assembled modularized skid units, designed and
built to Exterran standard design requirements, and International codes and Standards with simplifying
the facilities and to meet the project schedule and minimizing site construction time.
The proposed approach fits well with Exterran’s execution philosophy where utilization of existing
designs for skid mounted equipment and associated skids will lend itself well to the fast track approach
and minimization of site construction time based on simple interconnecting hook up of pre-tested
modules on arrival at site.
Maximum utilization of Exterran standard design in accordance with International standards will be
employed with the additional acknowledgement that there will also be compliance to DEM2
requirements.
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Project Location
The NGL facilities will be installed at the Ar Ratawi site which is located approximately 12 km west
of the existing NR NGL facilities.
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Engineering, Procurement and Fabrication of Plant equipment and facilities with CIF Iraq delivery,
comprise of the following list:
a) Civil Design, including Foundation Calculations and Drawings
b) Balance of Plant Design
c) HAZOP and SIL
d) Feed Gas Inlet Facilities, includes Slug catcher
e) Gas Processing Facilities, including Sulphur Recovery Unit
f) Ethane Extraction Facilities
g) Utility Systems
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Fired Heater
1. F-13101: Regen Gas Heater
2. F-41101: Hot Oil Heater
Centrifugal Pumps
1. P-11102 A/B: Amine Booster Pumps (S-205)
2. P-11103 A/B: Amine Still Reflux Pumps (S-205)
3. P14101 A/B: NGL Pipeline Pumps (Off Skid)
4. P-62101 A/B: Flare KOD Pumps (S-701)
5. P-41101 A/B/C: Hot Oil Circulation Pumps (S-601)
6. P-63101 A/B: Chilled Water Pumps (S-602)
Multistage Pumps
1. P-11101 A/B/C: Amine Circulation Pumps (Off Skid)
PD Pumps
1. P-50102: Methanol Injection Pump (On Skid)
2. Chemical Injection Pump
3. Corrosion Inhibitor Injection Pump
IA Package
N2 Package
Flare Package (F-62101)
Thermal Oxidizer Package
EOT Crane
Fabricated BOP Pipe Spools
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Pipe supports for ISBL supplied interconnecting pipe spools (shipped loose)
Aboveground drain system ISBL. Installation of Drain System by COMPANY
Utility stations within ISBL process & utility areas. Utility stations located on modules / skids
installed by CONTRACTOR. Piping for utility stations within pipe racks installed by
CONTRACTOR.
ISBL Plant control system - (DCS, SIS system). Control System is PLC based.
ISBL Control room (Field Auxiliary Room).
ISBL Local Unit Control panels for compressors
ISBL Local Unit Control Panel for SRU. For control panel that is installed in a pre-fabricated
building / container. SRU Control panel is containerised.
ISBL Local Unit Control Panel(s) for Hot Oil Heater(s)
ISBL Local Unit Control Panel for Regeneration Gas Heater
ISBL Local Unit Control Panel for Expander Compressor
MCC Building & electrical distribution within ISBL’s scope. Electrical cabling within modules,
skids & MCC Building by CONTRACTOR to JB on edge of module, skid or equipment. Electrical
cabling between adjacent MCC containers installed by COMPANY. Modules, skids & MCC
installed by COMPANY.
Instrument, control & electrical cable pre-installed on skids; terminated at modular skid junction
boxes (except power to motors)
Electrical power cable to motors (on-skid & off-skid) from MCC
Cable tray & bulk material for connection of ISBL supplied ship-loose instruments. Cable tray
shall be pre-installed on pipe rack modules.
Interconnecting cable trays & electrical bulk materials between ISBL supplied equipment.
Earthing lugs on modular skids, pipe racks & off-skid equipment. CONTRACTOR installs
earthing to single earth point on skid & off-skid equipment. COMPANY connects earth point to
site-wide earthing grid.
ISBL skid lighting. Electrical cabling within modules, skids & MCC by CONTRACTOR to JB on
edge of module, skid or equipment. Modules, skids & MCC installed by COMPANY. Area lighting
assumed to be sufficient. Exterran shall ensure lighting is sufficient to safely operate equipment in
multi deck modules.
Design of Aircraft warning lights on high structures. CONTRACTOR shall design the support
brackets for installation and for cable routing.
Emergency power system for ISBL equipment, including emergency diesel generator, diesel
storage day tank.
Design of Foundation for ISBL supplied equipment, pipe supports & pipe racks.
Anchor bolts & anchor bolt templates for off-skid towers & vessels.
Shelters associated with ISBL scope equipment, e.g. compressor shelters, including fixed
maintenance equipment. For Compressor Shelters, Manual gantry crane will be provided.
Design of foundations & paving ISBL area.
Design of Site drainage & water run off for areas in ISBL Process Units area.
As built drawings for ISBL scope of supply. As built drawings for ISBL skids / module and pipe
racks is part of CONTRACT and supplied prior to shipment. Any site modified / marked up
drawings are provided under the Site Services Scope CONTRACT.
