22 execution plan-epc-250 mw power plant

Buildings Practice Facilities Plants/PetrochemicalsChapter 22

Project Execution Method EPC 225 MW Combined Cycle Power ProjectOwner:

Project Execution Method(Project Implementation Strategy)

Civil, Buildings & Plant Installations

An Overview1 Document for General/Specific Directives for EPC Contractor, Subcontractors,2 Design Engineers & Project Managers, & Informative to Employer & Engineer

3 In Compliance to Article …………. EPC Contract

EPC Contractor……………………….Scope of works in EPC Contract1 Objective of this document is to outline applicable strategies & proposed methods that shall

be adopted in prosecution of all items covered within EPC contract scope, for which given procedures would certainly be intended to be implemented in entirety on site.

2 Project helps in electrical production & distribution in state of …………. & certainly shall corroborate national electrical grid to an extent, electric supply is concerned.

Essence of project:1 EPC contract comprises based on contractor’s designed/ defined building works, contractor’s

designed defined Infrastructural works & contractor’s designed supply, installation, commissioning of complete processing equipment, meant to successfully deliver this operating plant facility to produce 250 MW Gas based combined cycle power project.

Project Status:1 Land has been leased by employer for project.2 Proposed completion duration of project delivery is 16 months.3 In all 3 # interrelated structured contracts do exist between employer & EPC contractor.4 Design works have to start from stretches.5 All design philosophies shall be adopted by creating FEED considerations.6 Site prosecution works have to start from zero.7 Many permits have been obtained by employer.8 Many permits have to be applied by EPC contractor.

Summarized Scope-Buildings: 1 Power generation block-control room, electrical & electronic equipment rooms, steam

turbine generator hall, switchgear room, computer room, service/maintenance bay, 220 KV switch yard, earth mat & earth pits, transformer yard civil works, rail track near transformer yard to road near yard

2 Natural gas conditioning system-complete civil & structural works for system 3 Main & auxiliary cooling water system (CW)-CW conduit, chlorination area civil works,

auxiliary cooling towers including basin etc, water & effluent treatment plant, fire water storage & pump house systems, overhead water tanks to be located on buildings for services water & potable water, civil works in connection with pipe laying,

4 Auxiliary structures & facilities

Attachments required - Level 1 Schedule, Resources allocations, Cash Flow, Man Hours, equipment Hours Page, S Curve, Resource’ leveling, Demobilization of personnel stages. of 28 2012 Int. P Eng Suraj Singh


Project Execution Method EPC 225 MW Combined Cycle Power Project

Summarized Scope-Infrastructure Facilities:1 Main internal roads, pavements, plant drainage system, sanitary, sewerage system, fencing &

gates, piling, storm water drainage system, other structures, drains, roads, culverts etc. bonded warehouse & facilities

Summarized Scope-Equipment & Electromechanical:1 Equipment, vessels, services discipline requirements in line to appendix… 2 Engineering designs based on contract FEED input data:

Building Engineering Design 1 Management necessitates an integrated approach to formulate an overall design philosophy,

capable to achieve an intellectual engineering design product, covering & incorporating a wide range of performance & serviceability requirements that should completely meet intended functions of proposed buildings adequately, satisfying architectural, structural & allied services compatibilities with highest reliability factor.

2 For target achievement of this fast track EPC project, it shall be kept in consideration by all discipline engineers/designers to release applicable necessary useable documents on scheduled planned line.

3 Though contract document provided design criteria for all scope of areas involved, yet applicable selection shall be conducted by design section from practical aspect viewpoint.

4 Prior to commencement of formal working designs for construction, applicable FEED shall be proposed/constituted from available documents for formal approval.

5 FEED provisions are required to be complied with by design leaders. 6 Adopted approved FEED provisions shall be used for implementation on designs. 7 To accomplish good performance respecting this part of package meeting best possible

standards, EPC contractor shall invite, either to bid for consultancy certain (possibly 3#) reputed & leading architectural engineering firms to serve as engineering services subcontractor or organize its own in house experts’ section or division for design participations.

8 Design teams shall constitute experienced certified engineers from all disciplines. 9 All team members shall be competent to understand, interpret, conceive, develop & apply

design propositions to achieve a functional/performance delivery plant facility.10 Based on merits of each offer as well as, complying with demanded competency criteria, a

preliminary selection for designs firm shall be made in case, no in house team is schemed. 11 After obtaining engineer/client/owner approval respecting proposed firm or in house design

personnel, a formal appointment shall be made by executing an engineering services agreement with subcontractor or in house section head, supported by design team shall be appointed to carry out project designs tasks.

12 Engineering services subcontractor hereinafter shall be called ‘Design Firm’ or for in house application, shall be called EPC contractor design section.

13 Quantum of design tasks is considerable on this project, when evaluated from FEED to as built status.

14 Design teams should be well experienced & efficient to provide prompt deliveries about design documents, so that all works on project move smoothly throughout duration of construction part of project.



Project Execution Method EPC 225 MW Combined Cycle Power Project15 EPC contractor shall ensure that design team or design subcontractor do have adequate

support of engineering designs state of art software, good printers of all sizes, good strength of support staff & well to do inter communication medium such as E mail, internet, video conferencing etc.

Scope of Firm or in house design section shall include, but not be limited to carrying out design works within scope of EPC contract as well as, following defined engineering services’ operations/activities for all buildings included within ‘EPC contract1 Undertaking topographical surveys, intrusive surveys and investigations as may be necessary

for providing support to engineering designs/design team. 2 It is essential to conduct current soil investigations, since existing report giving such

investigation might be old one & requires ratifying verification.3 Soil explorative investigations as required on defined engineering specification basis for

considering on accomplishing engineering designs shall also, be conducted.4 Topographic survey shall be performed & permanent bench marks established by contractor

employing a qualified GPS competent party on a third party basis.5 Production of all architectural, structural & allied services schematic designs in all respects,

beginning from FEED documentation or provided with FEED interpretation.6 Perform all project intended engineering studies, designs calculations etc. for all major

activities & components, within project works scope.7 Study all codes to check out or identify relevant provisions to be applied with, on various

designs components.8 Secure support to all statutory applications to be moved on to governmental and local

authority permits and approvals, if so necessary, when not procured by owner or client.9 Provide statutory design certifications based on adopted considerations & applied code

provisions, as required by bye laws, regulations or other laws.10 Compiling all outstanding data deemed necessary for prosecution/completion of project

detailed engineering design.11 Producing all architectural & structural detailed designs for engineer/owner or client’s approval to

comply with relevant provisions on contract & match subcontract requirements.

12 Act as EPC contractor design & engineering representative for relevant buildings contract scope of works.

13 Civil & architectural scope from its inception to completion as & when so required.14 Produce all FEED documents, engineering information design drawings, drawings for

review, drawings for constructions, drawings for coordination, all applicable specifications indicated point to point on drawings or otherwise, all engineering & technical schedule production for fabrication etc.

15 Have all these documents submit to engineer for approval & after having approval, issue master copies of all designs documents through document control centre to project.

16 Produce further revisions, whenever so required due to change on type of equipment or occurrence of conditions to meet intended/updated specifications/requirements.

17 It should be noted that in many cases of equipment procurement processes, due to non availability of certain significant equipment, proposals are changed, so that long lead equipment procurement should be delivered in time.



Project Execution Method EPC 225 MW Combined Cycle Power Project18 Such situations lead to proposition of alternative equipment meeting original specifications,

which may require redesign of foundations or tabletops.19 On such projects, keeping abreast enormous design task, absence of confirmed information

or datasheet respecting major equipment, designers should consider such amendments positively, as a part of professional assignments & relevant cost margins must have been included within respective quotes.

20 Many major drawings shall be required to be revised a number of times from information stage to approved for construction stage.

21 Equipment are generally, very expensive, while foundation cost is not that high comparatively, which allows a variation on modification.

Building Engineering Allied Services: 1 Pre FEED provided key philosophical conceptual drawings only, for plumbing & sanitary,

drainage, small power & lighting, HVAC, firefighting & fire & gas detection/loss prevention, structured cabling system, security system etc.

2 Design team shall now care about remaining procedures from initiation of designs through to prosecution & to close out.

