terra construction plan rev0

7/27/2019 Terra Construction Plan Rev0

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Clients Name: Terra International

Projects Name: UAN Expansion Project

Project No.: 4686-011

Date: 7/28/09

Page: 1 of 45

Terra International

UAN Expansion Project

Woodward, OK

CONSTRUCTION EXECUTION PLAN

Rev No: 0 A B 1 2

Issue Purpose Issue for

Comment

Issue for

Approval

Issue for

Construction

Issue for

Construction

Date

By

ApprovedOwner Approval

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TABLE OF CONTENTS

I GENERAL.....................................................................................................................................3

A.Constructability and Preconstruction Activities........................................................................3

C. Major Subcontracts ..................................................................................................................5

1. General 5

a.Construction Manager (CM)......................................................................................................29

b. General Superintendent (GS)....................................................................................................30

c. Superintendents...........................................................................................................................30

d. Project Controls Manager (PCM) ...........................................................................................30

e. Field Project Engineer (FPE)....................................................................................................31f. Site HSE Manager (SHSEM)......................................................................................................31

g. Site Quality Assurance Manager (SQM)..................................................................................31

h. Site Subcontracts Manager (SSM)............................................................................................32

7. Health, Safety, and Environment Site Plan............................................................................32

a. HSE Plan......................................................................................................................................34

b. Environmental.............................................................................................................................34

c. Security.........................................................................................................................................34

d. General Lifting Requirements...................................................................................................35

8. Local Labor Conditions.............................................................................................................37

10. Mechanical Completion ..........................................................................................................38

11. Construction Communications...............................................................................................39

a. Communications.......................................................................................................................39

II. TEMPORARY FACILITIES...............................................................................................................40

A. Mobilization of Temporary Facilities to the site.....................................................................40

B. Telecommunications...................................................................................................................41

III. PERMITS.............................................................................................................................................41

A. Owner Permits...........................................................................................................................41

B. Ventech Permits.........................................................................................................................42

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I GENERALThe Woodward Expansion Project consists of a new 1,500 STPD UAN Solution Plant

(UAN-II) to be built at Terras Woodward, Oklahoma Plant. The new UAN Plant is anintegrated facility consisting of the following production units:

Nominal 535 STPD Urea Plant

Nominal 525 STPD Nitric Acid Plant

Nominal 665 STPD Ammonium Nitrate Plant

The integrated facility will produce two products forTerra: UAN Solution, and Urea

Liquor (UL). Provisions will be made in the layout and design for the future addition

of Ammonium Nitrate Solution (ANS) as a third product.

Weatherly will provide all the required basic and detailed engineering for the ISBL

facility. Terra will provide the procurement for the ISBL facility per Weatherlysspecifications. Weatherly will provide the process technology (specifications, detailed

drawings and contract documents). Ventech will provide the construction of the ISBL

facilities.

The ISBL facilities will require CO2 and Ammonia, which will be obtained by tie-in

to the existing Woodward Ammonia Plant.

Utilities required by the ISBL facilities include 350 psig steam, 600 psig steam,potable water, plant air, instrument air, demineralized water, cooling

water, firewater, and boiler feed water.

Firewater, demineralized water, potable water, 350 psig steam, and 600 psig steam

will be obtained by tie-in to the existing Woodward Plant supply systems. Plant air,instrument air, boiler feed water, cooling water, and process water for UAN dilution

will be supplied by new OSBL facilities.

A. Constructability and Preconstruction Activities

Ventechs construction implementation strategy includes a strong pre-construction effortwith the participation of the key construction management personnel in the engineeringoffice during the early phases of the engineering and procurement cycle.

During this pre-construction phase, the construction team will:

1. Participate with project scope review;

2. Develop site specific procedures, work methods, and inspection and test plans;

3. Develop plans for the construction temporary facilities;

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4. Provide input to schedules and estimates for detailed construction activities,

5. Participate in the first project planning and start up planning processes;

6. Develop Systems Turnover philosophy, identification, and sequencing;7. Providing general construction input to the engineering, material management and

procurement activities.

Ventech will initiate the pre-construction effort with a comprehensive constructability

checklist that includes details for a division of responsibilities matrix between theengineering/procurement and construction organizations. This standardized approach will

facilitate a smooth transition from the engineering office to the early field construction

activities and provide the framework for field construction.

B. Ventech Construction Subcontracting Strategy

Work will be contracted by Ventech in support of the overall project execution. It is

anticipated that work performed on a subcontracted basis will include:

1. Civil Subcontractors

a. Site preparation and development

b. Installation of auger cast pilings for foundationsc. Installation of foundations for equipment and structure

d. Final grading and finish grading and concrete paving

e. Underground piping and electrical installation

2. Mechanical Subcontractors

a. Temporary facility installation and maintenance

b. Installation of aboveground piping components & systems

c. X-ray and N.D.E. requirements for piping components & systems

d. Installation of steel for structure, pipe rack, etce. Installation of rotating and static equipment

f. Painting / Insulation for piping components and equipment

g. Installation of the main power systems and utilities

3. I&E Subcontractors

a. Installation of the power and control cabling systemsb. Installation of the control devices & systems

c. Heavy Haul Transport / Lifting for Specialized Equipment

4. Miscellaneous - Subcontractors

a. Cooling Tower Installation

b. Field Installed Firewater System

For the portion of the work being subcontracted by Ventech, the use of local subcontractors

for specific work packages is expected, depending on the work scope, subcontractor

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capabilities, and approval by the client. All subcontracted work will be preformed under

subcontract terms and conditions that are established for the project and which are

consistent with the primary EPC contract. These terms and conditions will provide forcoordination with the work of others and compliance to the technical, safety, quality,

industrial relations, cost, and schedule objectives that are established for the project.

C. Major Subcontracts

As a basis of the EPCM estimate and the current construction execution plan, Ventech has

considered the following subcontract work scopes:

.a Civil Package

Piping Underground Site Preparation

Auger Cast Piles Foundations

.b Mechanical Package

Structural Steel

Setting Major Equipment

Piping Above Ground

.c Instrument

.d Electrical

1. General

a. Construction Manager to ensure work released by QC at each stage.

b. Subs must redline drawings as changes in filed are made and maintain a set inthe office.

2. Civil Package

a. Piping (Underground)

The Subcontractor will ensure that installation of iron and carbon steel underground

piping systems (including fire protection U/G piping) is accomplished incompliance with project specifications, applicable codes, and contract requirements.

1) Procedure

a) Welding and Nondestructive Examination (NDE) shall be accomplished inaccordance with Reference 2.1 (CQP A15) form and or their equivalent

in addition to the requirements of this CQP.b) Fabrication and installation of underground carbon steel piping shall be

supervised and controlled by the Subcontractor as piping is fabricated

and installed.

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c) The Subcontractor shall assure that underground carbon steel piping

conforms to the engineering drawings and sketches, specifications, and

applicable codes and standards.d) Engineering drawings and sketches shall be used to confirm, in detail, the

location, orientation and dimensions of underground piping, valves, and

accessories.e) Engineering drawings and specifications shall define the requirements for

materials, construction practice and testing.

f) Verify ditch excavation (route, depth, width, grade, and shoring) andverify sand or other required bedding in ditch.

g) Verify installed pipe materials are the correct diameter, wall thickness and

material type and grade.

h) Verify line slopes are in accordance with approved drawings and branches,

vents, drains and reducers are installed correctly.i) Verify valves are installed correctly (item number, flow direction, bypass,

and extensions).j) Verify gaskets and bolting are correct (materials & installation) and piping

and valves are adequately supported and anchored.

k) Verify thrust blocks are installed where required by the engineeringdesign, each designated test section or total system has been pressure

tested, exterior coatings are correctly applied and before backfill, that the

cathodic protection system is installed, when required.l) Subcontractor shall ensure documentation is correct and complete to meet

project requirements.

m) Wrapped and coated pipe shall be holiday tested, where applicable, by aspark or holiday tester of appropriate voltage for the coating systembeing tested and recorded in accordance with Reference 2.5 (CQP

B21.02) Coating Underground Piping form and or their equivalent.