Final documents & data books per agreed document register.
Split AC for the control building (FAR) & MCC building. Split A/C units only considered.
Fire suppression system within ISBL designed & supplied buildings (if required)
Offline sample conditioning system. Considered as part of sampling system.
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Above to be read in conjunction with EXT-App-G D3 ISBL Scope of Supply Matrix 22 Feb’18
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Above to be read in conjunction with EXT-App-G D3 ISBL Scope of Supply Matrix 22 Feb’18
This gives a distinct advantage of the complete Balance of Plant execution to be under the control of a
single entity and under a single location.
BGC will have the full opportunity to see the fabrication progress at first hand and give the required
assurance to BGC that the fast track schedule is implemented.
The Overall Project Manager will be the contractual single point of contact between the customer and
Exterran and will have the overall authority and responsibility for managing and executing the project
according to the execution plan.
The overall Project Manager is responsible, in conjunction with the engineering team for the full
integration into the plant of the equipment and compressor skids supplied as part of the Out of Country
Scope. This will cover all engineering reviews including HAZOP, SIL and other coordination between
various centers to ensure smooth execution. (Whereas Exterran will coordinate and provision for the
associated costs of the HAZOP and SIL all other safety studies will be arranged by BGC with Exterran
support and attendance as required. All workshops, where required, will take place in the UAE).
Multiple HAZOP will be required to avoid delays to the schedule – firstly the process and treating plant
including reciprocating compression packages will undergo HAZOP, followed by subsequent
HAZSOPs for packaged plant such as the SRU, Refrigeration package and turbo expander followed by
a final HAZOP for remaining packages such as flare and thermal oxidizer
The Overall Project Manager will ensure integration of work performed by all Exterran business units
from Engineering, Procurement, Manufacturing, Logistics, HSE, Quality and In Country Operations
team to ensure streamlined execution of the Project.
The Overall Project Manager’s responsibilities will cover but not be limited to the below
a) Scope management, including establishment of Work and Cost breakdown
structure(WBS/CBS)
b) Project Change Management
c) Time management, including schedule baseline, detailing, tracking and control
d) Cost management
e) HSE management in close coordination of the HSE Manager
f) Quality management
g) Resource management
h) Communication management
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i) Risk management
j) Stakeholder & Interface management
k) Contract management
l) Engineering management
m) Procurement management
n) Manufacturing management,
o) Logistics management,
p) Lessons learnt and Process improvement
q) Closeout
Engineering – The engineering team will be responsible for ensure safe design of all the project
scope according to project requirements and applicable standards and will also facilitate and
conduct various studies as applicable.
Procurement - The procurement team will be responsible for the sourcing of all materials and
bulks needed for the fabrication of the process modules and will also be responsible for the
procurement of all bought out tagged items. Procurement also comprises expediting and
logistics.
Project Document Control – a single point of contact will be established for client
documentation transfer, they will be responsible for the collation and control of all necessary
documents to be issued to and from the client.
Project Controls - will be responsible for the control and monitoring of the project progress in
relation to schedule and commercial on going execution plus assistance in monthly report
preparation for the client and continuous internal monitoring.
HSE - will coordinate HSE activities during the initial design execution ensuring compliance to
the necessary codes and standards.
Quality - will coordinate with the project team, including internal and external manufacturing,
to ensure compliance to Exterran standard quality activities and International codes and
Standards
Fabrication and Assembly – a full multi discipline fabrication and assembly team will be made
available for manufacturing of all equipment, Skids, Piping, structural and misc. items.
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Logistics: Exterran Logistics Team will be responsible to get all equipment to the required CIF
destination. The logistics department will ensure adequate packaging of all equipment for freight
and all equipment / materials shall be moved by Exterran to CIF Basrah Port, Iraq. All relevant
detail packing list and commercial paperwork for Export from CIF location and import to Iraq
will be provided and coordinated with BGC according to the required document to ensure the
release of the frights based on Iraqi customs requirement.
Operations: An Operations Manager will coordinate the operations preparation phase and in-
country operations and maintenance activities. This will be closely coordinated with the
overall project manager to ensure smooth operation support. Exterran already have
Operations established in Iraq and will utilize their in country experience to assist in the
construction, commissioning and operation phases of the project. (In country works being
subject to separate service agreement under BGC 0353)
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(iii) Schedule, Progress and Productivity (including progress curves, quantity tracking, etc.)
