5th GAS TRAIN PROJECT PREQUAL PREQUALIFICATION IFICATION QUESTIONNA QUESTIONNA IRE FOR ENGINEERING, PROCUREMENT AND A ND CONSTRUCTION (EPC) BIDDERS Rev.
Date
00
3-Nov-2012
01 02 03 04
Descript ion
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION PREQUALIFICA TION QUESTIONNAIRE
Table of Contents Descri Descri ption
Page Page No.
1.0
Introduction
3
2.0 3.0
5 7
4.0
Overview Engineering, Procurement and Construction (“CONTRACTOR”) Responsibilities Pre-Requisite for Prequalification
5.0
Instructions to Companies Registering for Qualified Bidders List
10
9
Documents Required: CONTRACTOR CONTRACTOR Declaration
13
FACT SHEET
15
Attachment No. 1 Contractor Information Information
17
Attachment No. 2 Experience
21
Attachment No. 3 Resources
22
Attachment No. 4 Financial
29
Attachment No. 5 Project Execution
31
Attachment No. 6 Quality Management
33
Attachment No. 7 Health, Safety and Environment
34
Forms, Tables and Exhibits Form-1 : Experience World-Wide
35
Form-1.1 : Experience World-Wide Summary
38
Form-2 : Contractor Reference Inquiry
39
Form-3 : Contractor Safety Performance
41
Exhibit A : Minimum PQ requirement for Bidder
47
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION PREQUALIFICA TION QUESTIONNAIRE
Table of Contents Descri Descri ption
Page Page No.
1.0
Introduction
3
2.0 3.0
5 7
4.0
Overview Engineering, Procurement and Construction (“CONTRACTOR”) Responsibilities Pre-Requisite for Prequalification
5.0
Instructions to Companies Registering for Qualified Bidders List
10
9
Documents Required: CONTRACTOR CONTRACTOR Declaration
13
FACT SHEET
15
Attachment No. 1 Contractor Information Information
17
Attachment No. 2 Experience
21
Attachment No. 3 Resources
22
Attachment No. 4 Financial
29
Attachment No. 5 Project Execution
31
Attachment No. 6 Quality Management
33
Attachment No. 7 Health, Safety and Environment
34
Forms, Tables and Exhibits Form-1 : Experience World-Wide
35
Form-1.1 : Experience World-Wide Summary
38
Form-2 : Contractor Reference Inquiry
39
Form-3 : Contractor Safety Performance
41
Exhibit A : Minimum PQ requirement for Bidder
47
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1.0
INTRODUCTION This prequalification procedure and attached documents are presented by Kuwait National Petroleum Company (“KNPC” or “Owner”), for the purpose of establishing a list (“Qualified Bidders List” or “QBL”) of qualified Engineering, Procurement and Construction Contractors (“CONTRACTOR”) for the KNPC 5th GAS TRAIN Project (“Project”) to be constructed in the State of Kuwait.
This project is to cater for associated gas and condensate from KOC gathering centers at South East Kuwait (SEK), and north Kuwait (NK) oil fields. In addition, existing refinery gases from SHU AGRP and MAA AGRP are also supplied to the GT5 facilities. Current/Future non-associated gas from the Jurassic and Dorra gas fields are also considered in the design cases.
Submission of the required prequalification information by the CONTRACTOR shall in no way bind the Owner to invite any of the CONTRACTOR submitting qualifications to enter into any contract and shall also not bind the Owner to make any financial commitment in connection with any individual projects within the overall Project. The information contained in this document and attachments is strictly confidential and all companies submitting for qualification are required NOT to divulge the contents to any third party.
The Owner, likewise, shall treat information submitted by the CONTRACTOR as strictly confidential and will not make it available to any third party except to its Partners and/or Consultants where the Owner deems it appropriate and applicable.
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The selection of companies to be compiled on the QBL shall be based on specific selection criteria which is solely determined by Owner and shall be applied equally to all CONTRACTORs responding to this letter. Final selection of contractors contractors to be on the QBL will be approved by Owner and shall be solely at Owners discretion. Bid Basis: Basis : The EPC Package will be tendered on Lump Sum Turnkey basis and will be issued by the Kuwait Central Tendering Committee (CTC).
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2.0
OVERVIEW 2.1 KNPC currently owns and operates three refineries in the State of Kuwait; Kuwait; Mina Al Ahmadi (MAA), Mina Abdullah (MAB), and Shuaiba (SHU) Refineries, all located along the coastal zone south of Kuwait city, and within approximately 10 kilometers distance apart overall. 2.1.1 The Fifth Gas Train Project at MAA Refinery is designed to process associated gas and condensate from KOC gathering centres at South East Kuwait (SEK), and North Kuwait (NK) oil fields. In addition, existing refinery gases from SHU AGRP and MAA AGRP are also supplied to the GT5 facilities. Current / future non-associated gas from the Jurassic and Dorra gas fields are also considered in the design cases. 2.1.2 GT5 will have a design capacity capacity of 805MMSCFD 805MMSCFD gas and 106.3MBPD external condensate, in addition to the condensate produced in the NGL recovery section of the process. Product recoveries should be at least 75% Ethane, 97% Propane and 99% Butane. 2.1.3
GT5 shall be located at the south of GT4. Inside Battery Limit (ISBL) design of GT5 containing the main process units is to be a replica of the Fourth Gas Train (GT4) design; Outside Battery Limit (OSBL) design shall be based on the FEED developed by M/s AMEC.
