Report TE 501- Sample Project Implementation

Civil, Structural and Mechanical/Piping Works for the:1. LGPF Upper Mahiao Pad 403 Wells Hook-Up (EDC 08-070)2. LGPF Tongonan 1 Hook-Up of Wells 218D/ 219D/ 216D/ 208D to SV 270/280

(EDC 08-076)3. Mahanagdong “B” MG-F Pad Hook-Up Project (EDC 08-097)4. LGPF Upper Mahiao Condensate R.I. Line to 4RD (EDC 08-106)5. Mahanagdong “A” Condensate Disposal System (EDC 08-103)

Project Implementation Procedure

ENERGY DEVELOPMENT CORPORATION

Leyte Geothermal Production Field

Direction

Organization

Cost

Tracking/Monitoring

Operations Control

Revisions/Variations

DIRECTION

z

A. PROJECT GENERAL INFORMATION

1. Project Title : Civil, Structural, and Mechanical/Piping Works for the LGPF Upper Mahiao Pad 403 Wells Hook-Up

Contract Number : EDC 08-070

Contract Amount : Php 108,581,215.13

Contract Duration: 180 Calendar Days

Start Date - October 21, 2008

Completion Date - April 19, 2009

Cost Tracking OperationsOrganization RevisionsDirection



DIRECTION

z

2. Project Title : Civil, Structural, and Mechanical/Piping Works for the LGPF Tongonan 1 Hook-Up of Wells 218D/ 219D/ 216D/ 208D to SV 270/280





Completion Date - April 19, 2009




DIRECTION

z

3. Project Title : Civil, Structural, and Mechanical/Piping Works for the Construction of Mahanagdong “B” MG-F Pad Hook-Up Project





Completion Date - May 19, 2009




DIRECTION

z

4. Project Title : Civil, Structural, and Mechanical/Piping Works for the Construction of LGPF Upper Mahiao Condensate R.I. Line to 4RD




Start Date - December 4, 2008

Completion Date - May 4, 2009




DIRECTION

z

5. Project Title : Civil, Structural, and Mechanical/Piping Works for the Construction of Mahanagdong “A” Condensate Disposal System





Completion Date - February 18, 2009




DIRECTION

z

B. SCOPE OF WORK

The contract calls for the supply of materials, labor, equipment and supervision necessary to complete the works in accordance with the drawings / plans and technical specifications.

The Work includes but is not limited to the following:

a. Civil, Structural, and Mechanical/Piping Works for the LGPF Upper Mahiao Pad 403 Wells Hook-Up (EDC 08-070)

1. Mobilization / Demobilization

1.1 Allow to move in and remove equipment and personnel

1.2 Set up and remove temporary facilities

1.3 Clean up and reinstatement of the site as required upon completion of the project




DIRECTION

z

2. Earthworks/ excavation and preparation of pipeline corridor

3. Construction of pipe trenches (3 units)

4. Construction of separator vessel foundation and supports, anchors and supports, and x-mas tree supports

5. Construction of rock muffler (1 unit) including RCPC drain pipe installation

6. Installation of approximately 97 meters of 1”Ø and 2”Ø instrument airline

7. Supply, fabrication and installation of structural steel supports including stanchions, shear keys, girders/ pipe heads, pipe shoes and anchors, airline supports and other structural steel accessories with surface protection made by application of EDC approved high heat paint to sandblasted surface

8. Pipeline installation of approximately 3,801 meters carbon steel pipes with diameters ranging from 2”Ø to 36”Ø. All pipe welding works are subject to radiographic testing satisfying 100% passing. EDC will supply the pipes, fittings, various valves, rupture disk, isokinetic sampling probe, spring hangers and separator vessel

9. Installation of various sizes and types of valves

10. Installation of isokinetic sampling probe and spring hangers




DIRECTION

z

11.Installation of 30 MWe steam-water separator vessel (1 unit)

12.Flushing of pipes, testing and commissioning of the fluid collection and reinjection system

13.The Contractor shall submit detailed fabrication drawings to EDC of all items for fabrication in exploded isometric view with complete dimensions and other details using AutoCAD:

13.1 Shear keys, stanchions, cross girders, special supports, and other structural steel accessories

13.2 Isometric drawings of pipeline with symbols indicating (i) field weld, (ii) shop weld, (iii) Material specifications, (iv) joint number and (v) spool number among others

Three (3) copies in legal size paper shall be submitted to EDC for correction. Five (5) copies in A3 size paper of the corrected drawings shall be submitted to EDC for approval. No work shall commence without the approval by EDC of said drawings.




DIRECTION

z

14.EDC supplied materials to be covered by the Contractor’s All Risk Insurance (CAR) shall include the following:




Item Materials Cost (P)

1 Pipes, Fittings, Studbolts & Nuts 137,895,391.20

2 Valves 8,166,224.09

3 Mechanical Equipment 2,319,706.86

4 Steam-Water Separator 4,410,745.80

5 Instrument Airline 315,998.22

Total 153,108,066.17

DIRECTION

z

b. Civil, Structural, and Mechanical/Piping Works for the LGPF Tongonan 1 Hook-Up of Wells 218D/ 219D/ 216D/ 208D to SV 270/280 (EDC 08-076)





2. Earthworks such as side slope trimming, loop excavation and preparation of pipeline corridor

3. Construction of pipe trench crossing (1 unit), masonry wall, lined canal and riprap wall

4. Demolition and restoration of existing grouted riprap

5. Clearing of areas of vegetation by tree cutting

6. Construction of anchors and supports, separator vessel foundation, pad trenches (4 units) , bleedline supports on trench and x-mas tree supports

