aml-b195-prj-032-000(monthly report 21 march 2012 to 20 april 2012.pdf

AL-HASSAN ENGINEERING CO. S.A.O.G PROJECT: AMAL POWER STATION

PDO CONTRACT NO: C-310987

DOCUMENT NO.

AML-391-AA -6944-0032-000

21st

March 12 – 20th

April 12

AL-HASSAN ENGINEERNG CO. SAOG PROJECT: AMAL POWER STATION

(PDO CONTRACT NO: C-310987)

AML-391-AA-6944-0032-000

01 25.04.12 1 to 57 For Approval A.R.D K.G.B.

Document No Rev

No Date

No. of

`Pages Description

Prepared

By

Reviewed

by

Approved

by PDO

MONTHLY PROGRESS REPORT

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TABLE OF CONTENTS

Page

Section 1 Contract Particulars

1.01 Salient Features of the Contract 7

1.02 Contract Scope of Work in brief 8

Section 2 Project Summary Report

2.01 Project Progress Statistics 11

2.02 Narrative Summary Report 12

2.03 Over-all Progress Curve for the Project 12

2.04 Areas of Concern 12

Section 3 Detailed Report

3.01 Health, Safety and Environment (HSE) 14

3.02 Engineering & Design Documents 14

3.03 Procurement 14

3.04 Manufacturing 14

3.05 Delivery 14

3.06 Mobilization 14

3.07 On plot construction and commissioning 15

3.08 Off Plot construction and Commissioning 17

3.09 Equipment Deployment 17


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3.10 Manpower Deployment 19

3.11 Quality Assurance 20

3.12 Plan for Next month 21

3.13 Contract Financials 23


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Section 4 Appendices

I Project Milestone Dates 26

II Project Schedule (Updated) 31

III Drawing Control Register 32

IV Material Tracking Register 33

V Critical Project Material List 34

VI Health & Safety Statistics (Monthly Return) 35

VII HSE Audit / Inspection Schedule 36

VIII HSE Training Matrix 38

IX Quality internal and external audit schedule 39

X Summary of progress 40

XI S-curve for Engineering Progress 42

XII S-curve for Procurement Progress 43

XIII S-curve for Construction progress 44

XIV S-curve for Overall progress 45

XV S-curve for VOWD 46

XVI Manpower & Equipment Histogram 47

XVII Subcontract Details 48

XVIII Variations Register 50

XIX Omanisation Requirement 51

XX SPIR Progress 53

XXI Progress Photographs 55


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SECTION 1

CONTRACT PARTICULARS


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1.01 Salient Features of the Contract

Project Title : Amal Power Station

Company / Employer : Petroleum Development Oman

LLC

Company Contract Holder : Mr. Harith M Al Amry – UIE/5

Company Representative : Mr. Saud Al Habsi – UIE/52

Contractor : Al-Hassan Engg. Co. S.A.O.G

Contract Value : Rial Omani 22,950,786/-

Effective Date of Contract : 24th

June 2009

Commencement Date : 4th

July 2009

Contract Duration : 730 Days

Substantial Completion : 5th

April 2011

Completion Date : 4th

July 2011

Engineering Sub-Contractor : Mott MacDonald & Company LLC,

Oman

SAP Purchase Order No : 4500439405


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1.02: Contract Scope of Work in Brief:

The Amal Power Station will be of modular construction and will comprise initially of

two Frame 9E Gas Turbine Generator (GTG) units.

Construction and commissioning of Amal Power plant comprising two

frame 9E Gas turbine units– Installed capacity 252 MW.

Provision will be made for the future addition of Once through Heat

Recovery Generators (OTHRS’s) on the back end of the GTG.

Amal Power Station with Frame 9E GTG’s will have an ISO rated installed

capacity of 252MW. At a site ambient temperature of 48 deg C,

corresponding to maximum summer temperatures, this will drop to

197.4MW.

