TENAGA TIUB SDN BHD CONSTRUCTION EXECUTION PLAN

Lot 41, Jalan Permata 1,

Arab Malaysian Industrial Park,
DOC. NO. : TT22102/CEP/01 REV. NO.: 0
71800 Nilai, Negeri Sembilan,
Malaysia.
DATE: 30/09/2022 PAGE: 1 OF 8 ISSUE NO.: 01

CONSTRUCTION EXECUTION PLAN

PROJECT TITLE :
ENGINEERING, PROCUREMENT, FABRICATION, INSTALLATION AND COMMISIONING (EPIC) FOR
NEW AIR-COOLED HEAT EXCHANGER REPLACEMENT PROJECT AT DERIVATIVES PLANT IN
PCDSB

EQUIPMENT / ITEM:
AKM-E-6350
(UCON REACTOR TEMPERED WATER COOLER )

CLIENT :
PETRONAS CHEMICAL DERIVATIVES SDN BHD (PCDSB)

TTSB PETRONAS CHEMICAL DERIVATIVES SDN BHD (PCDSB)

Prepared by
(Mohd Zaki) Reviewed and Approved by
(Mechanical)
Reviewed by

(CK Chow)
Reviewed and Approved by
(Inspection)
Approved by
(Jimmy Lee)

Revision History

REV DATE ISSUED REVISION DESCRIPTION

0 30 SEPTEMBER 2022 ISSUED FOR REVIEW & APPROVAL

 TENAGA TIUB SDN BHD CONSTRUCTION EXECUTION PLAN
Lot 41, Jalan Permata 1,
Arab Malaysian Industrial Park,
DOC. NO. : TT22102/CEP/01 REV. NO.: 0
71800 Nilai, Negeri Sembilan,
Malaysia.
DATE: 30/09/2022 PAGE: 2 OF 8 ISSUE NO.: 01

TABLE OF CONTENT

NO. DESCRIPTION PAGE

1.0 INTRODUCTION 3

2.0 PROJECT DESCRIPTION 3

2.1 SCOPE OF WORK 3

3.0 FIELD ORGANIZATION 4

3.1 ROLES ANS RESPONSIBILITIES 4

4.0 SITE INSTALLATION SCHEDULE 5

5.0 MATERIAL PLANNING AND DELIVERY AT SITE 5

6.0 MAJOR SITE WORK ACTIVITY 6

7.0 MECHANICAL COMPLETION OF THE WORK 7

ATTACHMENT-1 8
 TENAGA TIUB SDN BHD CONSTRUCTION EXECUTION PLAN
Lot 41, Jalan Permata 1,
Arab Malaysian Industrial Park,
DOC. NO. : TT22102/CEP/01 REV. NO.: 0
71800 Nilai, Negeri Sembilan,
Malaysia.
DATE: 30/09/2022 PAGE: 3 OF 8 ISSUE NO.: 01

1. INTRODUCTION

This Construction Execution Plan is prepared and planning by Project Department specifically for Installation of
One (1) Unit UCON Reactor Water Cooler Tube Bundle AKM-E-6350 at Petronas Chemical Derrivatives Sdn Bhd.
The objective of this Construction Execution Plan is to achieve the following:

 To outline and the execution of the installation work.

 To provide planning for the expected installation activities

 To execute construction activities according to the requirement of contract, project specification and in
accordance with the applicable engineering codes, standard, drawings, procedures.

2. PROJECT DESCRIPTION

Petronas Chemical Derrivatives Sdn Bhd is undertaking the Engineering, Procurement, Fabrication and
Installation of UCON Reactor Water Cooler Tube Bundle AKM-E-6350. This PROJECT has main objective to ensure
the new tube bundle unit is safe and reliable for continuous operation without any major failure or breakdown.

2.1 Scope Of Works

2.1.1 Fabrication

 Fabrication like to like material as per existing drawing

 Fabrication like to like on the dimension to avoid site modification during site installation

 To follow new design criteria as below :

a) To resolve gap between finn and end tube by fully finned from end to end for each tubes

b) To increase minimum tube thickness from 2.11mm thickness to 2.77mm thickness

c) Minimum design life of 30 years for headers and 15 years for tubes

d) Shall include latest edition API 661 Air Cooled Heat Exchangers for General Refinery Services

 Design shall consider maintenance and operation philosophy including spare part strategy

2.1.2 Installation of New Equipment

 Installation of new Reactor Tempered Water Cooler to the existing foundation

 Utilized existing structure support and any auxiliary system

 To avoid piping modification at site

 TENAGA TIUB SDN BHD CONSTRUCTION EXECUTION PLAN
Lot 41, Jalan Permata 1,
Arab Malaysian Industrial Park,
DOC. NO. : TT22102/CEP/01 REV. NO.: 0
71800 Nilai, Negeri Sembilan,
Malaysia.
DATE: 30/09/2022 PAGE: 4 OF 8 ISSUE NO.: 01

3. FIELD ORGANIZATION

Adequate number of site management staff and proper organization structure are crucial to ensure smooth and
efficient management at site during installation.