7. Installation of approximately 17 meters of 1”Ø and 2”Ø instrument airline




DIRECTION

z

8. Supply, fabrication and installation of structural steel supports including stanchions, shear keys, girders/ pipe heads, pipe shoes and anchors, airline supports and other structural steel accessories with surface protection made by application of EDC approved high heat paint to sandblasted surface

9. Pipeline installation of approximately 2,251 linear meters carbon steel pipes with diameters ranging from 2”Ø to 36”Ø. All pipe welding works are subject to radiographic testing satisfying 100% passing. EDC will supply the pipes, fittings, various valves, rupture discs, isokinetic sampling probe, spring hangers and separator vessels

10. Installation of various sizes and types of valves

11. Installation of isokinetic sampling probe and spring hangers

12. Installation of two units 10 MWe steam-water separator vessel

13. Flushing of pipes, testing and commissioning of the project

14. The Contractor shall submit detailed fabrication drawings to EDC of all items for fabrication in exploded isometric view with complete dimensions and other details using AutoCAD:

14.1 Shear keys, stanchions, cross girders, special supports, and other structural steel accessories




DIRECTION

z








1 Pipes , Fittings, Studbolts & Nuts 77,500,909.25

2 Valves 13,894,760.00


4 Separator Vessel 7,475,000.00

Total 101,306,944.25

DIRECTION

z

c. Civil, Structural, and Mechanical/Piping Works for the Construction of Mahanagdong “B” MG-F Pad Hook-Up Project (EDC 08-097)





2. Earthwork/ excavation and preparation of pipeline corridor

3. Construction of pipe trenches (5 units)

4. Construction of grouted riprap

5. Revision of drainage crossings (14 units)

6. Construction of reinforced concrete foundations, anchors and supports, support on trenches, and x-mas tree supports

7. Construction of concrete silencer (1 unit)




DIRECTION

z

8. Pipeline installation of approximately 3,158 linear meters carbon steel pipes with diameters ranging from 2”Ø to 42”Ø. All pipe welding works are subject to radiographic testing satisfying 100% passing. EDC will supply the pipes, fittings, various valves, rupture disk, isokinetic sampling probe, shock arrestor, spring hangers and separator vessel

9. Supply, fabrication and installation of structural steel supports including stanchions, shear keys, cross girders/ pipe heads, pipe shoes and anchors, counterweights, airline supports and other structural steel accessories with surface protection made by application of EDC approved high heat paint to sandblasted surface

10. Installation of various types and sizes of valves

11. Installation of instrument airline

12. Installation of isokinetic sampling probe, shock arrestor, spring hangers and tapping connections.

13. Installation of 30 MWe steam-water separator vessel (1 unit)

14. Flushing, testing and commissioning of the project





DIRECTION

z

15.1 Isometric Shear keys, stanchions, cross girders, special supports, and other structural steel accessories








1 Pipes, Fittings, Studbolts & Nuts 89,078,641.13

2 Valves 18,168,055.86


4 Steam-Water Separator 4,724,333.60

5 Instrument Airline 152,459.02

Total 117,340,606.59

DIRECTION

z

d. Civil, Structural, and Mechanical/Piping Works for the Construction of the LGPF Upper Mahiao Condensate R.I. Line to Pad 4RD (EDC 08-106)





2. Development of pipe corridors including cut slope, construction of masonry wall and lined canal to convey direct surface run-off to designated outfalls

3. Construction of three (3) units Christmas tree supports at deep cellar and three units (3) of pad trenches

4. Construction of reinforced concrete foundations and supports for pipes

5. Supply, fabrication and installation of structural steel stanchions, shear keys, cross girders/ pipe heads, pipe shoes and anchors, and other structural steel accessories with surface protection made by application of EDC approved high heat paint to sandblasted surface




DIRECTION

z

6. Pipeline installation of approximately 1,288 linear meters of 10”Ø and 24”Ø carbon steel pipes. All pipe welding works are subject to radiographic testing satisfying 100% passing. EDC will supply the pipes, fittings, various valves and spring hangers

7. Installation of various sizes and types of valves (i.e. gate valves, ball valves and through conduit valves)

8. Installation of constant effort spring hangers (bottom mounted)

9. Flushing of pipes, testing and commissioning of the project








DIRECTION

z






1 Pipes and Fittings 35,578,833.33

2 Valves 797,500.00

3 Mechanical Equipment 400,000.00

Total 36,776,333.33

DIRECTION

z

e. Civil, Structural, and Mechanical/Piping Works for the Construction of the LGPF Mahanagdong “A” Condensate Disposal System (EDC 08-103)





2. Construction of pipe supports, pipe trenches (5 units), grouted riprap, installation of concrete traffic delineator post and 4”Ø pipe detachable railing assembly.

3. Pipe bridge rectification including dismantling, temporary re-routing and reinstallation of alvenius pipes.

4. Supply, fabrication and installation of structural steel supports including alvenius pipes supports, stanchions, shear keys, girders/ pipe heads, and other structural steel accessories with surface protection made by application of EDC approved high heat paint to sandblasted surface.




DIRECTION

z

5. Pipeline installation of approximately 1,543 meters 13 3/8”Ø production casing, 4 meters 12”Ø carbon steel pipes and 20,010 meters 6”Ø alvenius pipes. All pipe welding works are subject to radiographic testing satisfying 100% passing. EDC will supply the production casings, pipes (carbon steel and alvenius), fittings, and various valves.

6. Installation of alvenius pipe valves and gate valves.

7. Supply, fabrication and installation of 13 3/8”Ø x 12”Ø reducer mating flange and 13 3/8”Ø x 1.0 meter inspection spool. EDC will supply the 13 3/8”Ø production casing.