Each GTG unit will be unitised such that any equipment failures

associated with one GTG unit will not cause a trip of an adjacent GTG

unit.

The fuel gas for Amal Power Plant will be supplied from 18” Hubara to

Amal Pipeline and the tie-in point for fuel gas will be provided on 18”

bypass line near Amal pie receiver A-2075.

A unitized gas treatment trains will be provided to ensure the gas

delivered to the gas turbine meets the gas turbine Original Equipment

Manufacturer’s (OEM) requirements at all times.

The Amal Power Station is designed for unmanned operation and under

normal operation will be remotely controlled by SCADA and monitored


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from the Yibal/QA Master Control Room with backup from the

Marmul\Nimr Control Room.

Facilities Service water, DM water, Instrument air system incorporating

screw type compressors and membrane dryers will be provided.

Facilities for transferring Diesel fuel to the Emergency DG set will be

provided.

Gas turbines shall be free issued by PDO. Design, supply of BOP is part

of AHEC scope.

Design and construction of Unit Electrical buildings and Gas treatment

plant building.

Design, supply and construction of OHL from Nimr Central to LILO

location AP05(28 KM) and from LILO location AP05 to Thuleilat ( 70 KM)

HVAC System.

Power Station internal and external communication with provision of

CCTV.

Fire detection and alarm system.

Scope includes interfacing with GTG OEM supplier/ Vendor.

Pre commissioning and commissioning.


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SECTION 2

PROJECT SUMMARY REPORT


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2.01 Project Progress Highlights:

Highlights of April, 2012.

10.1 KM New OHL erection and bolt tightening 34 / 34 no’s completed.

10.1 KM New OHL ELM conductor stringing completed except 2 shut

down location.

10.1 KM OHL OPGW installation works in progress.

Unit # 1 & 2 punch point attending in progress.

2.02 Narrative Summary Report

Project progress during the month of March 21st to April 20th

is summarized as follows

Overall project progress for the month has reported 0.05% against the

planned progress 0.10%.

Cumulative overall progress for the month has reported 99.85% against

the planned progress 100%.

Cumulative engineering progress for the month has reported 100%

against the planned progress 100%.

Cumulative Procurement /Manufacturing/ delivery progress is 100%

against the planned progress 100%.

Cumulative construction progress for the month is 99.58% against the

planned progress 100%

2.03 Overall progress curve for the project

As per section 4, Appendix XII

2.04 AREAS OF CONCERN

Receipt of inputs from PDO/BHEL –


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1. Unit # 2 - CO2 system connecting Hose. CO2 panel battery back up for

unit # 1 & 2.

2. Unit # 2 - 125V - DCDB - Variable Resistor - 01 set. (3 no’s) for DC

Jacking oil pump cubicle.

3. Lube oil NRV, Step down transformer (220V/110V) for the MOV's in U#2

Accessory Base. Shaft for ABOC Fan#7 bearing block

4. Refer critical material list for balance materials.

Other area of concerns –

1. Communication between Marks V1 and DCS.

2. MFM – SCADA communication.

3. Passing of ESD valve in GTP


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SECTION 3

DETAILED REPORTS


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3.01: Health, Safety and Environment (HSE).

Major highlights of the month:

Weekly HSE gate meeting conducting on every Saturday.

Conducting daily tool box for driver and work force before starting of

work.

HSE Monthly meeting conducted.

Vehicle inspection completed 50% along with plant department.

3.02: Engineering & design documents


3.03: Procurement


3.04: Manufacturing


3.05: Delivery

3.06: Mobilization:



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Mobilization and demobilization of manpower and equipment in progress.

3.07: On plot Construction and commissioning.


Civil

Unit # 2 - Punch point attending in progress.

Unit # 2 – Test pack submission completed.

Mechanical

Unit # 2

Unit # 2 – Punch point attending works completed.

Unit # 2 – Test pack submission completed.

