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