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AL JABER ENGINEERING

PROJECT: LUBE OIL BLENDING PLANT

PROJECT EXECUTION PLAN


1- Introduction
MAG Lube LLC intends to set up a Lube oil Blending Plant (LOBP) in Dubai Techno Park. The basic designs for civil, mechanical, electrical, control and Automation has been completed by Mott MacDonald Engineering Company. Al Jaber precision is submitting proposals for the detailed design and execution of this project.

2- Scope of this Plan


This Plan describes the project execution phases and major activities for each phase. Stating the priorities and critical issues and taking into consideration the resources required for the project and the resources that can be allocated with the relative availability schedule. The project phases are the following: - Basic Design for facilities that still need calculations and verifications. - Detailed Design to adapt the basic design to the allocated and approved Material and equipment stated in the specifications. This is split in 4 categories for Civil, Mechanical, Electrical, Instrumentation and Control. - Technical Submittals for all Materials and Equipment needed for the Project execution. - Ordering and Supply of Material and Optimization of Delivery periods to Synchronize it with the construction activities. - Construction of Foundations, Structures and other civil works. - Construction of Vertical Storage Tanks, Piping Systems, Installation of Mechanical Equipment and Accessories, Painting and Insulation. - Installation of Electric distribution and control Panels, Electric Fixtures for Power outlets, lighting, lay down and termination of related cabling with all necessary accessories and cables trays. - Installation of field and control room Instruments for the monitoring and control of the critical parameters of the plant process and Control Devices with automation software and hardware for the plant Operation. In this plan, Al Jaber Precision is demonstrating the adopted methods and strategy for the completion of works

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Execution Plan

AL JABER ENGINEERING

PROJECT: LUBE OIL BLENDING PLANT

3- Basic Design Phase The Basic design is required to be performed for the following items, knowing that all the other items basic design is performed by Mott MacDonald and provided on the relative drawings and data sheets. This design will be performed by our design department and affiliated companies. The tanks design with relative foundations will be performed by our design Department and verified by third party. The structural steel design will be carried by our design department that has carried designs of complex structures for industrial as well as architectural purposes. 3.1 Basic design and calculations should be carried, according to the required industry standards (API 650, 2000, AISC, AISI), for the selection of material, with relative sizes and attached accessories, The design and construction of the Tanks is one of the critical activities of this project and is required to be carried from the very early stages due to the long construction time required for these tanks. This design will include the verification of the relative foundations. 3.2 Basic design and calculations for the Fire protection system would be carried out, according to the required industry standards (AWWA D100, NFPA22, NFPA25 and NFPA10). All materials for the fire fighting system shall be UL listed or FM approved. This activity will be executed in parallel the process piping. 3.3 Basic Design and structural calculations for the sheds of the Product Pump House, Utility Shed, Loading/ Unloading Area, Hot Oil and Stem Unites and Platforms. The design of these sheds will allow for the allocation of relative material and provide the transmitted loading to the relative foundations, which allows verification and the sizing of foundations as well as design of Anchoring for the foundation. The erection time of these sheds is not as critical as for the tanks erection, but due to the number of sheds, it is important to start this activity in parallel with the tanks basic design. 3.4 All the mechanical equipment, specifically the positive Displacement pumps for Base oil, Finished Product Base oil, Additive Loading and Fuel Feed Pumps (P-301, P-302, P-303, P-304, P-305, P-311A and P-311B), Hot Oil Unit, Steam unit and Fire fighting monitors, needs foundations to bear the static and dynamic loads transmitted to it. Accordingly, the relative design of these foundations is either provided by the supplier or loading data provided by the supplier in order to allow for proper design. This can be received, from the suppliers, only after getting approval on the equipment itself and placing the order for the relative equipment with a lag time going up to one month from the order date. Data for the Drum filling should be provided by the Client. All other facilities are considered as ready for detailing.