ELECTRICAL

Unit -1

Punch point attending in progress.

Test pack submission completed except 1 package.

Unit -2

Punch point attending in progress.

Test pack submission in progress for 6 packages.

Instrumentation

Unit # 1 & 2 – Punch point attending works 95% completed.


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Unit # 1 & 2 Test pack preparation and submission in progress for 10

packages.

Testing

Pre Commissioning and Commissioning

Unit-1 & 2

Unit # 1 & 2 - DCS punch point attending in progress

DCS SAT 84% completed.

Alarm rationalization 45% completed.

3.08: Off plot Construction and commissioning.


AP07 to Nimr Central OHL

Tower assembly 34/ 34 completed. Tower erection 34 /34 completed.

Stringing for 9 section completed out of 10 sections.

FOC stringing works in progress.

Spacer damper installation works completed.

3.09: Plant And Equipment Deployed At Site:

1. Station wagon 5

2. Pickup 3

3. Potable water tanker 5000 Gallon 1

4. Tipper 1

5. Diesel Tanker 1


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6. Shovel/Loader 1

7. Grader 0

8. Bucket truck 0

9. 62 Seat Big bus 0

10. Crew cab 3

11. 7 Ton Truck 1

12. Box Tailor 1

13 7 Ton Hiab 1

14 Brackish water tanker 1

15 Excavator 1

16 1 T Roller 1

17 JCB 1

18 10 T Roller 0

19 Concrete Mixture machine 0

20 Power generator portable 2

21 Plate compactor 2

22 Jumping compactor 2

23 Welding machine 2

24 Air compressor 3

25 24 Seater Bus 2

26 Crane 140 T 0

27 Crane 50/25 T 2

28 Generator 225 KV 0

29 Ambulance 1


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30 Folk lift 1

31 Transit Mixer 1

32 Cement Bulker 0

33 Batching plant 1

34 Waste Disposal Truck 1

35 60 Seated Big Bus 1

36 Bobcat 0

37 Vibrator 2

38 Generator 350 KVA 0

39 Hydra 1

40 Truck Gas 0

3.10: Manpower Deployment:

Project Office at Muscat

1. Project Manager 1

2. Interface Manager

3. Planning Manager 1

4. Procurement Manager

5. Design Manager

6. Design Electrical Engineer

7. Design Civil Engineer

8. Project Coordinator

9. Cost Accountant 1


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10. Draughts man 1

11 Secretary

12 Drivers (Omani) 2

MMC (Engg. Consultant) Office at Muscat 1. Project Manager

2. Civil Discipline

3. Electrical Discipline

4. Mechanical Discipline

5. Process Discipline

6. C & I Discipline

7. Piping Discipline

Manpower Deployed at Site

1. Staff ( Expat) 30

2. Staff (Omani) 10

3. JE (Expat) 92

4. JE (Omani) 59

5 Sub contract 35

3.11: Quality Assurance:

Major Highlights of the Month:


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Unit # 2 - Tests pack preparation and submission for Electrical and

instrumentation in progress.

Mark up drawings preparation and submission works in progress.

3.12, Plan for Next Month:

Health, Safety and Environment.

Inspection of plant and equipments.

Conducting monthly HSE Meeting.

Gate meeting on every Saturday

Tool box talk for driver and work force

Driver’s forum.

Mobilization:

Manpower and equipment mobilization and demobilization.

On Plot Construction / Commissioning:

Civil

Punch point attending works to complete.

Mechanical

Punch point close out.

Electrical

UEB # 1 & 2

De energizing of temporary transformer. Termination of cables for SUAT.


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Punch point attending

Commissioning

Unit # 1 – Reliability run to start

Unit # 2 – DLN tuning.

Unit # 1 & 2 – Marks V1 e and DCS communication establishment through

Matrikon.

Instrumentation

Punch point close out.

Off Plot Construction:

AP07 to NIMR CENTRAL(TWIN ELM)

Shut down jobs at Tower location 2 & 3 and 34 & 35 to complete.