2.1.4 Under OSBL of GT5, a Fuel Gas Treatment Unit (FGTU) with maximum operating capacity of 94MMSCFD is included to provide treated fuel gas for both GT5 and GT4. Amine solution (45wt% MDEA) is used to remove H2S in fuel gas. A Sour Water Stripping Unit (SWSU) is provided to strip out H2S in sour water. The stripped H2S gas is sent to existing / future SRUs along with H 2S from FGTU. A Demineralised Water Plant is also provided to produce Demin water and Boiler Feed Water (BFW) for GT5. The above OSBL units will be located adjacent to and south of the ISBL units inside GT5 block. 2.1.5
Under Utilities, Utilities, GT5 GT5 shall be provided with a flare system system for for pressure relief and depressurizing. The flare will have an acid gas flare line flowing independently to the GT5 flare stack and a separate flare tip for this stream.
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Other utilities to support the GT5 includes de-aerator, boiler feed water pumps, boiler feed water dosing system, HP and LP steam system, sea water cooling, closed cooling water system, closed cooling water chemical dosing, instrument and plant air system, nitrogen system, effluent system, waste water sump and pumps. The GT5 DCS controls will be executed from Gas Plant Central Control Room (GPCCR). A fire alarm and protection system will also be provided for the GT5. It will be integrated with existing system at the GPCCR and Fire Station. There will be Fire Siren / Public address system in the plant area and in all buildings. Electrical, Instrumentation, Civil & Structural works and Tie-ins with the existing facilities shall also be required for GT5. 2.1.6
Mixed phase feed gases received from KOC are separated in feed separator, compressed (by gas compressors driven by gas turbines) and cooled before routing to dehydration section. In dehydration section, moisture is removed. Traces of mercury is removed in mercury guard bed. Natural Gas Liquid (NGL) is recovered from the feed gas which involves expansion of the gas through turbo-expander followed by distillation in a Demethaniser column. The gas exiting De-methaniser column is cooled, compressed and then routed to ethane recovery unit (ERU) / fuel gas system. The recovered NGL stream, condensate stripper bottom and LPG processed through a fractionation train consisting of three distillation columns in series: a De-ethaniser, De-propaniser and De-butaniser. The overhead product from Deethaniser is Ethane (C2) and the bottom is fed to the De-propaniser. The overhead product from De-propaniser is Propane (C3) and the bottom is fed to the De-butaniser. The overhead product from De-butaniser is a mixture of normal and iso-Butane (C4), and the bottom product is Kuwait Natural Gasoline (KNG). The Propane and Butane products are sub-cooled and then routed to respective product treatment units for removal of sulphur compounds viz., H 2S. The purified Propane and Butane are cooled in a refrigerant cooler and sent for storage. Propane refrigeration system shall be provided as the main cooling duty to liquefy C2 and heavier components and C3 / C4 storage. A deep refrigeration system also shall be provided for Propane product cooling down to -49 O F (45 O C).
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3.0
ENGINEERING, PROCUREMENT AND CONSTRUCTION (“ CONTRACTOR” ) RESPONSIBILITIES
3.1 The CONTRACTOR’s scope of work for the Project shall be clearly stipulated in the Tender documents. 3.2 The FEED prepared by consultants will be issued to the bidders and to be endorsed by them. The important aspect of the design of the new system shall be to cause minimum disturbance and to ensure that the operation of the existing system is not stopped during implementation of the new design. Towards this extent, the new facilities shall be completed and commissioned before the existing system is shut down for the revamp works. 3.3 However, in general the scope of work for CONTRACTOR shall include, but shall not be limited to the following: 3.3.1
Detailed engineering for the various units and facility segments as listed above.
3.3.2
Prepare and issue Issued For Construction (IFC) drawings to site along with illustrating all tie-ins to the existing utility and offsites facilities as required.
3.3.3
Engineering, procurement, inspection, supply, transportation, unloading at the Project site, construction, installation and testing of all new equipment, machinery and materials including proprietary equipment and long lead equipment in accordance with the contract documents and requirements.
3.3.4
Engineering, procurement, inspection, supply, transportation to the Project site, unloading at site, installation and testing of all field instrumentation, Control Systems, ESD and Electrical equipment.
3.3.5
Procurement, inspection, supply, transportation to the Project site, unloading of capital, operational and startup spares (to include the supply
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of spares and special tools for the construction, pre-commissioning and commissioning activities). 3.3.6
Liaison with KNPC and Kuwait statutory authorities regarding obtaining any and all permits required in the execution of the Project.
3.3.7
Demolition of facilities including disposal of all debris and unusable materials
3.3.8
Full and complete erection / construction, testing / inspection, and mechanical completion of the plant.
3.3.9
Tie Ins to existing facilities, where required.
3.3.10 Preparation of the required detailed operating / technical manuals. 3.3.11 Supply and loading of first charge of oil and chemicals, as seen necessary. 3.3.12 Implement a quality management program to provide procedures for engineering, procurement, construction and commissioning which meet the Project and ISO 9001 quality system requirements. 3.3.13 Provide an inspection and quality management program which shall ensure that all equipment and materials meet the requirements of the project and that all construction activities are inspected and tested as required by the quality management program. 3.3.14 Implement and comply with all local regulations on health, safety and environment in the design and the execution of the works and maintain an effective safety plan on site during construction, precommissioning, commissioning and start-up of the projects. 3.3.15 Conduct HAZOP and other similar studies for the projects in association with the chosen Licensors and Owner. 3.3.16 Implement and maintain an effective, well established and approved planning system for the control and scheduling of all activities and
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development of reports to Owner in accordance with the requirements of the Project. 3.3.17 Provide assistance and coordinate with Owner, Licensors, and Vendors during commissioning, start-up and performance testing of plant. 3.3.18 Provide required services of vendor representatives and specialists for critical or specialized activities during construction, precommissioning and commissioning as deemed necessary by Owner. 3.3.19 Carry out any warranty or guarantee obligations during the maintenance guarantee and / or warranty periods. 3.3.20 Provide Owner with all electronic files (computer files) of drawings and documents of the plant. 3.3.21 Supply and erect materials or equipment and perform any engineering work which is deemed necessary to fulfill any process and safety requirements or environmental and governmental regulations. 3.3.22 Carry out the final EIA study, perform the necessary marine / environment monitoring during the Project implementation and obtain K-EPA approval. Contractor shall engage K-EPA approved consultant as advised by the Owner. 3.3.23 FEED documents utilizes both SHELL DEPs and KNPC Engineering Standards. Same logic shall be utilized for preparation of Engineering documentation during Detailed Engineering. 4
PRE-REQUISITE FOR PRE-QUAL IFICATION 4.1 Only those contracting companies that have successfully executed major EPC Projects in Refinery, Petrochemical, Oil & Gas (New/Upgrade/Revamp Projects) including GAS Projects worldwide over the past ten (10) years shall be considered.