8. Flushing, testing and commissioning of the condensate disposal system.








DIRECTION

z






1 Pipes and Fittings 42,366,775.21

2 Valves 1,251,023.45

Total 43,617,798.66

ORGANIZATION

z

A. ENERGY DEVELOPMENT CORPORATION

1. Head Office

President - Paul A. Aquino

Executive Vice-President - Ernesto B. Pantangco

Senior Vice President - Agnes C. de Jesus

Vice President for Technical Services - Manuel S. Ogena

Vice President for Operations - Marcelino M. Tongco

Vice President for Power Generation - Danilo C. Catigtig

Vice President for Supply Chain Management - Glenn I. Funk

Supply Chain Management Senior Manager - Ignacio B. Gimenez

Supply, Property and Materials Mgt. Senior Mgr. - Elvira L. Punsalan

Supply Management Department Manager - Danilo D. Guevara

Eng’g, Project Planning & Construction Senior Mgr. - Martin Jude V. Lacambra

Engineering Design Deputy Manager - Emil E. Macalinao

Project Planning Deputy Manager - Lorna R. Preclaro

Cost Tracking RevisionsOperationsOrganizationDirection



ORGANIZATION

z

2. Leyte Geothermal Production Field

Steam Field Operations (SFO)Resident Manager - Manuel C. PaeteProduction Manager - Ulysses Rex P. BontiaMaintenance Manager - Alberto G. Daffon, Jr.Administration Manager - Dominador R. MiroCivil Works Manager - Rodolfo B. PolResource Management Manager (TSS) - Edwin H. AlcoberAccounting Supervisor - Wenifredo S. AlayonSecurity Officer - Nerelito M. PascualSafety Officer - Felipe A. Manatad, Jr.

Project Management Team

PPC Department Manager - Ernesto R. Gagto, Jr.Construction Superintendent - Anacleto P. Columnas, Jr.Project Control Supervisor - Jose Renante D. Bacierto Mechanical / EI Supervisor - Geronimo L. CortesMaterials Control Supervisor - Luisito F. Delos ReyesQA-QC Site Supervisor - Jose M. BongonCivil / Structural Representative - Genario C. Canama




ORGANIZATION

z

B. FIRST BALFOUR, INC.

Project Implementing Team

1. LGPF Upper Mahiao Pad 403 Wells Hook-Up (EDC 08-070)

Project Manager - Danilo D. AguilarField Civil/ Structural Engineer - Danilo B. EscarlanField Mechanical / Piping Engineer - Reynaldo C. TaguraProject Control Engineer - Roderick A. VergaraQuality Control Engineer - Josephine C IsidroSafety Supervisor - Emil A. EstraboCivil / Structural Foreman - Ramil C. SuanMechanical / Piping Foreman - Ronil E. Fenix




ORGANIZATION

z

2. LGPF Tongonan 1 Hook-Up of Wells 218D/ 219D/ 216D/ 208D to SV 270/280 (EDC 08-076)Project Manager - Danilo D. AguilarField Civil/ Structural Engineer - Virgilio J. BandalanField Mechanical / Piping Engineer - Glicerio G. TauthoProject Control Engineer - Roderick A. VergaraQuality Control Engineer - Josephine C IsidroSafety Supervisor - Emil A. EstraboCivil / Structural Foreman - Ronilo A. UbalubaoMechanical / Piping Foreman - Zaldy F. Bolneo

3. Mahanagdong “B” MG-F Pad Hook-Up Project (EDC 08-097)Project Manager - Danilo D. AguilarField Civil/ Structural Engineer - Honorato M. DalawampuField Mechanical / Piping Engineer - Josefino S. VidanesProject Control Engineer - Roderick A. VergaraQuality Control Engineer - Josephine C IsidroSafety Supervisor - Emil A. EstraboCivil / Structural Foreman - Felipe G. Hamiz, Jr.Mechanical / Piping Foreman - Rodney C. Lutao




ORGANIZATION

z

4. LGPF Upper Mahiao Condensate R.I. Line to 4RD (EDC 08-106)Project Manager - Danilo D. AguilarField Civil/ Structural Engineer - Elenor L. AsoField Mechanical / Piping Engineer - Danilo S. CastroProject Control Engineer - Roderick A. VergaraQuality Control Engineer - Josephine C IsidroSafety Supervisor - Emil A. EstraboCivil / Structural Foreman - Alfredo L. SantosMechanical / Piping Foreman - Rolando M. Lugtu

5. Mahanagdong “A” Condensate Disposal System (EDC 08-103)Project Manager - Danilo D. AguilarField Civil/ Structural Engineer - Gene C. UmaliField Mechanical / Piping Engineer - Nestor C. CampilanProject Control Engineer - Roderick A. VergaraQuality Control Engineer - Josephine C IsidroSafety Supervisor - Emil A. EstraboCivil / Structural Foreman - Gary A. LisboMechanical / Piping Foreman - Ricky R. Paolibar




ORGANIZATION

z

C. CORRESPONDENCE

Formal Letter - Matters with Contractual Implications

1. Letters related to the implementation of the project.

Mr. Ernesto R. Gagto, Jr.PPC Department ManagerEngineering, Project Planning and Construction Division

Thru: Mr. Anacleto P. Columnas, Jr.Superintendent PPC DepartmentEngineering, Project Planning and Construction DivisionLeyte Geothermal Production Field

2. Letters that may have contractual or policy implications will be referred to the sector Vice-President for approval and signature.