OPGW stringing works to complete.

Aviation light and sphere installation works to complete.

QUALITY ASSURANCE

Unit # 1 – Balance test pack submission for CO2, EDG and CEMS.

Unit # 2 – Test pack submission for Electrical and instrumentation

packages.

Unit # 1 & 2 – As built drawings submission and approval.

CONTRACT FINANCIALS:

Milestone 1 payment invoice submitted on 26.08.09 payment received on

05.10.09.

Milestone 2a payment invoice submitted on 26.08.09 payment received on

05.10.09.


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Milestone 02B payment invoice submitted on 18.11.09, payment received

on 26.12.09.

Milestone 03 invoice submitted on 05.03.10, payment received on

09.04.10.

Milestone 02D payment invoice submitted on 10.04.10, payment received

on 28.05.2010.

Milestone 02C payment invoice submitted on 15.05.10, Payment received

on 14.06.10.

Milestone 05A payment invoice submitted on 24.04.10, payment received

on 28.05.10.

Mile stone 06A payment invoice submitted on 16.07.2010, payment

received on 06th

September 2010.

Mile stone 04 A documents submitted and approved, Invoice submitted on

19th

August 2010, payment received on 30th

September 2010.

Mile stone 05 B documents submitted for approval, payment received on

26th

December 2010.

Mile stone MS 04B completion certificate received. Payment received on

30th

April 2011.

Mile stone MS 06 C completion certificate received. Payment received on

30th

April 2011.

Mile stone MS 06 D completion certificate received. Payment received on

27th

August 2011.

Mile stone MS 06 E completion certificate received. Payment received on

27th

August 2011.

Mile stone MS 06 B completion certificate received. Payment received on

13th

September 2011.

Mile stone MS 07 B completion certificate received. Payment received on

23rd

October 2011.

Mile stone MS 05 C completion certificate received. Payment due on 12th

December 2011.


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Mile Stone 07 A and 08 completion certificate received 50%. Payment

received on 9th

January 2012.

Mile Stone 07 A and 08 completion certificate for balance 50% received.

Invoice submitted for payment.

Mile stone 09 completion certificate for 50% received. Invoice submitted for

payment.


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SECTION 4

APPENDICES


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APPENDICES-I

PROJECT MILESTONE DATES


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Project Milestone Schedule / Dates

Milesto

ne

Description Weight

-age

Amount

in

Million

R.O

Sch.

Comple

tion

Act

Completi

on date

Payment

Receive

d

Remarks

MS-1 Mobilization 6% 1.377 15-Aug-

09 15-Aug-

09 05-Oct-

09

MS-2a

PO for 3 critical items ( Generator transformer,GCB,6.6KV switchgear

6% 1.377 18-Aug-

09

18-Aug-

09

05-Oct-

09

MS-2b

PO issue for wooden poles and steel towers of OHL

4% 0.918 17-Nov-

09 17-Nov-

09 26-Dec-

09

MS-2c

Upon completion of issue of PO for remaining engineered item purchase order for electrical ,C &

4% 0.918 15-Feb-

10 02-May-

10 14-Jun-

10

MS-2d

Upon the completion of issue of PO for remaining engineered item purchase orders for mechanical

5% 1.147

13-Jan-10

25-Mar-

10

28-May-

10

MS-3 Site Establishment

5% 1.147 11-Dec-

09 02-Mar-

10 09-Apr-

10

MS-4a

Upon Completion of Engineering activities for Design review, IPF/HAZOP,SAFOP

2% 0.459 31-Mar-

10 19-Aug-

10 30 –

Sep-10

MS-4b

Upon Completion of Remaining Engineering activities

4% 0.918

29-Jul-10

16-Mar-11

30-Apr-11


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Milesto

ne

Description Weight

-age

Amount

in

Million

R.O

Sch.

complet

ion

Act

Completi

on date

Payment

Receive

d

Remarks

Ms-5a

Upon Completion of following Civil work Amal power station site leveling & grading

2% 0.459 24-Feb-

10

15-Apr-

10

28-May-10

Ms-5b

Upon Completion of following Civil work UEB, GTP, GTG and Off base foundation.