 For Field Organization Chart, please refer to Attachment-1 Site Organization Chart.

3.1 Roles and Responsibility

The Field Organization is led by the Site Engineer and supported by Installation Group, HSE, and QA/QC. All of the
Personnel in Field Organization is responsible for the site management, control, and integration of site activities.

3.1.1 Site Engineer

Site Engineer shall:

 Responsible to company’s successful execution of the site activities until Mechanical Completion of the
plant.

 He is responsible to monitor and control site activities daily progress and works quality.

 During construction activities, Site Engineer acts as the contractor’s official primary contact with Petronas
Chemicals Derivatives SB.

 The Site Engineer is authorized to act on behalf of the Project Manager in the latter’s absence as regards all
aspects of project management at the site.

3.1.2 Health, Safety, Environment (HSE)

The HSE personnel shall:

 The HSE Officer or HSE Supervisor is responsible to assist Site Engineer in coordination of site’s safety of
personnel, materials and equipment throughout the site installation works.

 HSE Officer and HSE Supervisor are responsible to arrange for attaining and maintain effective
communications amongst workers and management.

 The HSE Officer or HSE Supervisor is responsible to report any incident or accident to Petronas Chemical
Derivatives Sdn Bhd.

3.1.3 QAQC

The QAQC Inspector shall:

 QAQC Inspector plans for quality assurance and quality audit for every aspect during the project execution.
 TENAGA TIUB SDN BHD CONSTRUCTION EXECUTION PLAN
Lot 41, Jalan Permata 1,
Arab Malaysian Industrial Park,
DOC. NO. : TT22102/CEP/01 REV. NO.: 0
71800 Nilai, Negeri Sembilan,
Malaysia.
DATE: 30/09/2022 PAGE: 5 OF 8 ISSUE NO.: 01

3.2 Power and Compressed Air Supply

Tenaga Tiub Plan to use portable Generating Set and portable compressor for the activity that require power and
compressed air such as lighting, hot works and impact wrench for unbolting (if necessary based on Tenaga Tiub
planning) . The portable Genset and Compressor shall undergo inspection by PCDSB and having Portable
Electrical Temporary Installation (PETI) prior to operate the equipment.

3.3 Subcontracting Strategy

Tenaga Tiub shall maximize the utilization of Malaysian resources in the execution of work and where possible
shall appoint suitable qualified and skilled Malaysian subcontractor.

Work activity Scope of Work

Installation of new  Removal of inlet and outlet spool
Cooler Tube  Removal existing Cooler and accessories, wind
Bundle shield etc.
 Installation new Cooler Tube Bundle
 Re-instatement spools and wind shield

Scaffolding  Erection of scaffolding to the desired height

(by others)  Any modification required during the installation
 Standby of manpower during the installation
Crane and lifting  Provide crane for lifting activities
 Provide lifting plan and lifting gears
 Lifting of pipe spools and wind shield for removal
and re-instatement

4. SITE INSTALLATION SCHEDULE

Tenaga Tiub will develop a detail Site Installation Schedule for the installation activities. The Site Installation
Schedule shall cover the entire scope of work (site) and having a detail sub-activity and estimation time of
completion for each activity.

5. MATERIAL PLANNING AND DELIVERY AT SITE

Prior to receiving of new Cooler Tube Bundle at the site, the following planning and preparatory works shall be
carried out.

 Establish and follows Journey Management Plan to ensure smooth inland delivery of the Cooler

 Transportation schedule (Estimated Time of Arrival)

 Transport type and lashing arrangement of the new Cooler

 Laydown area at site

 Planning on the unloading at site by crane

 TENAGA TIUB SDN BHD CONSTRUCTION EXECUTION PLAN
Lot 41, Jalan Permata 1,
Arab Malaysian Industrial Park,
DOC. NO. : TT22102/CEP/01 REV. NO.: 0
71800 Nilai, Negeri Sembilan,
Malaysia.
DATE: 30/09/2022 PAGE: 6 OF 8 ISSUE NO.: 01

5.1 Site Operation Hours and Designated Days

For the execution of Construction work, the appended table shall be the operation hours. These working hours
are excluding the overtime working period for work outside the normal working hour where applicable.

Period Working Hours Lunch Break Working Days

Non-Shutdown 0800hrs to 1700hrs 1230hrs to 1400hrs Saturday to Thursday
(6 Days)
Shutdown 0800hrs to 1900hrs 1200hrs to 1400hrs Saturday to Friday
(7 Days)
1200hrs to 1430hrs Friday Only
(for Muslim workers)
Extended hrs Saturday to Friday
1900-2400 (7 Days)

NOTE:
24 Hours or 2 Shifts Working Schedule during Shutdown Phase shall be subjected to actual site requirement and
evaluation by Petronas Chemical Derivatives and Tenaga Tiub Sdn Bhd.