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4.2 Consortiums and / or Joint Ventures are acceptable, however the same will be evaluated indivdually. 4.3 Please note, it is the Owner’s sole decision to determine whether or not the prequalification
information
submitted
by
CONTRACTOR
is
acceptable.
Furthermore, it is the Owner’s sole decision as to whether or not a CONTRACTOR submitting interest and information as specified in this document will be placed on the QBL. 4.4 See Exhibit A for the Minimum Pre-Qualification Requirements for Bidder.
5
INSTRUCTIONS TO COMPANIES REGISTERING FOR QUALIFIED BIDDERS LIST 5.1 All documents, lists, certificates and information required from the company must be in the English language. 5.2 All prequalification documents shall be treated with strict confidence by the Owner in assessing the suitability of CONTRACTOR for the above mentioned work. Any prequalification documents submitted after the closing date shall be disregarded. 5.3 It is important that all information requested be presented in an orderly and sequential manner using the formats and tables attached to this inquiry document wherever and whenever provided. 5.4 CONTRACTOR agrees that the Owner shall have the right to contact any reference given by the CONTRACTOR in support of answers to this questionnaire. 5.5 CONTRACTOR shall complete the “ Fact Sheet” and submit it with the questionnaire. The Fact Sheet, although it contains some repetitive information, is a required document for the screening process and shall be completed in its entirety. The Fact Sheet shall be submitted by the CONTRACTOR. 5.6
CONTRACTOR must complete and answer each and every question, in full clarity, in the same sequence as presented in the pre-qualification document. A company’s
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request for inclusion onto to the Qualified Bidders List will be subject to disqualification if the documentation and information requested by Owner is not submitted as stipulated, is not fully answered, or if any section is inappropriately left blank in the forms or tables. Disqualification may also occur if, for any reason, cross references given in these forms or tables are missing or incomplete, information or documents requested documentation are shared, copied, compared, or discussed in any way with other companies. 5.7 In the event prequalification information is not submitted in full clarity, Owner is under no obligation to proceed with clarifications with the CONTRACTOR. 5.8 CONTRACTOR is requested to electronically complete the forms and tables included or attached to these documents while maintaining the same format. 5.9 All information submitted by the CONTRACTOR must be accurate, clear and within the context of the form submitted. Any information found to be misleading or ambiguous shall be considered as void. Owner reserves the right to discard any unclear information provided by the CONTRACTOR if found in doubt. 5.10 Contractor shall submit clearly in his PQ Application, all evidential documents relevant to his experience in such particular field with all possible details such as; Contract Value, Completion Certificates, Letters of Appreciations, Experience World-Wide, Safety Records (minimum past Five Years), Claims & Suits, Latest Three years Financial Audited Statements, Brief Scope of similar executed Projects and Durations as well. 5.11 Owner will require that minimum twenty percent (20%) of the work (P + C) be awarded to the local Kuwaiti contracting and/or supplier sector. CONTRACTORs shall take this into account during the prequalification documentation preparation. 5.12 CONTRACTOR shall understand the Project descriptions and relevant contract conditions are exclusively for prequalification purposes only. The prequalification documents are not and should not be construed as an Invitation to Tender. Replies to the prequalification questionnaire are deemed to be without obligation whatsoever on the part of the Owner.
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5.13 The Owner is under no obligation to prequalify any CONTRACTOR or to give reasons for either prequalifying or disqualifying any CONTRACTOR. The Owner is also under no obligation to proceed with the contract or invite a prequalified CONTRACTOR to submit a subsequent bid or to enter into any correspondence to this effect. 5.14 Responses to the prequalification questionnaire shall be submitted in two (2) original, single bound documents completed in all respects and duly signed and stamped by the CONTRACTOR’s authorized person only . These must be submitted in sealed envelopes, marked “PREQUALIFICATION DOCUMENTS – KNPC SHFP” and addressed and sent to : ITC Reception Desk, Room # 1A-046, 1st Floor, KNPC H.O., Ah madi – K uw ait. Fax : 00965 23986262 (ITC, Secretary) 5.15 In addition to the above submitted bound copies and included in the same sealed envelopes shall be a CD / DVD that contains the files in a logical sequence of ALL submittal documents. These electronic files shall be in either MS Office Program(s) format (e.g. MS Word / Excel) or as a “PDF” file accessible by Adobe Reader 6.0. 5.16 Queries if any, regarding the Project or other information given herein, shall be addressed to: Chairman, 5th GAS TRAIN Project PQ Committee Mina Abdullah Projects Building 1st Floor, Manager Projects II office P.O. Box 69, Safat Kuwait 13001 Fax: 00965 23280619 and/ or e-mail to :
[email protected]
