Rihan Height Project Execution Plan-Rev00

Project Execution Plan 2045Rev.00

KHARAFI NATIONAL - UAE

AWI 202 Att. 2 Rev. 1 12 Sep. 2006

District Cooling for Rihan Heights

PROJECT NO. (2045)

PROJECT EXECUTION PLAN Part A: TECHNICAL SECTION

Date: 30-Oct-2010


1. TABLE OF CONTENTS

Description Pages

Part A: Technical

1. Table of Contents 1- 2

2. Key Features 3

3. Scope of Work 4

4. Safety 5

5. Quality 6

6. Execution Strategy 7-8

7. Schedule 9-12

8. Early Critical Items 13

9 Major Quantities of Material 14

10. Non Manual Organization Chart 15

11. Non Manual Manpower 16

12. Manual Manpower 17

13. Construction Equipment 18

14. Temporary Facilities 19

15. Subcontracts (Strategy) 20

Appendices

1. Schedule Implementation Portfolio

a. Schedule Narrative

b. Work Break down Structure at Level 3,5

c. Project Calendar

d. Project Implementation Schedule Report

e. Project Implementation Schedule

f. Project Critical Path

g. Progress Monitoring System

h. Project Progress S-Curve

AWI 202 Att. 2 Rev. 1 12 Sep. 2006 Page 1 of 22


2. Major Quantities of Material

3. Non Manual Organization Chart

4. Non Manual Schedule

5. Manual Manpower Histogram

6. Manual Manpower Schedule

7. Construction Equipment Schedule

8. Subcontracts

9. Procurement Plan

10. List of Tendering Staff (All Benefit Bands)

11. Signatures of Project’s Senior Staff (Benefit Bands A to E)(Applicable for final PEP only)



2. KEY FEATURES

Project No.: 2045

Project: District Cooling for Rihan HeightsLocation: Zayed Sports City, Sector W-57, Abu Dhabi, UAE.

Contract No.: C51003

Client Entity: Mubadala CapitaLand Real Estate LLC.

Client Representative: Innotech Construction Company (L.L.C)

Main Contractor: Kharafi National

Consultants: WS Atkins Partners Overseas

Brief description of work:

• The project consists of total estimated District Cooling Plant Load of 4,000 TR.

• The project covers the design, procurement, civil construction, architectural finishing and MEP works, including the district cooling plant itself, the reticulation network and the energy transfer stations. KN will also test and commission the DCP and will operate and maintain the plant for 12 months following commissioning.

• As a provisional Sum Item, Kharafi shall supply, operate and maintain power to the site by means of on site Generator until public supply is connected.

Contractual Dates:

Start Date: 18-July-2010

Substantial Completion Date: 13-May-2011

Final Completion Date: 13-May-2011

Duration: 300 days

Maintenance Period: 12 Months

Type of Contract: Lump Sum Fixed Price



3. SCOPE OF WORK

The scope of KN’s work on the district cooling plant (DCP) for Rihan Heights covers the design, procurement, civil construction, architectural finishing and MEP works, including the district cooling plant itself, the reticulation network and the energy transfer stations. KN will also test and commission the DCP and will operate and maintain the plant for 12 months following commissioning.

This plant has been designed to be modular in construction and to be self-contained within a compound of 1,000sq m, from which it will supply chilled water to the apartments and villas in Rihan.

The plant will consist of chillers, cooling towers, pumps, storage tanks, ancillary building, both medium-voltage and low-voltage power distribution and the compound wall. KN is sourcing the chillers from York (USA), the pumps from Armstrong (UK), the electrical switch gear from Schneider (France), and the transformers from ABB. The cooling tower will come mainly from Western Europe with some components from the USA.

The reticulation network will include the supply-and-return jacketed pipelines, control valves, chambers and control systems for the interface equipment – all of which will be coordinated with the other contractors on the site so that they fit in with the general infrastructure of the development.

The energy transfer stations will provide the interface with the consumers and will include heat exchangers and connections for the chilled water reticulation pipes coming from the chilling plant to the primary side of the heat exchangers. They will include all valves, controls and accessories.

KN manpower on the project will peak at about 99, excluding subcontractors’ manpower. The project is a fast track one and is due for completion on the 13th May, 2011.

The DCP in Rihan Heights will be a relatively small plant. However it is being wholly designed by KN using the experience, capabilities and know-how Kharafi National has built up in recent years on several successful district cooling projects and the Rihan Heights project is already helping to consolidate the company’s reputation in this field.