2) Records and Documentation

a) One set of drawings shall be kept by the Construction Manager/Field

Engineer for inspection and testing records. They will be marked-up toindicate which parts of a piping system have been tested, inspected and

found to be in accordance with the specifications, codes, standards, and

drawings.

b) Completed documentation will be forwarded to the Field Engineer orConstruction Site Quality Control Manager for review and retention in site

files.

When applicable, "as built" data shall be recorded for all routing installationchanges, the "as built" data must be included in the piping test package.

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3) CQP Forms for Reference: (if applicable)

a) CQP B04.01A - Pipe Pre-Test Checklist (Steel/Iron Underground Pipe)b) CQP B21.02 A- Coating Underground Piping

b. Site Preparation

Due to the relatively small ISBL area of proposed construction, the installation of

pilings, foundations, underground piping and electrical boxes and conduits will need

to be coordinated so that construction begins with deep installations. It will be

necessary to over excavate the ISBL area and backfill with a structural fill material(locally referred to as red select) to facilitate trenching in lower parts of the

excavation.

Conceptual sequence of Scope of Work is recommended as follows:

a) Excavate area to Elevation 90-0 (see drwg.) # 4686-SK-1017 Rev Ab) Backfill lower one half with structural fill (red select) Elevation 95-0.

Area backfill to be compacted to 90% modified Proctor density where as

backfill placed directly under foundations to be compacted in accordance

with project earthwork specifications.c) Install test pilings for load testing within the ISBL area and conduct

necessary load tests to verify design depths and piling capacities prior to

installation of permanent pilings.d) Proceed with installation of permanent pilings and pile caps.

e) Proceed with the excavation and trenching scope of work for installationof cable boxes, conduit and underground piping.

1) Procedure

The Construction Manager/Field Engineer shall direct earthwork activities in

accordance with project specifications, applicable codes, and contract requirements.The results of Field Density Test Record shall be documented on an, Form B02.01B

The Field Engineer shall assure "Dig Safe" permits are obtained as required by local

regulations.

Inspection and documentation shall be provided as required for each phase ofearthwork construction activity, including:

a) Cofferdams

b) Excavationsc) Line and grade

d) Backfill and compaction

e) Roads and storage areas

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f) Aggregate production

g) Dewatering

h) Tie-backs and anchorsi) Gradations

j) Proctor

k) Moisture content

2) Field Density test(s) shall be performed by a qualified specialist. The results

of the test(s) will be recorded on a Field Density Test Record,FormB02.01B, or approved third party documentation.

3) Completed Earthwork Inspection Daily Reports, shall be submitted to the

Construction Site Quality Control Manager or Resident Engineer for review

and retention.

4) The Construction Site Quality Control Manager shall perform sufficientmonitoring of in-process work to assure compliance with the engineeringdesign.

c. Auger Cast Pile Installation

This specialty subcontract will be required for the installation of the (200) Auger

Cast Piles associated with the equipment foundations and structure. This work will

be performed only after soil test have been tested and (six) test piles have beeninstalled. Test piles must be approved for suitability of equipment, techniques and

source of materials by a qualified Inspector. Documentation must be completed and

signed by the Inspector and witnessed by Client or their designee.

Potential subcontractors for this specialty work will most likely be from outside thelocal area. This work is foreseen to be on the critical path of the project schedule.

It will be critical that this subcontract is placed and field activities are scheduled to

start as soon as permits are set in place.

d. Foundations

Formwork will be constructed to the shape, form, line and grade required; and shall

be maintained sufficiently rigid to prevent deformation under load. Unlessotherwise specified, formwork and details shall conform to ACI 318. All exposed

concrete edges shall be chamfered x 45 degree.

Exposed form surfaces will be coated with form oil before placing reinforcement.

Unexposed surfaces may be wetted in lieu of form oil, except in freezing conditions.

Formwork design and construction will be in accordance to ACI 347 and the

responsibility of the Subcontractor.

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Reinforcing Steel will be free of oil, mud, loose rust or other loose coatings, and

will be properly secured in position by concrete blocks or metal chairs and by

spacers.

The details of design and construction for reinforced concrete, including thebending, splicing and placing of reinforcing steel will conform to ACI 318.

Concrete protection over steel reinforcement will not be less than 3 inches betweensteel and ground footing; 2 inches for exposed concrete aboveground and for

columns, beams, girders and inch for slabs and walls not on ground or exposed to

weather.

1) Procedure

a) Prior to initial delivery of concrete, and at intervals as noted onCQP Form B08.01A, Batch Plant Inspection Report, current

NRMCA Certification or local regulatory certifications of Ready

Mixed Concrete Product Facilities (see Reference 2.1) shall be on file

at the batch plant.

b) Prior to initial delivery, and at intervals as noted on the Batch Plant

Inspection Report, the batching process shall be inspected to ensure

that it is in compliance with project specifications and Reference 2.2,

if referenced by applicable project specifications.

c) Prior to initial delivery, inspection will be performed to verify that

the plant scales, volumetric water batching device, and volumetric

admixture dispenser have been calibrated and the results recorded.d) Prior to initial delivery, an inspection will be performed to verify the

batch plant is using an acceptable Concrete Delivery (Batch) Ticket

system and concrete delivery trucks are serviceable and meet

contract requirements.

e) Prior to initial delivery and at intervals established in project

specifications, verify that materials meet the specification and

originate from acceptable supplies.

f) Documentation of verifications will be via Form B08.01A, BatchPlant Inspection Report, with copies of batch plant supplied

documentation attached.

g) The completed reports shall be forwarded to the Resident Engineerfor review and retention in site files.

Anchor bolts to be checked for diameter to projection.

Concrete will be proportioned and mixed to achieve minimum compression strength

of 4000 psi after 28 days. Batch mix must be approved by Ventech.

Concrete Forms: Pour Cords, Form and rebar checks.

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Note: ISBL foundations specifications are Engineered by Weatherly Inc. (see

Civil Engineering Documentation) Ref.# 3.5.1-01

3. Mechanical Package

a. Structural

1) Procedure

The Subcontractor shall erect structural steel in accordance with the engineeringdesign and construction practices. As a minimum, this shall include the following:

a) Subcontractor shall verify that base plates are set level, at the proper elevation,

and on the proper location and that concrete is properly cured before setting

steel.b) Drawings shall be marked to record readings, dates, and approvals and be kept

as a permanent record. Sub shall verify latest revision with drawings inoffice.

c) Subcontractor shall monitor and report erection progress on a daily basis to

ensure that the type and grade of structural steel installed and that

installation activities are in compliance with project specifications and

applicable codes.d) Subcontractor shall also verify daily and report that the erected structure is left

in a guyed stable condition.

e) Subcontractor and the Construction Site QA/QC Manager shall verify that

erection torque wrenches are currently calibrated prior to use.f) Bolt tightening methods shall be as specified in the project procedures. If none

are specified, the Field Engineer, in concurrence with the client, shalldesignate the "turn of the nut" method.

g) Subcontractor and the Construction Site QA/QC Manager shall check

connections including; bolts, nuts, washers are the correct type, grade, sizeand finish, bolting tightening practice.

h) Bolting inspections and checks shall be noted on a record set of erection or

design drawings indicating satisfactory or unsatisfactory, date, month and

piece mark number and the Subcontractors and the Construction SiteQA/QC Manager initials for each connection checked. Mark inspected

bolts? Line across nut and bolt.i) Subcontractor and the Construction Site QA/QC Manager will verify

structural steel welding is in accordance with project welding requirements.

j) Subcontractor and the Construction Site QA/QC Manager verify the

plumbness of erected columns, ladders, platforms (grating), stairs andhandrails are correct and complete as directed in the specification.

k) `At final inspection, incomplete items or items requiring rework will be

documented on CQP Form B12.01A, Structural Steel Punch List.

