3.5.1 engineering

TANKAGE PACKAGE & ASSOCIATED INTERCONNECTING PIPING

RUWAIS REFINERY EXPANSION PROJECT

TAKREER PROJECT NO. 5578

TENDER ENQUIRY NO. 09-5578-E-4

3.5.1 ENGINEERING PLAN

3.5.1.1 ENGINEERING EXECUTION STRATEGY

3.5.1.2 DISCIPLINE ENGINEERING RESPONSIBILITIES AND ACTIVITIES

3.5.1.3 ENGINEERING SOFTWARE

3.5.1.4 ATTACHMENTS

ATTACHMENT 1 – PROPYLENE TANK GENERAL VIEW

ATTACHMENT 2 – PROPYLENE TANK CONCRETE DESIGN DESCRIPTION

ATTACHMENT 3 – PROPYLENE TANK PILE FOUNDATION PLAN DETAIL

ATTACHMENT 4 – PROPYLENE TANK PILE FOUNDATION CROSS SECTION

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3.5.1 ENGINEERING PLAN

All services associated with the engineering implementation of the RRE Project will be performed under CONTRACTOR’s single point responsibility at one location, CONTRACTOR’s Engineering Center in Seoul, Korea. Maximum use will be made of CONTRACTOR’s prior pertinent experience, in particular the experience gained and the lessons learned from CONTRACTOR’s performance on comparable current and recent projects in Qatar.

In order to accomplish the objective that is to provide engineering and design deliverables timely in line with project specification and other contractual requirements, Contractor will execute the engineering work stressing the following:

Safety Engineering

Quality Management

Compliance with Owner Standards

Constructability

Design Consistency

Plant Operability and Maintainability

CAD and CAE System

3D Mathematical Model System

Very soon after the contract effective date, project kick-off and team building meetings will be held with COMPANY Project Management Team and COMPANY management representatives to foster personal relationships and mutual understanding and to emphasize the combined team’s common purpose.

Engineering execution plans presented in this proposal and further developed or modified during discussions leading to contract award, will be put into immediate effect and plans for the weeks following the contract effective date will be detailed and expanded to assure quick and effective mobilization and project start.

For the FEED Document and site data, CONTRACTOR will reconfirm the design prepared by the FEED Contractor and will purchase the main materials and equipment.

The emphasis throughout project execution will be to perform and complete the work in accordance with the required quality standards at or within the agreed project schedule and cost.

3.5.1.1 Engineering Execution Strategy

1) Project Execution

CONTRACTOR will execute the project in accordance with COMPANY standards and procedures in Instruction to Tenderers as well as CONTRACTOR Practices. This execution basis forms the foundation of all engineering work performed in the Home

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Office and in the field. This will constitute the basis for CONTRACTOR’s quality certification and provide instructions and guidance in all fields of project execution. The practices provide the basis for development of project execution plans and procedures which are tailored to the specific aspects of the project.

2) Engineering Management

Upon project award, CONTRACTOR will appoint an Engineering Manager who will be responsible for the overall success of all engineering work performed in the Home Office and in the field.

He will be fully supported by the Engineering Management Team together with a selected team of experienced and capable Lead Discipline Engineers.

The engineering team will be mobilised in accordance with the manpower plan, in a dedicated task force area located in Head Office, Seoul Korea.

The organization structure for the engineering team is shown in Section 3.2 of Technical Proposal.

3) Overview of the Project Work Areas

CONTRACTOR fully understands the complexities and interfaces associated with the Project. In order to align the Engineering and Design with this strategy and to meet COMPANY’s requirements for sound interface management with other contractors we propose to develop a work breakdown structure based on 3 main areas.

These areas will be:-

Tankage System

Interfaces with RRE Inside Area

Interfaces with RRE Outside Area

By developing detailed plans for each of these key areas and by identifying the critical activities associated with the successful completion of each area we are confident of meeting COMPANY’s requirements.

We will also effectively manage the interfaces between each of these areas to ensure the overall success of the project.

4) Project Specifications and Alignment with COMPANY Requirements

CONTRACTOR understands the requirement to develop the FEED Design Package into a fully developed Detailed Engineering Design in compliance with COMPANY Standards.

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CONTRACTOR’s documentation and design deliverables will comply fully with COMPANY’s “Computer Systems and Data Management “ requirements set forth in the following procedures:

Exhibit B.13 Information Technology Requirements

Exhibit B.39 Review, Comments and Approvals

Exhibit B.40 Project Handover Documentation

Exhibit B.41 Document and Drawing Format Procedure

Exhibit B.42 Document Numbering Procedure

Exhibit B.43 Document Control Procedure

Exhibit B.44 Document Inventory Form

Exhibit B.45 Vendor Manuals

Exhibit B.46 Equipment Data Form Procedure

Exhibit B.47 Manufacturers Data Report

Exhibit B.51 Documentation and Drawing Control

Our design team is fully conversant with most of the software detailed in COMPANY’s list provided in Exhibit B.13 Information Technology Requirements including, PDS, Primavera, Microstation, HYSIS and PIPESIM

Also, in order to ensure full understanding and alignment with COMPANY’s Information Management Systems, CONTRACTOR welcome COMPANY’s proposal to hold a “familiarisation” session early in the project.

5) Critical Execution Issues

Process Review and Implementation of FEED Documentation

CONTRACTOR understands that the Front End Engineering Design (FEED) deliverables were produced by International Bechtel Co., Ltd. The FEED documents were issued on the early of June 2009 during Tender Stage. CONTRACTOR’s review work will start with FEED document included in ITT and EPC Addendum issued with Tender Bulletins.

It is therefore essential to start process review of the overall design, in order to reach a firm basis for design initiation for set of PFD’s ,P&ID's, and Utility Summaries as soon as possible.

It is also essential to review the process equipment data sheets for critical, long lead equipment items, to allow the issue of equipment enquiry requisitions in a timely manner.

CONTRACTOR understands that the system designs for the EPC Addendum is in preliminary stage and conceptual design only, performed by International Bechtel Co., Ltd. Therefore they will be developed by CONTRACTOR based on the schematic information issued with Tender Bulletins. Necessary operation philosophy for those systems shall be provided in detail by COMPANY and they will be the basis of the design.