4. SAFETY

A Project specific HSE Plan covering all aspects of construction safety, environmental protection and security protection has been submitted to the Client for approval.

A dedicated Health and Safety team will be deployed to the site under the supervision of a Health and Safety Engineer and Safety Officers. The project will be controlled as per the approved health and Safety plan.

It is KN’s policy that every employee shall be provided with a healthy and safe environment in which to work. To this end, every effort will be made and positive action taken at all times, by all employees, to ensure healthy and safe working conditions at all company project work site and facilities.

The general philosophy is each person on site is responsible for safe working practice, and no one will be punished for refusing to work in unsafe working environment. The function of HSE team is to monitor, guide and train all employees’ to achieve a safe working environment.

KN approved Safety Plan will be given to all Subcontractors to follow in their scope of work and every big Subcontract will include Safety Officer from the Subcontractor side who will report to KN Safety Team.

Some, but not limited to, work rules that will be implemented to achieve these goals.

• Regular job safety analysis• Regular awareness programs• Special training programs• Encourage communication from work force• Encourage daily reminders by each supervisors• Weekly surveillance of all rigging equipment and tools, site manpower distribution• Fire prevention program, identify hazardous areas, material and storage, establish Alarms response teams, regular checks on fire fighting equipment, fire watcher’s Training and fire fighting training.• Daily tool box meetings for supervisory and non supervisory work force.



5. QUALITY PLAN

A Project Specific Quality Plan will be followed, identifying all applicable procedures for procurement, construction, testing and pre commissioning activities. This plan will conform to the Company Quality Assurance Procedures and will be approved by the QA / QC Department and the Client.

The project team will be responsible for all QA/Qc activities and the QA/QC team will be responsible for enforcing it on site. The field construction team shall be fully conversant with the Project Quality Plan requirements.

A dedicated team of inspectors shall be employed to carry out inspections and surveillances during all phases of Procurement and Construction to ensure that correct specifications and procedures are being adhered to.

KN approved Quality Plan will be given to all Subcontractors to follow in their scope of work and every big Subcontract will include Quality Engineer and Inspectors from the Subcontractor side who will report to KN Quality Team.



6. EXECUTION STRATEGY

Kharafi National will deploy staff to manage, supervise and execute the works in addition toEnsuring the Company’s QC/QA procedures are adhered to and implemented.

Due to the fast track requirement to complete the project works on Time and within Budget,KN project management and team will adopt the following Execution Strategy. This strategyIs as follows:-

Design and Engineering

• All design and engineering works pertaining to civil, process, electrical, mechanical and Instrumentation will be carried out by Kharafi National’s in house Engineering Services Department (ESD) located in Abu Dhabi.

• Stellar (SGL) will be responsible for carrying out the design and engineering works pertaining to mechanical module and Electrical modules.

• Stellar (SGL), the proposed supplier for the mechanical and electrical modules Such as: Cooling towers, Pumps, Chillers, MV Switchgear and LV switchgear in Addition to plenty of equipments/systems such as; Chilled Water Chemical Treatment System, Air Separator, Refrigerant Reclaim Unit, SCADA, FRP cooling towers, Instrumentation outside the modules. • Kharafi will appoint Consultant for Stamping Purpose only in addition to obtaining the Building Permits and relevant NOC’s from different Authorities.

Procurement

• Follow and implement the KN central procurement procedures to ensure the maximum Discount will be obtained.

• The material selection will be considered for nominated and un nominated sources in Order to ensure that the best competitive process is obtained and our budget and timely Deliverable is met.

• Procurement department of Kharafi national will be responsible for the procuring of Many items as mentioned at the procurement plan in Appendices 9, however the Balance Materials will be purchased directly by the project engineers. • KN will subcontract plenty of packages for subcontractors as mention in Appendices 8.



Construction

• KN will start to execute the Ancillary Building and Storage Tanks and then will execute The foundation of LV Module and Chillers module.

• The execution of external pre insulated pipes network will start as soon as the material Will be delivered to site, the start date expected to be by the last week of Nov-10.

• A highly coordination will be made with the infrastructure contractor who is working in The same area of pre insulated pipes networks.

• The installation works inside ETS Rooms will commence as the heat exchangers And relevant pipes will be delivered to site, the start date expected to be by the 3rd week Of Jan-11.

Testing and Commissioning

• Testing and commissioning of mechanical modules, electrical modules and control System will be done By Stellar; however KN will provide only the technical Support on site.

• Testing and commissioning of Transformers will be done by subcontractor.

• Termination of MV Cables will be done by subcontractor however the termination of LV cables will be done by KN.