10% 2.295 27-Sep-

10 27-Sep-

10

26-Dec-10

Ms-5c

Upon Completion of following Civil work balance foundation, fencing on plot and off plot, Road works.

3% 0.688 11-Mar-

11 10-Nov-

11

09-Jan-12

Ms-6a

Upon receipt at Site of following Equipment (including documentation) materials for OHL (wooden poles, steel towers, FOC)

4% 0.918

19-Jun-10

16-Jul-10

6-Sep-10

MS-6b

Upon receipt at Site of following Equipment (including documentation) ( Generator transformers,15/6.6KV transformer, Control & automation cable, bus duct )

10%

2.295 16-Nov-

10 25-Jun-

11

13-Sep-11


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Milesto

ne

Description Weight

-age

Amount

in

Million

R.O

Sch.

complet

ion

Act

Completi

on date

Payment

Receive

d

Remarks

Ms-6c

Upon receipt at Site of following Equipment (including documentation)(GCB,6.6KV switchgear,415V switchgear,6.6KV cables & termination)

4% 0.918 3-Oct-10

20-Mar-11

30-Apr-11

Ms-6d

Upon receipt at Site of following Equipment (including documentation)( vent system ,drain system)

3% 0.688 22-Jul-

10

25-Jun-11

27-Aug-11

Ms-6e

Upon receipt at Site of following Equipment (including documentation)( DC and AC UPS, EDG, Instrument air compressor, DCS)

4% 0.918 03-Sep-

10

23-Jun-11

27-Aug-11

Ms-7a

Upon completion of 132kv switchyard works at Nimr West 132kv Substation including

2% 0.459 03-Nov-

10

Ms-7b

Upon completion of 132kv OHL’S

2% 0.459 23-Oct-

10 15-Jul -

11

23-Oct-

11


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Milesto

ne

Description Weight

-age

Amount

in

Million

R.O

Sch.

complet

ion

Act

Completi

on date

Payment

Receive

d

Remarks

Ms-8

Upon completion of pre-commissioning of GTG package including all auxiliaries (pre-commissioning completed, ready for introduction of hydrocarbons)

5% 1.147 16-Jan-

11

30-Jan-12

Ms-9

Upon Substantial Completion of the Work for GTG Package

9% 2.065 05-Apr-

11

Ms-10

Upon Completion of the Work (Demobilization)