3 Liaison, coordinate & lead EPC contractor in house design team/services subcontractors’ design & engineering efforts to streamline all stages pertinent such designs up to site implementations.

4 EPC contractor’s services subcontractors/in house design team shall be responsible for delivering detailed designs and engineering input for relevant scope, based on provided conceptual drawings and other basic documents, directing initial designs criteria issued by design firm to obtain necessarily approvals from engineer/owner/client as case may be.

5 Firm or contractor’s in house team shall issue its package drawings/documents production schedule immediately, post award to commence its designs work at various levels, keeping in line meeting delivery on programme schedule.

6 Issue of drawings in time shall be considered very significant input for project prosecution requirements, so that project progress keeps in line to schedule.

7 Firm or contractor’s in house team shall represent EPC contractor at engineer/owner/client offices/officials at whatever locations, on site or off sites or overseas as EPC contractor’s design & engineering representative, during course of this contract, from its inception to completion as & whenever, so required.

8 Engineering coordination with design firm or contractor’s in house team shall be conducted from EPC contractor’s head office.

9 All field interfaces shall be conducted from site offices in collaboration with EPC contractor’s field engineers

10 All other remaining functional descriptions shall be conducted by EPC contractor’s personnel, located both in its head office as well as, on its site offices, depending on discipline wise technical nature required to be conducted with for either resolution or for implementation or for records.

11 All engineering design products shall be managed, conforming to national & international standards or as indicated/included within contract documents for demanded applicable technicalities as well as, for project standard documents controls.



Project Execution Method EPC 225 MW Combined Cycle Power Project12 Firm or contractor’s in house team shall comply with provisions on agreed documentation

system & conduct its relevant operations in all respects accordingly. 13 All produced approvable design documents shall be given appropriate numbering/s meeting

traceability requirement. 14 EPC contractor operates its own system pertinent centralized document control, which shall

be used fully complying in accordance to fit in, with compatibility on engineer/client/owner/company procedures by reformation, if so required.

15 Firm or contractor’s in house team shall produce & issue required scheduled documents at various stages of works for review, approval & achieve AFC status etc. efficiently keeping in line with approved project construction plan on various phases, while any delay on this account would not be acceptable to EPC contractor management.

16 Immediately, after issue of control documents to project site team, field/design engineers shall conduct review of design to ensure constructability & consequently, relevant design engineer/site engineer raise technical queries to remedy certain discrepancies among such provided documents, if so noticed, which should immediately, be resolved by design firm or contractor’s in house team & duly informed to EPC contractor/engineer.

17 All such documents shall be processed through ‘in action’ documentation system facilitating most convenient traceability for consultancy & references.

18 Consequent upon relevant resolution pertinent discrepancies, affected design drawings shall be revised & reissued for construction, duly incorporated with agreed solutions & circulated through documents control regularly, to all concerned personnel.

19 Buildings services schematic drawings shall be issued to subcontractors for further development of shop & working drawings for EPC contractor’s approval & issued to concerned parties, after getting duly approved for construction.

20 Necessary structural shop drawings shall be produced by EPC contractor’s own engineering personnel located in head as well as, on site offices, which should also, be processed into document control system for EPC contractor/engineer & issued to relevant concerned parties after getting duly approved for construction.

21 Preparation of requisitions for enquiry and award, technically evaluate bids and review of vendor/lower tier subcontractor documentation, shall be done by purchase manager in collaboration with project manager.

22 All foregoing procedures have been incorporated on project plan/organization manual procurement procedures document.

Detailed Engineering Design: 1 Preparing preliminary designs, control of calculations, writing applicable specifications,

production of construction drawings, production of shop drawings, raising material requisitions and production of bills of materials, all shall require detailed & descriptive input for project to run.

2 Extent of computer applications respecting foregoing activities should be well considered but, solely reliability on computer standalone is not encouraged.

3 Experienced designers should have an understanding to ensure about what should be right sizes of members & sectional detailing.

4 Simultaneously, site working difficulties should also, be imagined during designs stages, so that a construct able design is delivered.



Project Execution Method EPC 225 MW Combined Cycle Power Project5 Objective of design is to optimize executive design from viewpoint of keeping plant facility

functioning smoothly, throughout its calculated life without causing accidental shut downs or processing failures.

6 At its very first stage of commencement, respecting detailed designs, Firm or contractor’s in house team shall formulate positioning of all framing members vertically & horizontally, befitting coordinates as well as, level controls, meeting/conforming to intended architectural requirements, maintaining applicable basic design principles that conventionally, whole structural skeleton behaves as an integral unit with its centre of gravity passing through or within its permissible vicinity/resultant of imposed forces, while resultant of all over applied forces considered avoiding non tolerable eccentricity and that settlement of formation soil should be within permissible limits.

7 After considering all direct & indirect imposed loadings according to provisions on various relevant codes, design model shall be generated using firm licensed software.

8 Loadings shall include, direct loads such as dead load, live load, seismic shear (though may or may not be applicable in project location geographical location, that requires reference to seismic zoning map of India or relevant area)/wind load, blast load/effect, test load/application & also, considering various analysis, a most critical case of resulting stresses should be considered to be adopted for preliminary dimensioning & further details of various vertical & horizontal members, forming initial framing skeleton.

9 Generated model in 3D may be made available for formal presentation to engineer/client to explain & justify design adopted philosophy, if so required.

10 Calculations shall be done trying various options of loadings in 2D/3 D & included with its design proposal for approval.

11 These calculations shall be done & certified by a chartered engineer or a professional engineer employed by firm or otherwise, for ascertaining structural adequacy & structural intended performance.

12 Detailed designs & relevant calculations does not mean that designer should present volumes of design calculations, but to an extent justifying & ensuring whole processes pertinent to designs have been taken care of.

13 Soft copies of design calculations would suffice complete details. 14 Voluminous production of hard prints should be avoided.

Allied Services Designs 1 Designs of services shall be carried out each discipline wise. 2 Each discipline design details should be compatible with other designs detailing for deciding

procurements & activities or systems performance criteria. 3 Such design procedures requires collaboration among all design discipline engineers at

frequent intervals to meet together to confer on whatever parts of designs have been achieved to avoid possible clashes or incompatibilities or problematic interfaces.

4 Past experience has noticed that lot of precious project time is consumed by conducting such coordination, which happens due to lack of coordination at design stages itself.

Electrical discipline 1 In accordance to provision of electrical loadings design criteria as indicated on

engineer/client/EPC contractor’s documents, loadings, distribution of loading & all other parameters shall be adopted, applied for calculations adhering to national & international



Project Execution Method EPC 225 MW Combined Cycle Power Projectstandards, IEE as well as, Indian/State authorities regulations.

2 Schematic electrical drawings shall be produced meeting/matching intended architectural schematic drawings plans & relevant details.

3 Similarly, all loads from HVAC system disciplines as well as, from other remaining disciplines shall be worked out accurately for inclusion into electrical load calculation.

4 Foregoing design coordination shall be conducted in close coordination of interfaces with all disciplines to be affected & supported by responsible services design coordinators/design project engineers or services manager.

5 All such engineering details shall be included on drawings documents for approval. 6 All designs data shall be generated using appropriate computer software packages.

Specialized disciplinesLoss Prevention & others- smoke detection, fire alarms, FM 200 & Inergen gas systems etc..1 On similar pattern as described in foregoing, detailed designs shall be worked out meeting all

FEED requirements/contract specifications, disciplinary performance standards as well as, meeting international & conventional industrial standards, complying with local bodies statutory regulations/provisions.

2 From foregoing approved documents, bill of quantities shall be generated discipline wise & area wise/building wise, which document should be utilized for purpose of material procurement approval proposals & issue of requisitions of approved materials to procurement manager.

3 Bill of quantities shall not constitute part of contract documents, but serve as guidance.4 All bills of quantities shall be generated using appropriate computer software package.5 Specialized discipline is very critical, since experts pertinent to such engineering disciplines

are rarely available. 6 Naturally, specialist licensed by relevant authority or fire department, shall be allowed to

certify such documents. 7 Even, materials & installations shall be required to be authorized by such statutory authority

personnel.

Specifications/Supplement Specifications1 It is intended to adhere to engineer/client provided specifications within documents to every

extent possible, however to meet some particular requirement, supplement specifications shall be drawn & proposed for approval, wherever necessary for producing better products or include better materials, for which no specification is defined.