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Execution Plan

AL JABER ENGINEERING

PROJECT: LUBE OIL BLENDING PLANT

4- Detailed Design Phase


Based on the provided design drawings, detailing will be carried, by our engineering Department or subcontractors, for the electric and automation works, for the following items, split in four categories, and following the same sequence as below: Civil Design - Foundation, slab and bund wall for the Tank Farm, considering the anchoring devices required to be embedded in the concrete as per the tanks supplier design. - Foundations and slabs for junction and Distribution boxes taking into consideration the requirements of electric and control cables access. - Foundations and Slabs for Hot Oil and Steam Units, - Foundation and slabs for fire monitors, hose cabinets, Hydrants and valve pits. - Slabs and Foundations, of structures, at Pump Houses and Equipments Sheds, taking into consideration the required anchor bolts to fix the steel structures. - Foundations of equipment and pumps - Necessary pipe sleepers, pipe supports and trenches for aboveground pipes and underground pipes for the Supply and transfer lines, storage and transfer and for the Hot Oil Supply and Return lines. - Excavations for the Fire fighting piping and necessary supports for fire equipment. - Oily water and drainage system with related drain and collection pits. - Details of miscellaneous supports and foundations. - Details of roads and paving. Mechanical Design Storage tanks including necessary fabrication and erection drawings with details of all nozzles, structures, attachments and insulation. - Fire water tank including necessary fabrication and erection details with nozzles and attachments. Hot Oil and Additives supply and return piping systems including jacketing and heat tracing where required with necessary isometric drawings at the connections to the different equipment. Insulation details will be also developed for the required systems. - Fire Fighting system including piping, hydrants, monitors, fire hoses and related accessories. Isometrics at connections to equipment included. - Instrument Air piping system and connection to the Package Unit and delivery points.

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Execution Plan

AL JABER ENGINEERING

PROJECT: LUBE OIL BLENDING PLANT

Electric Design - Cabling layouts covering the power supply for equipment as well as for lighting and power outlets with necessary ducting and trays inside each of the following: o Electric, Control, Sampling and Laboratory. This should cover the power supply o the UPS, Capacitors Bank and to the Air Conditioning and Ventilation units. o Product pump house o LV Power, control and earthing cables o Tank, structural steel and equipment earthlings and integration into the existing earthlings system o Loading / Unloading Shed. o Structural steel for utility services area - Cabling layouts covering the power supply for equipment as well as for lighting, with necessary ducting and trays to interconnect from the electric room panels to the equipment or local panels for lighting and power distribution to the following areas : o Product pump house. o Hot Oil Unit panel. o Fire Fighting monitors o Loading / Unloading Area. o Street lighting - Wiring diagrams of the SMDB, MCC, SCADA, EMDB as well as for the lighting and distribution panels. - Fire Alarm Control Panel and interconnection to the call points, heat detectors and alarm sounders. - Earthing system for tanks, steel structures and for power distribution. - Telephone and administration computers cables. - UPS cabling layout. Control and Automation Design - Based on the plant process description, detail the Philosophy of operations and develop the logic algorithm for the plant control and monitoring system. - Detail the ESD system operations and define interaction with the plant operating system. - Identify the Field I/O parameters to be transmitted to the Scada System in order to be able to control and operate the plant through this system. This will be developed in coordination with the packaged units suppliers. - Identify the Field I/O parameters to be transmitted to the ESD System in order to be able to manage the emergency situations. - Provide necessary details and geometry, required for the mechanical department, necessary to properly embed the field instruments. - Details of the Radar Gauging system. - Details of the Flow Metering system.
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AL JABER ENGINEERING

PROJECT: LUBE OIL BLENDING PLANT

Layouts for the control cables inside the control room with necessary ducting. Layouts for control cables to interconnect between the main control room and the packaged units control panels.

5- Technical Submittals and Materials Ordering.