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l) Upon completion of the structure, pipe rack or area, etc., CQP Form B12.01B,

Structural Steel Inspection Record shall be completed.

Completed documentation shall be forwarded to the Field Engineer for review andretention in site files.

b. CQP Forms for Reference: (if applicable)

1) Form B12.01A, Structural Steel Punch List2) Form B12.01B, Structural Steel Inspection Record

c. Major Equipment Setting

1) Procedure - Fixed

Fixed and specialty equipment (exchangers, reactors, drums, tanks, towers, fin

fans, heat-recovery-steam-generators, fire protection/safety systems and similar

types of fixed equipment) are installed in accordance with applicable

specifications and drawings. As a minimum, this shall include the following:

a) Verify correct personnel equipment and materials are in place for the

installation. Lifting plans required for loads in excess of 20,000 lbs.

b) Verify foundation or structure is completed and released for setting

equipment (anchor bolt holes confirmed to match anchor bolts).c) Verify Anchor bolt holes in baseplate match foundation before lifting.

d) Verify elevation is correct.

e) Verification of correct orientation.f) Verify foundation scrabbled and correct shims sets are correct elevation.

g) Ensure correct plumbness and anchor bolts tightened.

h) Verify Grouting Correct.i) Verify internal and external components and attachments are correct

j) Verify required grounding is installed.

k) Verify protective coatings, insulation and fireproofing.l) Verify any special process work (welding/NDE) is correct and complete

(if required)

m) Verify ASME Code work, if applicable, is correct, complete and signed

off by the Authorized Inspector (apply appropriate ASME QC manual

requirements).n) Verify CQP, General Fixed Equipment Installation and or the specific

verification subcontractors form is completed for each installedcomponent.

o) Verify CQP, Mechanical Equipment Closing Authorization is completed

for opened components and or the specific verification subcontractorsform.

d. Equipment Completion and Release shall include the following:

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1) The appropriate CQP forms and or their equivalent shall be prepared for each

piece of major fixed equipment as listed on the project equipment list and

for any piece of major fixed equipment being reinstalled in a different orrelocated service. In such cases, the record should reflect complete

information associated with the change.

2) Additions or changes to existing CQP forms and or their equivalent may benecessary to address the specific inspection requirements associated certain

types of special fixed equipment.

3) Each record shall be originated by the Quality Control Manager or his/herdesignee, who shall complete the applicable portions of the record once the

equipment is released to the field for installation.

4) The Construction Manager, in coordination with the Field Engineer and/or

the Construction Site Quality Control Manager will ensure that each item of

work is signed and released prior to allowing the next step to begin.5) Completed records will be forwarded to the Field Engineer or Construction

Site Quality Control Manager for review. The Field Engineer orConstruction Site Quality Control Manager shall be responsible for storing

documents in Project Data for retention, with a copy to the home office QC

department.

e. Completed CQP forms will provide the following information:

1) A record of each piece of equipment, its manufacturer, and its

characteristics.

2) Signatures indicating that the equipment has been properly set, assembled,

connected, tested, and accepted.3) Information required by the materials management and project controls

groups for completion of required records and reports.

4) Permanent, complete equipment record for the Owner's operations andmaintenance organizations.

5) Attached test and inspection reports including any construction related

documents required by the equipment manufacturer's representative.

f. Quality Records will provide the following information:

1) The applicable test & inspection records / CQP forms and or their equivalentshall be completed by the Construction Site Quality Manager or designee for

each piece of fixed mechanical equipment identified in the projectequipment list.2) These forms can be found in the CQP manual. The completed reports will be

forwarded to the Field Engineer or Construction Site Quality Control

Manager for review and retention.

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g. Records Retention:

1) Copies of proprietary forms required by equipment suppliers/erectors shallbe obtained by the Construction Manager/Engineer and forwarded to the

Field Engineer or Construction Site Quality Control Manager for review andretention.

2) Completed documentation shall be retained by the Field Engineer or

Construction Site Quality Control Manager in site files.

h. CQP Forms for Reference: (if applicable)

1) Form B25.01A, Exchanger Installation Checklist

2) Form B25.01B, Mechanical Equipment Closing Authorization Report3) Form B25.01C, Air Cooler Installation Checklist

4) Form B25.01D, General Fixed Equipment Installation Checklist5) Form B25.01E, Tower Tray Installation Checklist6) Form B25.01F, Pressure Vessel/Tank Installation Checklist

7) Form B25.01G, Fired Heater Installation Checklist

8) Form B25.01H, Packaged Unit Installation Checklist9) Form B25.01I, C02/Deluge/Sprinkler Valve Skid Installation Checklist

10) Form B25.01J, Safety Shower/Eyewash Installation Checklist

11) Form B25.02A Coupling Alignment Report (pages 1 of 3)12) Form B25.02B General Rotating Equipment Installation Checklist

13) Form B25.02C Chain/Belt Driven Alignment Report

14) Form B25.02.D Laser Alignment Report

15) Form B25.02 E Fan/Cooler Alignment Report16) Form B25.02 F Mixers/Agitators Installation Checklist

17) Form B25.02 G Diesel Engine Installation

18) Form B25.02 H Compressor Installation Checklist19) Form B25.02 I Gas Turbine Installation Checklist page 1 of 3

i. Mechanical Acceptance Requirements

1) Procedure - Rotating

The subcontractor will assure that rotating mechanical equipment is installed andtested in accordance with applicable specifications and drawings. As a minimum,

this shall include the following:

a) Verify proper identification of equipment.

b) Verify equipment base is prepared for grouting and shop applied coating (if

not removed) is compatible with the proposed grout to be used.c) Verify foundation or structure is complete and released for setting

equipment (anchor bolt holes confirmed to match anchor bolts and

foundation surface is prepared for grout).

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d) Verify correct shimming, orientation and elevation is correct.

e) Verify driver and driven coupling hub run out acceptable.

f) Verify grouting is correct and complete.g) Verify piping is appropriately cleaned and inspected before being connected

to equipment (inspection point).

h) Verify piping is connected to equipment without stress.i) Verify driver and driven final aligned.

j) Verify soft foot checked and accepted, seal oil system cleaned and operable

and seals installed.k) Verify driver direction of rotation correct and driver run-in complete

(vibration and temperature acceptable).

l) Verify coupling guard installed, suction screens installed, electrical and

instrumentation connections are complete; including grounding.

j. Equipment Completion and Release

The appropriate CQP Forms and or their equivalent shall be prepared for each pieceof major rotating equipment as listed on the project equipment list and for any piece

of major fixed equipment being reinstalled in a different or relocated service. In

such cases, the record should reflect complete information associated with the

change.