5.17 CONTRACTOR to complete, sign Declaration” on the following pages.
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and
submit
the
“CONTRACTOR
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
Pre-Qualification Questionnaire for CONTRACTOR For 5th Gas Train Project CONTRACTOR DECLARATION To:
Chairman, Internal Tendering Committee (ITC) KNPC
Full Name of Contractor:_______________________________________________ We, the undersigned wish to participate in prequalification for CONTRACTOR for the Project to be established in the State of Kuwait and we warrant our competence to execute the entire work to the highest levels of professional standards. We also warrant that our presented answers are complete to the best of our knowledge and that the details submitted by us in these prequalification documents and all attached documents are true and accurate in every respect. We acknowledge that Owner has the discretion in selecting the qualified CONTRACTOR for its services, and shall not be required under any circumstances to assign or give reason(s) for disqualifying us, and that Owner decision in this regard is final and not subject to appeal and that we shall not enter with Owner or others into any correspondences or debates concerning this selection. We authorize Owner to investigate or verify any statement or information given in our prequalification document and that it is free to contact any person or any of our clients, banks, auditors, etc. to obtain any clarification related to the information given in this document. We declare that in case of award of contract to us, we shall fully comply with all rules, regulation and Health, Safety and Environment guidelines set forth by Owner or any other Government body in the State of Kuwait. We declare that we or any of our subcontractor or personnel required to work on this project, shall have no objection in signing secrecy agreement with Owner, if so requested. We declare that, if we are qualified (Short Listed) by Owner for its project we shall be committed to present our bid in reply to Owner’s Invitation to Bid procedure of this project.
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We understand that Owner will not be responsible for payment of any expense which we may incur in the preparation and submission of the prequalification documents. Name : Signature and stamp:
Address : Tele. No.: Fax No: E-mail Address:
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Fact Sheet Notes: 1. Response to each question is mandatory. 2. Fact Sheet to be filled.
A. Your experience during the past five years with KNPC or affiliates. Please list the affiliate names, Contract No., Contract Duration and the scope of work performed.
B. Do you have experience in executing large jobs (greater than $ 400 MM) outside your home country during the past 10 years. Answer Yes No
Check one
Please list the 3 largest contracts in last 10 years you have performed as a prime contractor in an EPC capacity, including the contract amount.
C. Do you have experience in using SHELL DEPs for current / past EPC Projects Answer Yes
Check one
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No D. Your bonding ability. Please state the bonding capacity of your company. Answer Below $100 million $100 million and above
Check one
E. Indicate the maximum value, in US Dollars, of an EPC contract outside your home country that you are capable of executing. Answer $ 400 MM to $ 700 MM Over $ 700 MM
Check one
F. Construction Safety Record - Specify your Lost Time Accident Frequency for the projects that Applicant has implemented over the last five (5) years, including the number of fatalities and the cause of death. Answer LTA rate of higher than 1.0 LTA rate of 1.0 or less
Check one
G. Your willingness to execute a Confidentiality Agreement regarding this work. Answer No Yes
Check one
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ATTA CHMENT No. 1 Pre-Qualification Questionnaire for CONTRACTOR For 5th Gas Train Project 1.0
CONTRACTOR Infor matio n
1.1
Internet Website (If applicable)
1.2
Postal Information for any future Correspondence 1.2.1
Legal Name of CONTRACTOR (Company):
1.2.2
Country of origin:
1.2.3
Postal Address:
1.2.4
Telephone Number: (Incl. Area Code)
1.3
1.2.5
Fax Number:
1.2.6
Visiting Address (If different than postal address)
Contact Personnel information for any future Correspondence 1.3.1
Name in Full:
1.3.2
Title:
1.3.3
E-mail Address:
1.3.4
Fax Number:
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1.3.5 1.4
Telephone Number:
Date of Business (Company) Establishment Day
1.5
Month
Year
Type of Business 1.5.1 Public, Private, Partnership, Limited Liability, Un-Limited Liability, etc. (Give Details)
1.6
1.5.2
Fields of Business Activities (Give Details)
1.5.3
Country of registration / Registration Number:
Affiliates / Associates / Subsidiary Companies 1.6.1
Name:
1.6.2
Address:
1.6.3
Name:
1.6.4
Address:
1.6.5
Name:
1.6.6
Address:
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1.7
Other Offices Worldwide 1.7.1
Legal Company Name:
1.7.2
Country:
1.7.3
Postal Address
1.7.4
Telephone Number: (Incl. Area Code)
1.7.5
Fax Number:
1.7.6
Contact Person Name and E-mail Address: (Repeat as required if more offices)
1.8
CONTRACTOR Profile 1.8.1
Provide the CONTRACTOR’s Organization Chart from the upper hierarchy level to Managers level. Indicate Group or Division who will be responsible for execution of the EPC work and its management team.
1.8.2
Parent Company; state legal name and country of residence of direct parent company and the ultimate holding company, if any.
1.8.3
Change of Ownership; has there been any major change of Ownership of the establishment over the past five (5) years. If so, kindly provide details and if not, please affirm by “NONE”.
1.8.4
Affiliates / Associates / Subsidiary Companies; provide details in the form of a graphic representation to clearly identify each of the
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CONTRACTOR’s Affiliates / Associates / Subsidiary Companies and their interrelation to one another. 1.8.5
1.9
Stock Exchange; state on which stock exchange the CONTRACTOR shares and/or the shares of the parent and/or holding company are traded. If this is not applicable, please affirm by “NO SHARES ON STOCK EXCHANGE”.
Litigation / Arbitration / Disputes 1.9.1
Contractor is requested to inform whether its business, regardless of current company name, is presently or has ever been involved in any litigation or arbitration proceedings in relation to project work undertaken by EPC for a claim value exceeding (USD) $10 Million. If so, kindly provide details and if not, please affirm by “NONE”.
1.9.2
Contractor is requested to inform whether its business, regardless of current company name, is presently in dispute with either clients or subcontractors/suppliers over unresolved contract claims or other matters for a claim value exceeding (USD) $10 Million. If so, kindly provide details and if not, please affirm by “NONE”.
