ORIGINATOR: DOCUMENT NUMBER:

4TH TRAIN INTEGRATED TEAM 4TPFC-400-QO0-0000-00001

PROJECT:
KARACHAGANAK 4th STABILISATION & SWEETENING TRAIN
KPO CONTRACT JOB NO: HOLDS: PAGE NO:
NO: JI-184 NO 1 OF 12
AP/M/06/0441
DOCUMENT TITLE:

FIELD PROJECT CONTROLS PROCEDURE

Revised as per rebase line schedule

3 BP IM QA/QC JS 15-01-08
& AFC drawings

2 Format revised to Approved Template RV IM QA/QC AD 05-10-07

1 PDD Comments Included RV IM QA/QC AD 08-08-07

0 Review & Comments BP IM QA/QC AD 06-06-07

REV. DESCRIPTION OF REVISIONS PREP’D CHK’D VERIFIED APPROVED DATE
 PROJECT: DOCUMENT NUMBER:
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
AP/M/06/0441 3 15.01.08 2 of 12

TABLE OF CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 PROCEDURE

6.0 DOCUMENTATION

7.0 ATTACHMENTS
 PROJECT: DOCUMENT NUMBER:
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
AP/M/06/0441 3 15.01.08 3 of 12

1.0 PURPOSE

The purpose of this procedure is to provide guidelines for implementing the Field
Project Control System successfully utilised on other major projects. The Field
Project Control System is to be a fundamental mechanism for the Project
Management Team to identify areas of concern and opportunity, and to initiate
appropriate action for the successful execution of the work.

2.0 SCOPE

2.1 This procedure applies to 4TH TRAIN SIT Karaghagnak 4th Train Construction
Project Management team.

3.0 REFERENCES

3.1 4TPFC-OOD-QO-0000-09009 Quality Plan – Construction Management

4.0 DEFINITIONS

4.1 QMS Quality Management System

4.2 PDD Project Development Directorate

4.3 WBS Work Breakdown Structure

4.4 4th Train SIT 4th Train Site Integrated Team

5.0 PROCEDURE

The key elements of the Project Control System will include:

 Project Planning & Scheduling
 Progress Measurement System
 Progress Reporting

The following software will be used for Project Control:

 Planning & Scheduling Primavera (P3.1 & 6.2)
 Spread Sheet Applications MS Excel – MS Office
 Word Processing MS Word – MS Office
 Presentations Power Point – MS Office


5.1 PROJECT PLANNING & SCHEDULING

The Construction Schedule will be a detailed network created in Primavera

(P3.1 & 6.2). Baseline shall not be modified. However baseline 2 will be made
when significant changes to CONTRACT occur and prior approval of
COMPANY is obtained.
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
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The scheduling system will be based on detailed breakdown of the scope of

work into basic measurable activities on the basis of Work Breakdown
Structure (WBS). The WBS recognises that there will be common activities
and specific activities at all levels. A common activity coding structure will be
followed throughout the Project duration for the planning and progress
reporting. Provision for Company defined Codes will be available both in WBS
and Activity ID.

The schedules will at any time reflect the total scope of work, duration and the
logic for the different phases viz.:
- Construction
- Pre commissioning, Commissioning

P3 network schedule will be updated on a Weekly basis and attached to

Report. The updation of Project Overall Schedule will be done at 4T site,

5.2 PROGRESS MEASUREMENT SYSTEM

The Project Level II Schedule together with the Work Breakdown Structure will
form the basis of the Progress Measurement System (PMS).

The WBS on which the entire Construction activities are broken down is as
follows.

Level Phase Weight (%)

I Construction Phase 100%
II Civil and Structural Works 30
II Mechanical Works 5
II Piping Works 25
II Electrical Works 10
II Instrumentation Works 8
II Telecom works 1.5
Pipe Fabrication off site 4
Insulation 5
Fire proofing 5
HVAC 5
II Tie-in 2006 & site Prep 1.5

Construction progress will be measured by calculating equivalent quantities

achieved against Construction commodities. Each Construction activity is
quantified as per the work scope from engineering drawings. Based on the
actual physical progress achieved, the site planning engineer will log in the
progress figures against defined construction stages in a data based program.
 PROJECT: DOCUMENT NUMBER:
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
AP/M/06/0441 3 15.01.08 5 of 12