Knowing that data sheets with specifications and operating parameters of all equipment is provided by Mott MacDonald, the allocation of equipment and material can proceed from the project starting date, except for the items that needs basic design or needs detailed BOQ for ordering. Accordingly, the following equipment will be allocated from approved suppliers, except if new suppliers are required to be approved, and technical data provided and submitted for approval as following: Mechanical Part - Looking at the suction heater unit is one of the long lead delivery items this will proceed as soon as possible in order to finalize a technical offer. - Another critical item is the delivery of the positive displacement pumps for the various products. As soon as a delivery time, matching with the project schedule, is confirmed a technical submittal will be presented for approval. - The hot oil unit is also of major importance, knowing that after arrival at site its installation will take time specially that it cannot be shipped as a skid and it is consisting of many systems like firing fuel, exhaust, expansion unit, and interconnecting piping between the unit itself and the plant lines. As soon as commercial negotiations are concluded, technical submittal will be presented for approval. - The plug valves, with very limited number of suppliers who can offer the required specs, represent also an item of high priority regarding its delivery. Technical submittal will be prepared as soon as commercial terms are finalized in order to get approval and proceed with the order. - Other equipment like fire fighting pump skid, other types of valves, air packaged unit as well as fire fighting accessories will follow in order to have it at site as soon as possible. - The tank material will be fabricated at our workshops in Abu Dhabi, blasted and primed, where necessary, prior to shipping to the site. - The piping and fittings material can be allocated after completion of the relative BOQ. Allocation of this material is easier than for tanks, and needs to be processed as soon as the relative quantities are finalized. Spools, for pump houses, can be prefabricated at our workshop upon getting the material and pumps data. - Bulk material like welding electrodes, painting, insulation, cladding, etc, will be submitted prior to proceed with the relative works.

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Execution Plan

AL JABER ENGINEERING

PROJECT: LUBE OIL BLENDING PLANT

Civil Part - Submittal of the reinforcing bars material, Ready Mixed Concrete and Backfill material will be processed from the early stages of the project. - Other bulk material for civil and architectural works, will be identified and submitted on priority lists for approval. - Buildings utilities like Air conditioning units and sanitary facilities will be submitted during the course of works. Electric Part - The SMDB, DB MCC wiring diagrams and components material will be submitted upon finalization of the equipment selection and relative required power. - The cables will be submitted upon calculation of relative, either if not final, quantities and sections. - The explosion proof lighting fixtures will be submitted from the early stages knowing that its deliver time is not short. - Other electric fixtures and devices will be submitted from the early stages. Control and Automation Part - The field instruments will be submitted as soon as the relative quantities are calculated and commercial terms are finalized with the suppliers. - The Radar level gauges and Flow metering systems are considered of first priority for submittal and approval, looking that it is requiring long delivery time. - Control cables and related accessories will be submitted as soon as relative quantities are finalized. Ordering of each item will be processed, through a Purchase Order, issued by AJP, as soon as the technical submittal is approved. For bulk material, the Orders will be placed for partial deliveries.

6- Construction.
Same as for all phases of the project, the construction is divided in four major sections as following: Civil Works The civil part is the first phase to start at site after completion of the prestart activities and mobilization of the relative equipment and personnel and the site setup with the relative facilities. The main activities in the civil phase are as following:

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Execution Plan

AL JABER ENGINEERING

PROJECT: LUBE OIL BLENDING PLANT

Upon completion of the detailed design of the Electric, Control, Sampling construction of this item can take place taken into consideration Looking the critical issue of tanks construction, the foundations of the tanks will start immediately after completion and approval of the relative detailed drawings. Removal of the top soil layers, Excavation at the ring beam area and then compaction will take place using diggers and compaction rollers of appropriate size to allow for efficient performance of works. The soil being prepared, the ring beam will be cast in two parts, the annular part and then the cylindrical part. Embedment of the anchor bolts, at the right positions, will be given high importance. The bund wall around the storage tanks will be left until completion of the tanks construction and can go in parallel with the testing and insulation activities. In parallel with the tanks foundations, the footings and slabs at the sheds for the Pump Houses and Equipment will be carried, taking into consideration the embedded anchors necessary for these sheds and keeping necessary area for the equipment foundations that needs to be finalized upon completion of the relative design. The steel structures sheds will be erected and roofing installed with necessary flushing and down spouts will be installed as soon as the steel fabrication is complete and the concrete is cure and ready to receive these structures. The shed of the Hot Oil Unit and the steam unit may be delayed until completion of this unit installation, due to the dimensions of this unit. Pipe supports, trenches, drainage system as well as excavations for under ground piping will take place as soon as the above activities are complete and allowing for the piping works to be carried out. Roads and paving as well as fencing and gates will be carried as the last item of the civil works in order to save this part from potential construction damages.