1) Each record shall be originated by the subcontractor, who shall complete the

applicable portions of the record once the equipment is released to the field

for installation.

2) The record shall be maintained during the course of installation and testing,properly signed and dated by the respective responsible person.

3) The Construction Manager, in coordination with the Field Engineer and/or

the Construction Site Quality Control Manager will ensure that each item ofwork is signed and released prior to allowing the next step to begin.

4) Completed records will be forwarded to the Field Engineer or Construction

Site Quality Control Manager for review and retention.

k. Mechanical Equipment

Although the equipment for the Terra UAN Expansion Projectis identified in theEquipment List, the majority of the mechanical equipment includes:

Columns 2

Drums 4

Vessels 35

Reactors 2

Exchangers 41

Cold Boxes 0

Compressors / Fans / Turbines 3

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Heaters / Boilers 2

Pumps 68

Storage Tanks 3PSA Unit 0

Ejectors 1

Injection Package Units 3

Filters 11

Cooling Tower Cells 3

Reactor Valves / Hydraulic System 0

Miscellaneous Equipment 19

4. Piping (Aboveground)

The Subcontractor will ensure that field fabrication and installation of aboveground

piping is accomplished in compliance with project specifications, applicable codes, andcontract requirements.

a. Procedure

1) Activities within the scope of the ASME Boiler and Pressure Vessel Code or

National Board Inspection Code (NBIC) shall be accomplished in

accordance with the appropriate ASME Quality Control Systems Manual.

2) Piping systems shall be inspected by the Subcontractor & Construction SiteQuality Control Manager as they are fabricated and installed, to assure that

the system conforms to the engineering drawings and sketches,

specifications, and applicable codes and standards.

3) Isometrics or P&ID's and Piping Plans may be the controlling documentsdependent on the engineering design. They are utilized to inspect for proper

general arrangement of the piping, valves, instruments, equipment, andaccessories.

4) Engineering drawings and specifications shall be used to inspect the work

for conformance to designated materials, equipment, supports and hangers,

and tests.

b. Piping and associated components shall be visually inspected for the

following:

1) Piping - class, size, and identification, valves - Class, identification,

orientation, equipment - identification, compliance with specifications andmanufacturers' drawings.

2) Pipe supports and hangers - Identification, compliance with specifications

and manufacturer's drawings, and a completed marked-up set of engineering

drawings showing as-built locations.3) Fabrication and installation verification of above grade pipe systems shall be

carried out by the Subcontractor in accordance with, but not limited to CQP

Form B17.01A, Pipe Pre-Test Check-List. Installation errors shall be

reported on CQP Form B17.01D and or their equivalent.

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4) Subcontractor will assure the work is completed and signed off accordingly

by qualified Inspector. Final pipe test completion shall be documented in

accordance with CQP Form B17.01E Pipe Test Completion Checklist.5) Welding, post weld heat treatment (PWHT) and nondestructive examination

(NDE) of piping systems shall be performed in accordance with

specification and applicable codes and standards.6) Project specific pressure test procedure shall be developed and approved

prior to pressure testing that addresses modifications required, release

system configuration, valve line-up, vents, restoration, pneumatic concerns,flush requirements, etc.

7) Subcontractor shall complete CQP Form B17.01A, Pre-Pipe Test Record.

Attached to the Pre-Pipe Test report will be CQP Form B17.01B, Pipe Test

Record, and marked-up P&ID/Isometrics to indicate pressure test boundaries

that identifies every line and equipment item tested. These forms will beused as a support documents for the subsequent release of piping for

insulation and/or painting.

c. Records and Documentation

1) One set of drawings shall be kept by the Construction Manager/FieldEngineer for inspection and testing records. They will be marked-up to

indicate which parts of a piping system have been tested, inspected and

found to be in accordance with the specifications, codes and standards, anddrawings. Other notes pertaining to the piping system may be included on

the P&ID's.

2) Test packages shall be prepared and controlled by the Construction SiteQuality Control Manager.

3) When a subcontractor prepares Test packages, The Construction Site Quality

Control Manager shall verify that the activity meets the intent of this Plan.

4) Completed documentation will be forwarded to the Field Engineer orConstruction Site Quality Control Manager for review and retention in site

files.

d. Test Package Content

Subcontractor will generate a piping test package for each piping system segment to

be pressure tested, including trim on fixed equipment. Each package will contain

pertinent information appropriate to the test.

1) Typical test package contents include:

a) Colored set of P&ID's and ISO's (approved for construction) illustrating

test boundaries.

b) Applicable CQP Forms and or their equivalent, including punch-lists, withsignature acceptance from all responsible parties.

c) Deviation documentation including any RFI's and "red-lined" drawings

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d) Cleaning / flushing information, if applicable.

e) Welding sign-off to confirm completion of welding, PWHT, N.D.E., weld

tracking and mapping.f) Reference to any support drawings, or piping specifications.

g) Required pressure gauge calibrations.

h) Location of piping test blinds and indication of blinds to remain in the lineafter the test (verify test blind material and thickness with the Field

Engineer).

i) Location and description of items to be removed from the line for the test.j) Location and description of machinery or equipment to be tested through

(verify with the Field Engineer).

Although turnover of welding and NDE records as a stand-alone package is

preferred, certain projects may contractually require inclusion of applicable weldingand NDE documentation into each test pack. This should be confirmed at the startof the project and test packs must be assembled accordingly.

e. Test Package Development and Test Control

The Construction Manager shall assure the development of test packs occurs asearly as practical in the project. This should begin following final systems definition

and mark-up on P&ID's.

1) Test boundaries shall be laid out on P&IDS and ISO's to logically manage

testing within each defined turnover system boundary.

2) Test package drawings will be highlighted in color to define test limits. Thesame color should be used throughout the test package.

3) The Subcontractor will control test package distribution. Usually, two (2) setsof test packages are assembled. One set for field use and one master set that

remains in the site QA office file.

4) Field test packages will be signed out to the Subcontractor as the piping to betested is completed. The test packages must be returned and signed in at the

end of each work shift.

5) Office test packages remain in the Quality Control office and shall not be

signed out by anyone other than the Construction Site Quality ControlManager.

6) Office test packages are the official sign off documents and bear all originalacceptance signatures. Signatures in black ink are preferred. Signatures inpencil are unacceptable.

7) As each piping test segment becomes complete, the Construction Manager

must request the quality control department provide a welding and NDEclearance. A pre-test punch (inspection) will be performed before involving

the owner. All deficiencies shall be noted and a pre-punch list shall be

generated.

8) After all pre-test punch list items have been completed; the punch list must be

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signed off by the Construction Manager or his/her designee and turned over

to the quality control department. The punch list items will be inspected and

signed off by the Construction Site Quality Control Manager. The qualitycontrol department must then notify the owner for a pre-test approval.

9) All test gauges will be stored and issued in the designated control location

and will be visually inspected before and after each use, test gauges musthave calibration certifications and be re-calibrated per job specifications.

10) Once the test segment has been reinstated, a post walk down will be

performed. All deficiencies shall be noted and a post-punch list shall begenerated. After all punch list items have been completed, the punch list

must be signed off by the Construction Manager or his/her designee and

turned over to the quality control department.