ORGANIZATION

z

D. MEETINGS

1. Weekly Coordination Meeting - Take-up / document relevant concerns

2. Emergency / Special Meetings - Take-up pressing matters




COST

z

A. CONTRACT COST

LGPF STEAM AUGMENTATION PROJECTS

Organization Tracking Operations RevisionsCostDirection



1.0 LGPF Upper Mahiao Pad 403 Wells Hook-Up (EDC 08-070)

1.1 Preliminary and General Works Php 10,288,343.621.2 Civil Works Php 7,770,254.581.3 Structural Works Php 48,822,056.961.4 Instrument Airline Php 208,818.851.5 Mechanical / Piping Works Php 41,430,806.62 1.6 Flushing, Testing and Commissioning Php 60,934.51

Sub-Total Php 108,581,215.132.0 LGPF Tongonan 1 Hook-Up of Wells 218D/ 219D/ 216D/ 208D to SV 270/280

(EDC 08-076)2.1 Preliminary and General Works Php 6,849,163.662.2 Civil Works Php 4,659,560.292.3 Structural Works Php 38,932,032.892.4 Instrument Airline Php 61,033.412.5 Mechanical / Piping Works Php 21,267,349.632.6 Flushing, Testing and Commissioning Php 50,469.65

Sub-Total Php 71,819,609,523.0 Mahanagdong “B” MG-F Pad Hook-Up Project (EDC 08-097)

3.1 Preliminary and General Works Php 9,945,183.743.2 Civil Works Php 11,909,862.873.3 Structural Works Php 45,271,456.163.4 Instrument Airline Php 69,201.693.5 Mechanical / Piping Works Php 68,734,514.433.6 Flushing, Testing and Commissioning Php 60,934.51

Sub-Total Php 105,991,153.40

COST

z




4.0 LGPF Upper Mahiao Line to 4RD (EDC 08-106)4.1 Preliminary and General Works Php 3,384,567.794.2 Civil Works Php 7,551,089.594.3 Structural Works Php 17,101,604.894.4 Mechanical / Piping Works Php 6,796,834.974.5 Flushing, Testing and Commissioning Php 35,236.03

Sub-Total Php 34,869,333.265.0 Civil, Structural, and Mechanical/Piping Works for the Construction

of the LGPF Mahanagdong “A” Condensate Disposal System (EDC 08-103)

5.1 Preliminary and General Works Php 3,760,155.885.2 Civil Works Php 3,009,180.355.3 Structural Works Php 21,446,336.115.4 Mechanical / Piping Works Php 10,504,590.505.5 Flushing, Testing and Commissioning Php 10,332.385.6 Provisional Items Php 8,093.47

Sub-Total Php 38,738,688.70

GRAND TOTAL Php 360,000,000.00

COST

z

B. WEIGHT FACTOR

1. Based on Bid Price Schedule

2. Proposed Detailed Progress Monitoring Form

C. PROGRESS BILLING

1. Billing Processing Flowchart

2. Checklist of Billing Attachment




TRACKING

z

A. FORECASTING / PLANNING

1. Construction Schedule / Barchart with S-curve and Resource Loading and PERT – CPM Network

Develop in consideration of actual field condition For EDC evaluation and approval

2. Manpower Loading

Per Bid Submittals For EDC evaluation and approval

3. Equipment Loading

Per Bid Submittals For EDC evaluation and approval

Direction Operations RevisionsCost TrackingOrganization



TRACKING

z

4. Materials Delivery Schedule

5. Look Ahead Program

B. PROGRESS EVALUATION

1. Daily Work Activity Report (DWAR)

For EPC CD site management appreciation of development Critical for evaluation of claims (Cost and Time Extension)

2. Contractor Weekly Report

Cut-off : Every Tuesday Submit on : Wednesday Morning

3. EDC Monthly Progress Report

Reference of Progress Billing For the information of higher management

Organization Operations RevisionsCost TrackingDirection



OPERATIONS

z

Project Control

Project Implementation

Materials Control

Quality Control

Safety

Security

Civil, Structural and Mechanical/Piping Works for the:

1. LGPF Upper Mahiao Pad 403 Wells Hook-Up (EDC 08-070)2. LGPF Tongonan 1 Hook-Up of Wells 218D/ 219D/ 216D/ 208D to SV

270/280 (EDC 08-076)3. Mahanagdong “B” MG-F Pad Hook-Up Project (EDC 08-097)4. LGPF Upper Mahiao Condensate R.I. Line to 4RD (EDC 08-106)5. Mahanagdong “A” Condensate Disposal System (EDC 08-103)

TrackingCostOrganization RevisionsOperationsDirection



Project Control

z

A. PROJECT CONTORL

1. BONDS AND INSURANCES

1.1 PERFORMANCE BOND / SECURITY

Covering original contract duration Covering Time Extensions / Change in Contract Amount Forms of Performance Security

i. Cashier’s Check or Manager’s Check - 2.5% of the

Contract Amountii. Bank Guarantee or Irrevocable Letter of Credit - 5.0% of the Contract

Amountiii. Surety Bond - 10 % of

the Contract Amount

The performance security shall be valid until at least sixty (60) calendar days from completion date.

Project Control | Civil/Structural | Mechanical | Materials Control | QA/QC | Safety | Security




Project Control

z

1.2 ALL RISKS MARINE CARGO INSURANCE (OCEAN AND INLAND)

Shall not cover the permanent and temporary installation cost Coverage shall be one hundred and ten percent (110%) of the delivered cost

1.3 CONTRACTOR’S ALL-RISK / ERECTION ALL RISKS INSURANCE

To cover the entire Works (permanent and temporary) to their full replacement value, from any causes whatsoever including Sabotage and Terrorism.