2 Such specifications shall be drawn in collaboration with firm & contractor’s design team keeping in view, an overall approach to comply with documented specification criteria as well as, conventional engineering & construction practice in similar circumstances.

3 Supplementary specifications are not very commonly proposed, but when certain long lead items is not available within contract schedule defined time or some specified item is out of manufacturing, proposal could be made provide, demanded performance criteria is met with.

Coordination ProcedureFollowing entitled coordination procedures shall be conducted during various stages of design & execution, which have been outlined below:



Project Execution Method EPC 225 MW Combined Cycle Power ProjectCoordination between contractor & engineer/client head office1 This coordination part shall be conducted by regular interaction among engineer/client

representative & contractor representatives head office based in India/elsewhere to help resolve all pre & post award issue pertinent engineering services & charting our relevant methods to be utilized for monitoring project controls.

2 Specific discussion can be attempted or special conferences arranged for considerable value involving items & suggested that regular records be made for future tracking.

3 Contractor’s agent or project manager/director can write to engineer on contract & voice versa.

4 Personal level interactions & mail transmissions can be used as medium for conducting such coordination for fast results/ prompt decisions.

Coordination between contractor & engineer/client site office1 This coordination part shall be conducted by regular interaction among contractor & engineer

or resident engineer/client site representatives to help resolve all pre & post award issue of engineering services & monitoring project controls.

2 Specific discussion can be attempted or special conferences arranged for considerable value involving items & suggested that regular records be made for future tracking.

3 Contractor’s agent or project manager can write to resident engineer & voice versa. 4 Site memos, personal level interactions & mail transmissions can be used as medium for

conducting such coordination for fast results/ prompt decisions.

Coordination between contractor & design firm/in house designs1 This coordination part shall be conducted by frequent interaction between contractor’s

management & design firm representatives pertinent all disciplines for reaching intended resolutions on all designs issues, issue relevant all documents, approval of all documents & resolutions of all engineering issues on site, whatsoever could be required on priority.

2 Continuous informative interactions shall also, be conducted with resident engineer & assistants keeping them update.

Coordination between contractor/firm & client1 This coordination part shall resolve all issues respecting engineering designs particularly,

during design stage as well as, generally, occurring during construction phases for efficient decisions making to help smooth execution of all activities involved.

2 Technical queries & engineering queries shall be raised for clarifications. 3 Site visits could be made frequently, to chart out serious problems. 4 No delay can be digested on reaching technical resolutions pertinent to such impending

issues.

Coordination between contractor/firm & client on site1 This coordination part shall resolve all issues respecting engineering designs during

construction phases on site for efficient decisions making to help smooth execution of involved activities.

2 Designers shall often visit sites & performing areas, interact with project managers, project supervisors etc. to understand practical difficulties & clashing engineering or technical issues to have an comfort to resolve them on site spots & document accordingly.



Project Execution Method EPC 225 MW Combined Cycle Power Project3 Site cannot wait for decisions consuming many days from contract duration.

Coordination between contractor site & firm/in house designs 1 This coordination part is essential to keep on fast track availability of complete design

information for all ongoing as well as, planned activities & should some information be pending or overdue, it shall be identified, coordinated & made available on site, prior to its requirement to avoid any problem on execution.

2 Continuous interaction shall be effected between site & design office. 3 Site to keep update designers about proposed areas to be undertaken for construction, while

existing problems & requirement respecting non-issued drawings & other documents, would be requested to be released on certain defined dates to avoid expected hold on activities.

4 In this instance, planning/schedule engineer shall remain in contact with designers as well.

Contractor internal coordination among various sections1 Contractor’s coordination in head office by well organized teams constituted with all

corporate sections, necessary to meet requirement on this project shall operate as an integral functional team/s group/s keeping on resolving regularly/as it is required, all impending issues on project designs & designs follow up in all respects.

2 This coordination part is schemed to be ongoing on daily basis with frequent interactions among all corporate managers as well as, supporting professionals help resolutions respecting all current & forthcoming issues.

3 Management meetings are conducted regularly for making decisions to avoid certain pending/outstanding identified problems.

Contractor’s internal coordination among various sections on site1 Similarly, on site, all project sections managers & supporting professionals shall coordinate

to resolve all types of problems to avoid certain pending identified problems or unexpected clashes/certainly would notify to corporate management for delivering immediate resolutions, should solution not be derived possible from site.

2 All team members shall interact regularly, under control of construction manager & project manager to bring forth various discipline wise issues to meeting table, so that relevant queries could be raised to designers for earliest resolutions.

3 Interactions are significant, though some personnel may complain about wastage of time by asking all to sit at one place leaving site areas unattended.

4 This approach is not supported, since investment of 1 hour during meeting avoids a whole day on site.

5 Information flow is required to executive personnel, so that works are not held up.6 Site senior personnel may virtually, interact with engineer & designers for conferring

informally, site problems & draw help or assistance to reach on site resolution that could be red lined on records.

Review and Approval of Documents 1 This requires effecting an instant action on part of contractor, whenever, whatever document

is received, it must be reviewed by its design team located at head office/site office, as case may be prior to formally submitting to engineer/client



Project Execution Method EPC 225 MW Combined Cycle Power Project2 After its submission to engineer/client, engineer/client shall process it through its document

approval system & after given engineer/client’s approval, return approved or commented original to contractor for further necessary contractor’s action.

3 All documents shall be processed adhering to contractor’s approved documentation control system, after tuning that in line to engineer’s/client’s requirement.

CAD Procedure1 It is intended to use standard CAD software for production of design & drawings. 2 All standard systems of designing shall be adopted at every workstation available in design

firm’s offices as well as, on site offices, where shop drawings or working drawings could be produced.

3 Details respecting all available software & hardware have been given elsewhere. 4 Also, included hardware & software details, which are functional in proposed design

subcontractor/firm’s office.

Engineering Reporting and Change Control1 Status of design progress indicating schedule, preparation status, prepared, submitted,

approved or rejected, being revised, being issued etc. shall be submitted to engineer/client on a weekly basis during progress meeting.

2 Should some change be required that shall be affirmatively, considered subject to cost impact resolution & then change incorporation request issued by contractor to firm.

3 Firm shall then work on revision, its calculations, advice to contractor & engineer/client of possible adverse effect on structural adequacy/intended performance or others, if required amendment to be applied to already worked elements/structural members.

4 Should there be no such adverse cost impact or consideration, design shall be revised & revised document issued following documentation & approval procedures.

Document Control Procedure1 Contractor operates its centralized DCC in head office that shall be tuned to engineer/client

documentation system & also, extended to site office to meet defined project requirement.2 Contractor’s document control system is enclosed for reference.3 DCC should be very smart, who well understands project briefs & contract documents, which

knowledge shall enable DCC to properly deal with all documents ranging gradation from highest significance to informal significance.

Vendor Print Numbering, Review and Distribution Procedure 1 All vendors shall be issued schedule of proposed documents submission numbers to be

printed on documents, adequately in advance of documents preparation. 2 Additional documents references may be added as supplementary, in case schedule requires

more such submissions3 All approved procedures of documents shall also, apply to vendors' provided designs.4 Vendors & subcontractors shall submit relevant documents to contractor first. 5 Contractor shall review all such documents & submit to engineer/client for formal approval.6 After receipt of documents from engineer/client shall be forwarded to vendors/ subcontractor

by project manager or agent through documents controller, in addition to be circulated to relevant area engineers/construction manager or those pertinent.




As-built Drawings 1 As built drawings serve purpose of telling user about building records that should be used for

purpose of maintenance/or for, whatever intended post project delivery future possible purpose.

2 It is therefore, considered an important & significant part of documentation as well as, also, constitutes a contractual obligation on part of contractor & engineer/client, which should be affected smoothly & regularly, throughout duration of project.

3 Should there be no change on ‘released for construction’ drawings i.e. where construction has been carried out all in accordance with approved documents’ provisions, there shall be no practical or virtual purpose of producing ‘as built’ drawings.

4 All such contract drawings & documents shall be sealed after completion of works as ‘as built’ & submitted for engineer’s/client’s approval.

5 But in practice, to produce physical structures, some design changes are imminent due to arising new project requirement, other changes, effects pertinent all disciplinary interfaces to bring proposed work to proper/defined use functions etc.