11) The quality control department will then notify the owner for a post-test

walk-down.12) Completed, signed off test packages shall be retained in the project files until

turnover to the owner.13) The Field Engineer or the Construction Manager shall control retention and

turnover of test packages to the owner

f. CQP forms for Reference: (if applicable)

1) Form B17.01A, Pipe Pre-Test Checklist2) Form B17.01B, Pipe Test Record

3) Form B17.01C, Pipe Test Inclusion Record

4) Form B17.01D, Pipe Test Punch List

5) Form B17.01E, Pipe Test Completion Checklist

5. Instrumentation and Electrical

a. Electrical (Underground)

The Subcontractor is responsible for issuance of cable/termination tickets (or liaison

with the project engineering organization when engineering issues thecable/termination tickets), and for maintaining site files for retention of required

documentation.

1) Prerequisites

a) Prior to the start of duct-bank installation activities, requirements for

coordination of inspections and verifications, and associated

documentation, shall be established.b) A site procedure should be established for the routing, filing, and retention

of completed Inspection Reports, as-built drawings, and other

documentation as required by project procedures, specifications, and theCQP for the project.

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c) The Subcontractor will be responsible for generating and maintaining the

forms and inter-discipline interface necessary to coordinate the combined

electrical and civil activities appropriate to duct-bank installations.

2) Procedure

The Subcontractor shall direct the installation of duct-banks and associated cable

pulls in compliance with engineering specifications and drawings and applicableprocedures.

The progress of duct-bank installation activities shall be maintained by marking-

up installation drawings or a log in a manner that indicates the following status.

Status may be included in Systems Turnover and Reporting (Reference CQP A16)and or equivalent.

a) Duct-bank work in progress, duct-bank nearly complete, inspected, andready for cable pull or duct-bank (including cable pull) complete,

inspected, and accepted.

b) The Subcontractor and Construction Site QA/QC Manager shall verifythe completion and conformance of duct-bank installation activities and

document acceptance of the work via signature on the corresponding

CQP Forms and or equivalents.

3) Duct-bank Installation

a) The Subcontractor shall direct the installation of the duct-bank incompliance with engineering specifications and drawings and applicableprocedures.

b) Form B03.02A, Duct-bank Installation Checklist shall be prepared for

each duct-bank installation to identify pertinent data concerning theinstallation.

c) Duct-bank installations shall be accomplished in accordance with the

engineering requirements.

d) The Subcontractor and Construction Site QA/QC Manager shall verifycompletion and compliance of duct-bank installation activities to

engineering requirements and document acceptance of the work via

signature on Form B03.02A and or equivalent.e) Duct-bank Installation Checklist.

4) Cable Installation

The Construction Supervisor/Engineer shall direct the installation and terminationof electrical cables in compliance with engineering specifications, applicable

procedures and CQP B18.01 and or equivalent.

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The Subcontractor and Construction Site QA/QC Manager shall assure the

following:

a) Verify inter-discipline coordination (Civil & Electrical).b) Verify correct conduit and associated materials (correct size and type).

c) Verify trench depth and routing per drawings and specifications (trench

elevation, location, dimensions and forming).

d) Check for conflicts with other underground construction and ensuretrench free of debris.

e) Check conduit sizes, types, location and ensure conduits are properly

sloped.f) Verify rigid steel elbows used for all stub-ups, including PVC runs when

required as well as conduit fittings and seals are installed per the

engineering design.

g) Verify that the conduit position will allow minimum concrete coverageon all sides of the conduits and conduit spacing, supports and tie downs

correct.

h) Verify stub-up dimensions and locations, field bend radius correct perthe engineering design and bends free of deformities.

i) Verify caps on conduit ends prior to release for concrete pour and

conduit connections tightly made.j) Confirm all field changes recorded on as-built drawings.

k) Concrete pour report completed to release duct bank for pour (CQP

Form B08.02B) and or equivalent.l) Check that pulling wires are in place, stub-ups have not moved during

pour and cable pull rigging is adequate to handle cable.m) Verify cable reel assignments, cable voltage rating, minimum pulling

temperature and pulling compound is compatible with cable to be pulled.

n) Inspect cables for jacket damage before pull and verify direction of pull

and method of pulling.

o) Verify the trench is backfilled with the correct material free of stonesand debris, to the correct depth and required compaction tests performed.


a) Form B03.02A Duct-bank Installation Checklist

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b. Electrical (Grounding below Grade)

1) Procedure

a) The Subcontractor Construction Site QA/QC Manager shall verify

completion and compliance of grounding below grade installation and

testing activities and indicate acceptance of the work via signature on

Form B03.03A, Grounding Below Grade Installation Checklist andForm B03.03B, Ground Rod Installation Checklist.

b) ITO forms shall be signed off as appropriate to indicate acceptance of

ITO activities.

2) Inspection and Verification

The Construction Site QA/QC Manager or qualified designee shall assure thefollowing meet the requirements of project drawings and specifications:

a) Check ground grid loop cable (correct size and type) and verify proper

identification, grounding cable depth and routing per drawings.

b) Check for conflicts with other planned underground construction and

connection (thermal/compression).c) Verify ground well/rod locations and installation per the engineering

design and confirm ground rod connections correct.

d) Perform and record continuity test of ground grid per the engineeringdesign.

e) Verify ground rod resistance-to-earth checked and recorded per projectrequirements.f) Measure resistance between grounded equipment and nearby known

ground after connection to ground grid. Perform as required by the

engineering design.

g) Assure grounding excavations are backfilled with the correct materialand backfill to the correct elevation and required compaction tests

performed.

h) Assure any required grounding markers are in place.

3) Subcontracted Work

During grounding below grade installation and testing activities, FieldEngineer/Construction Site QA/QC Manager shall monitor and verify thesubcontractor's work for compliance with engineering requirements and

applicable procedures. As a minimum, this shall include:

a) When subcontractors are working to this Construction Plan, compliance

shall be maintained to the applicable sections of this manual, as requiredby the contract.

b) When subcontractors implement their own program for control of the

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work, the Construction Site QA/QC Manager or designee shall verify

compliance with that program.

Installation, verification and testing activities shall be documented in accordance

with this plan or the subcontractors own program for control of the work asrequired by contract.

The Construction Site QA/QC Manager shall assure the implementation of thisprogram consistent with the engineering design and the contract.


a. Form B03.03A Grounding below Grade Installation Checklist

b. Form B03.03B Ground Rod Installation Checklist

c. Electrical (General Electrical Equipment Installation)

1) Procedure

The Electrical Subcontractor shall assure that electrical equipment is installed inaccordance with applicable specifications and drawings. As a minimum, this shall

include the following:

a) Verification that equipment installations and tests are in accordance with

applicable project drawings, specifications and applicable vendor

requirements. Documentation of inspection activities shall be inaccordance with applicable CQP, Vendor Manuals, and applicable

Commissioning/ Startup Procedures.

b) When required, verification that equipment conforms to manufacturers'drawings.

c) Ensuring that preventative maintenance is performed in accordance with

(CQP A14) and or equivalent.d) Resolution of any nonconforming items or conditions in accordance with

(CQP A06) and or equivalent.

e) Assuring that foundation or structure is released for setting equipment.

2) Equipment Completion and Release

a) CQP Form B18.02A, General Electrical Equipment Installation

Checklist shall be prepared for each piece of major electrical equipmentas listed on the project equipment list and for any piece of major

electrical equipment which is being reinstalled in a different or relocated

service. In such cases, the record should reflect complete informationassociated with the change.

b) Additions or changes to existing CQP forms may be necessary to address

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the specific inspection requirements associated certain types of major

electrical equipment. Changes shall be accomplished in accordance with

(CQP A08).c) Each record shall be originated by the Subcontractor, who shall complete

the applicable portions of the record once the equipment is released to

the field for installation. The record shall be maintained during thecourse of installation, properly signed and dated by the respective

responsible person. The Subcontractor, in coordination with the Field

Engineer and/or the Construction Site QA/QC Manager will ensure thateach item of work is signed and released prior to allowing the next step

to begin. Completed records will be forwarded to the Field Engineer or

Construction Site QA/QC Manager for review and retention.