1.4 THIRD PARTY LIABILITY INSURANCE (part of CAR/EAR of item 1.3)

To cover a combined single minimum limit of Php 5,000,000.00 With a cross-liability provision to cover both the properties and personnel of

the contractor and EDC as if separate insurance policies were issued to them; shall be explicitly stated in the policy

Must also state EDC, the contractor, and its subcontractor(s) as named and additional insured, and assumes the consequences of failure to do so





Project Control

z

1.5 WORKMEN’S COMPENSATION INSURANCE

As required under the Social Security Law

1.6 VOLUNTARY THIRD PARTY MOTOR VEHICLE LIABILITY INSURANCE

With a combined single limit of Php 300,000.00 per unit/occurrence

1.7 WARRANTY SECURITY Valid for a period of one (1) year between project completion and final

acceptance of the project Form of Warranty Bond

i. Surety Bond - 10 % of the Contract Amount





Project Control

z

2. LIQUIDATED DAMAGES In case of undue delay or failure on the part of the contractor Equivalent to one-tenth of one percent (1/10 of 1% or 0.1%) of the total

Contract cost per package for every day of delay until the acceptance of work by EDC

Shall not exceed twenty percent (20%) of the total Contract cost per package, in which event, EDC may terminate the Contract and impose appropriate sanctions over and above the liquidated damages to be paid

3. SUB-CONTRACTED WORK

2.1 Extent of work to be sub-contracted

2.2 Accreditation of nominated sub-contractor

4. CONSTRUCTORS PERFORMANCE EVALUATION

3.1 Based on NEDA approved Constructors Performance Evaluation System Guidelines





Civil / Structural

z


B. PROJECT IMPLEMENTATION

a. CIVIL / STRUCTURAL

1. START UP STAGE

1.1 “Work Permit” acquisition from EDC SFO Production

1.2 Preparation and submittal of detailed Fabrication Drawing to EDC

1.3 Daily Work Activity Report (DWAR) submission

2. CONSTRUCTION STAGE

2.1 Establishment of existing control points

2.2 Survey Laying-out and excavation of foundation

2.3 Validation of location of buried cables with SFO E/I Maintenance




Civil / Structural

z


2.4 Request for Penetrometer Test and request for issuance of Permit to Proceed

2.5 Issuance of Permit to Proceed

2.6 Lean Concreting

2.7 Installation of rebars and formworks

2.8 Installation and setting of structural steel items

2.9 Concreting works

2.10 Removal of forms and backfilling works

3. PRELIMINARY INSPECTION / PUNCHLISTING / HOUSEKEEPING

4. PREPARATION AND SUBMITTAL OF “AS-BUILT” DRAWINGS




Mechanical

z


b. MECHANICAL / PIPING

1. START UP STAGE

1.1 Contractor will submit to EDC / PPCD Mechanical Section two (2) copies of A3 size (297mm x 420mm) isometric drawing for pipeline construction and fabrication drawing for structural steel items (shear key, cross girder and pipe shoe).

1.2 EDC / PPCD Mechanical Section will check the submitted isometric and fabrication drawings.

IF DRAWING IS DISAPPROVEDIsometric and fabrication drawings will be returned to contractor for

correction and re-submit to EDC in two (2) copies for re-checking. IF DRAWING IS APPROVED

Isometric and fabrication drawings will be returned to the contractor for minor corrections if there are any and to be re-submitted to EDC in five (5) copies for final approval.




Mechanical

z


2. MATERIAL WITHDRAWAL

2.1 Contractor will prepare a letter for Material Line-up for Withdrawal (MLW) and submit to EDC / PPCD Mechanical Section for evaluation and approval. The said MLW will be endorsed to Material Control for proper documentation and release.

2.2 Contractor to submit a random pipe and trim elbow pairing for EDC evaluation and approval.

3. CONSTRUCTION STAGE

3.1 A “Work Permit” shall be secured by EDC / PPCD from EDC / SFO Production prior to the start of piping activities. Please observe strictly the “No Permit – No Work” Policy.

3.2 “As-Staked” quantities will be based on the approved isometric drawings.




Mechanical

z


3.3 Contractor’s QC should inspect all alignments and fit-up prior to EDC / PPCD inspection and approval.

3.4 During inspection, Contractor should submit to EDC /PPCD Mechanical Section an “Inspection Permit” (ex. “Welding Permit”) for pipeline and fit-ups to be inspected / signed by the Contractor’s Quality Control.

3.5 Contractor should prepare DWARs (Daily Work Activity Report) in three (3) copies and submit to EDC daily. DWAR for the day should be submitted on the next day.

4. COMPLETION STAGE

4.1 Punchlisting / Testing / Commissioning.

4.2 Submit four (4) copies “As-Built” drawing in A2 size paper and in latest Autocad digital format of the completed mechanical / piping component of the project (Submission of As-Built drawing is same procedure as in fabrication drawing).

4.3 Reconciliation of “As-Staked” vs. “As-Built” quantities.




Mechanical

z


4.4 Housekeeping in all areas.

5. TURN-OVER

5.1 Upon completion of works, EPC PPCD will officially turn-over the completed project to SFO.




MatCon

z


C. MATERIALS CONTROL

1. Mobilization and Demobilization of Contractor’s supplies, tools and equipment:

1.1 The Contractor shall advise EDC the list of all supplies, tools, and equipment that they will mobilize to the project site and demobilize after project completion.

1.2 The Contractor shall prepare a request for inspection of the items.

1.3 A joint inspection will be conducted by EDC and the contractor representative once the supplies, tools and equipment arrive at site.

1.4 The Contractor shall prepare a request for the Gate Pass issuance of all equipment, tools and excess supplies that will be demobilized of the project site.

1.5 Materials Control Section shall inspect the items and issue the Gate Pass.




MatCon

z


2. Inspection of Contractor’s Supplied Materials

2.1 The Contractor shall prepare a request for inspection of materials indicating among others the following:

a. Packing Listb. Mill or Manufacturer’s Certificatesc. Date and place of inspectiond. Contractor’s contact person

2.2 The Contractor must, give at least two (2) days advance notice prior to the actual inspection of the materials.

2.3 All Contractor supplied materials will be marked properly by EDC / EPC QC after the inspection either accepted or rejected.

2.4 The rejected materials will be isolated by the Contractor from the accepted materials.




MatCon

z


3. Materials Storage and Handling

3.1 The Contractor shall confine and store all materials, equipment, tools, consumables and operations of its workman within the limit provided for by EDC.