(iv) Key milestone summary
(v) Main accomplishments in the reporting period
(vi) Summary of events per work package/discipline
(vii) Summary of events for upcoming reporting period
(viii) Areas of concern - risk and opportunity
(ix) Technical query and Deviation Request summary
(x) Invoicing and Payment status
Exterran’s Monthly Project Management Reports will also include the native file (.XER) of the latest
updated Primavera Schedule (but without resource /cost loading as this is deemed proprietary
information)
It is the Project Manager’s responsibility to generate and update the project report to Executive
Management on a monthly basis as defined by the project requirements. Other members of the project
team (Project Controls, Project Accounting, Planning etc.) will be required to support the project report
updates
2.2.3. Meetings
The Project Manager will schedule regular, recurring team meetings as indicated by the stage of project
activities, internally these will be weekly. The intent of these meeting is to disseminate pertinent project
related information and to facilitate direct communication between the various groups. Internal weekly
meetings will be recorded with actions and distributed to the Project team the same day.
A summary of the anticipated meetings both internally and externally are listed below
Weekly conference call skype meetings between the respective discipline engineers will be recorded in
an ACTION LIST which will track items discussed and their status
Separate Project related meetings/workshops are to be coordinated by BGC for which Exterran will
be in attendance as required (QRA, FERA Alarm and Trip Management for example)
Additional meetings can be called at any time by Exterran or BGC for the purpose of keeping all
parties fully informed with respect to the progress of the scope and for discussing technical subjects
and resolving such problems as may arise in the execution of the project.
All meetings will be conducted in English and the Minutes of Meeting will be issued in English
Language.
Where possible and practical meeting agenda and objectives of the meeting will be shared in advance
The respective Representatives should chair the meetings or at least nominate a deputy as required
Exterran will use their standard Minutes of Meeting format for recording of the meeting outcome and
actions. Exterran unless otherwise agreed will record the meeting and intend to share them within 48
hours of the meeting.
As a minimum the Minutes will include
Date of issue
Sequential No.
Sheet number and total number of sheets
Attendees and distribution List
Contract Number
Subject (brief but explanatory title)
Agenda/Objectives
Venue and Date of Meeting
Actions and proposed completion dates
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Approval cycle for documentation is 14 calendar days. The approval cycle period is under contractual
discussion, since BGC team not being able to work in CONTRACTOR's document management
system.
BGC must ensure that all multiple discipline comments should be returned on a single document
without any confliction that is only 1 set of consolidated comments should be received and there should
be no discrepancy or contradiction provided from the various multi discipline departments in relation
to the comments received. Consequences of not following this requirement in terms of timing and
completeness of comments will have a detrimental impact on the project schedule.
In order to maintain the schedule this is necessary and if for any reasons documents are delayed beyond
14 days Exterran will then proceed with design on the basis that the overdue returned document is to
be considered as approved. The approval cycle period is under contractual discussion, since BGC team
not being able to work in CONTRACTOR's document management system.
In line with Appendix G C5 List of Documents for Approval per Section XIV of Section V Scope
Definition, Exterran submitted schedule is based upon approval of those documents identified for
Approval. If additional documentation is identified for Approval this may have a detrimental impact
on schedule.
A Master Document Register (MDR) will be produced and maintained that details current status of all
drawings, and Project documentation. BGC should use the MDR to verify and confirm exactly what
documentation is required for what purpose (i.e. Information, Review or Approval) a practical approach
the document exchange will benefit the project schedule.
The MDR will monitor the date of issue of each document the date of the return, the status and the
latest revision of each specific document. This enables the Document Controller to generate a snapshot
to track any overdue documents. The MDR is a live document that is continually updated on a daily
basis. The MDR will be shared with BGC as part of the monthly Progress Report
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Exterran will comply with BGC document numbering philosophy and tagging philosophy for plant
equipment.
A separate but similar Document Register is generated for vendor documentation. This is for internal
purposes and is not intended to form part of the MDR shared with BGC. It will follow a similar format
for the Internal MDR with similar coding and submission options. The Vendor Document Register
can be shared with BGC
However there will be limited instances where vendor documents will have to be shared with BGC and
these will be submitted in the same fashion as all other project documents and will be issued under the
cover of an appropriate transmittal The Vendor Document Register can be shared with BGC for
tracking of the related vendor documents that are exchanged
Per the final agreed MDR, Exterran will submit the required documentation to BGC under one of the
3 required Issue Codes i.e.
For Approval
For Revised
For Information
BGC will clearly identify on the returned transmittals the review code that has been applied to each
particular document
A or 3 Approved – re issue if required
2 Accepted with comments noted, Revise and Resubmit
1 Rejected – revise and resubmit – Do not proceed
If BGC have no comments to documentation issued for information then those documents will not
have to be returned to Exterran.
Rejection of an issued for Review document does not infer that Exterran cannot proceed. Rejection
should only apply to documents submitted for approval. However should Exterran proceed following
receipt of a “Rejected” (for Review) document, they do so at their own risk and compliance to Contract
Requirements is mandatory regardless of any return status code from BGC.