7. SCHEDULE

• Project Planning and Schedule Procedure

7.10 Project Schedule

This section of the procedure sets out the principles, practices and systems that will be employed to ensure the effective management of the project schedule.

The following levels of schedule will be employed:

Level I – Executive Summary and Milestones, reflecting principles and contract requirements.

Level II – Project Master Schedule (PMS), reflecting strategy(Work Packages).

Level III – Detailed Working Schedule, showing activity detail per discipline and per deliverable.

Compatibility will be maintained between all levels of schedule as far as possible.

The detail schedule at Level III, i.e. what is delivered and when, is owned by the Discipline (Functional Group) leaders responsible for doing the work and not by the scheduling team. The scheduling team analyses, presents, reports and advises but does not make decisions on the ‘what and when’.

The planned dates will not be amended unless and until all involved parties agree that such an amendment is both feasible and desirable.

In the event that it becomes necessary to revise the Project Schedule, any such amendment must have the agreement of the Project Manager, Project Controls Manager, Engineering Manager and Client.

Such schedule amendments will be determined and agreed in the Level III Detailed Working Schedule before being reflected in the higher level schedules

7.11 Level I Schedule (Milestones)

7.11.1 Purpose

The purpose of the Level I Milestone Schedule is to provide a high level executive summary of the project schedule, identifying key phases and/or milestones. The Level I Schedule will be updated to show current status.

7.11.2 Scope and Content

The Level I Schedule will show the planned, actual and forecast dates for a number (approximately 15-20) of key milestones.



7.12 Level II Schedule (Project Master Schedule)

7.12.1 Purpose

The purpose of the Level II Project Master Schedule (PMS) is to provide a high level schedule that summarises on one page the Level III Detailed Working Schedule whilst clearly defining the overall project strategy.

The main function of the PMS is to communicate to all project participants an ‘at a glance’ view of all the key project schedule objectives that must be achieved if the Overall Schedule is to be met.


The Level II Schedule (PMS) will reflect the Project Work Breakdown Structure by dividing the scope of work into major elements such as Engineering, Design; Procurement, Construction, Testing and commissioning.

These will be further subdivided into major disciplines for each of which a number of key milestones will be depicted.

7.13 Level III Schedule (Detailed Working Schedule)

7.13.1 Purpose

The Level III Detailed Working Schedule will be used for day-to-day control of the project. The Level III schedule will be used to integrate the efforts of all of the Disciplines participating in the project. It will also be used as the basic tool for reviewing progress, identifying any problem areas and evaluating recovery options.


The Level III schedule will reflect the detailed activities under each Work Breakdown Structure (WBS). Such activities will be used for progress measurement. Other activities required to complete the work, which are of a general nature and do not involve the production of documents, will be identified separately and monitored, but will not be used for progress measurement.



7.20 Progress Measurements

7.20.1 Purpose

The purpose of implementing a physical progress measurement system is to periodically establish, by objective assessment, the progress achieved to date and current trends in respect of rates of progress being attained.

This information is used in evaluating the overall performance of the project with regard to the likelihood of achieving the principal objectives. It also helps to identify areas of the project where problems or resource availability and/or data availability are occurring, in order that a more detailed investigation can be initiated.


Progress measurement will be performed within Primavera P6 at the Detailed Work Schedule level (Level III) by weighting deliverable activities and charting the cumulative weighting over time on a scale of 0 – 100%.

7.20.3 Progress Reviews

In order for Discipline Leaders to report on the status of progress and performance against the schedule at the weekly review meetings, a package comprising the following will be issued to them in accordance with the timetable of events established for the meetings:

- Look-ahead Schedule, based on the Discipline’s level III schedule. This will be marked up with a front line on the same sheet for a reporting month.

- Current Overall Progress S-curve - Current Discipline Progress S-curve - Late Activity Report

The above S-curves will be generated on an early and late start & finish basis, directly from the network data.

The discipline leaders will mark up the Look-ahead Schedule and the Late Activity Report prior to each meeting and will discuss these at the meeting.



7.30 Manpower Histograms

Any manpower analysis shall be directly extracted from the resourced Schedule and shall indicate the levels of manpower required overall and by classification at each stage of the work to enable the overall Project schedule to be met.

The initial submission shall be the ‘Baseline’ Histogram derived from the approved overall Project schedule and indicating the planned Manpower required per period to successfully achieve Contract Completion Date.