3.2 The Contractor shall properly document all materials being delivered at site and to ensure that all these materials are properly inspected and accepted by EDC / MatCon prior to storage and installation.

3.3 The Contractor shall properly handle materials from storage to work site to ensure the materials installed are of the same quality as when they were delivered and inspected.

4. Withdrawal of EDC Supplied Materials

4.1 The Contractor shall prepare a request for the withdrawal of materials, stating among others, the name of the project, approved isometric drawing reference, and the summary of materials to be withdrawn.




MatCon

z


4.2 EDC Materials Control will review / evaluate the request in one (1) to two (2) days (depending on the volume of request) and will prepare a “Summary of Materials Approved for Withdrawal” (SMAW). The Contractor will be furnished a copy of the SMAW immediately after approval.

4.3 Upon receipt of the SMAW the Contractor shall coordinate with the EDC Materials Control for the actual withdrawal of the materials. The Contractor shall prepare its equipment for hauling / lifting / handling the materials and manpower complement complete with PPE while EDC Materials Control will prepare the withdrawal documents, i.e. Materials Issued to Contractor (MIC) and / or Local Storehouse Order (LSO) and Gate Pass.

4.4 Material withdrawal time shall be between 9:00 AM to 4:00 PM. (Note: For special request for materials withdrawal beyond 4:00 PM and during holidays or Sundays, the contractor shall seek an advance approval from EDC two (2) days before the scheduled activity).




MatCon

z


5. Materials Reconciliation

5.1 The Contractor to submit “As-built MTO” duly approved by the EDC / PPCD.

5.2 The Contractor to submit request for material reconciliation.

5.3 Upon approval of the request, the Contractor will send a representative to Materials Control Section and reconcile the materials withdrawn against “As-Built MTO”.

5.4 All company supplied materials issued to the Contractor in excess of the “As-Built MTO” will be returned by the Contractor to the EDC / PPCD Warehouse in good condition.

5.5 Cost of all excess materials not returned by the Contractor shall be charged to their account plus 15% incidental cost. The “As-built” drawings shall be used as one of the basis for material reconciliation and in determining the excess materials issued to the Contractor.

5.6 Prior to demobilization and as part of its contractual obligation, the Contractor is requested to deposit all scrap metal cut-offs in a place that will be designated by EDC.




QA/QC

z


D. QUALITY CONTROL / QUALITY ASSURANCE

The main purpose of this provision is for the Contractor and its subcontractors to create Quality Control and Assurance group that will effectively establish a system of monitoring and maintaining the quality condition of the entire aspect and duration of the project in accordance to the approved technical specification and established standards.

1. DOCUMENTS

1.1 Quality Management Plan - ensures that the performance of the project work fulfills the requirements of the contract documents and that the materials, equipment, and all elements of the work will perform satisfactorily for the purposes intended. Accordingly, the Quality Management Plan document should contain, but not limited to, the following:

a. the mission and quality policy of the organization;b. the specific roles, authorities, and responsibilities or management and

staff with respect to QA and QC activities;c. the means by which effective communications with personnel actually

performing the work are assured;d. the processes used to plan, implement, and assess the work performed;




QA/QC

z


e. the process by which measures of effectiveness for QA and QC activities will be established and how frequently effectiveness will be measured; and

f. the continual improvement based on lessons learned from previous experience.

1.2 Quality Control Inspection Plan - should provide for an adequate and qualified force for inspection of the construction of the project works. The program description should contain detailed information including, but not limited to, the following:

g. introduction describing the project and proposed construction;h. organization chart of the construction inspection force;i. description of duties, responsibilities, necessary qualifications, and

scope of authority of the QCIP staff;j. field tests to be performed and frequency of testing;k. field Laboratory facilities or commercial testing services to be provided;l. description of Inspection Plan including documentation and reporting

procedures; andm. schedule of all major features of the project.




QA/QC

z


2. QUALITY CONTROL PERSONNEL

The Contractor shall provide Quality Control Personnel as skilled and competent to give proper supervision and handle and coordinate all quality control related activities and issues. The QC personnel shall conduct regular inspection necessary for the proper and timely execution and maintenance on the entire aspect and duration of the project.

The Contractor and its subcontractor(s) shall at all times during the duration of the

project have its QC Engineers and inspectors continuously monitoring the actual implementation of the project to adherence to quality workmanship. The Contractors and its subcontractor(s) QA/QC group should have a regular meeting with EDC’s QA/QC group in order to ensure that all QA/QC matters are properly coordinated and updated.




QA/QC

z


3. MATERIALS All orders for materials and equipment purchased by the Contractor specifically for this

Contract are subject to inspection, tests and expediting. Material documents must be submitted prior to use should contain, but not limited to, the following:

a. Traceable Mill Certificates/Material Certificates/Test Results b. Inspection Report

The Contractor shall advise the manufacturer of these interventions of EDC or his authorized representative(s).

4. OTHERS

During the course of the Contract, EDC Quality Control reserves the right to monitor the implementation of the Contractor’s quality assurance program. Monitoring will be by means of surveillance of activities at work locations and where appropriate by formal audits. The requirements for a specific work shall include, but not limited, to the following:




QA/QC

z


4.1 Concrete Works

a. Complete Quality Test Results of Fine and Coarse Aggregatesb. Cement Mill Certificatesc. Concrete Design Mixtured. Trial Mix and Test Results prior to start of concreting workse. Concrete Pouring Permitf. Sampling and Testing at 7th, 14th and 28th days

4.2 Steel Works

g. Mill/Material Certificatesh. Test Reports

4.3 Installation/Erection Works

i. Installation/Erection Methodologyj. Installation/Erection Permitk. Inspection Report




QA/QC

z


4.4 Welding Works

a. Welding

i. Welding Procedure Specification (WPS) and Performance Qualification Records.

ii. Welders Qualification Test (Witness by EDC)iii. Welders Qualification Recordsiv. Welding Permitv. A Welder Certification shall be revoked on any of the following grounds

His monthly overall rejection rate computed in linear inch of production weld length exceeds 3%

In any production joint, his rejected weld length exceeds 30% of the total pipe circumference of 18” whichever is shorter

vi. Welded joints are requiring full penetration weld shall be done using GTAW process at the root / hot pass. Succeeding weld layer shall be SMAW process.

vii. Small bore shall be done using GTAW process.




