KNPC Refinery

KNPC NEW REFINERY PROJECT (NRP)

PREQUALIFICATION QUESTIONNAIRE

FOR

ENGINEERING, PROCUREMENT

AND CONSTRUCTION (EPC)

BIDDERS

Rev.

Date

00 01

Description Issued for PQ

20-May-2012

Revised pages 69, 70, 71,72, 73 & 74 (Exhibit A & Exhibit B)

NEW REFINERY PROJECT EPC CONTRACTOR PREQUALIFICATION QUESTIONNAIRE

Table of Contents Description 1.0

Introduction

Page No. 3

2.0 Overview 3.0 Engineering, Procurement and Construction (“CONTRACTOR”) Responsibilities 4.0 Pre-Requisite for Prequalification

28

5.0

29

Instructions to Companies Registering for Qualified Bidders List

5 26

Documents Required: CONTRACTOR Declaration

33

FACT SHEET

35

Attachment No. 1 Contractor Information

37

Attachment No. 2 Experience

41

Attachment No. 3 Establishment

42

Attachment No. 4 Financial

45

Attachment No. 5 Project Execution

47

Attachment No. 6 Quality Management

49

Attachment No. 7 Health, Safety and Environmental

50

Attachment No. 8 Construction and Procurement Strategy

51

Attachment No. 9 Litigation / Arbitration / Disputes

54

Attachment No. 10 IT Support System

55

Forms & Tables Form-1 : Experience World-Wide

56

Form-1.1 : Experience World-Wide Summary

59

Form-2 : Contractor Reference Inquiry

60

Form-3 : Contractor Safety Performance

62

Table-1 : Contractor’s Interest

68

Exhibit A : Minimum PQ requirement for Bidder

69

Exhibit B : Minimum PQ requirements for JV Leader

72

KNPC NRP PQ QUESTIONNAIRE KNPC-EPCPQ-NRP-002 Rev. 01

Page 2


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 New Refinery Project (NRP) (“Project”) to be constructed in the State of Kuwait.

The objective of the New Refinery Project is to safely and economically build a grass roots refinery complex which shall be designed, procured, constructed and commissioned in accordance with Owner requirements utilizing world class execution standards and procedures. The project will be divided in five (5) EPC packages. 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. 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


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all CONTRACTORs responding to this letter. Final selection of companies to be on the QBL will be approved by Owner and shall be solely at Owners discretion.

Bid Basis: The EPC Package(s) will be tendered on Lump Sum Turnkey basis and will be issued by the Kuwait Central Tendering Committee (CTC). It is currently anticipated that the tenders for the Project will be issued in the last quarter of calendar year 2012 and an expected award in the last quarter of calendar year 2013.


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2.0

OVERVIEW

GENERAL PROJECT SCOPE INFORMATION KNPC is constructing a new world-class grass roots refinery in Kuwait to produce low sulfur fuel oil to replace high sulfur fuel oil used in local power plants. This large scale refinery is designed to process 615,000 BPSD of light Kuwait crude oil or 535,000 BPSD of heavy mix Kuwait crude oil. This refinery uses latest technology to comply with stringent environmental regulations to protect the local environment, and at the same time produces the latest environmentally friendly ultra-low sulfur diesel fuels for worldwide markets as well as jet fuel, kerosene, and naphtha feedstock for petrochemical plants. State of the art hydroprocessing technology, ARDS (Atmospheric Residuum Desulfurization), is used to produce the low sulfur fuel oil from the wide ranging mix of crude oils. The largest ARDS facilities in the world are to be constructed, consisting of six world scale ARDS trains. Over 500 MMSCFD of hydrogen will be produced in multiple trains to support the conversion from high sulfur to low sulfur products. Other multiple train Naphtha, Kerosene, and Diesel Hydroprocessing plants will reduce sulfur in their products to ultra-low levels of less than 10 wppm of sulfur. These ultra-low levels will satisfy the most stringent fuel specifications. Sulfur is removed from processing by sulfur recovery processes which comply with the most stringent regulations governing emission to the atmosphere, and convert the sulfur to harmless solid form for transportation and sales to world markets. These refinery processing facilities are supported by a full complement of offsites and utilities infrastructure including; receiving and product shipping pier, electrical systems, boilers, etc. Maximum recycle of water is practiced in the refinery to minimize effluents from the facility. The contract will include detailed engineering, procurement of materials and equipment, installation, and construction based on KNPC provided Front End Engineering Design documents.