6 During whole currency of contract, it should be made an endeavour on part of contractor that all changes are recorded on contract documents as ‘red lines mark up’ & issued to engineer/client for approval.

7 These ‘red lines marks up’ shall form basis of producing all ‘as built’ documents on project, therefore, from time to time, all changes of whatever type or size should be recorded officially for ‘as built’ references.

8 It is not used drawings only, that require to be recorded, but also, all changes whatsoever, for certain documents on record such as schedules, specifications etc.

9 All ‘as built’ records shall constitute part of handover dossiers. 10 Should ‘as built’ records be maintained regularly, this part of project dossiers shall be

comfortably produced. 11 Site/field design engineers shall keep an eye on ‘as built’ activity & record changes regularly,

as ‘red line mark up’ & process ‘as built’ documentation for approval to fulfil contractual obligation to required extent possible.

12 It is expected of site engineers, design engineers as well as, land surveyors to coordinate on site to comply with ‘as built’ contractual obligation efficiently.

13 All survey changes or variations shall also, be recorded on drawings, based on ‘pre pour’ & ‘post pour’ records obtained from survey section.

14 Surveyor shall present all such changes on corresponding documents to be recorded as ‘red line mark ups’.

15 It has been practically, noticed that ‘red lines’ & ‘as built’ documents do remain pending, while engineers responsible for those changes have left projects, which situation causes an issue of recording such changes, when manipulation is effected by newer engineers, which manipulation practice should be avoided in whatever case.

16 It is therefore, suggested that a dedicated experienced engineer should be entrusted with this part of recording changes responsibility.

17 Details of changes or deviations from design details should be indicated as red lines mark ups as nearly as possible on record, so that it would not be difficult & time consuming for this record user or operational personnel to locate for, what was constructed.



Project Execution Method EPC 225 MW Combined Cycle Power Project18 All ‘red lines mark ups’ require to be incorporated, after having been approved by resident

engineer or engineer as case may be, with original or contract drawings or documents successfully.

19 All notes written with changes must be incorporated with records clearly. 20 All specifications changed due to whatever reasons, must be included as ‘red lines & then ‘as

built’ records.

Inspection & Test Plans1 All necessary inspection & test plans shall be originated by quality engineer/manager in

collaboration with engineering in charge located in head office & also, to engineering in charge located on site team.

2 ITPs formats shall be issued for engineer/client approval according to procedures laid down on project quality plan & also, on project procedures manual.

3 Production & submission of all such documents shall be responsibility of contractor quality manager/engineer.

4 Complete details about quality management system have been included on respective quality procedures document entitled as project quality plan.

5 Generally, ITPs for all disciplinary activities shall be produced for engineer’s/client’s approval from site office in due course.

6 All defined tests shall be conducted by engineer/client approved laboratory located on site. 7 All such tests shall be witnessed by site engineer, quality engineer, resident engineer or

discipline engineer. 8 Laboratory manager shall submit all such reports to project manager for information &

actions. 9 Project manager shall forward to quality manager & after being reviewed, quality manager

shall prepare to submit such reports to resident engineer.10 For all those items, tests shall be conducted by one engineer/client nominated laboratory, for

which testing facilities are not available on site. 11 Quality relevant samples of materials shall be selected by resident engineer, which material

samples contractor would submit to nominated laboratory & after tests having been conducted, test results submitted to resident engineer as defined in foregoing.

12 Details of applicable quality plans shall be submitted separately, giving quality procedures in details.

13 Every ITP shall be allotted a document number along with a numbered checklist. 14 Check list shall form basis of inspection requirements.

Project ControlsProject control management requires formation of strategies, which can be utilized optimally, to achieve target with minimum cost & with best quality product delivery. 1 To achieve as aforesaid, it is extremely important that complete project should be analyzed

from whole to one & all necessary resources required to be included for use should be known, prior to commencement of physical works.

2 Based on project designs, construction, commissioning and maintenance durations all analysis, planning & charting out at various levels including required resources loadings shall be carried out by planning engineer.



Project Execution Method EPC 225 MW Combined Cycle Power Project3 Further based on these duration periods, all necessary resources shall be arranged &

mobilized by human resources, materials managers, and technical managers in collaboration with project manager.

4 Plans shall be monitored regularly as project construction progresses on a weekly basis, monthly bases with no delay allowed & if specific delay noticed, immediate recovery should be planed, so as to keep project progress on line to defined or as indicated on schedule.

5 Relevant reporting shall project real quantum of planned & actual physical works, resources available, deficiency of resources, material procurement status, materials delivered & expected time of arrival etc. all necessary measures, required to keep construction on line & valuation amount for payment certificate worked accordingly.

6 Every effort should be made to keep progress in line with plan, since earned progress is related to set time on contract.

7 Time is one of three factors, critically considered on project management considerations 8 Time, quality & cost are three basic criteria, while aberration on even one criterion, impacts

progress adversely, on project directly. 9 Time delay supports increased cost, such as increase on additional human resources &

equipment hire as well as, imposition of liquidated damages & loss on reputation.10 Quality compromise means substandard product, which may or may not be saleable or

acceptable, while in case, due to substandard quality production, delivery is rejected, it has to be worked again, which means rework should be affected, consequently adding to cost of reconstruction plus cost involved with dismantling or removing rejected substandard quality work.

11 It is therefore, of utmost significance that all these 3 factors must be considered all times, from project initiation to project closure.

12 Cost controls procedures for operations require be very effective for handling successful delivery of project as well as, for making profits monies or else, project runs in losses.

ProcurementNote-Term ‘Material’ herein includes ‘equipment’ also.1 According to site requirement & provisions made on plan for temporary materials &

consumables, requisitions shall be raised from site by relevant engineer, checked, numbered, coded by material controller & approved by construction manager for transmission to head office procurement manager for further action.

2 Cost controller shall further check budgetary provisions applicable & give clearance to purchase manager for procurement.

3 Purchase manager shall then invite inquiries from various vendor sources of material, negotiate, prepare a comparative statement & based on merits of responses/quotations, record observations/comments based on comparative statement as well as, recommendations for considerations by management.

4 After reviewing proposal, management shall either approve or reject proposal. 5 Purchase order shall be made on approved proposal. 6 An alternative source shall be located for rejected proposal. 7 A copy of approval shall be provided to project manager for follow up delivery.8 For permanent works, proposed material shall be submitted for engineer/client approval on

requisite ‘material approval request’ form along with brochures, samples when so applicable, processed through document centre after project manager’s approval.



Project Execution Method EPC 225 MW Combined Cycle Power Project9 After obtaining engineer’s/client’s approval on request, procurement manager shall process

requisition/approved item based on budget quantities following in line procedures applicable for procurement of temporary materials.

10 After material is delivered to site, material controller & relevant engineer shall check quality & quantity of delivery.

11 Deficiency in quantity, quality or certain transit caused damage observed shall immediately, be notified to procurement manager through construction manager.

12 Delivery information shall be circulated to concerned personnel & quality manager in person shall do or delegate relevant inspector, who would check adequacy of quality & if so necessary, according to ITP provision, shall invite engineer/client to inspect/examine delivery.

13 Selected samples of delivered materials shall be sent to an approved laboratory for technical tests for purpose of obtaining certification of compliance.

14 After inspections & approvals, delivered materials shall be recorded in stores receipt documents following which, an issue of materials to site may be undertaken thereafter.

15 Post placement of purchase order, procurement manager shall track various stages of material production & transportation or shipment to site/delivery & if so noticed that an expectation exists for delay in delivery shall apply all efforts to expedite delivery on or before appointed date.

16 Materials shall be stored in proper designated areas complying with manufacturer’s instructions.

17 Separate area shall be located for materials requiring certain temperature range for storage, which stores should be well constructed & shaded.

18 Generally, all consumables shall be stored in shade, provided with proper lock & key arrangement.

19 Materials, which remain unaffected by exposition to weather, may be stored in open areas, duly protected under proper watch & ward.

20 Proper protection shall be provided for all stored materials, whether located inside covered area or located outside.

21 Necessary protection by removable membranes, such as polythene sheets or tarpaulins sheets shall be used to protect material from ingress of moistures or from damaging effect of dust.