QA/QC

z


b. NDT/Inspection Procedure

i. Visual Inspectionii. RT, UT, MPT, PT Testingiii. Inspection Report

c. PWHT

i. Post Weld Heat Treatment Procedure (if required)ii. If weld joint is completely cut-out and re-welded without removing heat

affected zone.iii. If weld joint have undergone three (3) or more repairs at same

location(s). PWHT is not required if welded joint is removed and an insert spool is provided. All cost incidentals to this repair shall be chargeable to the Contractor.

iv. PWHT Report

d. Others

i. Production welding report shall be submitted weekly prior to the coordination meeting.




Safety

z

E. SAFETY

EDC CONTRACTOR’S SAFETY REQUIREMENTS General Terms and Conditions Safety

The Contractor shall abide by all occupational Safety and Health laws, standards, rules, regulations and procedures set, ordered, enforced and administered by the DOLE – Bureau of Working Condition (BWC), the Department of Energy (DOE) and EDC.

EDC shall have the incontestable right to halt or order the cessation of any operation of the contractor not in accordance with such law, standards, rules, regulations and procedures.





Safety

z

In this respect, it shall be the responsibility of the contractor, among other things, to:

a. Provide its employee assigned to this Project all necessary safety

equipment;

b. Submit to EDC a written report of all accidents involving its property, equipment or employees, whether the same occurs on Project Site or while traveling to or from Project Site;

c. Submit to EDC, at least five (5) days before the end of each applicable month, a summary of all occupational injuries sustained or suffered by its employees assigned to the Project.





Safety

zFAILURE BY THE CONTRACTOR TO COMPLY WITH ANY OF THE

ABOVE-STATED REQUIREMENTS, WITH OR WITHOUT CAUSE,

SHALL BE GROUND FOR THE IMMEDIATE CANCELLATION OF

THE CONTRACT

TAKE NOTE!





Safety

z

THE CONTRACTOR MUST:

Submit a project Safety Program;

Have full-time Safety Engineer or appointed person specialized / in-charge of Safety;

Submit safety procedures of all critical activities;

Provide its employees the appropriate Personal Protective Equipment (PPE);

Submit to EDC Safety Management Office (SMO) a formal report of all accidents involving its people, equipment, materials and environment; and

Contractor’s personnel should report to the Safety Officer in the field Safety Management Office for appropriate orientation and other safety requirements prior to the start of project in the area.





Security

z

F. SECURITY

LGPF SECURITY STANDARD OPERATING PROCEDURES FOR THE CONTRACTORS AND ITS WORKERS

1. Requirement before engagement

1.1 Clearances:

a. NBI - For transient, like key personnel of the Contractor and other personnel who came from other places other than Province of Leyte.

b. Local Clearance – For local personnel, like from Ormoc City, and neighboring towns and cities, the following local clearances are required

i. Barangay Clearanceii. Police Clearanceiii. RTC / MTC Clearanceiv. EDC Security Clearance





Security

z

1.2 List of Personnel – This is to be submitted at least 1 week prior to engagement of their project at LGPF for security review.

a. Key Personnel

b. Local hired personnel (those Ormoc City, neighboring towns and cities within the Province of Leyte)

Note: As much as possible, the contractor shall initiate efforts not to hire personnel with derogatory records or with dubious personalities.

2. Requirement and standard operating procedures during engagement of the project at the LGPF:

2.1. NO ID, NO ENTRY.

2.2 LGPF Security Group shall issue COLOR CODED IDs in exchange for the workers’ ID issued by their contractor. The same shall be surrendered upon exit or knock-off time to the guard on duty.

2.3 In the event that the contractor has a barrack for their stay-in personnel, it must have a house rule for the control of its personnel and furnish the security group with a copy of such as reference. No liquor, No gambling policy should be observed.





Security

z

3. Materials Control in the Field

3.1 Housekeeping and safekeeping of construction materials in the field is a must.3.2 Any loss of EDC construction materials in the field, the contractor shall be

answerable as a result for such.3.3 The contractor must provide their own guards to safeguard their own

materials, equipment and personnel.





VARIATIONS

z

A. VARIATION ORDERS

Variation Order - to cover any increase / decrease in quantities including the introduction of new work items that are not included in the original contract or reclassification of work items that are either due to changes of plans, design or alignment to suit actual field conditions resulting in disparity of quantities.

Two Forms of Variation Orders:

1. Change Order - to cover any increase / decrease in quantities of original work items in the contract.

2. Extra Work Order - to cover the introduction of new work necessary for the completion, improvement or protection of the project which were not included as items of work in the original contract.

OperationsTrackingOrganization CostDirection Revisions



VARIATIONS

z

B. DRAWINGS

1. Bid Drawings

2. Construction Drawings

3. As-Built Drawings

C. CONTRACT CHANGE AUTHORIZATION

1. CCA No. 1 - As-bid Quantity vs. As-Staked Quantity

2. CCA No. 2 - Suit to actual field condition

3. CCA No. 3 - As-Staked vs. As-Built Quantities

D. MATERIAL RECONCILIATION

1. To identify quantity of materials delivered against installed




VARIATIONS

z

E. DOCUMENTATION

1. Prompt processing of claims is dependent on completeness of references.

2. Need for thorough documentation can never be overstated. DWAR Letters of instructions Other related documents (PAGASA Weather Reports, Drawings, Certifications,

etc.)