All resubmitted documents will follow the Project required revision update protocol
For Information Initial submission 01I subsequent submission 02I
For Review Initial submission 01R subsequent submission 02R
For Approval Initial submission 01A subsequent submission 02A
In addition to the above subsequent submission codes will be utilised for
Issued for construction eg 06C
Issued for construction with Holds eg 06H
Issued As Built eg 07Z
All above will be applied in compliance with BGC coding and Reference Data document 0000-BGC-
G000-GE00-G00000-JA-7880-00001
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Email communication is deemed the formally recognized contractual format for project
communication. Only Contractual matters related to changes to price, scope and schedule are deemed
necessary to warrant communication via letter.
In this fashion both parties will avoid generation of unnecessary project letters.
A log for project letters will be retained for both outgoing and incoming correspondences. This log will
not record email communication. The letter and the log will contain the following detail
Project Name
Contract Title:
Contract Number:
Chronological Reference No:
Security/Confidentiality Classification: (where applicable)
From/Sender:
To/Addressee:
Date sent:
Copy to:
Subject:
In the event of oral communication of instructions or information exchange, related to the project, this
shall be followed up with a confirmed written communication within 7 days.
All correspondences shall be via the respective COMPANY and CONTRACTOR representatives.
Other will be included in CC as the subject dictates.
A standalone Project Communication Protocol document will be issued to BGC giving further
instruction and detail on project team member contact details.
Project Communications Protocol 7000-EXTR-N004-BNGL-G00000-YA-6048-00001)
The exception to this is that the respective Project Document Controllers will communicate directly
with each other with BGC Project Manager and Project Engineer included in the CC
In addition, Exterran will generate an internal Communication Distribution Matrix to assist the
Document Controller to ensure the specific documents are shared with the right internal personnel.
(Refer Attachment - 03 to this document)
Project Folders on a common drive will be utilized for the recording, filing and control of all related
project documentation, this is for internal use only
The Project Drive is structured as follows with numerous sub folders under each Main folder
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2.5.1. Scheduling
An overall project Level 4 schedule will be developed to ensure adequate focus and attention to a fully
logic linked Programme. The schedule will be in Primavera and will incorporate the following phases:
(WBS)
Project Milestones
Engineering
Procurement
Fabrication
CIF deliveries of all scope of supply and Milestones attached to them
This schedule will be used to identify and track the project critical path. The schedule will be updated
on a regular basis as defined by the project requirements. Bi weekly progress reporting figures will be
shared with BGC.
The fabrication section of the schedule will be structured such that fabrication activities associated with
either train1 or train 2 can be monitored and reported separately
Exterran will prepare separate documents to demonstrate the basis of the schedule construction and
define the methodology for progress measurement and reporting per the below documents.
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Should variations be required to the scope of works, these will be discussed and agreed on an individual
basis prior to implementation in accordance with the contract.
A separate document will be provided to BGC giving an overview of Exterran Project Controls
Procedure as identified below
Project Controls Procedure 7000-EXTR-N004-BNGL-G00000-YA-5759-00001
Engineering will in the vast majority be executed internally with the flexibility to utilize Exterran
approved engineering support services for detail design if required... The facilities design is based on
proven designs.
2.8. Permitting
Exterran will strictly comply with BGC site permitting requirements. All environmental and operational
permits shall be BGC responsibility.
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Ensure invoice(s) are in the paper and/or electronic format as agreed between both parties.
Include all relevant BGC coding and supporting documentations as specified in this Section
VII;
On achieving the completion of a particular milestone activity Exterran will formally request, by letter
from BGC, the signed Milestone Completion Certificate related to that particular milestone, with
supporting evidence. On receipt of the signed milestone completion certificate the invoice will be
prepared generally in line with the below requirements.
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Payment will be in accordance with the achieved Payment Milestones is described in Section IV -
Schedule of Prices. Once BGC have given acceptance of the Payment Milestone, achievement will be
issued via the Payment Milestone Certificate
It has been agreed that certain Milestones and related Liquidated Damages may be split on a per train
basis. In particular this is applicable to Milestones 9 onwards
Refer to Attachment - 04 of this document for a summary of the key dates that illustrates the number
of milestones, the anticipated dates and where LDs apply to a specific milestone. For further
definition of each milestone specific requirements refer to SECTION III C Schedule of Key Dates
and Liquidated Damages for Delay.
In addition there are project requirement of CONTRACTOR must utilise vendors and suppliers for
the scope of work that are capable of and willing to travel to Iraq to provide the necessary services
associated with the supply, warranty and rectification of any issues covered under the CONTRACT.
Regular meetings and teleconferences will be held as required to ensure good communications and
provide information to parties on the process and status of manufacture or fabrication.
A detailed Procurement schedule is produced covering all placed purchase orders. This is a continuously
updated spreadsheet monitoring and recording delivery status all the way up to equipment delivery and
final documentation delivery.