22 Storage of all materials delivered shall be done complying to set & approved procedures making sure that all inventories can be verified all time & that all materials can be traced all time easily.

23 All entries pertinent incoming deliveries shall be recorded into material register, verified by store keeper & material controller that delivered material complies with details on deliveries documents.

24 Whatever deficiency noticed shall be immediately, reported to procurement manager.25 After acceptance of delivered material by concerned authority only, a store issue shall be

affected & recorded on required issue documentation. 26 Regularly, status pertinent all receipts, issues & balance in stores shall be reported to

construction & project manager, who should act further, depending on project requirement. 27 Elaborate details have been given on contractor’s procurement procedures document.




International customs clearance and local transportation1 Materials & equipment that have to be imported from overseas shall also, follow foregoing

procedures with addition that necessary letters of credits require to be opened by contractor adequately, in advance of expected date of delivery/adhering to schedule date, so that delivery is shipped in time from original source of manufacturing.

2 Contractor procurement manager shall arrange all port clearances, immediately of shipment arrival & material shipped to work site.

3 Tests & examinations shall be conducted similarly as aforesaid. 4 Claims of insurances for damaged material shall be made immediately, after inspections. 5 Process to replace damaged material shall be carried out at once to avoid possible delay. 6 If so required, contractor shall apply in time for any statutory road permit for efficient

transportation of material by suitable vehicles. 7 Elaborate details have been given on contractor procurement procedures document.

Procurement and provision of construction spares, commissioning spares, insurance spares and special toolsa These shall be processed applying same methods of procurement & delivery received by

contractor/its services or specialist subcontractors. b Most probably, spares shall form part of order package. c Elaborate details have been given on contractor’s procurement procedures document

1 Recommendation for two year/or as included operating spares for approval by engineer/client in accordance with the G-SPIR format requirements

2 Foregoing provision shall be followed & spares delivered according to contract & company requirement by contractor/its services subcontractors.

3 Elaborate details have been given on contractor procurement procedures document

4 Procurement and provision of two years operating spares, (at cost and extra over lump sum subcontract price)

5 Similarly, this provision shall be effected & spares delivered according to engineer/client instruction to contractor, subject to approval of procurement cost, prior to purchase order placement by contractor.

6 Source inspectiona If so required by engineer/client, arrangement shall be made by contractor after

meeting with vendor or manufacturer, a date & time appointed for inspection to convenience of all parties concerned & required inspection at source conducted to satisfaction of engineer/client.

b Representatives from engineer/client, contractor, services subcontractor & vendor shall constitute ‘an inspection at source team’.

c Proper record of inspection shall be made. 7 Compliance with company’s criteria and procedures for selection of vendors including,

but not limited to compliance with local registration requirements and approval of purchase requisitions, bidders lists, technical bid summaries and award recommendations.

8 We shall adhere to engineer/client requirements.



Project Execution Method EPC 225 MW Combined Cycle Power Project9 Involvement by India in particular and Asia in general with respect to provision of local

materials and services shall be encouraged.10 Contractor honor & respect with due regards to provisions of India policies for materials

& professional services, which need be availed out of India sources, subject to compliance with quality requirement.

11 Every effort shall be attempted by Procurement Manager to chart out available ‘local sources’ & prepare a database to be used, whenever an applicable procurement arises.

12 This procedure is already followed by contractor. 13 Contractor’s vendors shall also, comply with this requirement.

Pre Mobilization Planning1 A thorough and logical mobilization plan is essential for successful start up of construction

activities. 2 Mobilization plan must detail all planning, preparation and pre construction activities

necessary to ensure timely availability of drawings, personnel, construction equipment, temporary facilities and materials at job site to properly support construction efforts.

3 Required plan had already been under preparation at bid stage.4 Preliminary mobilization plan shall be further developed now, after contract has been

awarded and finally concluded, within a week of contract award.5 Mobilization plan shall be closely coordinated with construction plan to ensure its activities

properly lead into and provide a smooth transition into initial construction operations.6 A time scale bar chart schedule shall be prepared with early and late activity bars detailing

main activities to achieve full mobilization of staff, labour, construction equipment and camp/site facilities, would be prepared at commencement of contract.

7 Mobilization plans for staff & labour, accommodation and temporary facilities established during bid stage (as conceived in pre mobilization planning) would be studied and re evaluated in light of possible changes, which may have occurred, since day one of preparation.

8 All necessary adjustment measures shall be incorporated/implemented9 Additional site visits shall be conducted immediately, after project kick off, to confirm data

collected during bidding stage, reconfirm assumptions and establish additional information, required to permit smooth and timely mobilization.

10 Following items shall be reviewed and confirmed.a Access to job site proposition, for whole duration convenienceb Locations of temporary facilities onsite investigation/studyc Company requirements for properly, validated licenses and certificates to be held by

construction personneld Transport plans from & to site life campse Transport plans on site movement/circulationf Arrangements for establishing stores, warehouses, lay down areas etcg Arrangements for establishing various site yards for preparatory works & vehicle repairsh Arrangements for resting areas for workers to avail rest pauses during breaks.i Loss prevention and safety requirements for site areasj Arrangements for first aid facilities & nursingk Arrangements for drinking water and construction water l Arrangements for electricity both by direct power supply or by generation



Project Execution Method EPC 225 MW Combined Cycle Power Projectm Arrangements for storage fuels and lubricants in a protected arean Arrangements for sanitary & its disposal facilitieso Final arrangements for security interface with engineer/clientp All other items required to be integrated with proposed mobilization

Work Centre/s1 Contractor head office is location of main work centre/s to control project.2 Upon notification of contract award, key personnel to site management team shall be

assigned their respective positions & immediate tasks. 3 Construction personnel shall be mobilized to project site office to provide input and direction

to project team key personnel. 4 Successful project execution requires construction experts to be active from onset of project,

which requirement shall be effected promptly, by deploying all such experts working from office currently, preparing for all submissions.

5 Only, activity to continue to conduct from head office, after mobilization period is over shall be materials & equipment procurement.

6 All procurement activities for project shall be conducted from corporate procurement section located in contractor head office at ……………………..

7 All decisions on subcontracting vendors shall be conducted from head office.8 Following specific activities must be addressed early, so as to be fully effective

a Finalize construction schedule requirements and subsequent approval from engineer/client.

b Review manpower requirements for both non manual and manual personnel, update these requirements by means of staffing schedules, histograms and craft mixes and ensure subcontractors manning levels are compatible.

c Review construction equipment needs/requirements and ensure that timely subcontractors’ mobilization plans are in place.

d Review field procedures and method statements defining standards, policies and procedures, required for execution of works and ensure that they constitute ‘Project Specific’ status.

e Review environmental, safety and health (ES&H) and site security plans to ensure compliance with client’s specifications and guidelines.

f Review construction quality plan, which should be in line with guidelines of ISO 9001 and check established QC parameters by discipline whether or not, they fit in to with project requirements.

g Overview temporary facility requirements, including in directs, such as tools, consumables, gases and like and ensure subcontractors’ compliance.

h Actively, pursue preliminary site activities, such as approvals, permits, establishing various subcontracts/contract.

i Ensure lessons learned & practices from previous projects are well understood & should be applied effectively from onset of works itself to achieve professional products.