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Design for Modules

Where practicable, Bidder will consider preassembled units and prefabricated materials and equipment to minimize activities at the Work Site. Final preassembly and prefabrication plan will be prepared during the early stage of the Project and included in the overall constructability plan. Pre-assembled units and/or pre-fabrication will be considered for the following:

Package Units

Modularization of package units such as analyzer buildings, lube oil units, etc. will be considered. These modules and units will not require special transportation and handling on the Work Site, and their use will substantially reduce the work content at the Work Site.

Prefabrication for Piping

Bidder plans to prefabricate large and small bore pipe spools off plot and deliver to the WORK Site for erection. Pipe bending using high frequency induction coil will be considered when feasible under local conditions and beneficial to the overall project execution. Bidder plans to provide prefabrication shop in the Work Site.

Bidder will also consider grit blasting and painting (prime and intermediate coat) of all pipe materials and fittings prior to prefabrication. Finish painting prior to erection will also be investigated subject to Company’s approval. The painting and sand blasting facility will be located as per Company requirement.

Placement of Purchase Orders for Long Lead items

The purchase orders for equipment and materials should be placed at the earliest, most appropriate date. It is therefore essential to place orders for Critical Long Lead Equipment and materials early.

The highest priority will be given to producing equipment data sheets and issuing enquiry requisitions for key equipment and material items including:-

Tank Materials such as Shell Plates

Propylene Compressor Packages

In order to issue purchase orders for tank materials such as steel plate, tank design shall be of the utmost priority. Once process review for storage tanks to be completed at initial stage, mechanical design will be immediately followed to estimate the volume of steel plates. Based on preliminary volume of required steel plates, engineering team will issue this information to procurement team so that procurement team will initiate contact with steel plate sources.

Design freeze for the tank design will be expedited to finalise order volume of steel plate as per the procurement strategy in sequence.

Interface with Other Contractors

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The smooth "tie-ins" to interface system is a critical activity to be addressed early in the project. It will be essential to understand the requirements and factors which affect interface design such as flares, utilities, etc will be considered "high priority", when carrying out any tie-ins or "change-overs".

Tie-in lists will be developed for all disciplines (Piping/Mechanical/Electrical/Civil/C&I) identifying tie-in numbers, nature and the key documents affected. Designs for tie-ins will be reviewed with COMPANY to ensure the design and proposed installation method for the interfaces meets the project and COMPANY requirements.

6) Overall Approach to the Project

CONTRACTOR's proposal is based on executing the work in full compliance with COMPANY's ITT requirements. The work will be executed in accordance with CONTRACTOR Corporate systems and procedures for engineering activities. CONTRACTOR will produce all the necessary documents in a format consistent with the Exhibit B.13 of ITT.

CONTRACTOR will develop the 3D PDS model for Tanakage Area in PDS format and will extract layouts, plot plans, location diagrams, and isometrics from the model. Other key Engineering design drawings (PFD's ,UFD's, P&ID's,SLD's ,Structural Steel Layouts, will be produced in AutoCAD 14 or Microstation format extracted from the 3D PDS model/data base.

The Instrument data base will be developed in InTools. Bulk material MTO's will be developed from P&ID's and the PDS model, together with Electrical and Instrument schedules and cable routing layouts. CONTRACTOR will produce Mechanical Data Sheets for Equipment in Excel format in using FEED data sheet format. Enquiry requisitions for equipment will be issued based on the Mechanical Data Sheet, Project Specific Specifications and COMPANY standards.

CONTRACTOR's "EDMS" system will be used for the control and management of project documentation and be the basis on which Progress Measurement and Reports will be developed.

As the work progresses into the Construction and Commissioning phase, a Field Engineering team will be mobilised to provide technical support to the Construction team. The number and discipline of these Engineers will be based on the Construction/Commissioning activities being carried out at the time.

7) Subcontracts for Engineering

CONTRACTOR expects to subcontract the following elements of engineering work:-

Topographical Surveys and Geotechnical Investigations at the Tankage Area

Process Safety related Study by utilising 3rd Party Specialist

Dynamic Simulation, if required

Corrosion Study

Tank Fabrication Drawings

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Detail Design for Civil Works for Propylene Storage Tanks

General Drafting Services

3.5.1.2 Discipline Engineering Responsibilities and Activities

1) Health and Safety Engineering (HSE)

The HSE ‘organisation’ for the project will involve all members of the project team. First and foremost, each manager, department, discipline and individual on the project will have a direct responsibility for the HSE aspects of their own work, consistent with developing a safety-based culture for the project. They will be guided and supported in this by a dedicated team of HSE specialists in order to ensure that HSE is implemented effectively and consistently across the project.

CONTRACTOR’s project management team will include a dedicated HSE Manager reporting directly to CONTRACTOR’s Project Manager. The HSE Manager will be supported by dedicated environmental and safety specialists with assigned roles and responsibilities consistent with the overall agreed HSE activities and deliverables.

Additionally during the engineering and procurement stages a Lead Technical Safety and Environmental Engineer within the Process group will be assigned to implement and co-ordinate the Safety and Environmental aspects of the design. They will report directly to the Engineering Manager but will also have a reporting matrix through to the HSE Manager for co-ordination and completion of specific HSE activities.

During Detailed Engineering stages the HSE team will be based at Seoul office. Our expectation is that all the studies will be completed in-house with the exception of the more specialised aspects of Human Factors Engineering. The HSE team will be responsible for the following:

Identification of HSE objectives and responsibilities.

Planning and organisation of hazard identification, HAZOP and Environmental reviews, HSE studies, such as fire and gas detection layouts, flare studies and Noise Studies, and any initiatives necessary to meet the objectives, including assignment of responsibilities for HSE related actions.

Completion of study reports and other HSE deliverables to COMPANY or in support of regulatory submissions.

Working closely with Engineering, Procurement and Construction to communicate and promote HSE objectives and processes through all phases of the project.

Monitoring of HSE performance, and reporting to project management.