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This procurement schedule can be shared with COMPANY on regular basis and will be issued as part
of the monthly report
A Commercial bid tabulation will be completed on all main purchase orders (in additional to the
technical bid evaluation). It is not envisaged that either the technical bid evaluation or the commercial
bid evaluation will be shared with BGC and no BGC approval is required prior to Exterran placing any
purchase orders. Exterran may also opt to single source certain items where the project schedule
constraints dictate such and have also envisaged no restrictions on country of Origin
Exterran shall be responsible for planning and directing all expediting efforts and resources necessary
for maintaining and improving on Contractual Delivery Dates (CDD).
Exterran shall, maintain regular expediting contact with all vendor’s, identify focal points, and ensure
that the correct level of field expediting is applied to all purchase orders, with primary focus on all long
lead and critical path packages.
Exterran will provide personnel to be trained by BGC in the updating/population of ESPIR web based
data base (www.e-spir.com) for the supply of
Two years spares
Strategic / Insurance spares
Commissioning and start up spares will also be supplied in SPIR format but will not need to be entered
in the web based system,
Both Exterran and BGC vendor list are referenced and included within the contract. Refer SECTION
X Technical Information. Exterran vendor list is very much a live document and will be updated on a
regular basis to add or delete vendors selected to suit the project requirements and/or feedback from
supply chain performance. Any new identified vendors will be presented to BGC where it is not
anticipated that vendor approval will be reasonably withheld.
5. Manufacturing
Fabrication and assembly of the skid packages or modularized units is performed by Exterran. Exterran
reserves the option to utilize approved sub-contractors for items including equipment skids frames,
pressure vessels, tanks, etc. Exterran implements a strict check on subcontracted items. To ensure a
high quality product, the fabricators will operate (as a minimum) to the following:
a. All fabrication shall comply with Exterran’s manufacturing Quality System. All external
fabrication shall be performed using acceptable subcontractors. Suitably qualified management,
supervisory and inspection staff will be provided throughout.
b. All fabrication activities will be carried out by qualified tradesmen. All welding will be carried by
qualified welders working to accepted weld procedures. All weld procedures shall be established
and qualified in accordance with the applicable design and construction codes.
c. Marking, cutting, machining and assembly shall be performed using recognized engineering
practices. All dimensions shall be controlled to ensure that the product meet Exterran’s
engineering standards.
d. NDT, Painting, Thermal Spray Painting, Insulation and scaffolding works shall be carried out by
Exterran nominated sub-contractors at Hamriyah Facility.
e. Testing will be carried out in accordance with written procedures acceptable to Exterran.
f. Testing within the shop will comprise as a minimum – (Also refer Section XIV App G D4
Pre shipment Activities of modules, skids and packages) for further detail.
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NDT of piping
All visual and dimensional checks
Hydro testing of vessel and pipework
Drying of piping and equipment
Flushing of lube oil system
Flange Management (torqueing)
Pump alignments (primarily at vendor works)
Megger testing / insulation resistance testing
Instrument calibration (vendor works)
Loop / continuity checks of installed cabling
Bought out equipment standard factory acceptance test prior to delivery
Chemical cleaning of the Amine system.
Exterran shall carry out Trial-Fit work as much as possible for all the skids at its manufacturing location.
This will include complete build of multi-tier skids, trial fitting of all ladders and platforms. In addition
the absolute maximum insulation will be fitted (vessels, columns, and piping) in the shop to reduce the
extent of insulation works at site and Interface register shall be maintained by Exterran and provided
to BGC in the requested format per contract requirements.
Exterran shall design the Skid Modules and optimize the extent of modularization based on past
experience. However due consideration of shipping constraints and practical handling constraints at
site are also key to ensuring the delivered product is the most cost effective solution to suit the overall
project requirements.
The fact the fabrication and assembly takes place in the same location as the engineering team reside,
gives distinct advantages and immediate resolution of any concerns/clashes etc.
Exterran Construction Manager will also contribute to construction related design issues and
construction presence would be considered for the relevant model reviews. It would be beneficial to
have both Exterran Construction Manager and BGC lead construction personnel present at Hamriyah
during the final stages of disassembly. This will ensure a full understanding of the rebuild requirements
and clear visibility of the packing arrangements
12 month Preservation will be applied for all shipped equipment per Exterran standard guidelines
Location for the assembly of the compressor packages is based on packaging at Exterran facility in
Hamriyah. However Exterran reserve the right to consider Singapore and/or USA, if any schedule or
other project benefits are possible. Packaging in the UAE, does give distinct advantages to BGC for
close monitoring and first hand visual progress validation related to both compressor assembly and all
other vessel and module fabrication and assembly.
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Project Execution Plan Revision: 03R
The release of products for shipment shall not proceed until the planned arrangements have been
satisfactorily completed and the Certificate of Conformity has been signed-off by Project Quality
Manager and Project Manager or his representative.
In conjunction with the above Inspection and Test Plan completion a Punch List will be produced for
each item of equipment. The Punch List is a compilation of pending works from the approved
drawings, specifications, data sheets, codes, etc. or damaged, defective, missing, etc. items identified
during the final Inspection and installation of the particular item.