F. VARIATION CLAIMS

The contractor, shall within seven (7) calendar days after such work has been commenced or after the circumstances leading to such condition(s) leading to the extra cost and within twenty-eight (28) calendar days deliver a written communication giving full and detailed particulars of any extra cost in order that it may be investigated at the time.




VARIATIONS

z

Failure to provide either such notices in the time stipulated shall constitute a waiver by the Contractor for any claim.

Under no circumstances shall a Contractor proceed to commence work under any Change Order or Extra Work Order unless it has been approved by the approving authority of EDC.

Independent of mother contractCan be billed separately upon:

i. Completion of works or progress billing

ii. Approval and conforme of CCA

G. FCR / CCA PROCESS FLOWCHART




z

FIRST BALFOUR, INC.Rey G. Villar



z

OPEN FORUM



z

CLOSING REMARKSMartin Jude V. Lavambra



z

Attachments

† Billing Flowchart† Checklist for Billing† Manpower Loading† Equipment Loading† Work Permit† Isometric Drawing† Pipe Shoe Detail† DWAR † SMAW† MIC† LSO† Gate Pass† FCR /FCA Flowchart

Billing Processing Flowchart

Action By Duration

Contractor

Project Control / 7 daysImplementor

Site Accounting 13 days

Project Control 3 days

Office of the EPC Senior Manager 4 days/ VP of Technical Services

FB Payables 3 days

30 days

Office of the Construction Superintendent

Submit Billing

Receive Billing

Review / Assess Billing

OK

Attest Billing

OK

Send to Manila for Approval

Approval

Preparation / Release of Check to

Contractor

NO

NO

YES

YES

z


Attachments

z


AttachmentsEDC

08-070EDC

08- 076EDC

08-097EDC

08-106EDC

08-103

1. Mechanical Foreman 3 1 2 2 1

2. Mechanical Leadman 12 4 8 8 2

3. Pipe Fitter 24 8 16 16 4

4. Erector / Fitter 4 4 4 4 2

5. Rigger 4 4 4 4 2

6. Helper 82 53 74 39 16

7. Welder 15 8 12 4 28. Civil / Structural

Foreman8 6 8 6 6

9. Leadman 8 10 8 7 7

10. Mason 12 14 14 10 8

11. Carpenter 12 8 12 8 612. Civil / Structural

Steelman10 12 10 8 7

13. Laborer 46 34 46 20 15

-------- -------- -------- -------- --------

Total (838) 240 166 218 136 78

z


Attachments

1.00

Common Equipment

Crane 25T - 2Crane 45T - 1Crane 80T - 1Air Compressor - 2Service Vehicle - 6Truck, Elf - 4Genset

120 kW - 180 kW - 118 kW - 2

Water Truck - 1-------------------

212.0 EDC 08-070 (Pad 403)

Boom Truck 3T - 1Welding Machine - 15Genset, 10 kW - 1Backhoe - 1Dump Truck - 1Pay Loader 1.5CY - 1Walk Behind Roller - 1Concrete Vibrator - 21 Bagger Mixer - 3

-------------------

263.0 EDC 08-076 (Pad 208)

Boom Truck 3T - 1Welding Machine - 7Genset, 10 kW - 1Backhoe - 1Dump Truck - 1Pay Loader 1.5CY - 1Walk Behind Roller - 1Concrete Vibrator - 21 Bagger Mixer - 3

-------------------

18

4.0 EDC 08-097 (MG-F)Boom Truck 3T - 1Welding Machine - 12Genset, 10 kW - 1Backhoe - 1Backhoe w/ Breaker - 1Dump Truck - 1Grader - 1Pay Loader 1.5CY - 1Roller Compactor 10

Tonner- 1

10 Tonner Vibro Roller - 1Walk Behind Roller - 1Concrete Vibrator - 31 Bagger Mixer - 4

-------------------

295.0 EDC 08-106 (Pad

4RD)1. Boom Truck 3T - 11. Welding Machine - 41. Genset, 10 kW - 11. Dump Truck - 11. Walk Behind Roller - 11. Concrete Vibrator - 21. 1 Bagger Mixer - 3

-------------------

136.0 EDC 08-103 (MG “A”)

1. Boom Truck 3T - 11. Welding Machine - 21. Genset, 10 kW - 11. Dump Truck - 11. Walk Behind Roller - 11. Concrete Vibrator - 21. 1 Bagger Mixer - 3

-------------------

11TOTAL (118)

z


Attachments

z


Attachments

z

† Billing Flowchart† Checklist for Billing† Manpower Loading† Equipment Loading† Work Permit† Isometric Drawing† Pipe Shoe Details† DWAR † SMAW† MIC† LSO† Gate Pass† FCR /FCA Flowchart

Attachments

z


Attachments

z


Attachments

z


Attachments

z


Attachments

z


Attachments

z


Attachments

END OF PRESENTATION

CAST

PPC DEPARTMENT MANAGER ERNIE GAGTO

CONSTRUCTION SUPERINTENDENTLOLOY COLUMNAS

PROJECT CONTROL SUPERVISOR NANTE BACIERTO

MECHANICAL / EI SUPERVISOR RONNIE CORTES

MATERIALS CONTROL SUPERVISORLOUIE DELOS REYES

QA-QC SUPERVISOR JOEY BONGON

CIVIL / STRUCTURAL REPRESENTATIVE DODONG CANAMA

FIELD EI ENGINEER NONOY ORACOY

SPECIAL PARTICIPATION

- PPC Department STAFF AND PERSONNEL -

Thank You!

Documents

Report TE 501- Sample Project Implementation