5.2 Acquisition of Permits

Tenaga Tiub shall obtain necessary permit for the execution of construction work. The following table is the
preliminary Permit to Work (PTW) plan for the activity. The permit application system for the Shutdown activity
will be further discussed and the actual Permit-To-Work (PTW) plan will be finalize prior to commencement of
construction.

Work Permit Action by Tenaga Tiub Action by PCDSB

Daily Site Activity CONTRACTOR will submit request for Permit will be released once safe
(Cold Work and PTW one (1) day before the date to working condition is met
Hot Work) perform the work
Critical Lifting CONTRACTOR will submit request for Permit will be released once safe
(Hot Work) PTW three (1) day before the date to working condition is met
perform the work. The lifting plan shall
attached to the permit.

6. MAJOR SITE WORK ACTIVITY

6.1 Installation of New Cooler

 Tenaga Tiub will dismantle the existing UCON Reactor Cooler Tube Bundle and install new Fabricated Tube
Bundle to the existing foundation (by bolt and nut as per existing joint). Tenaga Tiub will minimize the site
work on drilling the bolt holes by verify the existing foundation bolt and the new cooler bolt location and
orientation. If there any modification needed to the bolt holes, Tenaga Tiub will do at site. The site
verification and dimensional will be done by QA/QC inspector and installation team and verify by PCDSB
inspector.

 As per earlier plan, there is no major modification on the Cooler dimensional since the fabrication is like-to-
like basis.
 TENAGA TIUB SDN BHD CONSTRUCTION EXECUTION PLAN
Lot 41, Jalan Permata 1,
Arab Malaysian Industrial Park,
DOC. NO. : TT22102/CEP/01 REV. NO.: 0
71800 Nilai, Negeri Sembilan,
Malaysia.
DATE: 30/09/2022 PAGE: 7 OF 8 ISSUE NO.: 01

6.2 Piping Tie-In Work During Shut Down

 During Shutdown, piping will be purge and hydrocarbon free during Operation day by PCDSB.

 Tenaga Tiub will perform EIS (Equipment Isolation) at the nearest possible isolation point prior dismantle the
inlet and outlet spools.

 All requirements such as manual bolt torqueing and new gaskets has been considered by Tenaga Tiub.

6.3 Quality Control

Tenaga Tiub shall be responsible for the specified quality of the equipment and materials, the workmanship
employed in the construction work and shall establish effective quality control measures, to ensure that the
construction work is carried out in accordance with the contractual specification, codes of practice and
engineering standards.

At such respective stages are required, Tenaga Tiub shall execute inspection to ensure the quality of the
construction work in accordance with Inspection Test Plan (ITP). The inspection and test program shall identify
the applicable code and standard, specifications for each inspection and testing category, witness and approval
classification of inspection, hold points, manner of application for inspection and testing and also the specified
form of quality records.

6.4 Inspection Procedures, Witness & Approval

A comprehensive check sheet of Inspection and Test Plan (ITP) will be prepared shall include all witness and hold
points for PCDSB inspection representative.

7. MECHANICAL COMPLETION OF THE WORK

CONTRACTOR will perform all the relevant system testing and inspection in accordance with the guideline, which
applicable, stated in ITB document. The following testing and inspection, but not limited to, will be perform to
conform to the MECHANICAL COMPLETION Work.

 The installation of new Cooler

 Inspection of overall condition of Cooler after installation

 Alignments of the piping spools to the Cooler nozzle

 Bolt torqueing inspection by JIT

 Punch List Closure

 Housekeeping
 PROJECT: TT22102
ENGINEERING, PROCUREMENT, FABRICATION, INSTALLATION AND COMMISIONING (EPIC) FOR NEW AIR-COOLED HEAT EXCHANGER
REPLACEMENT PROJECT AT DERIVATIVES PLANT IN PCDSB

Attachment - 1

General Manager

Yeng Yi Kye
012-333 3073
kye@tenagatiub.com.my

Project Manager
Project Manager
Mohd Zaki
019-318 3085
zaki@tenagatiub.com.my

Engineering Head QAQC Manager Procurement Head Production Head (Shop) HSE Personel (Site)

Jonathan Har Chow Chee Keong Ijay Ngan Zaihasrin binti Zakaria Nur Sharun binti Ahmed Khairuddin
016-599 3089 012 - 334 9887 012 - 357 3988 013-399 8017 011-2429 2900
johnathanhar@tenagatiub.com.my cheekeong.chow@tenagatiub.com.my ijay@tenagatiub.com.my erin@tenagatiub.com.my nur.sharun@tenagatiub.com.my