The punch list items shall be categorized as Category- A, B and C. following the discussion and
agreement with BGC
Category A: Punch list item that must be closed before the system handed over from a phase of
work after mechanical completion, generally the A category punch list shall be closed prior to the
hydro test.
Category B: Punch list item that can be allowed to roll over for later action completion- not
affecting the ability to do the next phase of the work. An item “B” in certain phase of work could
be transformed in “A” in the next phase if needed/relevant... Category B items generally closed
after the hydro test but before the mechanical completion.
Categorization of the punch list shall be in consultation with BGC and the approval to carry out at site
shall be agreed with BGC.
BGC will have the right to review the outstanding punch list items and, at its sole discretion, indicate
on the punch list any items that are not fully completed. The said items have to be completed by
Exterran prior to handover.
It is understood BGC’s appointed Installation Contractor will be responsible for the Commissioning
Management System (CMS) to be employed at the site. With adequate advance coordination it may be
possible to arrange for Exterran Inspection and Test Records to be aligned with the proposed CMS
such that there is seamless transition between completion of testing within the fabrication facilities and
the continued required testing post installation. Due recognition must be taken of the extent of testing
completed at the fabrication facilities such that repeat and unnecessary testing can be avoided at site
For further detail on Completions Management and Release prior to shipment refer to Project Quality
Plan 70000-EXT-N004-BNGL-G0000-QA-5798-00001
6. Logistics
Project logistics will be managed by Exterran’s logistics department.
The project team will coordinate the movement of all materials from the point of manufacture or
purchase to CIF Iraq Port. All shipping documents including, packing list, commercial invoice, and
certificate of origin together with any specific import document requirements fall under the Logistics
Manager’s responsibility. Any disassembly essentially required due to shipping restrictions will be
identified and coordinated by the Logistics team and Project Manager.
The logistics team will ensure the equipment and skids are packaged in accordance with Exterran
standard practices at the point of manufacture or at a centralized shipping facility to suit the mode of
shipping and the conditions at point of delivery.
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The Logistics team shall ensure and check that during handling and storage of materials; at least the
following general criteria are met:
- Use of appropriate procedures in handling, storage, packaging and preservation.
- Use of measures suitable to avoid damage, loss, or deterioration.
- Transport and lifting aids are suitable for the work to be carried out.
- That documentary evidence of equipment or material condition is kept.
- Removal of materials from the warehouse/storage is in a controlled manner.
- All materials that will require lifting are done using proper lifting technique.
- Pre-shipment transportation permit requirements en-route to port of loading will be obtained.
- Dimensions to be maintained within BGC advised envelop (25m x 5m x 5m LBH), with the
exception of 5.5m diameter for Thiopaq equipment as well as 40m length for towers/columns.
The location of the Exterran fabrication facility in Hamriyah (less than 1 hour from Dubai) has
distinct advantages as it is located just 1 km form the Hamriyah Port which will be used for load
out of the vast majority of the cargo
Exterran also own several low loaded multi axle articulated vehicles which are regularly used to
transport Exterran fabricated skids and columns for the fabrication yard to the port .This maintains
Exterran’s full control for the short transport journey to the port.
Exterran confirm that it is anticipated CIF destination and location will be Khor Al Zubair Port,
Basrah Iraq.
Documentation as per INCOTERMS 2010 CIF will be provided.
Preservation will be for a period of 12 months with packaging for sea worthy transport as necessary
It is anticipated there may be as many as 7 (separate dates) for major shipments, these being a
combination of all the process modules and vessels fabricated at Hamriyah plus other major
packages being delivered direct from vendors such as turbo expander, incinerator, SRU or flare.
7. Quality Management
Exterran will follow its internal manufacturing quality control mechanisms to ensure quality is
maintained. Exterran will utilize existing Manufacturing Quality Plans that will define the equipment
quality requirements. Exterran’s quality system is based on the ISO 9001:2015 series of standards and
recommended procedures and practices; it provides a framework used to define the control of materials
and processes, and verification of activities.
Exterran will provide a Project quality Plan per the below, which will be based upon the requirements
of Section IX Quality Management
8. HSE Management
Exterran HSE objective is to achieve the goal of zero incidents during the manufacture and operations
by following the Exterran HSE plan, as well as minimizing effects to the environment. Safe installation
and operability are equally important.
Exterran understands the importance of Safety, Health, and Environment during the execution of the
works, and is committed to insure that they and their subcontractors provide and maintain a safe
working environment. Exterran is also committed to incorporation of HSE principles in the design of
the facility, in order to maximize the long term protection of personnel, property, and the environment.
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From a HSE statistics reporting point of view all manufacturing related man-hours will be recorded
and reported. This will include all Exterran fabrication personnel and all Framework contractors
executing project works on Exterran premises (such a painters, scaffolders, insulators)
HSE statistics will not record man hours spent by Exterran’s nominated sub-contractors for any sub
contracted fabrication such as pipe racks or out sourced vessels.