The intermediate construction steps along with milestone progress for some of
the major commodities are detailed below. The actual progress of an activity
will be evaluated based on the following work steps:

Piling (Nos.):
Steps Cumulative
Description
(%) (%)
Survey & Mark pile location 5 5
Rebar fabrication 15 20
Boring 60 80
Pouring & Rebar Installation 20 100

Pilecap / Foundations (m3):

Steps Cumulative
Description
(%) (%)
Excavation 20 20
Chipping 5 25
Blinding Concrete 10 35
Rebar 15 50
Shuttering 15 65
Base Pouring 10 75
Pedestal pouring 5 80
Coating, If applicable / 5 85
Shuttering Strip
Backfill 5 90
Grouting 10 100

Building Construction:
Steps Cumulative
Description
(%) (%)
Pedestals / Columns 35 35
Brick wall / Plastering 34 69
Roof 10 79
Door / windows fixing 1 80
Flooring / Painting / False Ceiling 5 85
MEP works (Including HVAC) 10 95
Finishing works 5 100

Road:
Description Steps Cumulative
(%) (%)
PROJECT: DOCUMENT NUMBER:
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
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Excavation & Levelling 35 35

Sub base compacting 25 60
Road base compacting 25 85
Finish surface laying 15 100

Paving:
Description Steps Cumulative
(%) (%)
Excavation & Levelling 30 30
Sub base & Base compacting 30 60
Reinforcement 25 85
Shuttering 10 95
Pouring 5 100

Underground Works:
Description Steps Cumulative
(%) (%)
Excavation 30 30
Laying Pipe 55 85
Backfilling 15 100

Static Equipment Installation:

Vessels & columns

Description Steps Cumulative
(%) (%)
Install on Foundation 45 45
Alignment & Bolt-up 30 75
Install Internals, if applicable 25 100
Grouting ( By others) 0 0

Tanks
Description Steps Cumulative
(%) (%)
Install bottom plates 15 15
Install shell courses 60 75
Install roof assembly 10 85
Nozzles 5 90
Hydrotest 5 95
Insulation/Painting 5 100

Rotating Equipment Installation:

Description Steps Cumulative
(%) (%)
Install on Foundation 40 40
Preliminary Alignment: 1st Centering / 35 75
Coupling before Piping
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
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Grouting ( by others) 0 0
Final Alignment: 2nd Centering / 25 100
Coupling after Piping

Structural Steel Erection:

Description Steps Cumulative
(%) (%)
Installation on foundation 45 45
Welding / Bolt-up 35 80
Alignment, NDT 20 100
Grouting 9 (By others) 0 0

Shelter Erection:
Description Steps Cumulative
(%) (%)
Installation on foundation 45 45
Welding / Bolt-up 25 70
Alignment 5 75
NDT 5 80
Roofing & Cladding 5 85
Floor Concrete Works / Grouting 5 90
MEP Works 10 100

Piping Prefabrication:
Description Steps Cumulative
(%) (%)
Grinding / Preparation Works 10 10
Fit-up 25 35
Welding 55 90
NDT 5 95
PWHT, If applicable 5 100

Piping Erection:
Description Steps Cumulative
(%) (%)
Stringing 10 10
Fit Up & align 20 30
Welding 50 80
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
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Supports 5 85
NDT 5 90
Hydro-testing 5 95
Reinstatement/Punch List 5 100

Electrical Works:
Description Steps Cumulative
(%) (%)
Equipment / Panel Installation 40 40
Cabling 40 80
Glanding &Termination at both Ends 20 100

Electrical lighting work:

Description Steps Cumulative
(%) (%)
Lay Conduits 15 15
Lay Cables 35 50
Install fittings 20 70
Meggar / Continuity Test 10 80
Glanding &Termination 20 100

Electrical Heat tracing work:

Description Steps Cumulative
(%) (%)
Install heat tracing 70 70
Meggar / Continuity Test 10 80
Glanding & Termination 20 100

Electrical motors:
Description Steps Cumulative
(%) (%)
Lay Cables 70 70
Meggar / Continuity Test 10 80
Cable glanding & termination 20 100

Instrumentation Works: Field and Control board instruments

Description Steps Cumulative
(%) (%)
Instruments Installation 45 45
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
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Cabling from Instrument to JB 25 70