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ATTACHMENT No. 2 Pre-Qualification Questionnaire for CONTRACTOR For 5th Gas Train Project
2.0
Experience 2.1
Has the CONTRACTOR carried out minimum three (3) full EPC scope contracts with a value over $400 million for Refinery, Petrochemical or Oil & Gas Projects, worldwide (other than the Contractor’s home country) during the past the last ten (10) years that have been successfully commissioned or are expected to be commissioned during 2012. If the answer to the above is positive, give reference of these Plants as per details given in Form (1). CONTRCATOR is requested to fill a separate form for each project. Furthermore, CONTRACTOR is requested to summarize all its experience data provided in Form (1) in Form (1.1).
2.2
Contractor’s Gas Projects handling experience, even if value less than $ 400 million shall additionally be given, similar to 2.1 above.
2.3
Client References – CONTRACTOR shall submit Form 2, Contractor Reference Inquiry, for three of CONTRACTOR’S most recent, relevant projects. Have them completed and signed by a client representative. Client representatives should keep the reference confidential and send them directly to KNPC at the address shown on the form.
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ATTA CHMENT No. 3 Pre-Qualification Questionnaire for CONTRACTOR For 5th Gas Train Project 4.0
RESOURCES
3.1
Establishment 3.1.1
What is the total permanent manpower available within the CONTRACTOR’s organization for each of the following categories: Permanently Emplo yed With CONTRACTOR Having Contracted Category Experience TOTAL Manpower 20 10-20 < 10 Years Years Years CORPORATE Management Administrative Financial Sales PROJECT Engineering - Process - Mechanical - Instrument - Electrical - Civil Project Control (Planning, Contracting, Costing, Procurement) CONSTRUCTION Constr. Manager Quality Control Quality Assurance Safety Administrative Field Engineering Field Procurement Constr. Supv. Totals
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Note: Engineering and Construction personnel shall not be duplicated. 3.1.2
Does the CONTRACTOR have any established relationships or affiliations with specialist consultants and/or licensors of technology relevant to the proposed projects subject of this pre-qualification? If the answer is “yes”, kindly provide details and if not, please affirm by “NONE”.
3.1.3
CONTRACTOR is requested to provide information of EPC’s worldwide offices, indicating the activities and functions of each of these offices:
No
Country
Location (Province)
Sales
Eng.
Procur. Constr. Others
1 2 3 4 5 6 3.1.4
CONTRACTOR is requested to provide its typical Organization Chart for full EPC type projects, having the same order of extent, including positions, disciplines and responsibility relationships. CONTRACTOR is also requested to clearly identify the project connected to the Corporation’s Organization Chart.
3.1.5
CONTRACTOR is requested to provide in the table below the details / histogram of the number of engagements that it is currently committed to and/or bidding for as of the year 2013 projected through year 2018 showing available manpower versus committed and projected.
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KNPC 5 GAS TRAIN PQ QUESTIONNAIRE KNPC‐5GTP‐PQ ‐001 Rev. 00
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
Current Engagements (Manpower Availability) Project Name/Location
No. 1 2 3 4 5 6 7
TOTAL
:
2013 2014 2015 2016 2017 Committed Available Committed Available Committed Available Committed Available Committed Available Committed Available Committed Available Committed Available
In addition, Contractor is requested to provide the following information: Project Name, Location and Category
No
CONTRACTOR’s Role (E/P/C)
1 2 3 4 5 6 7 8 9
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Number of Personnel As si gn ed
2018
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
3.2
Construct ion and Procurement Strategies 3.2.1
Procurement / Expediting Strategy and Organization
i)
CONTRACTOR is requested to describe its strategy for the procurement, transportation to jobsite and subsequent erection of the major equipment items and the off-shore facilities.
ii)
CONTRACTOR is requested to describe the organization responsible for procurement and expediting and the strength of the organization and its location along with a brief description of the procurement methodology and the strategy for inspection and expediting.
iii)
CONTRACTOR is requested to provide its current purchasing workload and indicate whether expediting is carried out by buyers or specialists appointed for that purpose.
iv)
CONTRACTOR shall describe current procurement strategy and envisioned strategies to accommodate current market conditions as applied for the following disciplines: - Concrete - Structural Steel - Piles - Machinery & Equipment - Piping - Electrical & Control Systems
v)
CONTRACTOR shall describe strategies for freight movements and inland transportation to jobsite of major equipment items (i.e. Stacker, Reclaimer, Ship-loader, Off-shore items, packages, pumps etc.).
3.2.2
Material Management System CONTRACTOR is requested to describe its Material Management System and how tracking delivery, projections, slippages and initiating expediting actions are carried out.
3.2.3
Craft Labor Resources : Contractor is requested to provide Total Craft Manpower Curves and Peak Craft Manpower for each of the recent Projects for which Contractor has provided as relevant experience on FORM (1).
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
3.2.4
Construction Management and Craft Supervision practices For the Projects listed on FORM (1), provide the following breakdowns of your Construction Management Staff and Craft Supervision as a percent of Total Craft Manhours reflected in 3.2.3 above: a. Construction Management Staff as a % of Total Craft Hours (Site Manager through Area and General Superintendents, including support Staff). b. Craft Supervision as a % of Total Craft Hours (General Foremen through Craft Superintendents).
3.2.5
Construction Equipment and Heavy Lift Practices
1)
Rigging/Heavy Lift Engineering Capability and Practices. Please indicate Contractor’s resources and practices regarding Rigging Engineering and Heavy Lift Engineering/Planning as follows: a.
Please provide the Total Number of Permanent Construction Staff devoted to Rigging/Heavy Lift Engineering currently included in your Staffing Totals as provided in the resources listed in ATTACHMENT No. 3: (i) Total Permanent Staff; Rigging/Heavy Lift Engineers/Supervisors
b.