Identifying to project management, and implementing corrective actions.

Training and development.

Development of HSE basis of design documentation.

This leadership presence is considered critical to the effective control of the project’s HSE programme and to the ongoing implementation of hazard identification and risk

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based management processes, as well as environmental and social impact assessments across the span of the project.

We expect to work closely with COMPANY HSE representatives in confirming the scope of all HSE activities, selecting appropriate methods and procedures as specified in the ITB, and in developing and communicating HSE work instructions to the project’s engineering team.

2) Process

In the early part of the detailed engineering phase the Process Engineering team will take a lead role in firming up the design such that the project can proceed to an "approved for design" status. Once this stage is reached the process team takes more of a support role to the other engineering disciplines until the work is complete in the EPC office. When the project reaches the pre-commissioning, commissioning, and performance test phases, the process team will be a major contributor to the commissioning team.

Process Engineering will follow the methods and procedures as applied under CONTRACTOR's QA system. This includes the use of an Activity Plan which lists all activities to be undertaken by the Process Engineering discipline, the reference documents and checklists that are to be applied, and the level of checking and approval required, are included at the end of this section.

The CONTRACTOR Project Activity Models (PAMs) were developed to assist in defining the scope of work and defining the execution plan for Process activities.

The Lead Process Engineer is responsible for the technical execution of the process engineering scope of work, and for control of budget and schedule associated with the process engineering discipline. Results of the process engineering effort are communicated to the project through key communication documents such as the P&IDs and equipment data sheets. Process engineering will be working in close proximity to other disciplines on the project task force, thereby promoting good communication, and will also attend regular engineering status meetings.

The main process engineering deliverables/activities are listed below against generic work phases reflected on the Level 2 schedule.

CONFIRM/ DETERMINE BASIS

The Process Team will perform an overall Contract Scope Review and will also review and revise the Feed Design Package.

The Process Team will ensure that the remaining design basis issues, including those identified in the bid period have been adequately incorporated into the design. These requirements will be reflected in the key Process Engineering design deliverables and activities detailed below and any impact of these changes will be highlighted.

Revise and reissue Basis of Design if required

Review process simulation data

Additional Process Simulation Cases are not anticipated over those completed in FEED provided by COMPANY

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Simulation work will be reserved to as required to obtain specific additional stream data within existing cases.

Review, existing case heat and material balances with respect to equipment / instrument datasheets, line list

General plant simplified block diagram

Review PFD, P&ID’s and datasheets for inconsistencies.

Update PFD’s, UFD’S

Update Material selection diagrams

Update Relief and Blowdown Philosophy

Update Operating and Control Philosophy

Update Drainage Philosophy Update Utilities Philosophy

Update Utilities Balances

Any additional scope evolving from this phase will be reviewed for inclusion with COMPANY.

DETAILED DESIGN SCOPE OF WORK

The Process Team will then develop the FEED documents further to tailor them for the detail engineering.

The Process Team will modify the process parameters in the individual equipment/ instrument data sheets if required, based on the results of the FEED Verification Process.

During the Detailed Design Phase the Process Team will perform:-

Process calculations including Equipment sizing, Pump NPSH, hydraulic calculations

Equipment data sheets – it is planned to issue Long Lead Item datasheets at project kick off due to schedule constraints. Any modifications to design devolving after placement will be discussed separately with COMPANY.

Instrument data Sheets

Line sizing and system hydraulic checks

Process Engineering Flow Schemes

Utility Distribution

Shutdown hierarchy diagram

Provide inputs for Cause and Effect diagrams

Equipment List, (Mechanical Engineering Deliverable)

Line List

Relief and Blowdown Summary

Flare and Relief system calculations (including Flare Network Hydraulic Calculations)

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Depressurisation calculations including radiation, dispersion, back pressure, temperature including low temperature locations in flare pipework.

Input to Hazardous Area Classification schedules (Electrical Deliverable)

Inter disciplinary document / Drawing review

Review and approval of vendor documentation

Specify insulation requirements and insulation thickness

Utility summary, chemicals / catalyst summary

Preparation of a Safeguarding Memorandum

Process Safeguarding Flow Schemes (PSFS)

Participate in Startup and Commissioning Review

Commissioning Manual

Start-up, Operation & Maintenance Manual

As-Built drawings

Manuals (Vendor Documents)

Assistance with Performance Test Report (Commissioning Deliverable)

DESIGN REVIEWS

In addition, the Process Team will also conduct and participate in the design reviews consisting of:

Design Review of PFDs, P&IDs, Operating & Control Philosophies

HAZOP attendance

Execution of HAZOP action points and HAZOP close out

SIL

Operating Procedures Review

COMPANY operations attendance will be required for:

HAZID

HAZOP

SIL Review

Plot Plan Review

Constructability Review

The attendance dates can be drawn from the EPC Schedule submitted as part of this ITT in the Technical Addendum. Personnel required to attend will be agreed with concerned parties after contract award.

PROCESS STUDY AREAS

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Critical aspects of process design engineering which need special attention / emphasis include the following studies:

Dynamic simulation and/or preparation of any algorithms or other support required for dynamic simulations.

Transient analysis for multi-phase flow systems.

Hydraulic and Pipeline optimisation study - The process team will work with the pipelines team to ensure that the hydraulic and flow assurance issues associated with the operation of the various pipelines in the scope are adequately addressed

Input to Reliability and Availability Study.

NPSH available for critical pumps.

Flare, vent and blow-down studies

CONTROL AND AUDIT OF PROCESS ACTIVITIES

Validation of CONTRACTOR design data is governed by CONTRACTOR Corporate Work Instructions and Practices at the highest authority for each discipline. Within CONTRACTOR, Activity Plans are used to document the means by which preparation, execution, checking, inspection, and approval / acceptance of the various types of project deliverables and activities are to be performed, as well as the levels of personnel authorized to carry out these tasks. The Lead Process Engineer establishes the Activity Plan for use on the project by the Process Team.