Tubing from Piping 10 80
Termination at Both Ends 20 100

Instrument Equipment & Panels Installation:

Description Steps Cumulative
(%) (%)
Support Structure/Preparatory work 20 20
Erection 55 75
Leveling 5 80
Termination at Equipment /Panel End 20 100

Electrical / Instrumentation Cables Laying:

Description Steps Cumulative
(%) (%)
Lay Cables 55 55
Install clips / cleats 15 70
Meggar / Continuity Test 10 80
Termination and Connection 20 100

Painting:
Description Steps Cumulative
(%) (%)
Sandblast & Prime Coat 65 65
Intermediate Coat 15 80
Final Coat 15 95
Touch up painting 5 100

Insulation:
Description Steps Cumulative
(%) (%)
Surface preparation 5 5
Insulation lagging 60 65
Insulation cladding 35 100

Similar milestone break-up for the other major construction activities will be
developed and progress will be measured based on the milestones / physical
progress achieved.

The progress of items will be calculated based on Substantially Completed

Quantities, as per ‘Unit’ indicated against the respective, for example:
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
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 Cable Trays (LM)

 Lighting Poles (No.)
 Distribution Boards (No.)
 Junction Boxes (No.)
 Fireproofing Structure / Equipment (m2)
 Insulation (m2)
 Lighting Fixtures (No.)
 Earthing Cable Laying / Strip Laying (LM)
 Earthing Pits (No.)
 Lighting Cables including Clamping (LM)
5.2.1 PROGRESS MEASUREMENT FOR PRE-COMMISSIONING /
COMMISSIONING

Progress Measurement for Commissioning will be based on break up into

systems and sub-systems, which will be developed at an appropriate time later
after completion of WINPCS , Pre-commissioning/Commissioning manuals and
adequate vendor information is available.

5.3 WORK BREAKDOWN STRUCTURE (WBS)

The WBS will be of 1 to 20 digits allowing the schedule to be summarised up

and down from Level 1 to 5

6.0 DOCUMENTATION

6.1 PROGRESS REPORT

4th Train SIT will provide regular and comprehensive reporting to COMPANY to
ensure that an accurate, clear and transparent status of the Project is
communicated effectively.

The reports will highlight all trends that impact the schedule and will include
detailed information of the progress of work, variations, and explanations for
slippage in schedule and the recovery plan as may be required.

The progress curves and histograms will indicate the planned cumulative
percentage progress, forecast progress and the actual cumulative percentage
progress.

There will be a descriptive report section common to all Discipline and Activities
followed by specific reports. However, attachments, tables and curves will be
Discipline specific.
 PROJECT: DOCUMENT NUMBER:
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
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6.1.1 Weekly Progress Report

A Weekly Progress Report will be submitted by Tuesday Noon with a Progress

measurement cut off as of Thursday of the previous week.

6.1.2 Monthly Progress Report

The Monthly Progress Report cut off date will be last Thursday of the Month.
The Progress report will be submitted in 10 days from the monthly cut-off date.
The Monthly Report shall include the followings:

a) Management / Executive Summary

- Executive summary (narrative)
- Milestone Status
- Updated overall S- Curve and Histogram

b) HSE report

c) QA / QC
- Highlights
- Non-conformance status

d) Construction Phase
- A narrative of the months’ events by discipline
- Progress per discipline

f) Project Controls
- Planning narrative
- Updated Level 1, 2 & 3 Schedule bar charts
- Updated progress curve & Table – Discipline wise
-Manpower Histograms
- Cost narrative
- Value of Work Done (VOWD)
- Cost Trend Register

g) Contracts
- Invoicing Register
- Variations Log

h) Areas of Concern (Part of (a) Management / Executive Summary)

- Previous Last month’s areas of concern still valid
- Current this month raised areas of concern
- Recommendation for remedial actions

i) Site progress Photographs

 PROJECT: DOCUMENT NUMBER:
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KARACHAGANAK 4 STABILISATION & 4TPFC-400-Q00-0000-00001
SWEETENING TRAIN
DOCUMENT TITLE:
FIELD PROJECT CONTROLS PROCEDURE
KPO CONTRACT NO: REV: DATE: PAGE NO:
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7.0 ATTACHMENTS

NONE