Monday, June 29, 2015

Scope Matrix for Execution of Alumina Refinery Projects on EPC Contract Methodology

Hi Friends,

All of us are aware that each and every Alumina refinery is tailor made because of changes in processes, equipment and facilities because of variation in quality of basic input raw materials. Thus, generally Basic engineering & Process technology supplier, Detailed engineering consultants, equipment suppliers and of course the Project owners are involved in execution of Alumina refinery projects. In the recent past, some changes in execution methodology for Alumina refinery projects have been distinctly observed. 

These days, project owners across the globe are approaching various design, engineering and construction agencies to carry out execution of Alumina refinery projects on EPC basis. This methodology has its own advantages like single point responsibility, less involvement of project owner and remote chances of schedule & cost over run for the project. But capex may be little high because of loading on prices by EPC Contractor for their efforts in execution of project such as procurement of equipment & facilities from different sources and appointment of various agencies for inspection, quality control, safety, security and other associated activities within as well as outside the premises of project site. 

In present post, we are presenting the major responsibility matrix with indicative scope of services of EPC Contractor and The Project Owner for successful execution of green-field Alumina refinery project as tabulated here under-
  RESPONSIBILITY MATRIX FOR EXECUTION OF ALUMINA PROJECT ON EPC BASIS

S.No.
Activity Description
EPC Contractor
Project Owner
Remarks
1
Feasibility Study Report

Owner to provide data pertaining to hydrological, meteorological, geological, estimated ore reserves, bauxite quality specifications with range including available infrastructure in the vicinity of proposed site.
2
Technological Testing Report for characterization of Bauxite

Owner to provide, hard groove index of bauxite, digestion conditions, residue settling characteristics and other associated figures derived from quality specifications with detailed test results and conclusions.
3
Project Clearances

Owner to provide land acquisition status, site details with topography, EIA / EMP reports, consent for establishment, safety assessment and fire rating.
4
Geological Survey Report

Preliminary exploration and Detailed exploration reports.
5
Basic Engineering

Design basis, process description, PFDs, P&IDs, equipment List, motor list, data Sheets, MSDS, utility requirement, plot plan, SLD, list of packages, details of DCS with control philosophy, design drawings for tailor made equipment and tankages, list of instruments & controls, specifications for critical equipment, pollution control equipment, 3D piping drawing upto pipe size of 50 mm and more including instruments and other details as per scope for Basic Engineering.
6
Detailed Engineering

Development of general layout of plant, area-wise equipment arrangement drawings, technical specifications for equipment & facilities including utilities & services, SLD for MRDS & MCCs, construction drawings for civil, architectural & structural buildings, pipe & cable racks, roads, drains, environment & safety equipment, all foundation drawings, cable routing diagrams, firefighting system, 3D piping drawings incorporating utilities & services, equipment for maintenance workshop, water supply & distribution network, erection tenders for civil, architectural, structural, electrical, instrumentation and control work and other LSTK packages plus other work as per scope for detailed engineering.
7
Development of General Layout of Plant.

Starting from raw material unloading, handling & storage to storage and loading of products including all processing, utility & services facilities and Land escaping.
8
Construction Drawings

Construction drawings for all civil buildings including boundary wall, Main gates, foundations for footings of Pipe racks, footings for PEBs and operating platforms.
9
Site Preparation

Marking location of plant units and offices depending on topography of land, geotechnical study reports.
10
Temporary Construction Facilities

Temporary office space for Client as well as Contractor officials, communication equipment, arrangement for supply of construction power and construction water, Labour sheds and stores.
11
Fabrication drawings

Fabrication drawings of tanks with nozzle orientation and Fabrication drawings for pipe racks.
12
Structural buildings

Fabrication and erection drawings for Structural buildings and ware houses.
13
Cogeneration Plant
Only system design drawings to be provided by Owner and detail drawings to be developed by contractor.
14
Design, Fabrication and erection of non-standard equipment


15
Installation of Piping network


16
Design for electrical power receiving and distribution system.


17
Erection of PCC & MCCs


18
Electrical and Control Cables


19
Distributed Control System


20
Installation of all instruments & controls


21
Laboratory Equipment


22
Effluent Treatment Plant


23
Sewage Treatment Plant


24
Construction of Office buildings


25
Fire Fighting System


26
Plantation and development of greeneries


27
Preparation of Operation manuals



28
Preparation of Maintenance Manuals


29
Supervision during testing & Commissioning


30
Stabilization of plant operation


31
Supply of Commissioning Spares


32
Establishing plant performance guarantee parameters


33
Submission of ‘As Built’ drawings

‘As built’ drawings for entire plant within the premises to be prepared and submitted by contractor.














































The above stated scope matrix is for reference only which is also applicable for brown-field expansion of Alumina refinery and other industrial projects to be executed on EPC basis. These are just the guidelines and the same may be further elaborated on case to case basis.

Trust, our friends of Bauxite-alumina-aluminium fraternity will find this article useful more specifically while freezing & finalizing the scope of EPC contract. We will welcome your remarks and comments for further improvement by incorporating your valued suggestions, if any, at our end. Please feel free to put your remarks under "Comments" provided below each article published on this unique technical blog.
Regards.

Rajendra Kunwar
rajendra@ceti.co.in
www.ceti.co.in


3 comments:

  1. Nice post! Thanks for the post, I will look forward to see more posts from your blog. Zhejiang Yaang Pipe Industry Co., Limited is a leading manufacturer and supplier of Stainless Steel Flanges

    ReplyDelete
  2. Dear Sir,

    We are from Hyderabad.

    Our client has fluffy aluminium from medicine packaging.

    They are looking to manufacture Sodium aluminate.

    Please advise on How you can help and Where can they find buyers. My E-mail ID is info@grinva.com.

    Is there any other high value addition to this product.

    ReplyDelete
  3. Hi,
    If interested in putting of Aluminate, Hydrate / Alumina plant: please contact us at rajendra@ceti.co.in
    Regards.

    Rajendra Kunwar
    www.ceti.co.in

    ReplyDelete