Contractor’s Site Office1 Actual ‘on site management’ would be conducted from offices based on site next to

engineer/client. 2 Project manager dedicatedly & project director by visits shall control this office. Attachments required - Level 1 Schedule, Resources allocations, Cash Flow, Man Hours, equipment Hours Page, S Curve, Resource’ leveling, Demobilization of personnel stages. of 28 2012 Int. P Eng Suraj Singh


Project Execution Method EPC 225 MW Combined Cycle Power Project3 Project manager shall act as contractor’s agent on site for all matters connected with contract

& its implementations.4 Contractor site office shall be fully supported by contractor’s head office at …………. 5 This head office/back office shall provide front office/site office all time to time engineering,

technical, logistics & other supports.Following major activities shall be carried out at site offices.1 Interactions with resident engineer/supervision team2 Safety regulation enforcement3 Field engineering including designs reviews/controls4 Construction planning5 Cost control supports6 Material requisitions 7 Construction method statements8 Construction execution/prosecution9 Quality assurance enforcement and procedures10 Site documents control11 Documents submissions12 On site & contractual correspondences13 Subcontracts & respective administrations14 Materials control and tracking15 Materials storage16 Work procedures logistically oriented17 Site administration

Mobilizationa Mobilization shall be coordinated from contractor’s head office at …………. with input from

contractor personnel to be mobilized for execution of site preparation activity and temporary facilities establishment for contractor, engineer/client.

b Mobilization shall commence with following activities1 Kick off meeting between contractor & engineer/client to commence EPC Contract.2 Submission of various contractual documents, such as performance bonds, insurance covers

& whatever else, as required by contract provisions3 Proposal submission giving lay out & setting out respecting various offices, yards etc. based

on investigated record drawings allowing no live routes within such areas, for client’s approval

4 Construction of temporary facilities on site to accommodate all offices & yards etc.5 Commencement of required land surveys to establish various horizontal & vertical controls

bench marks, which activity could be affected using registered third party also.6 Incept of engineering designs at firm office/contractor’s in house design section.7 Soil investigation/exploration by an engineer/client approved laboratory8 Obtaining various permits from relevant authorities and conclusion of arrangements with

local committees, where necessary.9 Third party independent material testing laboratory credentials submission for approval.10 Shortly after contract award, site surveying shall begin utilizing total station system to

establish accurate control points for performance of work. 11 This surveying may be conducted by a certified surveyor.Attachments required - Level 1 Schedule, Resources allocations, Cash Flow, Man Hours, equipment Hours Page, S Curve, Resource’ leveling, Demobilization of personnel stages. of 28 2012 Int. P Eng Suraj Singh


Project Execution Method EPC 225 MW Combined Cycle Power Project12 As soon as practicable, plans and specification for site temporary construction facilities shall

be finalized and released for installation.13 On completion of site offices, contractor’s construction staff, after completion of site offices

shall be mobilized to site along with construction equipment, tools, consumables, warehousing, storage and other items necessary to commence work of other temporary facilities in accordance with construction schedule.

14 Temporary facilities at job site shall include generator yard and construction water storage tank, carpentry yard, reinforcing bar fabrication yard, lay down area, warehouse and workshop facilities at designated location.

15 At start of construction, an emphasis shall be given on critical requirements of construction schedule.

16 Work shall be carried out under continual supervision and inspection over performance. 17 Progress shall be monitored on basis of actual installed quantities, compared to scheduled

quantities.18 For construction areas, dedicated work crews shall be allocated for each discipline supervised

by foremen and general foremen, who in turn should report to discipline supervisors/site engineers.

19 Based on construction schedule requirements, necessary operational crews shall be formed and controlled over to meet planned progress target to be physically achieved satisfactorily.

20 It is responsibility of supervisor/site engineer to ensure efficient utilization of material, workforce, tools and equipment.

21 For ‘construction operation water’ requirement, unless an alternative arrangement is made available, water shall be trucked from some nearby water delivery plant.

22 Site ‘construction and temporary facilities electricity requirements’ shall be met by installing suitable size and suitable numbers of generators.

Subcontract Strategy1 Building engineering services shall be conducted by either appointing a consulting firm or

entrusting to contractor’s in house facility, to be responsible for complete architectural, structural design drawings & documents productions as well as, for services schematic designs drawings production.

2 Firm or entrusting to contractor’s in house facility shall also, represent contractor’s regularly during project currency

3 Detailed single & allied services designs shall be prepared by contractor’s services subcontractors.

4 Contractor shall carry out broadly all civil engineering works employing its own resources of manpower, machines, equipment etc.

5 Lower tier subcontracts shall be allowed for execution of single operations, such as supply of ready mix concrete, roofing finishes, flooring, walling etc.

6 Ready mixed concrete is envisaged to be supplied by an established RMC supplier, an establishment with proven track record, duly approved for supplying concrete by engineer/client located within 10 KMS of site.

7 However, in mean time without reservations, we are also, seriously considering installing our own concrete batching plant should project concrete quantity suggests to justify that proposition, but this proposition should not be considered officially.

8 In case, certain minor or specialized work is necessary to be subcontracted on lower tier, Attachments required - Level 1 Schedule, Resources allocations, Cash Flow, Man Hours, equipment Hours Page, S Curve, Resource’ leveling, Demobilization of personnel stages. of 28 2012 Int. P Eng Suraj Singh


Project Execution Method EPC 225 MW Combined Cycle Power Projectengineer/client procedures shall apply for prequalification and award of subcontracts.

Testing and Inspection1 A field inspection and testing program shall be organized to be in line with contractor’s

quality manual & approved project plan under overall responsibility of QA/QC manager.2 Prior to conduct whatever testing, contractor and company (as required by QC Plan and ITP)

shall be advised of proposed tests for witness. 3 Wherever required, vendor specialist shall be made available for conduct of testing and

inspections.4 Inspections & testing shall depend on item to item & discipline to discipline basis, while

scope of its description is not covered within this document.

Material Management1 Once material has arrived at site, material management shall come under purview and

custody of site store staff. 2 Storekeeper, supported by store assistant shall be responsible for custody of material prior to

issue. 3 Material arrival information shall be submitted to engineer for its inspection & approval by

relevant discipline engineer or construction manager.4 Materials shall be issued by stores only, once it has been approved by resident engineer for

purpose of payments.5 All damaged materials shall be recorded & reported to head office procurement manager for

further actions.6 Material tracking from source to place or location of installation shall be conducted by

computerized system. 7 Construction manager shall be responsible to provide technical oversight and direction for

control of materials at construction site area. 8 More information has already been elaborated in foregoing explanations.

Procurement1 Central procurement department located at contractor’s………………..head office shall be

responsible for all purchases adhering to following procedure. 2 Preparation of purchase requisition shall be made based on takeoffs quantities calculated

from approved drawings documents. Purchase requisition shall completely, identify material approval, all applicable drawings, datasheets, specifications, vendor documentation requirements etc. with inclusion of following information. 1 Quantity of each item required with comprehensive breakdown.2 Adequate information concerning nomenclature description, material approvals, quality

required, applicable specifications, design & other drawings etc/or detailed outline of material required.

3 Required delivery dates for all major items.4 Delivery points of major items.5 Inspection of goods at point of origin issue.6 Certification of test data and/or compliance/warranty. 7 Method of shipment (if goods imported), conditions/packing.Attachments required - Level 1 Schedule, Resources allocations, Cash Flow, Man Hours, equipment Hours Page, S Curve, Resource’ leveling, Demobilization of personnel stages. of 28 2012 Int. P Eng Suraj Singh


Project Execution Method EPC 225 MW Combined Cycle Power Project8 Instruction of holding, kitting consolidation, marking.9 Drawings, manuals etc.10 Spare parts requirements11 Special instructions to vendors.Purchase Requisitions1 A technical evaluation shall be done in house to verify conformity with specifications.2 Samples and technical information shall be submitted to engineer/client. 3 Once final approval from engineer is obtained, purchase order shall be raised.4 Upon receipt of purchase requisition, a purchase order shall be raised and entered in

computer register system, indicating cost and budget allocation.5 Procurement department shall maintain a follow up system, so that contact to suppliers

and/or to manufactures may be made on a continuous basis.6 All questionable delivery commitments shall be expedited on a daily, weekly and monthly

basis as required, ensuring prompt delivery in accordance with the requirements.

Organizations:Corporate Organization1 Contractor is an umbrella organization, which has got numerous divisions, within in itself

and which is also, parent company for various subsidiaries. 2 Contractor operating since 2008 is a registered company, specifically setup to target energy

sectors and its clients. 3 Broadly all activities pertinent above divisions and companies can be divided into:

a General constructionb Heavy works and management services.c Energy projectsd Project consultancye Plant construction.

4 Contractor has been progressing very well within India & also, trying its targets overseas. 5 Organisation is headed by professional engineers at its top management level.6 Middle & lower tier profile is placed in by cream of professionals from varying disciplines,

who are well energetic & experienced to support handle, such dimension of project prosecution.

7 Line management personnel placement shall be made from very well field experienced persons.

8 General & skilled workers shall be selected from craftsmanship & artisan background, who know their respective trades very well.