3) Completed "Equipment Installation Records" will provide the followinginformation:

a) A record of each piece of equipment, its manufacturer, and itscharacteristics.

b) Signatures indicating that the equipment has been properly set,

assembled, connected, tested, and accepted.c) Information required by the materials management and project controls

groups for completion of required records and reports.

d) Permanent, complete equipment record for the Owner's operations andmaintenance organizations.

e) Attached test reports including any construction related documents

required by the equipment manufacturer's representative.f) Check equipment nameplate details with data sheet.g) Verify hazardous area classification (if applicable).

h) Inspect for mechanical damage and note all damages.

i) Verify equipment is mounted and anchored and grounded in accordancewith drawings and Mfg. Instructions.

j) Verify all shipping stops, bracing and packing is removed, cables are

correctly installed, terminated and labeled.k) Verify spare entries are blanked/plugged with the correct fittings.

l) Verify Megger check or other electrical tests are accepted.

m) Verify Unit is internally and externally clean and covers are securely

fastened with all screws.n) Verify that equipment tagging is installed and visible, warning

labels/placards are installed and visible.

o) Verify instrumentation installation is complete and accepted

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4) Test Records

a) The applicable test records /other pertinent CQP forms shall becompleted by the Subcontractor or designee for each piece of electrical

equipment identified in the project equipment list. These forms can be

found in the CQP or Start-Up manuals. The completed reports will beforwarded to the Field Engineer or Construction Site QA/QC Manager

for review and retention. These reports shall be filed with Form

B18.02A, General Electrical Equipment Installation Checklist.

5) Records Retention

a) Copies of proprietary forms required by equipment suppliers/erectors

shall be obtained by the Subcontractor and forwarded to the FieldEngineer or Construction Site QA/QC Manager for review and retention.

b) Completed documentation shall be retained by the Field Engineer or

Construction QA/QC Manager.


a) Form B18.02A, General Electrical Equipment Installation Checklist

d. Instrumentation

1) Responsibilities

a) The Field Engineer is responsible for resolution of instrumentation

installation and calibration issues with the project engineering

organization, and the Startup Manager.

2) Procedure

a) The Subcontractor or designee, in coordination with the Construction

Site QA/QC Manager or Field Engineer, shall verify completion andcompliance of Instrumentation installation and calibration activities and

indicate acceptance of the work via signature on the appropriate CQP

forms as referenced in 7.0 of this procedure.b) Instrumentation loop checkout and testing shall be accomplished in

accordance with project the appropriate Startup procedures.

c) Installation of each instrument and loop shall be documented by the

Subcontractor on Form B19.01A, Instrument Field Installation CheckList and or equivalent. Each loop will be inspected for compliance with

the engineering design, as the work progresses, by the Subcontractor or

Construction Site QA/QC Manager. Each instrument or loop will then becalibrated as required by the engineering design. Calibration shall be

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documented on Forms B19.01B Instrument Pressure/Leak Test Report,

B19.01C Instrumentation Punch List Record, B19.01D Instrument

Calibration Report, B19.01E Control Valve Calibration Report, B19.01FPressure Relief Valve Calibration Report and B19.01G Orifice Plate

Inspection Report and or equivalent as appropriate for the activity.

3) General Instrument Installation Checks

a) Verify that the proper instruments are installed, and that auxiliary

equipment, e.g., solenoid valves, position switches, positioners, air sets,

etc., are properly installed, flow elements properly oriented and processpressure taps piped to the correct instrument ports, in accordance with

the design drawings.

b) Instrument stands and racks are the correct type, and are properly locatedand secured.

c) Instrument wiring and terminations, and/or piping, tubing, and fittings

conform to specifications and instrument design.d) Process analyzers/transmitters are properly mounted, wired, and piped.

e) Field run control loops are checked for proper mounting, wiring and/or

piping thermowells are properly installed.

f) Control valves are in the correct location and properly oriented.g) Drains, purges, vents, winterizing, and root/isolation valves are properly

installed.

h) Control wiring is properly pulled, terminated, and identified.i) Scales and charts are correct, as specified.

j) Tubing is free of kinks and dimples, minimum bend radii are maintained,

and proper flexibility allowed for expansion or movement.k) Cable and/or tube bundles are properly routed, supported, protected from

damage, separated, and identified.

l) Cutting, deburring, cleanliness, and seals for process instrument tubing

are in accordance with the specification.m) Junction/marshalling boxes are properly fabricated and located per

specifications.

n) Valves, positioners, brackets, and stem clamps are secure.o) Verify that all instruments are installed to allow access for calibration

and maintenance, all required test connections are properly installed, and

instruments and tubing are adequately supported.p) Verify that all loop components have been properly and permanently

installed, that all flex and conduit connections are complete and fittings

are secure, that all panel and device covers are properly installed, drainlines are complete, that all equipment and cables are properly identified,

and that all components are free from visual damage and contamination.

q) Verify that the instrument primary sensing and pneumatic piping has

been checked for continuity, blown down and leak tested, or perform

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these tests at this time.

r) Verify the instrument sensing lines slope in the proper direction, in

accordance with applicable installation detail.s) Verify that all instrument devices are identified with instrument mark

number stamped on metal tags. Tags shall be attached in accordance

with project requirements.

4) Construction Tests and Calibration

a) Pneumatic portion of loops are visually inspected and soap tested for

leaks.b) Thermocouple connections are checked to ensure that similar metals are

connected.

c) Instruments are field calibrated for mechanical and electrical operationas defined by the limited scope of Construction responsibility.

5) Instrument Device Calibration

a) Calibration shall include all plant instrumentation, all factory calibratedand factory installed skid mounted and equipment mounted

instrumentation after complete installation. This includes instruments on

the instrument list and any instruments added during startup. Thetechnician shall calibrate, re-calibrate, re-zero, adjust, re-span, repair,

and replace, if necessary, instruments as required to ensure all plant

instruments and control loops function as designed at the time of plant

turnover to the Owner. Instruments shall be bench calibrated whenreceived and field calibrated after tubing and cables have been

terminated. Best to check with GG to see if well have a bench lab set

up. A clean enclosed area shall be provided complete with a calibrationbench and storage shelves for test equipment and instrument storage. A

records file system shall be maintained for all instrument calibration

records and instrument test equipment calibration records.b) All instruments calibration set-points and ranges shall be obtained from

the Instrument Data Sheet when available or from the manufacturer

instruction manual.c) All instrument device calibration data (set-points/ranges) shall be

recorded on the appropriate Instrument Calibration Data Sheet.d) After each instrument is calibrated, a calibration "sticker" shall be placed

on the instrument for verification of calibration.

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6) Instrumentation Checkout

a) Startup Group or instrumentation subcontractor will typically beresponsible for all checkout, configuration changes and logic

verification.

7) Rework

a) Items requiring rework shall be documented on Form B19.01C,

Instrumentation Punch List Record. Items, which cannot be reworkedwithin the requirements of the drawings or specifications, shall be

processed for resolution in accordance with CQP A06.

8) Subcontracted Work

a) During instrumentation installation, calibration, testing and loop check

activities; the Field Engineer or the Construction Site QA/QC Manager

shall monitor and verify the subcontractor's construction related work forcompliance with engineering requirements and applicable procedures.