Mechanical Works The mechanical part includes the most critical items as long lead delivery and also includes activities that need long time for construction. Accordingly, is based our plan for the Mechanical works as following: - Tanks erection at site will start upon approval on the detailed design drawings, receiving the prefabricated material at site and the foundations are ready. The tanks will be started with lay down and welding the bottom and annular plates and then erection of the shell courses one by one starting from the lower course to the upper course. Automatic welding machines will be used for most of the welding in order to minimize the erection time. The roof structures will be prepared for erection in parallel with the shells and once a shell is complete the relative structure can be erected in position to receive the roof plates. Nozzles and accessories as well as supports for insulation
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AL JABER ENGINEERING

PROJECT: LUBE OIL BLENDING PLANT

and supports for the heating coil will be installed in parallel with the roof plates. At this stage the tank will be hydro tested. The suction heater inside tanks will be prepared in parallel with the testing in order to place it inside after draining the tanks. Touch up of painting and installation of insulation and cladding will be installed to complete the tanks. The piping works for the various products, Hot Oil and Solvents will start upon approval of the relative detailed design and arrival of pipes and fittings and pipe sleepers are ready to receive the pipes. For this purpose the Tees need to be ordered in two pieces and perform the longitudinal welding at site. Spacers will be welded on the internal pipes to allow for homogeneous opening for the hot oil circulation. Any change in direction will require attention for the sequence of work between internal and external piping, (internal straight line - external straight line - internal direction change - external direction change) in order to allow for proper fit up, welding and NDT. Also attention should be paid for the sizes of flanges at the jacketed valves. Upon arrival of equipment and in order to complete the piping systems, equipment will be installed, according to the installation instructions or under supervision of the manufacturer, where appropriate, considering that the foundations are ready to receive the equipment. Installation of the Hot Oil unit, according to the instructions of the manufacturer, and under his supervision, will be given importance due to the volume and diversity of works, installation of the diesel supply system, the exhaust ducts and connection of the Hot Oil Piping. The Fire fighting system and Instrument Air system will be installed in parallel with the other piping systems.

Electric Works - As soon as the Electric, Control Sampling and Laboratory building is ready as civil and architectural works and the steel sheds erected, installation of the electric lighting and small power distribution with the related cabling and lighting panels inside these areas can be started taking into consideration the cabling layout, related to the equipment power and control cabling, inside these areas. - The Main Distribution panels can be installed as soon as the Electric room construction is ready and the panels are available at site. - Cable trays for interconnection between the electric room and the different areas can be started upon completion of the piping works and once the trenches are ready, if needed. - Once the equipment are in place and the Distribution and Control panels are installed, with the trays ready the cabling can be laid down and terminated at both ends. Attention should be given for the solvent tanks and pump house area where explosion proof accessories should be considered.

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Execution Plan

AL JABER ENGINEERING

PROJECT: LUBE OIL BLENDING PLANT

Earthling rods and cabling for the power distribution as well as for tanks and structures will be performed in parallel with the electric cables lay down. External lighting for the roads and tanks can be installed after completion of the roads and paving and erection of the tanks. Installation of the power factor correction capacitors bank and the UPS system will be performed upon arrival of these equipments. Telephone and computers cabling will be performed to complete the electric works. Energizing the equipment and testing will take place after completion of the above works.

Automation and Control Works - Prepare the software and control program for the plant operation is a major part of the automation works and will be started upon approval of the philosophy of operations and the program logic sequence. - The PLC based control panels will be installed when the Control room is ready and the panel is available at site - The flow metering system as well as the filed instruments with relative cabling will not be installed until completion of the erection and testing of the piping systems. - The radar gauging system can be installed after completion of the tanks erection, testing and insulation. - Installation of the work stations and configuration of the system will take place when the control room is ready and the equipments are available at site. - Energizing the system and all field instruments will take place and loop by loop testing will be started and verified. - Final adjustments for the out put screens and control parameters regarding the plant operations will be carried as per the Client/ Consultant requirements. 7- Assist Commissioning and Handing Over. After testing all equipment on individual bases and the control system on loop by loop basis and then as complete system, the plant will be ready for primary handing over. Once handed over, commissioning of the plant can be started by the operations team of the plant, with assistance from our technical staff. Technical assistance for the plant operation will be provided through a technical coordinator who will be receiving the comments from the site, coordinating with the concerned parties and providing solutions in the shortest possible time, based on the emergency of the issue considered.

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Execution Plan