Site Organization1 Proposed site organisation and responsibilities pertinent key personnel are descriptively

given on project plan. 2 All middle level supervisory staff shall be highly experienced and qualified drawn from

ongoing projects, wherever possible from. 3 Site shall be manned by project manager on dedication basis, supported by other specialist

experts in respective fields. 4 Project manager shall lead, whole project from site offices & respond to resident

engineer/engineer/client contractually.Attachments required - Level 1 Schedule, Resources allocations, Cash Flow, Man Hours, equipment Hours Page, S Curve, Resource’ leveling, Demobilization of personnel stages. of 28 2012 Int. P Eng Suraj Singh


Project Execution Method EPC 225 MW Combined Cycle Power Project5 Construction manager shall dedicatedly manage works on construction activities in

conjunction with discipline site engineers, supervisors, safety engineers & quality engineers etc.

6 In case of non availability pertinent foregoing personnel from within organization, they shall be recruited on an urgent basis from external sources.

Manpower Resourcing and Mobilization1 All personnel on site shall be employees of contractor. 2 All required personnel to execute work are already in India and working on other sites. 3 These sites are due for allowing their demobilisation in coming months.4 Planning department shall produce histogram schedules of resources by category. 5 These schedules shall define monthly manpower levels. 6 Scheduled shall also, be indicative of manpower mobilization.7 Standard contractor site supervision is based upon principle of training. 8 A charge hand shall be trained and supervised by a foreman. 9 In normal cases, a foreman shall supervise four charge hands. 10 Charge hand shall then supervise approximately ten labours/unskilled workers. 11 Where a special process is conducted, this ratio may be revised accordingly.12 Training is a continuous requirement on contractor quality management system. 13 Foreman and charge hands shall conduct training of manpower within their respective roles

and functions. 14 Recruitment of manpower shall ensure that background in relevant job skill has been

achieved. 15 Training in quality awareness shall be an ongoing process through quality department and

foreman.16 Sufficient numbers of site supporting staffs, which consists of mechanics, electricians, auto

electricians, guards, water boys etc. and other ancillary staff shall be deployed for unhindered progress of work.

17 Contractor contains at all times a vast pool of manpower in all trade/occupation/vocation disciplines.

18 Such required workforces have at all times been working on various projects in multi discipline fields.

Equipment Resourcing and Mobilization1 Based on project schedule, planning department shall generate construction equipment

schedules.2 Contractor shall provide required equipment from its own source & whatever, equipment is

required, shall be hired for its well acquainted vendors.3 It has been our company policy to use only, best quality third party hoisting equipment to

have reliable precautionary safety measures intact. 4 Contractor believes in maintaining zero accident policy.

Construction Method Statement– Civil Works, Buildings & Structures1 Following award of project, a detailed contract scope works programme for whole project

shall be developed including all engineering disciplines on contract separately based on already approved outline preliminary programme, appended under coordination between our



Project Execution Method EPC 225 MW Combined Cycle Power Projectconstruction manager and planning engineer.

2 Personnel dealing on site should know in advance as a team, what procedure should be adopted to carry out an activity to avoid confusion on site, between resident engineer & contractor’s supervisors & managers.

3 This is resolved by approved construction methods in advance of commencement of every activity.

4 Method statements related to various project activities shall be submitted for engineer/client approval, prior to commencement of, whatever major activity during execution stage.

SubcontractingContractor to develop and manage a lower tier subcontracting plan and subcontractor list1 Contractor plans to carry out most of civil activities itself, but selected specialists & propriety

items shall be subcontracted on lower tier, such as ready mix concrete delivery, roofing application, doors & windows manufacturing, painting application, raised flooring application, suspended ceiling installation etc.

2 Action to perform all lower tier subcontracting activities, including specification of packages of work to be subcontracted, prequalification of bidders, issue of ITBs, bid evaluation, recommendation and award.

3 All relevant information shall be provided by project manager to purchase manager, who should act immediately, to conduct required functions & lower tier deal finalized after obtaining engineer/client recommendation by project manager

4 Management of lower tier subcontractors and their activities shall be effected & controlled by construction manager on site & reported to project manager

5 Monitoring and reporting of all lower tiers subcontracting activities shall be affected by project manager based on construction manager report.

6 Report shall be regularly, provided to planning engineer, head office & engineer/client.7 Involvement by India in particular and Asia in general, with respect to provision of local

services shall be encouraged. 8 As included earlier somewhere else, that India national policy shall fully be honored subject

to making no compromise to quality requirement 9 Construction including providing labour/skilled & unskilled workers, supervision, safety and quality

management, inspection, vendor support, temporary facilities and services, and construction equipment, tools, utilities and consumables shall be effected accordingly.

10 All these issues have been elaborated earlier somewhere else for reference.

Provision of Construction Camp, messing, transport to Jobsite, sanitation, utilities etc. for Subcontractor’s personnel1 All these shall be fully undertaken by contractor based on site requirement. 2 A suitable life camp shall be established to meet contract requirement. 3 Messing shall be resolved by employing catering subcontractors if so required, so that all

personnel & workers take good food. 4 All utilities shall be provided to maintain good housekeeping of camp. 5 All safety & emergency precautionary measures shall be undertaken meeting contract

requirements.



Project Execution Method EPC 225 MW Combined Cycle Power Project6 Contractor requires a hired system of transport, which shall be utilized for its workers

transportation. 7 Similarly, arrangements shall be made for employed high tier & low tier subcontractors on

this package.

All activities necessary for Mechanical Completion, Pre commissioning, commissioning and Provisional Acceptance 1 All activities for the buildings part have been described on method statements appendedAll testing facilities required at jobsite. 1 Contractor shall supply an independent testing laboratory provided with all equipment

necessary for involved tests for this package, properly managed by qualified personnel meeting all QA testing & certification requirement.

2 Full responsibility for coordination with certain third party inspectorate3 Contractor agrees to extend its full cooperation to meet, whatever third party inspections

would be required. 4 Project manager & construction manager shall be obliged to be responsible to affect this part

of contract.

Supply and coordination of lower tiers subcontractors and vendor representatives as necessary 1 Contractor shall supply & coordinate with all lower tier subcontractors & vendors or their

respective representatives to meet requirement. 2 Supply of these sub parties shall be managed by purchase manager, while project manager

should manage on site. 3 Coordination on site shall be conducted by construction manager.

Provision of waste management at all Jobsite locations, including disinvestments of all temporary works, upon completion of Work 1 Waste management shall be fully operational on a day to day basis, both for garbage & sewage

according to planned arrangements.

2 Safety manager shall be responsible for operations of all such activities & report to construction/project manager regularly.

Provision of medical and firefighting services at Jobsite and for temporary works 1 Medical male nurse may be employed on job site first aid centre. 2 Male nurse shall take care of providing first aid treatment to injured workmen immediately &

then worker if so necessary, in opinion of male nurse, shall be sent to contractor’s site clinic for further treatment.

3 Safety manager shall be obliged to be responsible for operations of all such activities & report to construction/project manager regularly.

Execution plan (project implementation strategy)

Civil works/site preparationsAttachments required - Level 1 Schedule, Resources allocations, Cash Flow, Man Hours, equipment Hours Page, S Curve, Resource’ leveling, Demobilization of personnel stages. of 28 2012 Int. P Eng Suraj Singh


Project Execution Method EPC 225 MW Combined Cycle Power Project1 Civil works & site preparations shall be executed according to engineer/client requirement depending

upon priorities.

2 It is expected that all design & relevant details pertaining to all involved structures shall be issued for construction by engineer/client in time according to agreed schedule of construction.

3 It is also, expected that site shall also, be made available in time to meet schedule requirement.

4 It is proposed to commence works from all available areas, respecting, which designs are available immediately, after mobilization & upon receipt of ‘permits to work’ if so applicable.

5 Areas belonging to standalone scope/s may also, be taken upon one by one, depending upon engineer/client’s priority.

6 Smooth execution of construction works necessitates organization of certain competent teams constituted of capable members, fully trained in their respective callings.

7 Team members upon receipt of project documents should not waste even a single day, but immediately, commence with practical works, with full involvement & try resolutions of all technicalities issues.

8 Engineering surveyor should efficiently, establish all setting outs & related controls with prompt approval according to guidance of site engineer/construction manager.

9 Site engineer in conjunction with site management should arrange all equipment necessary for smooth excavation & other following activities.