As a minimum, this shall include:

b) When subcontractors are working to this Construction Plan, complianceshall be maintained to the applicable sections of this plan, as required by

the contract.

c) When subcontractors implement their own program for control of the

work, the Construction Site QA/QC Manager or designee shall verify

compliance with that program.d) Installation, calibration, and verification, shall be documented in

accordance with this plan or the subcontractors own program for controlof the work as required by contract.

e) The Construction Site QA/QC Manager shall assure the implementation

of this program consistent with the engineering design and the contract.

9) Records

a) The records system as agreed with the Owner and Startup Manager shall

be used and maintained to provide for the identification and correlation

of installation, test and inspection records. Each instrument calibrationdata shall be recorded on a separate instrument calibration data sheet.

Upon completion, required documentation will be submitted to the FieldEngineer for review and retention in accordance with project procedures.

b) As needed, loop check folders shall be developed in accordance with

project procedures. The following are typical contents of a loop check

folder:c) P&ID with loop identified (color highlighted).

d) Loop Diagrams.

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e) Instrument Data Sheets.

f) Instrument Calibration Records.

g) Instrument Calibration Set Points and Ranges.h) Appropriate CQP Forms (complete and signed).

i) Applicable Startup Forms (complete and signed)

j) Specific Loop-check Instructions.k) Instrumentation Punch list Record (complete and signed off).


a) Form B19.01A, Instrument Field Installation Check Listb) Form B19.01B, Instrument Pressure / Leak Test Report

c) Form B19.01 C, Instrumentation Punch list Record

d) Form B19.01 D, Instrument Calibration Reporte) Form B 19.01E, Control Valve Calibration Report

f) Form B19.01G, Orifice Plate Inspection Report

e. Scaffolding

A specialty subcontract will be utilized to provide supervision, labor, and materials

for the erection and dismantling of all required construction scaffolds. The

subcontractor will adhere to the Ventech andTerras safety policies. Thesubcontractor will provide these services in a manner, which supports the overall

projects schedule. The scaffolding subcontractor will have the ability to provide

engineering support as required for any scaffolds that extend higher than typical

erection standards allow (i.e. scaffolds greater than 120 in height).

f. Paint and Coatings

Paint will be handled as a Supply, Assemble, and Erect type subcontract,including material supply/storage, material take-off, quality application of required

coating components, and supervision. Any removal from the site of generated

waste as a result of painting and coating activities will be coordinated under the

direction ofTerra.

g. Insulation

Insulation will be handled as a Supply, Assemble, and Erect type subcontract,including some phases of detailed engineering (application of the insulation

specifications to project generated piping and equipment drawings), material

supply/storage, and material take-off, fabrication/assembly of the insulation

components, erection and supervision.

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h. Specialty Installation Subcontract(s)

From time to time specialty installations may be identified that will besubcontracted; these types of installations might include Cathodic Protection,

Fencing, PWHT or Preheat services, Fiber Optic, etc.

i. Site Service Subcontract(s)

Site Services Subcontracts or local procurement efforts may be anticipated to

include the following:

1) Field Offices / Trailers;2) Geotechnical Survey & Engineering Services;

3) Service Contracts for Civil Testing & NDE;

4) Service Contracts for Mechanical Testing, X-Ray, & NDE;5) Concrete Pumping;6) Dump Truck Services (onsite);

7) Authorized Inspection (AI) Services;

8) High Voltage Electrical Testing (Hi-Pot);9) Specialty Instrumentation Testing or Independent Third Party Testing;

10) Portable Sanitary Service;

11) Equipment Tire Repair;12) Pipe Machining / Cutting / Bolt Torque / Hot Taps;

13) Traffic Control if needed;

6. Construction Organization

a. Construction Manager (CM)

The Construction Manager is responsible for coordinating all aspects of interfacesbetween Ventech and other interfacing parties (Major / Minor Subcontractors,

Client, etc.). The Construction Manager reports directly to the Project Manager

and is the senior construction representative onsite. In addition to the

responsibilities associated with the Interface Coordination for the project, theCMs responsibilities will also include overseeing administration, controls, safety

programs, onsite material procurement/control, subcontract administration and

coordinating construction execution, along with being responsible for the finalturn-over of all systems for the project to the customer.

The Construction Manager will also be responsible for the oversight of all field

erection activities to ensure that they support quality, safety, labor relations,

productivity of the workforce, resource planning (for manpower, material, and

engineering deliverables availability), work progress reporting, constructionequipment planning/usage, coordination of the work between the various crafts

and adherence to work plans and schedules.

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Construction Manager reports directly to the Manager of Projects and Ventechs

Construction Operations Manager.

b. General Superintendent (GS)

General Superintendents are responsible for the oversight of all field

subcontracted activities including erection, installation, and support including

quality, safety, labor relations, productivity of the workforce, resource planning(for manpower reviews, material management, and engineering deliverables

availability), work progress reporting, construction equipment planning/usage,

coordination of the work between the various crafts and adherence to work plansand schedules.

General Superintendents report directly to the Construction Manager.

c. Superintendents

Superintendents are responsible for the overview of all discipline related fieldsubcontracted activities including erection, installation, and support including

quality, safety, labor relations, productivity of the workforce, resource planning

(for manpower reviews, material management, work progress reporting,construction equipment planning/usage, coordination of the work between the

various crafts and adherence to work plans and schedules.

Superintendents report directly to the CM administratively and will report

functional to the GS for work associated within their respective disciplines. Forthis project, superintendent positions are anticipated to include:

1) Mechanical Superintendent (Equipment installation and erection),2) Piping Superintendent (underground and aboveground piping installation)

3) Electrical & Instrument Superintendent (Electrical/Instrumentation power

and control systems),4) Civil/Structural Superintendent (civil support for underground piping &

electrical, foundations, dirt work, grouting),

d. Project Controls Manager (PCM)

The Project Controls Manager (PCM) is responsible for the constructionexecution for the project, including all field controls processes at the site, such as

cost monitoring, scheduling, progress measurement, and the associated reporting.This manager and his staff track cost against the field budgets, ensures that the

tracking of physical progress is incorporated into the reports, predicts trends and

forecast construction cost, monitors and reports progress against the schedule,ensures field schedules are prepared and advises of variances. The Project

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Controls Manager reports directly to the Manager of Projects but will report

administratively to the CM and is located at the site during construction.

e. Field Project Engineer (FPE)

The Field Project Engineer (also referred to as the Field Engineer) is

responsible for the planning, set up, and operation of technical data document

control, interface with engineering resolution/liaison (using the Request forInformation RFI) / Nonconformance Report (NCR) / Field Change Order (FCO)

process), constructability, and system turnover reporting in association with the

Systems Turn-Over process. The Field Project Engineer is also responsible for allfield engineering, survey layout, and coordinates the vendor field representative

requirements. The Field Project Engineer will also coordinate representatives

from the Engineering group who may need to visit the site to provide immediateassistance and answers to technical construction issues when required. The FPE is

responsible to develop and maintain as-built records for engineering follow-up.

The FPE is responsible for reviewing IFC drawings and modifications to initiatethe Change Tracking Process for the project. The Field Project Engineer reports

directly to the CM. Responsible for developing requisitions for field required

materials and verifying these have not already been procured by the home office.

f. Site HSE Manager (SHSEM)

Site HSE Manager is responsible for supervising the health, safety,

environmental and security programs including inspections, training and

communication, corrective action follow up, incident investigations, adherence tothe clients substance abuse program, MSDS procedures, and reporting for all

subcontractors.