Please indicate Company Practices and Rigging/Heavy Lift Engineering and Planning:
Policies
regarding
(i)
Company Policy requires formalized Rigging/Lift Engineering for all lifts of _____Tons
(ii)
Company Permanent Rigging Engineering Staff reviews and signs off on all lifts of ______Tons.
(iii)
Where Construction Work is Subcontracted to Others, Company Permanent Rigging Engineering Staff reviews and signs off on all lifts of _____Tons.
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
2)
Construction Equipment Resources. Please indicate the following regarding Contractors Construction Equipment Resources: a.
Please indicate Mobile Construction Equipment Inventory of Contractor as would be utilized on major Projects (similar to those listed on FORM (1) and the proposed KNPC 5th Gas Train Project: Capacities Range 1) upto 100 Ton 2) 125-300 Ton 3) 350-500 Ton 4) Over 500 Ton Jack-Up Barge Barge Crane Boats
b)
Contractor Subsidiary Owned Provided
Contracted
Local Supplier
Please indicate what was the Heaviest/Largest Lifts accomplished directly under the CONTRACTOR’s Supervision for Projects covered in Form-1:
Project 1 2 3 4 5
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Heaviest Lifts (MT)
Largest Lifts (T-T Length/Diameter)
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
3.3.
IT Suppo rt System. 3.3.1
CONTRACTOR is requested to list the planning and scheduling systems currently being used within its establishment.
3.3.2
CONTRACTOR is requested to list the hardware and peripheral equipment and software available to support its: •
•
•
•
Planning and scheduling systems. Material management systems. Document management systems. IT communication systems.
3.3.3
CONTRACTOR is requested to explain its philosophy towards the application of software in engineering projects including data processing support and summarize the experience gained in employing CAD techniques directly in project related work.
3.3.4
CONTRACTOR is requested to list the hardware and principal peripheral equipment available for each of its CAD systems and the software available to support its CAD and Engineering procedures.
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
ATTA CHMENT No. 4 Pre-Qualification Questionnaire for CONTRACTOR For 5th Gas Train Project 4.0
Financial 4.1
CONTRACTOR is requested to provide audited copies of its annual reports for the last three years, including balance sheets of profit and loss accounts after final auditing.
4.2
CONTRACTOR is to indicate if there have been any significant changes in its balance sheet for this current year with reference to last year’s audited balance sheet.
4.3
CONTRACTOR is requested to provide copies of any financial statements released to its shareholders or to the public subsequent to the publication of the latest audited accounts.
4.4
CONTRACTOR is requested to provide the following financial information for the past three (3) years in the table below. (All Values to be given in US. $) No 1 2 3 4 5 6 7 8 9
Descr iption Borrowed Capital Net-Worth Current Assets Total Assets Current Liabilities Turn Over Turn Over (Refining / Petrochemical/Oil & Gas) Turnover Engineering Design Turnover Engg. Design (Refining / Petrochemical, Oil &
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2009(*)
2010(*)
2011(*)
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
7 8 9
Gas) Gross Profits before taxes Gross Profits after taxes Net profits
Note (*): 4.5
CONTRACTOR must indicate the end of financial year (If not March ending) as appropriate.
CONTRACTOR is requested to provide the name(s) and address(es) of its bank(s) and other information as requested below; Bank Name: Bank Address: Telephone No.: Fax. No.: Manager’s Name: (Repeat as required in case of additional banks)
4.6
CONTRACTOR is requested to specify the amount(s) (in US. $) of Tender and Performance Bond(s) of its current undertaken projects. (Do not include any contract with a value less than US $ 100 million) Project Name
Tender (Bid) Bond US $
Performance Bond US $
Contract Value in US $
4.7
CONTRACTOR to provide current bonding capacity.
4.8
CONTRACTOR is requested to provide the name and address of its external auditors used by it during the past five (5) years. Auditors Name: Address: Telephone No.: Fax. No.:
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
Contact Name: (Repeat as required in case of additional auditors)
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
ATTA CHMENT No. 5 Pre-Qualification Questionnaire for CONTRACTOR For 5th Gas Train Project 5.0
Project Execution
5.1
CONTRACTOR is requested to submit a summary of its proposed project execution plan which shall include amongst others, overall execution strategy, project management & organization plan, handling of critical execution issues, project administration plan, project control plans, engineering plan, procurement and material management plan, quality assurance & quality control plan, construction plan, pre-commissioning, commissioning and startup plan.
5.2
What are the types of work that the CONTRACTOR shall carry out independently for the Project without subcontracting to others: Category Project Management Engineering
Procurement Construction
Activity All Process Mechanical Civil / Structure Off-shore Instrument Electrical Safety QA /QC All Site Preparation Civil / Structure Off-shore Mechanical Electrical Instrument Inspection Safety Commissioning
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By CONTRACTOR
By Others
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
5.3
Where shall the CONTRACTOR typically carry out or cause to carry out the following project functions: Category Project Management Engineering
Procurement 5.4
Activ ity
Main Office
Regional Office
Other Location
All Process Mechanical Civil /Struct. Off-shore Instrument Electrical Safety Drafting All
CONTRACTOR is requested to provide a summary of its subcontracting practices and procedures indicating the methodology for selecting, awarding and administering subcontracts. Contractor to note that al l subcontractors shall be selected from the Approved List of Contractors maintained by the owner.
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
ATTACHMENT No. 6 Pre-Qualification Questionnaire for CONTRACTOR For 5th Gas Train Project 6.0
Quality Management 6.1
CONTRACTOR is requested to state which Quality Management system the CONTRACTOR is accredited to and provide certified copy of such accreditation. CONTRACTOR is also requested to submit a summary (Table of Contents) of its latest quality plan implemented for a similar CONTRACT in Refinery or Petrochemical or Oil and Gas EPC project.