A Project Specific HSE plan will be developed as below and this will cover Exterran contracted works
up to CIF. It will not include and out of country site related HSE and security issues
b) On site hands on training – This will be initiated prior to commissioning such that by operation
readiness the BGC staff will have an excellent understanding of the operational, maintenance and
safety aspects of the plant
c) Training of 6 off BGC operators (in batches of 2 for a period of 3 month each batch) at various
similar process related Exterran facilities (some flexibility on numbers and rotations may be
necessary to suit both in country (Oman/Pakistan and Iraq visa constraints
An option will also be considered for a full Plant Operator Simulator, to be housed in a dedicated
room in the BGC control room for training of operators on the control system prior to actual
operation on the plant control system. A more detailed Training plan will be established as detailed
design becomes more finalized
Exterran encourage early involvement of construction personnel so they can contribute to the
design development from a constructive perspective. Exterran will appoint a Construction
Representative who will participate in early design reviews and in particular the
constructability review to be organized and reported by Exterran.
Similarly Exterran appointed Commissioning Manager will be allocated early to the project so
pre commissioning and commissioning related initiates can be incorporated into the design.
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Project Execution Plan Revision: 03R
The Site Man Power histogram related to the Site Support Service (SSS) Contract will be developed
in conjunction with BGC to establish the optimum team and the required time of mobilization.
This will cover Construction, Commissioning and Operations personnel.
Due consideration should be given to the early involvement of the relevant personnel and to be
agreed with BGC.
Construction Manager is expected to be on site no later than 6 months before first equipment
deliveries
Commissioning Manager (CSU lead) is expected to be on site no later than 9 month before
start up
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Doc. no.: 7000-EXTR-N004-BNGL-G00000-YA-5760-00001
Attachment - 01
Contract "Effective Date" Engg. Weekly Skype Meeting for 2018 Monthly Progress Report Operations Review Non Working Days / Not applicable
Project KOM Weekly Meetings / Report Monthly Progress Review Meetings Constructability review TBC Risk Management Meeting (TBC)
Sponsor Meeting Design Review Meeting SIL Workshop Submission of VOWD - 2018 TBC Lessons Learnt Meeting (TBC)
Business Performance Review HAZOP 1, 2, 3 Model Review, 30%, 60%, 90% Fortnightly Progress Report - 2018 TBC Leadership Management review
Attachment - 02 (Part of PEP)
Page 1 of 3
Doc. no.: 7000-EXTR-N004-BNGL-G00000-YA-3352-00001
Attachment - 02 (Part of PEP)
Revision History
01R 22-May-2018 Issued for Review John O’Brien Gurcam John C. VonHaven
Page 2 of 3
Doc. no.: 7000-EXTR-N004-BNGL-G00000-YA-3352-00001
Attachment - 02 (Part of PEP)
Project Manager
John O’Brien
Construction Manager
Operations Support Operations Manager Construction Support
Training Santosh Wadekar
Team Cristian Donnet Team
Commissioning Manager
Commissioning Support
David Bolland
Team
Process Lead
Sergey Tatarinov Process Safety Supervisor Cost Engineer HSE Superintendant Document Controller
QA/QC Manager
(Hung Kai Jor) Jayasree Rhadedevi Ali Mohammed Industrial Engineers Victorino Lopez Kalish Bhosale Valeriano D’Souza
Manufacturing Industrial Engineers
Satheesh Kumar
Rotating Equipment Mechanical HSE Engineers Document Controller
Quality Planner
Sagar Sonavane Ramesh Vadivel Buyers Area Managers Superintendent Area Managers Peter Bernard Biju Sunny
Asit Bastia
Instrumentation Electrical
Sajan Joseph Rajan Nair Document Coordinator Cost Control Quality Assurance Cost control
Olive Puno (fabrication) Daniel Menguita (fabrication)
Document Control
* Same individual
Dileep Kumar Nair
Logistics Support
Skid's Manufacturing/Assembly
Buy-Out Equipment & Packaged
Fabricating/Assembling Weekly
Kick-Off Meeting MOM (Project
Electrical Engineering
Contract Management
Project Management
BGC‐NGL Project
Quality Management
Scope Management
Process Engeering
Static Engineering
Time Management
Cost Management
Risk Management
HSE Engineering
Monthly Report
PM Integration
Engineering
Fabrication)
Insulation)
Logistics
Licenses
material
Review
Internal document distribution Matrix
Report
Start)
Items
N
Name Position Location 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4.1 4.2 4.3 4.4 4.5 5.1 5.2 5.3 5.4 5.5 6.1 7.1
o.