The HSE Manager will be the primary contact for all safety, environmental, and

security issues at the construction site for all of the subcontractors. The HSEManager will develop HSE procedures and site-specific requirements.

The HSE Manager reports directly to the Construction Manager in matters relatedto the administration of the HSE Program at the site and the Ventech Corporate

Safety Manager.

g. Site Quality Assurance Manager (SQM)

Site QA/QC Manager is responsible for managing the site quality assurance and

oversight of the contractors quality control department. The QA/QC Manager

oversees department staff, inspector assignments, the site quality programs, andcoordinates testing (NDE) subcontract requirements. The site QA/QC staff is

responsible for review of all quality control programs, quality training programs,

and audit of all Ventech and Subcontractor work for compliance with standards,

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reporting non-conformances, and assuring that all inspection documentation is in

order for turnover to client.

The Site QA/QC Manager reports directly to the CM in matters related to the

administration of the QA/QC Program at the site and the Corporate Manager ofQA/QC.

h. Site Subcontracts Manager (SSM)

The Site Subcontracts Manager is responsible for the administration of allsubcontracts and the coordination of subcontracted work activities. For

subcontract inquiries issued in the field, the manager will prepare inquiry

documents, bidder evaluations, recommendations for award, monitorsubcontractors for progress, schedule, and any related HSE or Quality issues. The

Site Subcontracts Manager, will be the primary contact for all contractual issues,

notices, and responsibilities associated with the respective contractors. The Site

Subcontracts Manager will process subcontractors billing for payments andresolve any contractual issues. The Site Subcontracts Manager reports directly to

the CM in matters related to the subcontract execution at site and the Corporate

Subcontracts Manager.

The development of bidders list, and the respective contractual documents for allsubcontracts issued for the project will be developed, inquired, evaluated and

awarded based on Subcontract Procedures that are to be individualized for the

EPCM contract terms and conditions.

i. Materials Manager

The Materials Manager is responsible for field management of materials for the

project. This manager reports directly to the CM, and is responsible for theprocurement, material receiving reporting (MRR), and expediting material

requirements for the subcontracted field construction forces.

7. Health, Safety, and Environment Site Plan

Ventech is committed to a goal of zero safety incidents, both in the field and in the

home office. This applies to all Ventech, Subcontractors and Terrapersonnel, as wellas any other participants in the project.

The execution of the construction HSE program will be based on an established,

written HSE program that has been reviewed and accepted by the Owner prior to startof activities in the field. This program will contain the Ventechs Site Specific HSE

plan, policies, and procedures for implementing project requirements, and will

incorporate Terra Intl facility requirements.

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All work performed at the project site will be preformed in accordance within policies

and procedures established by the project safety program and will meet or exceed any

federal or local regulatory requirements.

In order to obtain the best possible HSE results it is recognized that it is necessary toestablish a safety culture and atmosphere where supervisors and workers are trained to

analyze the tasks to be performed, identify and eliminate the hazards/risks, and

communicate with each other how to perform the job safely. Supervisors will betrained to recognize and correct unsafe acts and conditions. A system will be set in

place to document observations and to pro-actively track/identify trends in HSE

performance.

Several key or important items that will be included in the HSE program include:

a. Ventechs Safety Procedures and Best Practices,b. Safety Task Analysis (STA) Pre Task Plan / Analysisc. Employee Based Safety (EBS / POP) Safe Behavior Observations

d. Employee Safety Recognition Program

While a program for safety analysis and task observation is key to the success of the

HSE results, the HSE Program, itself, must be based on a Site HSE Philosophy that isstrictly adhered to during the construction phase. These philosophies will include the

projects requirements for:

a. Safety policy and objectives;

b. Organizational structure and Manpower Resources with regard to safety

responsibilities;c. Systems and procedures to carry out safety objectives at all stages of the project;

d. Means of monitoring and reporting safety performance;e. Safety communications, meetings, and discussion on safety issues;

f. Safety Audit Program(s) to be performed by the Contractors;

g. Safety Orientation/Induction and Safety Training Program; and,

h. Safe Work Procedures

Within these project philosophies, the written HSE plan will be developed and

implemented on the project. The Terra UAN Expansion Project will require a

specific Site Health, Safety, Environmental Plan, which will be developed (made

project specific) and implemented for the project construction site.

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a. HSE Plan

This written HSE Plan addresses topics and subjects as follows:

1) Health, Safety & Environmental Policy;

2) First Aid / Medical Facilities, Accident Investigation and Recordkeeping;

3) HSE Education and Training;

4) Housekeeping and Sanitation;5) Vehicles and Equipment;

6) HSE and Health Requirements;

7) Fire Prevention / Protection;8) Hazardous Operation and Work Permits;

9) Emergency Procedures;

10) Environmental Hazards ;

Any employee, who disregards the rules, thus exposing himself and his fellow

workers to major incident risk, will be subject to disciplinary actions.Furthermore, it is Ventechs policy to encourage proposals from its employees on

how to maintain and improve standard of health and safety within the work

environment.

b. Environmental

The site construction team is responsible for adherence to and operating under all

the jurisdictional environmental laws, regulations, including permitting

conditions, and any owner established requirements for the construction project.The following are specific areas of concern that will have project specific

procedures developed during the preconstruction phase of the project, forimplementation during the construction project:

1) Pre-job Orientation Meetings

Ventech and subcontractors will be required to attend pre-job meetings todiscuss environmental issues and obligations relating to the job prior to

initiating work activities.

c. Security

It is expected that Terra Intl will provide security personnel to maintain the

integrity of the perimeter plant security. Other project security will be

subcontracted to provide normal access control to the construction facility and toensure control of construction related equipment and materials. During the pre-

construction phase of the project, a security plan will be developed for the

construction site which includes the following security issues, procedure, andstanding orders.

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1) Security Scope and Goals

2) Security Personnel

3) Security Patrols4) Emergency Communication, Power and Lighting

5) Entry/Exit to/from the ISBL site

6) Entry Authorizations7) Site Access by Visitors;

8) Material Exit Authorization

9) Site Access by Contractor Vehicles10) Site Access by Employees

11) Site Access by Private Vehicles

12) Employee Screening for Alcohol and Drugs

13) Parking Lots & Employee Transportation

14) Warehouse & Storage areas15) Animal & Insect Control Procedures

16) Emergency & Contingency Plans & Procedures

d. General Lifting Requirements

Lift Crane and related rigging operations are generally considered to be higher

risk construction activities and warrant serious planning and management of their

execution.

All heavy and/or critical lifts on this project will be performed in accordance with

approved rigging plans, practices and rigging procedures for the project.Ventechs procedures will include the definition for the identification of heavy or

critical lifts and the development of its detailed rigging plan.

It is important to note that as a minimum the rigging plans for heavy or critical

lifts should consider design of specialized lifting attachments and riggingapparatuses, load calculations for rigging gear including their arrangements,

ground bearing pressure calculations, crane matting, crane selection,

transportation equipment and lift equipment.

Standards considered as a minimum for projects crane operations and rigging

gear would include OSHA 1926 and ASME B30 series regulations, with thedesign basis for all rigging attachments being the AISC allowable stress design

method using 50% impact factor. In the event that jurisdiction requirements

recognize other requirements, the more stringent requirements would apply.

Ventech and subcontractors will only employ cranes and lifting equipment that

has been tested and certified as fit for purpose. All crane operators and riggers

shall be adequately trained and must be able to demonstrate that they hold the

appropriate certification and/or experience. Ventech will maintain records of tests

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and certification of all lifting equipment, cranes, and operato

terra construction plan rev0

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