Process information is defined as the information that constitute the process design represented as key deliverables such as Process Flow Diagrams with Heat and Material Balances, Process Data sheets, Piping and Instrument Diagrams, Line Lists etc. These deliverables will be checked and approved by CONTRACTOR in accordance with the Project Quality plan and issued to COMPANY. The tracking of these documents including the return of comments and approvals will be controlled by CONTRACTOR’s document control section.

The Lead Process Engineer will ensure that calculations, documents, drawings, data sheets, and other work performed by the Process Team are checked before the associated documents are issued. The extent and depth of checking required for each activity listed in the Activity Plan shall be appropriate to the importance and criticality of the work involved and will be established at the beginning of each project by the Lead Process Engineer against COMPANY norms shown below. Each activity in the Discipline Activity Plan can be linked to Work Instructions and checklists. To demonstrate this, the table below gives typical guidance for the process department on the activities to be performed on a detailed engineering project.

3) MECHANICAL

Responsibilities

Mechanical Engineering will be responsible for the engineering and selection of all mechanical equipment, metallurgy and welding within the project scope. Mechanical Engineers will be responsible for the preparation of standard drawings, mechanical data sheets, enquiry requisitions, technical bid summaries and purchase requisitions for all

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equipment. Vendor documentation will be reviewed as well as attending factory testing and engineering inspections of equipment. Mechanical Engineering will also provide support to other engineering disciplines.

The quality of mechanical engineering deliverables and activities will be controlled by an Activity Plan produced by the Lead Mechanical Engineer. The plan will detail the means by which preparation, checking and approval of the various types of project deliverables and activities are to be performed as well as the levels of personnel authorised to carry out those tasks. Regular audits of mechanical engineering activities will be carried out by the Discipline Manager or his nominee.

Organisation

Mechanical Engineering is organised into two groups: Static Equipment and Rotating & Package Equipment.

The Static Equipment group includes specialists with expertise in the following areas:

Pressure Vessels and Tanks,

Fired and Unfired Heat Transfer Equipment

The Rotating and Specialty Equipment Group includes specialists in the following areas:

Rotating Equipment (Pumps, Compressors, Turbines, and Drivers)

Specialty Process and Packaged Equipment

The COMPANY project task force will be staffed with equipment specialists from each of the above groups. Additional senior staff specialists from each group will be available to assist the task force assigned engineers in special areas of expertise on an as-needed basis.

Specifications and Standards

CONTRACTOR mechanical engineers will review COMPANY Specifications furnished with the ITT with respect to the project requirements. Addenda may be proposed to meet the project requirements and to ensure that all documents reflect current codes and practices. It is assumed that no new specifications are required for the project.

Standard drawings will be based on COMPANY Standard Drawings for vessels, heat exchangers, storage tanks, and direct-fired heaters. CONTRACTOR will review the drawings, include any comments or upgrades received from COMPANY and redraft, if required, to meet project requirements. It is assumed that the standard drawings will be available in both electronic and hard copy format.

Data Sheets

Wherever possible it is intended to use the COMPANY data sheets provided in the ITT. CONTRACTOR electronic data sheets will be used if there is no suitable COMPANY data sheet available. These electronic data sheets can be updated as necessary with project specific details and can be used for Mechanical Equipment RFQ's.

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Data sheets will be completed with sufficient mechanical and process data to allow quotations to be obtained from equipment suppliers for the following equipment items.

Storage Tank

Compressors

Pumps

Heaters

Vessels

Shell and Tube Exchangers

Mechanical Engineered Systems (Packaged Units etc)

Enquiry Requisitions

The assigned mechanical engineers will prepare and assemble the technical documents for soliciting technical proposals from suppliers/manufacturers of equipment and systems. These documents include data sheets, drawings, details, applicable project specifications, drawing and data submittal requirements, any necessary engineering notes, technical instructions to bidders and bills of materials defining scope of supply.

Technical Bid Evaluation Reports

Bids will be evaluated and short-listed to a maximum of three bidders. Each short-listed bidder will be conditioned to a compliant level acceptable to the project. Summaries of short listed bids will be tabulated on CONTRACTOR forms and include a standard array of information customary on CONTRACTOR projects for the type of equipment being reviewed. This will include confirmation of data on scope of supply, design basis requirements and compliance with project specifications and standards.

Purchase Requisitions

Purchase requisitions will be produced for all items of equipment.

Vendor Data Review

Mechanical Engineering will review vendor data for all equipment items as well as attending factory testing and engineering inspections of specific items. Metallurgy, corrosion and welding support will be provided for mechanical equipment and to other disciplines.

Long Lead Items

Fully conditioned technical bid evaluation reports will have been produced for long lead items during the bid preparation phase i.e. Propylene Compressor Package, In order to maintain the schedule it will be necessary to have approval of these reports at project kick off so that purchase orders can be placed. Any change to the process requirements will lead to schedule delay.

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Key Study Support

A mechanical handling study will be carried out but any additional equipment required as a result of this study has not been included in either the man-hour or cost estimates.

Various studies associated with the compressor packages will be carried out including a pulsation study, rotor stability analysis, machine stall analysis and machine torsional / lateral analysis. These will be carried out by approved consultants with input from mechanical engineering.

A noise study will be carried out using the data supplied by the vendors to ensure compliance with the COMPANY Standards and any other requirement as advised by COMPANY.

Materials, Welding, Corrosion and Coatings

CONTRACTOR will select materials based on using “standard” proven and cost effective materials appropriate for the service and conditions. The selected materials will be shown on the material selection diagrams.

Materials identified on drawings or other documents will be fully specified by our specialist. However, for packaged equipment, generic material specifications will be employed.

Design Reviews

The Mechanical Team will participate in the following design reviews:

HAZOP Review

Plot Plan Review

Constructability Review

Deliverables

The following deliverables will be produced by Mechanical Engineering:

Mechanical equipment data sheets for all items of equipment

Enquiry requisitions

Technical bid evaluation reports

Purchase requisitions

Material selection diagrams

4) Piping

Responsibility

Piping Engineering will be responsible for overall plant design, equipment arrangements, plot plan development, piping layouts and design utilising 3D PDS, piping specifications, standard details, piping material specifications, line list, piping speciality item list, pipe

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stress analysis, material take off and control to support procurement, support the development of the P&IDs, Perform and participate in project design reviews for the P&IDs, plot plan, Hazardous area classification, 3D Model and Buildings.