The manpower analysis shall be presented in the form of a Histogram aggregated over monthly periods showing manning levels throughout the Contract Period taking cognizance of such requirements as public holidays, vacation, rest periods and working hours per week etc.

The periodic and cumulative aggregated manpower/man-hour figures must be shown in tabulated form on the Histogram. The ‘Actual’ equivalent manpower shall be derived from the daily site report.

Manpower histogram reports showing planned, actual and forecast manning levels shall be re-issued after each update period having performed a time or resource limited schedule update using early start dates for aggregation purposes

7.40 Cash Flow

Cost loading should be done into the schedule activities in order to extract the Cash In data from the schedule besides, excel file which will be used to calculate the cash out data.

Resulted cash flow will show the liquidity available to KN during the project time.

Periodic updating to the cash flow will be prepared.



8. Early Critical Items

Our program had been developed to complete commissioning of Cooling System (4000 TR capacity) in 10 months.

The critical path is derived mainly by:-

1- The Procurement – Installation of FRP Structure Work for Cooling Towers. The FRP Structure will take almost 18 weeks between the approvals of Detail Design; Submit the material submittal, issuance of PO and shipping to the site. The installation will take around 8 weeks and then Installation of Cooling Tower will Consume another 3 weeks. The Termination of Control Cable will take another 2 weeks.

FRP Structure is driving the Concept, Detailed Design and Authorities Approvals to be On the critical path.

2- The Procurement – Installation of Chillers and Chilled Water Pumps.

The Chillers and Chilled Water Pumps will take almost 26 weeks between the approval Of Detail Design, Submit the material submittal, issuance of PO and shipping to the site. The installation will take around 2 week and then the Termination of Control Cable will Take another 2 weeks.

The Chillers and Chilled Water Pumps are driving the Concept, Detailed Design and Authorities Approvals to be on the critical path.

3- The Civil and Architectural Works of Ancillary Building.

The Civil and Architectural Works of Ancillary Building lead the Transformer and MV Switchgear to be on the Critical Path as Followings:- The Civil works will take around 16 weeks from start excavation to get the access for Finishing and MEP works inside the transformer room. The finishing and MEP work will consume another 6 weeks to get the access for cable\ Laying and equipment installation and then 2 weeks to install the Transformer and MV Switchgear.

The Testing and Commissioning of Transformer and MV Switchgear will consume 4 Weeks.

The Civil and Architectural works are driving the Construction / Building Permits to be on The critical path.



09. MAJOR QUANTITES OF MATERIAL/ EQUIPMENT

• The full list of Major quantities of material /Equipment is shown in Appendices 2.



10 - Non Manual Organization Chart

• The Non manual Organization Chart is shown in Appendices 3.



11. Non Manual Manpower

• The Non Manual Manpower Schedule is shown in Appendices 4.



12. Manual Manpower

• The Manual Manpower Schedule & Histogram is shown in Appendices 5, 6.



13. Construction Equipment

• The Construction Equipments Schedule is shown in Appendices 7.



14. Temporary Facilities

KN is going to install the following temporary facilities on the project site:-

• Site offices for Kharafi and Client.

• Generator and its fuel tank.

• Site Fence.

• Septic and Water Tank.

• Project Signboard.

• Store Yard.

• Workshop.

• Masjed and Water Facility.

• Labors Mess Hall.

• Toilet.

• Designated Smoking Area.



15. Subcontracts (Strategy)

As this is a fast track project, Kharafi National Project Management and team will adopt the Following strategy to ensure the subcontract works are completed on time and within budget In accordance with KN standards in order to minimize KN exposure to risk. This strategy is as follows:-

• For Design and Procurement, we plan to have 1 subcontractor to design and procure the Mechanical and Electrical Modules.

• For Stamping and Permits Purpose, we plan to have 1 subcontractor to stamp the design And obtain the required Permits and NOC’s.

• For Civil Works, we plan to have many subcontractors for plenty of work packages such as but not limited to :-

o Waterproofing.o GRP Lining.o Kitchen Equipments.o Geotechnical Reporto Material Testingo Steel Gates

• For Electrical Works, we plan to have many subcontractors for plenty of work packages such as :-

o HV Cable Lying & Termination.o Fire Alarm Systemo Telecommunication Systemo Cabling.

• For Mechanical Works, we plan to have many subcontractors for plenty of work

packages such as :-

o HVAC Initial Start-upo HVAC Testing, Balancingo Fire Fighting Systemo Electric Chain Hoist o Flushing /Chemical Flushingo Testing & Commissioningo Welding X-Ray Test.


Rihan Height Project Execution Plan-Rev00

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