6%

1.377 04-Jul-

11


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APPENDICES II

INTERGRATED OVERALL PROJECT SCHEDULE


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APPENDICES-III

DRAWING CONTROL REGISTER


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APPENDICES-IV

MATERIAL TRACKING REGISTER


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APPENDICES-V

CRITICAL PROJECT MATERIAL LIST


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APPENDICES-VI

HEALTH & SAFETY STATISTICS


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APPENDICES-VII

HSE AUDIT/INSPECTION SCHEDULE


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# Subject Auditor Schedule

Month

Actual

Month

Remarks

1 Journey management

HSE Advisor + Site Manager

August 09 October 09

2 Road transport safety

HSE Advisor + Manager HSE+ Construction Manager

October 09

November 09

3 Lifting equipment and lifting gears

Site HSE Advisor + Project Manager

November 09

November 09

4 Welding and gas cutting

Site HSE Advisor + Corp. HSE Manager

December 09

April 2010

5 Catering Site HSE Advisor February 2010

March 2010

6 Welding Site HSE Manager March 2010

April 2010

7 Transportation of compressed gas cylinder

Site HSE Manager + Project Manager May 2010 May 2010

8 Radiography Site HSE Manager + Construction Manager

June 2010 Nov 2010

9 Scaffolding Site HSE Manager July 2010 July 2010

10 Waste Disposal Site HSE Manager Aug 2010 Oct 2010


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APPENDICES-VIII

HSE TRAINING MATRIX


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APPENDICES-IX

QUALITY INTERNAL AND EXTERNAL AUDIT

SCHEDULE


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APPENDICES-X

SUMMARY OF PROGRESS


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DESCRIPTION MONTHLY

PLANNED

MONTHLY

ACTUAL

CUMULATIVE

PLANNED

CUMULATIVE

ACTUAL

ENGINEERING 100.00% 100%

PROCUREMENT 100.00% 100%

CONSTRUCTION 0.24% 0.12% 100% 99.58%

OVERALL 0.10% 0.05% 100% 99.85%


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APPENDICES-XI

S-CURVE FOR ENGINEERING PROGRESS


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APPENDICES-XII

S-CURVE FOR PROCUREMENT PROGRESS


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APPENDICES-XIII

S-CURVE FOR CONSTRUCTION PROGRESS


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APPENDICES-XIV

S-CURVE FOR OVERALL PROGRESS


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APPENDICES-XV

S-CURVE FOR VOWD PROGRESS


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APPENDICES-XVI

MANPOWER & EQUIPMENT HISTOGRAM


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APPENDICES-XVII

SUBCONTRACT DETAILS


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Sl no Description of subcontract Subcontractor

1 Design consultant Mott Macdonald & co LLC

2 Topographical survey AZD land survey LLC

3 Soil investigation Fugro middle east & Partners LLC

4 Lab Technician for soil testing Fugro middle east & Partners LLC

5 Grading and backfilling Sayouh Mahwees Trading and

contracting company LCC

6 Catering Socat universal sodexho

7 Pole hole drilling Ray Oman LLC

8 Block works & slope protection, Cable

trench works

Al Badea National trading & Cont.

Est

9 Block works Durat Al – Ghubra trading

10 Pole Hole drilling Powertech Engineering LLC

11 Rock Anchoring and Grouting for tower

foundation

IBN Salim Al Hadi trading

12 NDT Hi Tech Inspections services LLC

13 Back filling works & Cable trench works Harweel International LLC

14 Wadi protection works Al Badea National trading & Cont.

Est

15 Reaming works Singh Tool industries India

16 On plot Telecommunication M/s Bhawan projects and telecom

17 Off Plot Telecommunication ORB communications network LLC

18 Excavation and backfilling of tower

foundation

United International LLC

19 Tower Foundation concreting Global Design trading LLC


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APPENDICES-XVIII

VARIATION REGISTER


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APPENDICES-XIX

OMANISATION REQUIREMENTS


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OPAL – CVC certificate submitted to PDO.

All drivers shall be Omani nationals.


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APPENDICES-XX

SPIR PROGRESS


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SPIR FORMS ATTACHED FOR FOLLOWING MATERIALS

125 V DC UPS

I P Bus Duct

142 MVA Generator Transformer

14 MVA M V UAT

1.6 MV LV Transformer

2.25 MV LV Transformer

240 V AC UPS

Generator circuit breaker

MAC system

HVAC system

Instrument air compressor

415 V GTP UAS

415 V GTP UAS Sub DB

6.6 KV MVUAS

415 V LVMCC

Emergency Diesel Generator

GTP skids


Doc. No: AML-394-AA-6944-0032-000

Rev. No : 01

Date: 25.04.12

of 57

APPENDICES-XXI

PROGRESS PHOTOGRAPHS


Doc. No: AML-394-AA-6944-0032-000

Rev. No : 01

Date: 25.04.12

of 57

aml-b195-prj-032-000(monthly report 21 march 2012 to 20 april 2012.pdf

Documents

engineering progress

construction progress

summary of progress

project progress statistics

pdo monthly progress

procurement progress

progress photographs

spir progress