Piping Engineering will control the quality of the work on the project through the undertaking of discipline quality and technical peer review audits in accordance with the CONTRACTOR quality system.

Organisation

Piping Engineering and Design comprises the following subgroups:

Piping Design

Piping Material Engineering

Piping Material Control

Piping Stress Engineering


The COMPANY Specifications will be reviewed and modifications or addenda proposed to assure that all documents reflect current codes and practices agreed in the design basis. Lessons learned as provided by COMPANY will be reviewed for incorporation into the updated specification.

COMPANY standard details will be reviewed and modifications proposed to reflect current codes and any lessons learnt. Additional standard details will be produced as required to support any project specific requirements, to be approved by COMPANY.

Site Survey

Piping Engineering will carry out site surveys. The following are an example of the team's activities.

Review piping engineering and plant design criteria for the EPC phase of the project.

Review existing drawings and check status of existing facilities that are part of the EPC scope of work.

Review operations, maintenance and safety requirements.

Assist all other engineering discipline teams in finalising the project scope of work such as:

o Site location for equipment within the selected area for the new facilities

o Fire protection design criteria where applicable

o Drains and sewer design

Plant Design and Plot Plan Development

During EPC phase the plant design will be developed and then finalised, using piping layouts & the 3D PDS model. Piping and Mechanical engineering will work closely to determine equipment dimensional footprints for plot plan development, as required.

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Overall and Unit Plot Plans will be developed, emphasising safety, operability, maintainability and constructability , with the participation of all engineering disciplines, construction, HSE & COMPANY to achieve approved plot plans suitable for design and construction.

Piping design / layouts will be developed using 3D PDS Plant Design system which is a fully integrated system and allows other disciplines such as CSA, Electrical and Control Systems to utilise the model ensuring a totally integrated design. The 3D model is used to provide a clash free design and after clash checks and design reviews have been completed the 3D model will be updated to reflect comments / actions. Isometrics with bills of material for all lines will be generated from the 3D model and checked for content and accuracy against P&ID's and then issued for fabrication and / or erection to support construction of the facility.

Piping Tie-ins

Working with Process Engineering and COMPANY Operations piping will identify the optimum location and method of tie-in ensuring minimum Plant, Production disruption and prepare tie-in lists accordingly. The tie-in lists will indicate the tie-in number, a P&IDs drawing reference, the existing plant line number, the new piping line number and the line service. Tie-in Isometrics and location drawings will be developed that indicate the location of all tie-ins. Tie-in materials will be produced, procured and tracked ensuring that all materials required are at Site prior to work starting.

Material Engineering

Material engineering will support the development of the P&ID's and the Material Selection Diagrams which in turn will provide information for the development of material line classes, pipe wall calculations, piping special item, data sheets, line list and the reference data base used to support the 3D PDS model. Material engineering will also develop material purchase specifications and material purchase requisitions to support procurement. It is also their responsibility to perform technical bid evaluation reports on piping bulks and identify any long lead piping items. CONTRACTOR's material management system will be used to store and control material data so that it integrates with the 3D PDS model.

Material Control

Piping material control will develop material quantities provided from downloads from the 3D PDS model directly into CONTRACTOR's Material Management system. These downloads will be performed periodically to closely track materials throughout the development of the model. These bulk piping quantities will be used to develop purchase requisitions and orders to support procurement and construction. The material management system enables materials to be tracked from purchase order to delivery through to fabrication and erection.

Stress Engineering

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Stress Engineering will identify in the line list and analyse critical lines using Autopipe, taking into account equipment, flange loading and stress range to B31.3. Pipe supports will also be calculated, where applicable, and passed to Structural for review / analysis. Stress Engineering will also be responsible for identifying and specifying special engineered supports such as Springs, Snubbers and Struts and develop purchase requisitions and orders to support procurement.

5) Civil, Structural and Architectural

Responsibility

The CSA Engineering group will be responsible for the engineering design, 3D modeling, drafting, specifications, technical quality and support of construction for civil, structural, architectural and building service components of the project. The group will also participate in project design reviews for the plot plan, 3D model, buildings and constructability. CSA Engineering will control the quality of the work on the project through the undertaking of discipline quality and technical peer review audits in accordance with the CONTRACTOR quality system.

Organisation

The CSA Engineering group comprises of the following subgroups:-

Civil

Structural

Architectural

The Civil group includes specialists with expertise in surveying, geotechnics, site preparation, roads and paving, underground drainage and piling.

The Architectural group includes specialists with expertise in architectural layout and specification, heating, refrigeration, air conditioning, ventilation and plumbing.

The project task force will be staffed with specialists from each of the above groups. Additional senior staff specialists from each group will be available to assist the task force assigned engineers in special areas of expertise on an as-needed basis.


COMPANY specifications will be reviewed and any modifications or addenda proposed to assure that the project reflects applicable codes and practices in line with the ITT. We do not anticipate the need to create additional civil specifications.

As with the specifications, the COMPANY standard details as included with the ITT will be reviewed and modifications proposed to reflect applicable codes and practices and lessons learned where necessary. Additional standard details will be produced as required based on CONTRACTOR and COMPANY experience to cover the project specific requirements such as module to pile connections, steelwork connection details and anchor bolt requirements.

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CIVIL

Civil Engineering is responsible for the detailed design development of specifications, drawings and calculations for the following:

Verification of the FEED civil engineering designs.

Preparation of scope of work and specification for on-shore topographical survey and geotechnical investigation sub-contracts.

Site roads, paving and fences

Surface and Underground drainage systems, including storm water system, open drain systems and foul water systems.

Piling and Foundation Works

Special Studies-Topographic/Geotechnical Survey

In addition the extent of further Geotechnical investigations required at each of the sites will be established to verify the soil properties for pile and foundation design and to support the needs of Electrical engineering in terms of soils resistivity. Civil Engineering will be responsible for preparing the scope of work and specifications for these site investigations bringing together the requirements of all engineering disciplines. Subcontracts will then be awarded and executed to provide adequate information to engineer and construct the project.