10 It is also, advised that feedback & homework planning has also, been under charting process at pre mobilization stage, as envisaged somewhere else, in this document.

11 Since, our organization works adhering to set standards of execution in compliance with quality manual & project quality plan, all our staffing level shall affirmatively, follow guidance & direction provided to them, optimally utilize for discharge of their respective functional responsibilities entrusted by management for delivering product quality assurance as well as, value addition/delivering added customer satisfaction.

12 Our efforts shall be attempted to organize works in such a way that trained teams are established on site for important activities, such as steel reinforcing fixing, formwork, concreting, concrete protection etc.

13 Team members recruited shall be proficiently, skilled in respective trades & groups should be rotated on project various locations in sequence to perform jobs on various works front elements following guidance & direction of trade foreman & general foreman, adhering to instructions by site engineer and/or construction manager.

14 Quality team shall monitor fully all such operations carried out by construction teams.

15 These works activities executive teams shall be extended full technical & administrative support from engineering as well as, procurement & all other controllers, based on site as well as, in head office immediately, whenever so required.

16 This document gives an overall strategy pertinent proposed performance relating to site preparation & civil works keeping in view quantities of various items/descriptions involved & construction duration allowed according to defined milestones.

17 Engineer/client major policies have already been incorporated within main execution plan ‘civil works & buildings package’, which is, an EPC forming integrally, constituting a part of overall subcontract scopes.

18 This document should be considered as a supplementary extension of that execution plan, since main purpose herein is to serve on communication of specifically, significant



Project Execution Method EPC 225 MW Combined Cycle Power Projectprocedures that may be adopted on project based on our past experience of construct able competency, which has been exhibited by outlining procedures & definitions that should be adopted for proficient prosecution/execution respecting various preparatory works’ items involved on project, under works code groups entitling ‘site preparations & civil works’.

19 Scope involves subtitles & their description of constructions as follows, which cover major portions of preparation & civil works for project.

20 Site protection & preparation-surface leveling-area for this activity shall be selected according to scope indicated on IFC drawings.

21 Inspection of available surface shall be done first visually & then ascertained by spot leveling & undulations noted.

22 Undulation means certain types of ridges & valleys, generally, of irregular profile. 23 Ridges shall be chipped out & filled into valleys to form a balance throughout area under

consideration. 24 All unsuitable material shall be removed to specified thickness, using heavy equipment, such

as shovels or bulldozers & selected good material filled. 25 Dressing of whole area shall be conducted to form an acceptable level line profile.26 Surface compaction using water shall be carried out to maintain required profile. 27 Dry & wet compaction shall be carried out to a suitable state of acceptance. 28 Similar, procedure shall be applied to sloping surfaces. 29 Areas covered around obstacles for both flat as well as, sloping one, shall be dressed

manually & compacted by vibratory plate compactors or light rollers.30 Checking procedure- profile should be within acceptable limits, while soft spots should be

removed.31 All services shall be checked from ‘as built’ records received from relevant authorities or

local bodies. 32 Scanning of whole proposed area shall be conducted to ensure their existing routes, so that

adequate required protection could be resorted to.33 Survey team shall locate and set marks respecting all services that are present upon site (This

includes above ground services as well as, buried services). 34 These services, (electric, telephone, gas, oil, chemical, water etc.) shall be clearly marked

using stakes and warning tapes. 35 These existing services shall be marked upon a site drawing and issues should be raised with

client for reaching a practical resolution.36 Survey team shall also, mark upon site plan, all obstructions, structures and developments. 37 Whatever, obstruction encountered during excavation activities shall be plotted and recorded.

Site Preparation & Earthwork Typical1 Where hazardous material is encountered, it shall be identified and isolated. engineer/ client

shall duly informed. 2 Hazardous material shall be collected and removed to a licensed tipping place. 3 Details of material and tipping arrangements shall be documented for review by client as

appropriate. 4 Wherever, within subcontract scope, existing structures, fences and developments shall be

demolished in a safe manner, as site stripping activities proceed. 5 Necessary permits, approvals and permission shall be obtained from concerned authorities,

prior to commencement of activity. Attachments required - Level 1 Schedule, Resources allocations, Cash Flow, Man Hours, equipment Hours Page, S Curve, Resource’ leveling, Demobilization of personnel stages. of 28 2012 Int. P Eng Suraj Singh


Project Execution Method EPC 225 MW Combined Cycle Power Project6 Method of removal of these existing elements shall usually be conducted by dozer or breaker. 7 Where necessary, discussions on site shall be conducted concerning alternate methods of

removal, when full extent of these structures is exposed. 8 Removal of topsoil shall include all vegetation and rubbish material from work site. 9 Prior to start of topsoil removal, surveyor shall peg out haul roads that would be used by

construction equipment for all site preparation activities. 10 These roads shall be constructed by leveling of existing terrain. 11 Grade pegs shall be set to an agreed grid to indicate existing grade and reduced grade.12 It is dependent upon quality of existing soil, where roads shall be built suitably by

compactable filling, which may be imported or relocated from other parts of site.13 These roads shall be duly maintained as work proceeds.14 Where upon required, water shall be spayed for dust control.15 For general removal of topsoil activities using appropriate equipment, areas concerned shall

be excavated and graded to levels that ensure adequate surface water drainage.16 Geotechnical engineer shall monitor activity to ensure that topsoil material is removed.17 Sampling and testing of resultant material shall commence and conducted for specification

verification and compaction data. 18 Upon completion of topsoil removal activities, where appropriate exposed surface shall be

scarified, moistened and compacted to achieve required density criteria. 19 Areas shall be divided into manageable sections that would be defined upon sketches.20 Geotechnical engineer shall monitor and test all sections. 21 Results of tests shall be recorded upon relevant QC format. 22 Number of tests conducted shall reflect specification requirement. 23 QC engineer shall monitor activities regularly.24 In excavation areas, geotechnical engineer shall review material to be excavated to ascertain

its suitability for reuse as fill material. 25 This excavated material shall be transported to areas that require filling. 26 Material shall be deposited onto areas to receive filling, leveled, moisture conditioned and

compacted, if necessary, stockpiling may be required.27 Excavated areas shall be divided into manageable sections, which have to be defined upon

sketches. 28 Excavated areas shall be monitored by geotechnical engineer to ensure that no unsuitable

material appears. 29 Where unsuitable material appears, all that shall be removed. 30 Excavated formation surface shall be treated by scarifying, moistened and compacted in line/

according to specification requirement criteria. 31 All areas shall be tested and results recorded.32 Where areas are to receive fill, material that has been excavated shall be transported to fill

area, tipped, leveled, moisture conditioned and compacted. 33 Material shall be spread, leveled & compacted in 200mm layers. 34 Areas to be filled shall be divided into manageable sections that would be defined upon a

sketch. 35 Fill layer shall be moistened and compacted to achieve required specification criteria. 36 No further fill activity shall be conducted upon an area that has not been approved and

released by geotechnical engineer. 37 Attention shall be observed at edges and slopes, to ensure that compaction criteria are Attachments required - Level 1 Schedule, Resources allocations, Cash Flow, Man Hours, equipment Hours Page, S Curve, Resource’ leveling, Demobilization of personnel stages. of 28 2012 Int. P Eng Suraj Singh


Project Execution Method EPC 225 MW Combined Cycle Power Projectachieved.

38 Additional layers of fill material shall be placed in same method as described above until, designed elevation has been achieved.

Production procedure1 Verification exercise for fill activity on record has been conducted to establish economical

and effective method for fill activity.2 Import and place fill to controlled areas of approximately 25m wide by 100 - 150m long.3 Spread and level imported fill.4 Add water to fill layer by passing water tanker over fill layer. 5 Water tanker should pass over layer twice. 6 A time gap of approximately, two hours is allowed for water to soak into fill material.7 Layer is now mixed with grader, until a uniform blend of moist material is achieved.8 Additional water is added by passing water tanker over layer in a uniform sequence. 9 A time period of approximately, one hour is allowed for this water to soak into fill layer.10 Fill layer is mixed again with grader, leaving fill level to correct grade.11 Vibrating rollers shall now, compact fill layer in a logical sequence that would compact layer

uniformly.12 Field density testing of layer shall be conducted conforming to ITP requirement.