6.2
Does your quality management system accredited by international agencies also cover Project Management, Engineering, Procurement and Project Execution? Submit proof of the same along with the procedures and methodologies used.
6.3
CONTRACTOR is requested to state when their last audit was done and to submit a copy of the audit report of the quality assurance system carried out by third party.
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
ATTA CHMENT No. 7 Pre-Qualification Questionnaire for CONTRACTOR For 5th Gas Train Project 7.0
Health Safety and Enviro nment 7.1
CONTRACTOR is requested to submit details of their health, safety and environment performance by completing the attached Form 3, CONTRACTOR Safety Performance.
7.2
CONTRACTOR is requested to provide a summary of it’s safety program including details of its safety training program for its employees and workers assigned to work sites and describe how the requirements of its policy are published and communicated to inform its personnel on health and safety matters.
7.3
CONTRACTOR is requested to elaborate on what type of first-aid and other facilities are offered by the CONTRACTOR to its employees and workers on a working site.
7.4
CONTRACTOR is requested to elaborate on whether it carried out HAZOP Studies, Environmental Practices and Environmental Program Involvement in the past on any Petrochemical, Refinery Projects or Oil & Gas Projects, and if so, provide details and copy of such studies and the procedures being followed by the CONTRACTOR for such studies and the methodology (arrangement) between the CONTRACTOR, Technology Licensor and Owner.
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
FORM (1) Experience – World-Wide 1-
Project Name
2-
Owner Name
3-
Country & Location
4-
Contractor’s Execution Office. Note 1
5-
Nature of Project Yes abcde-
6-
No
Grass Root Extension Revamp Debottle Neck Others (Specify)
Product Slate Product Name
Capacity KTPA
abcdef7-
Licensed Technology Licensor Name
Process Unit
abc-
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
defFORM (1) Experience – World-Wide (continu ed) 8-
Project Total Value
US. $
9-
CONTRACTOR’s Contract Value
US. $
10- Other CONTRACTOR’s earned Values
US. $
11- Type of Contract Yes abcde-
No
Lump Sum Turn Key Cost Plus Reimbursable Unit Rate Others (Specify)
12- Contract Start Date 13- Contract Scheduled End Date 14- Actual End Date 15- Actual Start-up Date 16- Number and type of Sub-Contracts No. abcdef-
Sub-Contractor’s Name
Scope of Service
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE Note1 – Contractor to indicate the Legal Entity and office location that signed and executed the project being provided.
FORM (1) Experience – World-Wide (Continu ed)
17- Involvement in Licensed Technology License
CONTRACTOR’s Scope
abcdef-
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
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FORM (1.1)
Experience – Worldwide Summary
NO
PROJECT DESCRIPTION
OWNER NAME
COUNTRY & LOCATION
PROJECT TOTAL VALUE
EPC CONTRACT VALUE
CONTRACTOR SCOPE (E/P/C)
1
2
3
4
5
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
DATES (FROM START TO END)
SUBCONTRA CTED SERVICES
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
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FORM (2) Contractor Reference Inqui ry This section to be completed by EPC Contractor
Regarding _______________, who is attempting to prequalify for work associated with the Kuwait National Petroleum Company’s For 5th Gas Train Project , and who has cited your Company as a source of reference, please respond to the following: Your response will remain confidential. Please complete the following details:
FORM (2) Contractor Reference Inqui ry This section to be completed by EPC Contractor
Regarding _______________, who is attempting to prequalify for work associated with the Kuwait National Petroleum Company’s For 5th Gas Train Project , and who has cited your Company as a source of reference, please respond to the following: Your response will remain confidential. Please complete the following details: 1. 2. 3. 4. 5.
Project Description Contractor Work scope Contract Completion Date Approximate Contract Value Approximate Labor Hours
This section to be completed by Client Representative
6. 7.
Was Contractor the Main Contractor or a subcontractor? Main Did the Contractor perform the major elements of the Yes work without the use of subcontractors? If not, what was the volume of work subcontracted? 8. Contract Type (i. e. Lump Sum, Lump Sum, Unit Rate, Reimbursable etc.) 9. Was the work performed by this Contractor on time, taking Yes into account any awarded completion extensions? 10. Did the Contractor implement satisfactory Quality Assurance Yes and Control procedures? 11. Did the Contractor implement satisfactory Safety Programs Yes and Procedures? 12. Would you consider awarding further work to this Yes Contractor? 13. Work Execution: Good Average Quality of Workmanship Cooperation
Sub No %
No No No No
Poor
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
Management Quality Quality of Field Supervision Labor Quality Sufficiency Labor Relations Safety Performance Reaction to Changes Planning Quality 14. Commercial: Good
Average
Poor
Commercial Relationship Contractor attitude to claims Invoicing Quality 15.
COMPANY NAME BY
_____
TITLE/POSITION DATE PHONE_____________________________________________________ EMAIL______________________________________________________ 16. Completed forms should be sent to: ITC Reception Desk, Room # 1A-046, 1st Floor, KNPC H.O., Ah mad i – K uw ait . Fax : 00965 23986262 (ITC, Secretar y) (Note: Contractor after filling items 1 to 5 shall give this form to the cl ient representative. Client representative shall fill items 6 to 15 and send the document (Form 2) directly to the address / Fax No. given in item 16 above)
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
FORM (3) Contractor Safety Performance Injury and Illness Data a. Employee hours worked last three years: Provide the following data:
Hours Year: Field: Total:
2007
2008
2007 No.
Rate
2009
2008 No.
Rate
2010
2009 No
Rate
2010 No
Injury resulting in fatality Total No. of fatalities x 200,000 Fatality Rate= _________________ Total Employee Hours No. of Accidents resulting in Lost work day Cases (LWC)
LWC Rate =
Total No. of LWC X 200,000 ________________ Total Employee Hours
No. of accidents other than lost work Day Cases LWC Rate =
No. of Non-LWC X 200,000 _________________ Total Employee Hours
Highest ranking safety/health/environment professional in the company: Title
Telephone:
Fax:
Do you have or provide: a) Full Time Safety/Health /Environment Engineer b) Full Time Site Safety/Health /Environment Engineer
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Yes Yes
2011
No No
Rate
2011 No
Rate
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
c) Full time Job Safety/Health/Environment Officer
Yes
No
Do you have a written Safety and Health Program? Does the program address the following key elements? -Management commitment and expectation
Yes
No
Yes
No
-Employee participation
Yes
No
-Accountabilities and responsibilities for managers, Supervisors, and employees
Yes
No
-Resources for meeting safety & Health requirements
Yes
No
-Periodic Safety and Health performance appraisals for all employees
Yes
No
-Hazard recognition and control
Yes
No
a) Hearing Conservation
Yes
No
b) Respiratory Protection Where applicable, have employees been: Trained Fit Tested Medically approved c) Hazard Communication
Yes
No
Yes
No
Yes Yes Yes Yes
No No No No
Do you have written programs for the following:
Do your employees read, write and understand English/Arabic such that they can perform their job tasks safety without an interpreter? If no, provide a description of your plan to assure that they can safely perform their jobs. Medical a) Do you conduct medical examination for: -
Pre-employment
-
Replacement job Capability
-
Pulmonary
-
Respiratory
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
b) Describe how you will provide first aid and other Medical
Yes
No
Yes
No
services for your employees while on site Specify who will provide these services : _________________ c) Do you have personnel trained to perform first aid and CPR?
Do you hold site safety and health meetings for: Field Supervisors Employees New Hires
Yes Yes Yes
No No No
Are the Safety and Health meetings Documented?
Yes
No
Personal Protection Equipment (PPE) a) Is applicable PPE provided for employees? b) Do you have a program to assure that PPE is Inspected and maintained?
Frequency_____ Frequency_____ Frequency_____
Yes Yes
No No
Yes
No
Safety, and Environmental specifications for acquisition Yes of Materials and equipment?
No
b) Do you conduct inspections on operating equipment Yes (e.g. Cranes, Forklifts, and JLGs) by third party agencies
No
Do you have a corrective action process for addressing individual safety and health performance deficiencies? Equipment and Materials: a) Do you have a system for establishing applicable health
eg? Lloyds BV etc c) Do you maintain operating equipment in compliance with Yes
No
Regulatory requirement? d) Do
you
maintain
maintenance
the
applicable
Certification
records
inspection for
equipment?
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and Yes operating
No
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
Inspection and Audits a) Do you conduct Safety and Health Inspections?
Yes
No
b) Do you conduct Safety and Health program audits?
Yes
No
Yes
No
c) Are corrections of deficiencies documented? Safety and Health Orientation
New Hires
a) Do you have a Safety & Health Orientation Program for new hires and newly hired or Promoted supervisors?
Supervisors
Yes
No
Yes
No
b) Does program provide instruction on the following: Yes - New worker Orientation?
No
Yes
No
-Safe Work Practices
Yes
No
Yes
No
-Safety Supervision
Yes
No
Yes
No
-Toolbox Meetings
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
-Emergency Procedures -First Aid Procedures -Incident Investigation -Fire Protection and Prevention -Safety Intervention -Hazard Communication c) How long is the Orientation program?
Hours
Safety & Health/Environment training a) Do you now the regulatory safety health and Environments Yes
No
training requirements for your Employees? b) Have your employees received the required Safety & Health and Yes Environment training and retraining?
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No
5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
c) Do you have as specific Safety & Health and Environment Yes
No
training program for Supervisors? Do you have an Environmental Management System?
Yes
No
If yes, attach a copy of the policy. Have you obtained accreditation under any Standards/System viz ISO14001?
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
If Yes, attach the relevant certificates. Do you carry out Environmental Audit of your facilities? Please furnish the detail on frequency, internal/external and copy of the last audit. Do you practice Environmental guidelines in storage of Hazardous chemical, Materials at site/facilities? If yes, furnish the code/standards of guidelines. Do you take/adopt necessary precautions to control fugitive emissions form the site/facilities? If yes, furnish the methods/standards. Do you practice Environmental guidelines/standards in manufacturing facilities to reduce the air emissions, water & solid waste at the source? If yes, brief the measures taken at your facilities. Do you have procedures for taking appropriate actions to contain accidental spills/releases from the site/facilities? If yes, furnish the brief details. Does your organization any time subject to enforcement action by statutory authorities for violating Environmental regulations? If yes, furnish the brief details.
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5th GAS TRAIN PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE
What is the percentage towards Environmental expenses on your annual turnover? Are you aware of the prevailing environmental regulations in the state of Kuwait? INFORMATION SUBMITTAL
Yes
No
Yes
No
Please provide copies of checked ( √ ) item with the completed PQF: ____ ____ ____ ____ ____
Insurance Certificate (s) Safety & Health Program Safety &Health Incentive Program Hazard Communication Program Respiratory Protection Program
____ Environmental Policy ____ Accreditation Certification ____ Environmental Audit Reports & Procedures ____ Environmental Training Program (Outlines) ____ Procedure for spill control/fugitive emission
____ ____ ____ ____ ____ ____ ____
Housekeeping Policy Accident/Incident Investigation Procedure Unsafe Condition, Reporting Procedure, Control, etc. Safety Inspection Audit Procedure or form Safety & Health Training Program (Outline) Example of Employee Safety & Health Training Records Safety & Health Training Schedule (Sample)
Authorized Signature:________________________________ Name:__________________________ Date: _____________
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