Plot Plan Development

Civil Engineering will work with the Piping Group during plot plan development to verify the FEED requirements for grade elevations, finished surfaces and site drainage.

Roads, Paving and Fencing

Schematic finished surfaces drawings will be developed to define the extent of concrete, asphalt, crushed rock and landscaping. From these the detailed design drawings will be produced. Separate drawings will be produced covering the extensive security fencing requirements for all sites to enable this work to commence as early as possible.

Underground Service Layouts

Civil engineering is responsible for modelling all underground services in 3D including Surface Strom Water Ditches, open drains system, foul water drains, utility piping and cable trenches. The model is used to provide a clash free design that forms the basis for the detailed underground layout drawings. Prior to modelling Civil Engineering will verify the FEED designs as provided in the ITT for all underground services. In particular the levels for the gravity drainage systems need to be verified given the impact of high river levels during flood conditions.

Piling

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The pile design is a critical early activity for Civil Engineering and will be based on the findings of the Geotechnical verification investigations. The detailed design of the piles can only be finalised after the results of the geotechnical investigation are confirmed. With an agreed pile design in place Civil engineering will develop piling layout drawings for the facilities at an early stage to allow piling activities to commence as soon as practicable.

Foundation

Civil engineering will develop foundation design in accordance with the FEED documents and Geotechnical Investigation to be performed.

STRUCTURAL

Structural engineering is responsible for the detailed calculations, design drawings and specifications for structural steelwork and reinforced concrete associated with buildings, structures, pipeways and equipment foundations.

For the project, Structural Engineering will execute the following:

Plot Plan Development

Structural Engineering will work with the Piping Group during plot plan development to verify the FEED layout provided with the ITT. This will include involvement in verifying the general configuration of pipeways and modules for progressing the 3D model through to detailed engineering.

Piperacks

The piperacks will be engineered as stick built structures, with the steelwork fabricated off-site and shipped to site for erection. Structural Engineering will be responsible for the 3D modelling of the piperack structures and from these 2D GA drawings indicating connection loads will be produced for the steelwork fabricator. The structural steelwork fabrication will be subcontracted with Structural Engineering responsible for producing a scope of work and specifications. The steelwork fabricator will be responsible for producing the detailed connection designs in accordance with the GA drawing loads and standard details developed by CONTRACTOR in consultation with COMPANY.

Operator Shelters

The shelters will be engineered as stick built structures, with the steelwork fabricated off-site and shipped to site for erection. Structural Engineering will be responsible for the 3D modelling of the rain shelters and from this 2D GA drawings indicating connection loads will be produced for the steelwork fabricator. The structural steelwork fabrication will be subcontracted with Structural Engineering responsible for producing a scope of work and specifications. The steelwork fabricator will be responsible for producing the detailed connection designs in accordance with the GA drawing loads and standard details developed by CONTRACTOR in consultation with COMPANY.

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Buildings

The structural design of all buildings will be subcontracted to a buildings design specialist. Structural Engineering will liaise with the Architectural and Buildings Services (HVAC) groups to produce a scope of work and specifications for the Buildings design subcontract.

Foundations

Structural Engineering will develop foundation designs in accordance with the FEED philosophy and based on the results of the Geotechnical investigations. All foundations will be 3D modelled and from this 2D GA and RC drawings will then be developed together with rebar schedules.

ARCHITECTURAL

Architectural Engineering is responsible for developing the detailed design drawings and specifications for the non-modular buildings on the project. This responsibility also includes HVAC and plumbing requirements (referred to in some organisations as Building Services).

For the project it is intended to let the buildings design as a subcontract. Following verification of the FEED layouts and elevations for the buildings, Architectural Engineering will be responsible for updating and amending the conceptual layouts accordingly. Based on these agreed layouts they will then produce a scope of work and specifications for the buildings design subcontract. Architectural will be responsible for ensuring this subcontract is executed in strict accordance with the project requirements and ensuring any interfaces are managed. The buildings design subcontract shall cover the full architectural, structural (other than foundations) and building services scopes including electrical small power and lighting.

6) ELECTRICAL

The Electrical group is required at all stages of the project from bid estimate to client hand over of a completed process plant. They provide services for detailed engineering and design including field construction support and commissioning.

The Electrical group is capable of providing engineering and specifications of switchgear, transformer, Motor Control Centers, generators, etc. Some of the capabilities of electrical for detailed design are: development of area classification, one line diagram, standard assemblies, lighting layout, power layout (UG/AG), grounding & lightning protection, heat tracing layout, cable schedule, elementary and schematic diagram, connection diagram, and other related activities.

The Electrical group also has the capability of performing projects using Microstation, and Plant Design Systems (PDS). They also have Power System Study capabilities. Such studies include short-circuit calculation, load flow analysis, motor re-acceleration, relay co-ordination and several others

Electrical Engineering are also responsible for the development of the electrical specifications, design drawings and documents required for the project.

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Organisation

The Electrical function divides into two functions, the Electrical Engineering and Electrical Design.

Electrical Engineering has the capability to provide engineering and detailed design services such Power distribution and transmission. Development of area classification, lighting heat tracing and other related activities.

Electrical Design is capable of executing projects requiring deliverables by using state of the art automation technology.

Site Surveys

Site surveys/Data gathering will be performed for site cable routes and all off-sites areas to collect all necessary data. Electrical engineering will prepare a detailed check-list prior to any site survey. The list will be comprehensive and will combine all items identified by CONTRACTOR from the FEED documentation.

Single Line Diagrams

These are the first documents to be prepared. The overall single line diagram will include the information required to give an electrical over-view of the project including main high and low voltage feeders and sub-distribution equipment. Equipment ratings, impedances and earthing arrangements will be shown.

Detailed HV switchgear single line diagrams will be prepared and will include the data required for the specification of equipment. Typical LV detailed single line diagrams will be produced to show 400V switchgear and a typical tabulation for outgoing feeders. Details of LV loads will be shown on the associated Electrical Load Lists.

