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working at site at the peak of construction (figure 5).
Quality Control
The EPC Contractor along with its construction
subcontractors and with the active participation of the
PMC and Borouge were successful in breeding a
culture of high quality standards, through some
essential initiatives, including checking of piping
internals with boroscope (figure 6), large use of
microscope to detect impurities, stringent audits and
zero tolerance policies.
The level of welding defects at site was a clear example
of the results achieved: the weld repair rate was
significantly lower than the normal industry standards.
Constructability SIMOPS (SIMultaneous OPerationS) Fig. 6 - Quality checks
on equipment
Detailed constructability studies were carried out The introduction of hazardous substances like internals
during the beginning phase of the project in the most hydrocarbons, in five adjacent process Units at different
critical activities, like underground works and heavy lifts stages of the project, requires advanced detailed Fig. 7 -
(figure 7). The proper implementation of this tool, analysis to prevent any possible accident, putting in Constructability
involving construction knowledge and experience in place all the necessary countermeasures to allow studies for installation
planning from design to startup stage, resulted to be construction, commissioning and start-up activities to of main equipment
fundamental to plan the most efficient and effective be carried out simultaneously in the same area.
sequence of erection during the subsequent The SIMOPS (SIMultaneous OPerationS) assessment
construction works. was conducted through several dedicated
The site activities were also subject of regular “cold eye interdisciplinary (commissioning, construction, site
review” carried out by senior representatives of both HSE) meetings. The mitigation actions identified in the
joint venture partners organization, with wide SIMOPS assessment meetings were continuously
experience in construction and commissioning of large reviewed, and the implementation progress was
packages. The goal of this review was to ensure proper monitored by site HSE together with PMC and Borouge
proceeding of the EPC activities, especially in light of representatives, party releasing any Permit to Work in
their past performances on similar projects, and to the area affected by hydrocarbon.
minimize the risk of deviating from the right pace of All the resulting HSE hazards have been assessed and
required progress. appropriate control levels have been implemented to
Industrial Plants - May 2015
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