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AL-HASSAN ENGINEERING CO. S.A.O.GPROJECT: AMAL POWER STATION
PDO CONTRACT NO: C-310987
DOCUMENT NO.AML-391-AA -6944-0032-000
21st March 12 – 20th April 12
MONTHLY PROGRESS REPORT
Doc. No: AML-394-AA-6944-0032-000 Rev. No : 01 Date: 25.04.12 Page 2 of 57
AL-HASSAN ENGINEERNG CO. SAOGPROJECT: 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 Date No. of Description Prepared Reviewed Approved
No `Pages By by by PDO
TABLE OF CONTENTS
Page
Section 1 Contract Particulars
1.01 Salient Features of the Contract7
1.02 Contract Scope of Work in brief8
Section 2 Project Summary Report
2.01 Project Progress Statistics11
2.02 Narrative Summary Report12
2.03 Over-all Progress Curve for the Project12
2.04 Areas of Concern12
Section 3 Detailed Report
3.01 Health, Safety and Environment (HSE)14
3.02 Engineering & Design Documents14
3.03 Procurement14
3.04 Manufacturing14
3.05 Delivery14
3.06 Mobilization14
3.07 On plot construction and commissioning15
3.08 Off Plot construction and Commissioning17
3.09 Equipment Deployment17
3.10 Manpower Deployment19
3.11 Quality Assurance20
3.12 Plan for Next month21
3.13 Contract Financials23
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
SECTION 1
CONTRACT PARTICULARS
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
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 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.
SECTION 2
PROJECT SUMMARY REPORT
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 –
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
SECTION 3
DETAILED REPORTS
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
Major highlights of the month:
3.03: Procurement
Major highlights of the month:
3.04: Manufacturing
Major highlights of the month :
3.05: Delivery
3.06: Mobilization:
Major highlights of the month:
Mobilization and demobilization of manpower and
equipment in progress.
3.07: On plot Construction and commissioning.
Major highlights of the month:
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.
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.
Major highlights of the month:
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
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
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
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:
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.
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.
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.
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.
SECTION 4
APPENDICES
APPENDICES-I
PROJECT MILESTONE DATES
Project Milestone Schedule / Dates
Milestone
Description Weight-age
Amount in
Million R.O
Sch. Comple
tion
Act Completion date
Payment Receive
d
Remarks
MS-1 Mobilization 6% 1.37715-Aug-
0915-Aug-
0905-Oct-
09MS-2a PO for 3 critical
items 6% 1.377 18-Aug-
09 18-Aug- 05-Oct-
( Generator transformer,GCB,6.6KV switchgear
0909
MS-2b
PO issue for wooden poles and steel towers of OHL
4% 0.91817-Nov-
0917-Nov-
0926-Dec-
09
MS-2c
Upon completion of issue of PO for remaining engineered item purchase order for electrical ,C &
4% 0.91815-Feb-
1002-May-
1014-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-3Site Establishment
5% 1.14711-Dec-
0902-Mar-
1009-Apr-
10
MS-4a
Upon Completion of Engineering activities for Design review, IPF/HAZOP,SAFOP
2% 0.45931-Mar-
1019-Aug-
1030 –
Sep-10
MS-4b
Upon Completion of Remaining Engineering activities
4% 0.918 29-Jul-10
16-Mar-11
30-Apr-11
Milestone
Description Weight-age
Amount in
Million R.O
Sch. complet
ion
Act Completion date
Payment Receive
d
Remarks
Ms-5a
Upon Completion of following Civil work Amal power station site leveling & grading
2% 0.45924-Feb-
1015-Apr-
1028-May-
10
Ms-5b Upon Completion of following Civil work UEB, GTP, GTG and Off
10% 2.295 27-Sep-10
27-Sep-10
26-Dec-10
base foundation.
Ms-5c
Upon Completion of following Civil work balance foundation, fencing on plot and off plot, Road works.
3% 0.68811-Mar-
1110-Nov-
1109-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-106-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
Milestone
Description Weight-age
Amount in
Million R.O
Sch. complet
ion
Act Completion 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-1020-Mar-
1130-Apr-
11
Ms-6d Upon receipt at Site of following Equipment (including documentation)( vent system ,drain
3% 0.688 22-Jul-10
25-Jun-11 27-Aug-
11
system)
Ms-6e
Upon receipt at Site of following Equipment (including documentation)( DC and AC UPS, EDG, Instrument air compressor, DCS)
4% 0.91803-Sep-
10
23-Jun-11
27-Aug-11
Ms-7a
Upon completion of 132kv switchyard works at Nimr West 132kv Substation including
2% 0.45903-Nov-
10
Ms-7b
Upon completion of 132kv OHL’S
2% 0.459
23-Oct-10
15-Jul -11
23-Oct-11
Milestone
Description Weight-age
Amount in
Million R.O
Sch. complet
ion
Act Completion 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% 1.14716-Jan-
1130-Jan-12
Ms-9
Upon Substantial Completion of the Work for GTG Package
9% 2.06505-Apr-
11
Ms-10
Upon Completion of the Work (Demobilization)
6%1.377 04-Jul-
11
APPENDICES II
INTERGRATED OVERALL PROJECT SCHEDULE
APPENDICES-III
DRAWING CONTROL REGISTER
APPENDICES-IV
MATERIAL TRACKING REGISTER
APPENDICES-V
CRITICAL PROJECT MATERIAL LIST
APPENDICES-VI
HEALTH & SAFETY STATISTICS
APPENDICES-VII
HSE AUDIT/INSPECTION SCHEDULE
# Subject Auditor Schedule Month
Actual Month
Remarks
1 Journey management
HSE Advisor + Site Manager
August 09October 09
2 Road transport safety
HSE Advisor + Manager HSE+ Construction Manager
October 09November
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
APPENDICES-VIII
HSE TRAINING MATRIX
APPENDICES-IX
QUALITY INTERNAL AND EXTERNAL AUDIT SCHEDULE
APPENDICES-X
SUMMARY OF PROGRESS
DESCRIPTIONMONTHLY
PLANNEDMONTHLY 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%
APPENDICES-XI
S-CURVE FOR ENGINEERING PROGRESS
APPENDICES-XII
S-CURVE FOR PROCUREMENT PROGRESS
APPENDICES-XIII
S-CURVE FOR CONSTRUCTION PROGRESS
APPENDICES-XIV
S-CURVE FOR OVERALL PROGRESS
APPENDICES-XV
S-CURVE FOR VOWD PROGRESS
APPENDICES-XVI
MANPOWER & EQUIPMENT HISTOGRAM
APPENDICES-XVII
SUBCONTRACT DETAILS
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
APPENDICES-XVIII
VARIATION REGISTER
APPENDICES-XIX
OMANISATION REQUIREMENTS
OPAL – CVC certificate submitted to PDO.
All drivers shall be Omani nationals.
APPENDICES-XX
SPIR PROGRESS
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
APPENDICES-XXI
PROGRESS PHOTOGRAPHS