Electrical Distribution and Substations/ Switchrooms

Substations/switchrooms will be of the pre-fabricated, containerised type, fully equipped and tested before shipment to site. Testing before shipment will include the services within the substation module and hence when the substation is placed on the foundations it can be energised in the shortest possible time. Cabling connections can then be started and pre-commissioning/commissioning can commence.

Substations/switchrooms for each plant area, containing 11kV and 400V switchgear, motor control centres and ancillary equipment will be sized as required. A layout plan will be produced for each module showing major equipment.

Electrical Distribution System

The electrical distribution system at all sites will be developed and shown on plan drawings. These drawings will have the required definition for the Construction CONTRACTOR. Drawings will include Earthing, Cable routing, Lighting, Small power Cable trench details.

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Electrical Studies

The FEED documents identified a number of electrical studies which will be completed. Specifically:

Power System Studies.

CONTRACTOR will comply with the specified requirements for the Power System Study detailed in the Scope of Work, Exhibit C.1.6. The FEED study will be updated and validated.

During the detailed design stage the electrical system parameters are continually changing thus the data required for any study needs to be carefully controlled. In order to ensure the Power System Study correlates with meaningful data we envisage the studies will be performed in 2 stages:

Stage 1. Preliminary Study

The preliminary study will be performed allowing for the preliminary status of the data.

The following reviews and studies will be undertaken as early as possible during the detailed engineering phase using the preliminary data provided in the FEED documentation.

a. Review and comparison of Data model as received against FEED documentation. Significant differences between the data and FEED documentation will be identified.

b. Review of requirement for studies using ETAP Powerstation software. This suite of software is used to study electrical transient inrush conditions which occur when extensive HV cables and transmission lines also large transformers are energised. The power distribution system is such that these studies are not likely to be required.

c. Load flow. Normal system configuration also a transformer outage at each switchboard as applicable.

d. Fault level. 3-phase, Line-Earth, Phase-Phase. At each switchboard.

e. Stability Analysis/Study.

f. Harmonic analysis. Voltage harmonic waveform analysis will be performed at each switchboard. Any remedial measures required to reduce harmonics to acceptable levels will be highlighted.

As specified, a report will be issued detailing the calculations and results of the Preliminary studies. This report will confirm the equipment ratings and give confidence that the power system design philosophy is correct.

Stage 2. Final Study

This study will be performed using the model and data used for the preliminary study updated as required to reflect the final/confirmed vendor equipment data and the electrical load list. Comments from the preliminary study would also be implemented as necessary.

The final studies will be performed. A final report will be issued detailing the calculations and results of the Final studies.

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Protective Relay Co-ordination

CONTRACTOR will undertake Protective Relay Co-ordination studies in accordance with the Scope of Work. We envisage that the studies will be performed in 2 stages.

Stage 1. Preliminary study

In order to confirm the selection of the protective relays and current transformers a preliminary study will be performed. The study will consist of the co-ordination required for the Over-current and Earth fault protective relays located at the switchboard incomers and largest feeder. By confirming the selection of the relays and current transformers the manufacture of the electrical switchgear (long lead item) can continue without later modifications.

Stage 2. Final study

This study will be performed using final/confirmed vendor equipment data. The study will consist of the co-ordination required for the Over-current and Earth fault protective relays located at all switchboard incomers and feeders.

CONTRACTOR intends to use the ETAP suite of software to perform the co-ordination studies. CONTRACTOR use ETAP software to perform protection co-ordination studies hence the preliminary and final studies will be performed.

Hazardous Area drawings

Hazardous area classification drawings will be produced for all sites, as required.

Cathodic protection

Cathodic protection systems will be designed for each site and pipeline system as required. The requirements for Cathodic protection systems will be assessed during site survey and the results from soil surveys.

7) Control and Instrumentation (and Telecommunication)

Responsibility

The Control systems group is involved in every stage of a project from initiation to completion.

Control Systems deals with engineering, design, selection and application of instrumentation and control equipment hardware and software for control of plant processes and units. It involves understanding of principles for measurement of process variables and control methods for various types of plant processes and equipment.

The Control Systems group handles all detailed instrumentation and control systems engineering activities including construction engineering support, startup assistance, and PLC programming and graphics generation.

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The Engineering group has the capability to provide engineering and detailed design services such as: P&ID support, update, and review, instrument data sheets generation, instrument specifications, control valve sizing/selections, flow element sizing/selections, instrument procurement, and instrument index generation.

For detailed design, the design group is capable to execute projects requiring deliverables by using INTools and Plant Design Systems such as: PDS modeling, PDS Equipment Modeling.

Organisation

The Control System function divides into two functions, the Control Systems Engineering and Control Systems Design.

Control Systems Engineering has the capability to provide engineering and detailed design services such as P&ID support, update, and review, instrument data sheets generation, instrument specifications, control valve sizing/selections, flow element sizing/selections, instrument procurement, and instrument index generation.

Control Systems Design is capable of executing projects requiring deliverables by using state of the art automation technology.


The COMPANY Specifications will be reviewed and modifications or addenda proposed to assure that all documents reflect current codes and practices. Lessons learned from previous projects will be reviewed for incorporation into the updated specification.

COMPANY standard details will be reviewed and modifications proposed to reflect applicable codes and any lessons learnt. Additional standard details will be produced as required to support any project specific requirements, to be approved by COMPANY.

COMPANY Instrument specifications shall be utilised in order to purchase and install instrumentation and where applicable CONTRACTOR shall generate addenda to the COMPANY Specifications where non-compliances are unavoidable or where contradictions between specifications exist. The instrument index shall be developed utilising INtools. This software will allow sharing of data between process and control systems to ensure that transcribing errors do not occur.

Site Survey

Control Systems Engineering will carry out site surveys. This will be used to gather information on the existing systems and equipment. It will also be an opportunity to interface with plant operations personnel and receive input to help understand the plant operating philosophies along with COMPANY documents, and methods to identify problem areas so they may be avoided in the new design.

The field investigation will be performed by engineers who are experienced in all aspects of control systems engineering, with a special emphasis on engineers with systems integration, telecom, SCADA and DCS experience.