Lead QAQC Site Engineer

Ahmad Zulfadhli bin Mokhtar Wan Mohd Zailani bin Wan Hasan
013 - 665 5958 019-604 3323
ahmad.zulfadli@tenagatiub.com.my zailani@tenagatiub.com.my

Designer QAQC Inspector (Site) Site Supervisor

Nurul Syahidah binti Abu Bakar Muhd Zairul Azizi
016-442 3370 013-979 9590 Mohd Rabbani
nurulsyahidah@tenagatiub.com.my zairul.azizi@tenagatiub.com.my 017-307 1794

Mechanical Team Rigging/ Lifting Scaffolding

1. Fitter 1. Signalman 1. Scaffolder
2. Semi Skilled 2. Rigger 2. Scaffolding Inspector
3. Joint Maker/ JIT team
 Doc. No. F/OHSMS/JMS-001
JOB METHOD STATEMENT
Revision 0.0
CUSTOMER PROJECT CODE NAME OF ACTIVITY / JOB TITLE
PETRONAS
ENGINEERING, PROCUREMENT, FABRICATION, INSTALLATION AND COMMISIONING (EPIC) FOR NEW AIR-
CHEMICAL
TT22140 COOLED HEAT EXCHANGER REPLACEMENT PROJECT AT DERIVATIVES PLANT FOR PETRONAS
DERRIVATIVES SDN
CHEMICAL DERRIVATIVES SDN BHD
BHD
PREPARED AND REVISED BY REVIEWED BY APPROVED BY (PCDSB)
Mohd Zaki JIMMY LEE
30/09/2022 30/09/2022

No. Activities/Sequence of work Pic/ Action Party Remarks

Tools and equipment(genset and compressor) shall be

1 Mobilize to site and tools laydown at work area TTSB
located at designated laydown area as agreed by PCDSB

Transportaion and lashing procedure shall be submitted

2 Unloading New Air Finned Cooler AKM-E-6350 at designated laydown area TTSB
to PCDSB for approval before transport to site

3 Blinding and remova lof instrument (LOTO) as per EIS list provided by PCDSB PCDSB/TTSB Blinding as per EIS

4 Unbolting of inlet and outlet nozzle at header box TTSB By manual or inpact wrench

Lifting and removal of inlet and outlet spools by lifting and store at designated Lifting by using crane, lifting procedure and lifting plan
5 TTSB
laydown area shall be approved by PCDSB
Scaffolding erection for accessability to wind shield at top of the Cooler Bundle Scaffolding Temporary scaffolding to access bracing bolt and nut at
6
Frame Contractor wind shield
Removal and lifting of wind shield and store at designated laydown area by using Lifting by using crane, lifting procedure and lifting plan
7 TTSB
crane shall be approved by PCDSB
By manual or inpact wrench. Bolt and nut located at the
8 Unbolting Cooler to Fan Ducting studbolt TTSB
cooler bundle frame
To perform measurement (distance) for each frame bolt
Re-confirm measurement of bolt holes (existing foundation versus newly
9 TTSB to avoid mis-allignment of the new cooler at existing
fabricated Cooler frame bolt holes)
foundation
Dye penetrant test (DPT) on the existing lifting lugs to unsure no defect on the To identify any defect at weld lifting lugs weld joint and
10 TTSB
welding. Witness by PCDSB representative repair (if any)
Scaffolding
11 Scaffolding dismantle at the wind shield for lifting accessability
Contractor
Lifting by using crane, lifting procedure and lifting plan
12 Lifting and dismantling of existing Cooler and store at designated laydown area TTSB
shall be approved by PCDSB

13 Gasket face cleaning at new fabricated Cooler prior installation by power tool TTSB

Lifting and installation of new Cooler by using crane to the existing cooler bundle Lifting by using crane, lifting procedure and lifting plan
14 TTSB
foundation shall be approved by PCDSB

Re-instatement of stud bolt and nut to the new cooler foundation and manual bolt
15 TTSB
tightening
Workers shall not step on the fin tube to avoid damages
16 Re-instatement of existing wind shield TTSB on the fin. TTSB shall prepare temporary platform
(plywood)
Lifting by using crane, lifting procedure and lifting plan
17 Re-instatement of existing inlet and outlet spool by using crane TTSB
shall be approved by PCDSB

18 Inlet and outlet nozzle bolt tightening by using manual torque wrench TTSB The torque value shall be obtain from PCDSB

19 Joint Inspection (JIT) at all nozzle joint and foundation bolt PCDSB/TTSB

20 Final inspection before hand-over with PCDSB PCDSB/TTSB

TTSb shall standby manpower if any leakage during

21 Commisioning and test run PCDSB
commisioning/start-up

22 De-mobilization of manpower, tools and equipment TTSB