Project Manegement
Chris VonHaven Vice President - GPO HOU CC CC CC TO CC CC CC CC CC CC CC
Hesham Tashkandi VP regional HAM CC CC CC CC CC CC CC CC
Todd Akers Managing Director & Manufacturing Director HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
John O'Brien Project Manager HAM TO TO TO TO TO TO TO TO TO TO TO TO TO TO CC CC CC CC CC CC CC CC TO CC CC CC CC TO TO TO TO CC CC CC CC TO TO TO TO TO TO TO TO
John Gurcam Deputy Project Manager /Project Engineer HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Akbarkhan Sakharkar Project Engineer HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Rajesh Krishnarao Contracts Manager HOU CC CC CC CC CC CC
Elizabeth Crawford Legal Counsel HOU CC CC CC
Hari Shetty /Satesh Kumar QA/QC Manager HAM CC CC TO CC CC CC TO CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Albert White Technical support Manager HOU CC CC CC CC
Dave Bolland Commissioning Manager HAM CC CC CC CC CC
Cristian Donnet Operations Manager (Iraq) DAF CC CC CC CC CC CC CC CC
Santosh Wadekar Construction Manager OMAN CC CC CC CC CC
George Mohan / Kalish Bhosale HSE Supervisor HAM CC CC CC CC CC CC CC
Project Control
Jaspreet Kaur Project Control Manager HOU CC CC TO TO CC CC CC CC CC CC CC CC CC CC CC CC
Victorino Lopez Project Cost Engineer HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Krunal Parekh / Peter Project Planner HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Procurement and Supply Chain TO
Suraj Devadiga SC Director HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC TO TO CC CC CC CC CC CC
Saket Deshpande Supply Chain Manager HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Ali Mohammed Senior Buyer HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
David Kerr / Binod Kumar Expeditor HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
TBC Document Controller HAM CC CC CC CC CC CC CC CC CC CC CC CC
TBC Logistics HAM CC CC CC CC CC CC CC TO TO TO TO TO
Engineering
Chris Uzzell Sr. Director Engineering HOU CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Shashikanth Patil Engineering Manager Sr. HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Raghavendra Prabhakar Project Engineering Manager HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Selva Subramanian Engineering Project Engineering HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Dileep Kumar Nair (NOTE 1) Engineering Document Controller HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
Jayasree Radhadevi Process Safety HAM CC CC CC CC CC CC CC CC
Manufacturing / Hamriya PM
Andrew Okene Manager of Project Management HAM CC CC
Mahesh, Bhimrao Yesade Production Manager HAM CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC CC
BGC (NOTE 2)
Iwona Urbanek Project Manager HAM TO TO TO TO
Colin Forster Doc Controller / Information Managemen IRAQ TO TO TO TO
Arun Venugopal Project Engineer HAM TO TO TO TO
* Default Users
OTES
1 DISCIPLINE ENGINEERS ARE NOT LISTED IN THE ABOVE MATRIX - IT WILL
BE THE RESPONSIBILITY OF THE ENGINEERING DOCUMENT CONTROLLER
TO DISTRIBUTE ENGINEERIGN DOCUMENTS TO THE REQUIRED
DISCIPLINES
2 FOR DOCUMENTS THAT ARE TO BE SUBMITTEED TO THE CLIENT REFER TO
THE PROJECT MASTER DOCUMENT REGISTER (MDR) WHICH WILL TAKE
PRECEDENCE OVER THE ABOVE
Page 1 of 1
Attachment ‐ 04
BGC0352 ‐ Summary of Payment milestones and Penalty
After Effective LDs / day
Item Scope Actual date Milestone
date (2.5%) cap
1 Mobilisation 2 weeks 17th May 2018 10%
Early Engineering & Project
2 8 weeks 28th June 2018 5%
Control deliverable submission
3 Major PO (batch 1) 8 weeks 28th June 2018 10%
Design Layout for ISBL & Early
4 10 weeks 12th July 2018 $2,000
Civil Deliverables
Interface Design Data (per
5 10 weeks 12th July 2018 $2,000
COMPANY's interface table)
PEFS/ P&ID’s issued for Main
6 12 weeks 26th July 2018
Process Plant HAZOP
7 Major PO (batch 2) 26 weeks 1st Nov 2018 10%
60% 3D Model Review
8 29 weeks 22nd Nov 18 $2,000
complete
9 30% fabrication 30 weeks 29th Nov 2018 20%
Delivery of civil/underground
10 40 weeks 7th Feb 2019 $1,000 5%
material CIF Basis INCOTERMS
11 60% fabrication 45 weeks 14th March 2019 15%
12 90% fabrication 60 weeks 27th June 2019 10%
13 Substantial completion 70 weeks 5th Sept 2019 2.50%
Delivery to Khor Al Zubair Port,
14 Basrah, Iraq ‐ 'CIF' INCOTERMS 75 weeks 10th Oct 2019 $100,000
for final shipment
15 Company Handover Cert 75 weeks 10th Oct 2019 2.50%
127 weeks
Company Performance
16 estimated 1 year 10th Oct 2020 5%
Acceptance
afater shipment
179 weeks
17 Company Completion Certificate 10th Oct 2021 5%
estimated 2 years
100%
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