Control Systems will also work closely with COMPANY personnel to review the progress activities in order to meet COMPANY expectations

The following are an example of the team's activities.

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Existing DCS/ESD/Fire & Gas systems from both a hardware and software standpoint. Recommendations for upgrades will be made where appropriate.

Modifications to existing control systems. These will only be considered in those cases where the process requires common controls.

Current methods of alarm analysis and compare them with industry standard methods for analysing alarm and trip data. This survey will provide recommendations for alarm system design and alternate methods for Operations and Maintenance personnel to quickly review alarm data and resolve the problems

The interface compatibility between any newly proposed control system and existing systems; there should be a seamless introduction of the new facilities. The control system should fully support an early production scheme.

Existing metering systems and future requirements (if any).

PAS/SIS/Fire & Gas Systems

The Control System engineering activities, including telecommunications, shall be executed in accordance with COMPANY procedures utilising Project Activity Models (PAM), work instructions and check lists which shall be tailored to comply with the project specific requirements.

Senior engineers with previous systems experience will be dedicated to the project and will be responsible for supplier(s) coordination and shall act as the focal point for all technical matters and progress reviews.

In collaboration with Utilities & Offsite Contractor, CONTRACTOR will develop the DCS, ESD, FAS and MCM Functional Design.

The Category-1 System stated in the C.1.5.3 systems shall be supplied by a single Main Automation CONTRACTOR (MAC) which shall be selected based on technical compliance with the project requirements, commercial issues and a proven ability to execute this type and size of project.

The systems for the various locations associated with the project shall be designed to meet the operations requirements for that specific location in accordance with the basic concepts and philosophies included in the FEED documentation.

Telecommunications

The telecommunications systems integrator shall be responsible for the entire telecommunications system including CCTV and the public address system. The telecommunications systems integrator shall be selected based on technical compliance with the project requirements, commercial issues and a proven ability to execute this type and size of project.

A senior engineer with telecommunications systems experience will be dedicated to the project and will be responsible for supplier coordination, including interfaces with the ICS, and shall act as the focal point for all technical matters and progress reviews

8) Home Office Construction

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During the detailed engineering, a Construction Representative will be assigned to the home office. The Construction Representative will establish a formal constructability programme to provide assurance that construction requirements are incorporated in the design. These methods will include methods of construction, HSE requirements, schedule requirements, labour utilisation, cost effective methods, turnover system definition, material selection and quality plan.

Constructability reviews will include:

Input into the development of the detailed project schedules.

Review of engineering deliverables, to ensure that:

A safe and practical design which considers not only construction issues, but the efficient maintenance and operation of the facility.

The modularisation concept is maximised resulting in optimised sizes

Indentification of existing restraints.

Logistic and Infrastructure planning.

Develop systems turnover plans.

The selected design can be safely installed.

The WBS and Path of Construction are developed in conjunction with the detailed design.

The most appropriate construction techniques, equipment, methods and materials are employed.

Full consideration has been given to access requirements.

Engineering drawings and specifications are complete and complimentary to each other and are in sufficient detail to be readily understood for application by construction.

Impact to prioritising design and procurement activities.

Home Office construction activities will also include:

Performance of feasibility and rigging and transport studies.

Participation of material RAS (required at site) dates and delivery schedules.

Expedite engineering deliverables on a timely basis to meet construction needs.

Participate in Plot Plan reviews to input constructability, maintainability and operability needs.

Participate in HSE and Hazop reviews.

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3.5.1.3 Engineering Software

CONTRACTOR proposes to use the following Engineering software packages for the project:

Discipline Software Name Version Major Function Licensor

Process HYSIS V7Process Design & Simulation

Aspen Tech

HTFS V7Calculation of Heat E/H Thermal Rating

Aspen Tech

PIPESIM 2007.2 Plant Process Design Schlumberger

Mechanical API650 1.4.1Design of API Std-650 Tank

HEC

COMPRESS 6261Pressure Vessel Design System

Codeware

NASTRAN(N4W) 2005 R2 FEM Analysis MSC software

Thermoflow (GT Pro, Master, etc.)

19 Heat Balance Analysis Thermoflow

Nozzle Pro 7.5FEM Analysis for nozzle

PRG

PV-ELITE 2009Strength calculationFor heat exchanger of vessel

COADE

Piping CAESAR II 5.1 Piping Stress Analysis COADE

ElectricalPower Tools(Dapper, Captor,A-Fault)

6.5

Feeder, Raceway and Transformer Sizing Relay Coordination

SKM

InstrumentSmartPlant Instrumentation

2007

Instrument database for instrument indexes, specifications, process data, calculation, wiring, loop drawings, hook-ups

Intergraph

Structure Midas Gen 7.41General Structure Design System

Midas IT

Midas SDS 3.40Slab & Basement Design System

Midas IT

Midas Set 3.34Structural engineer's tools

Midas IT

Civil SAP2000 8.0 Structural AnalysisComputer and Structures Inc.

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Discipline Software Name Version Major Function Licensor

TALREN 2.2 Slope Protection TERRASOL

SUNEX 5.3Underground Excavation

Chun-il

SLOPE/W 7.0 Slope Stability Analysis GeoStudio

ALL-PILE 6.2f Integrated Pile Analysis Texas

GRL WEEP 2005Wave Equation Analysis of Pile driving

Pile Dynamics

SEEP/W 6.0Ground Wter Seepage Analysis

GeoStudio

AFES 3.0 Foundation Design GS E&C

3.5.1.4 ATTACHMENTS

ATTACHMENT 1 – PROPYLENE TANK GENERAL VIEW

ATTACHMENT 2 – PROPYLENE TANK CONCRETE DESIGN DESCRIPTION

ATTACHMENT 3 – PROPYLENE TANK PILE FOUNDATION PLAN DETAIL

ATTACHMENT 4 – PROPYLENE TANK PILE FOUNDATION CROSS SECTION

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3.5.1 engineering

Documents

art automation technology

flow element sizing selections

attending factory testing

tankage package

control valve sizing selections

additional standard details

stick built structures

telecommunications systems integrator