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The table below contains a list of the units in the New Refinery Project

Package #

Unit #

Name

Unit 01

Crude Distillation Unit

Unit 11


Unit 21


Unit 02

Atmospheric Residue Desulfurization (ARDS) Unit Atmospheric Residue Desulfurization (ARDS) Unit Atmospheric Residue Desulfurization (ARDS) Unit Diesel Hydrotreating Unit (DHTU) Diesel Hydrotreating Unit (DHTU) Diesel Hydrotreating Unit (DHTU) Naphtha Hydrotreating Units (NHTU) Naphtha Hydrotreating Units (NHTU) Kero Hydrotreating Unit (KHTU) Kero Hydrotreating Unit (KHTU) Saturated Gas Units (SGU) Heavy Oil Cooling (HOC) Unit

Unit 12 Unit 22 Unit 03 Package 1 Unit 13 Unit 23 Unit 04 Unit 14 Unit 05 Unit 25 Unit 34 Unit 06


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Capacity 205,000 BPSD 205,000 BPSD 205,000 BPSD 110,000 BPSD 110,000 BPSD 110,000 BPSD 62,000 BPSD 62,000 BPSD 62,000 BPSD

Licensor Open Art - Fluor Open Art - Fluor Open Art - Fluor Chevron Lummus Global Chevron Lummus Global Chevron Lummus Global Shell Global Solutions Shell Global Solutions Shell Global Solutions

18,200 BPSD

Haldor Topsoe

18,200 BPSD

Haldor Topsoe

53,000 BPSD

Haldor Topsoe

53,000 BPSD

Haldor Topsoe

-

Open Art - Fluor Open Art - Fluor


Unit 31 Unit 32 Unit 33 Unit 35

Package 2

Unit 39 Unit 43 Unit 75 Unit 86 Unit 92 Unit 96

Package 3

Unit 60 Unit 61 Unit 62 Unit 63 Unit 70/71 Unit 73 Unit 74 Unit 76 Unit 78 Unit 67

Package 4

Package 5

Hydrogen Recovery Unit (HR) Hydrogen Compression Unit Hyrogen Production Units (HPU) Sour Water Stripper Unit (SWS) Amine Regeneration Unit (ARU)* Sulfur Recovery Units (SRU) and Tail Gas Treating Unit (TGTU) Flare Sulfur Pelletizing / Conveying Acid Gas Flare

Unit 69 Unit 84 Unit 85 Unit 86 Unit 88 Unit 90 Unit 93 Unit 98

Open Art - Fluor Open Art - Fluor

4 X 145 MMscfd 3 X 450 Cu.M/Hr 3 X 1300 Cu.M/Hr

Open Art - Fluor

3 X 1000 MT/Day

Shell Global Solutions

-

-

Sulfur Storage Area

-

-

Steam Generation Unit Air Systems Water Systems Cooling Water Unit EICS & ICSS HV SubStations Interconnecting Piperack Waste Water Treating Building

-

-

-

-

-

-

-

-

Storage Tankage / Piping / Underground Plant fuel Oil & Slop Tankage Inter-refinery Pipelines Solids Pier Sulfur Pelletizing / Conveying


55 MMscfd

Subsea Outfall Lines

Construction Dock Offshore (Sea Island) Small Boat Harbor

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Haldor Topsoe

Open Art - Fluor


BRIEF DESCRIPTION OF PROCESS PLANT PACKAGE # 1 - SCOPE OF WORK

The Process Plant Package 1 Scope of Work consists of the following major Work Units: Work Unit 01, 11 and 21 -- Crude Distillation Units* Work Unit 02, 12 and 22 – Atmospheric Residue Desulfurization (ARDS) Units* Work Unit 03, 13 and 23 – Diesel Hydrotreating Units (DHTU)* Work Unit 04 and 14 – Naphtha Hydrotreating Units (NHTU)* Work Unit 05 and 25 – Kero Hydrotreating Units (KHTU)* Work Unit 34 - Saturated Gas Units (SGU) Work Unit 06 – Heavy Oil Cooling (HOC) Unit*

* Additional Unit specific details are as follows. Units 01, 11 and 21 – Crude Distillation Units (CDU) The CDU consists of three units(CDU 01, CDU 11 and CDU 21), which are identical in size. The three identical CDUs are each designed to process 1358 Sm3/h (205,000 BPSD) of Kuwait Export Crude (KEC) or 1391 Sm3/h (210,000 BPSD) of Kuwait Heavy Crude (KHC), whichever is controlling. The CDUs will normally operate in the Mixed Crude Operation Mode with CDU 01 processing KEC crude, CDU 11 processing KHC crude and CDU 21 processing either Eocene or Lower Fars. It is anticipated about 795 Sm3/h (120,000 BPSD) of Eocene or Lower Fars crude will be available to be processed in CDU 21. However, if the supply of Eocene or Lower Fars crude is less than 795 Sm3/h (120,000 BPSD), the balance will be made up of a lighter crude (KEC or KHC). Units 02, 12 and 22 – Atmospheric Residue Desulfurization (ARDS) Units The ARDS consists of three identical 728.69 Sm3/h (110,000 BPSD) processing units, each with two reactor trains. Atmospheric residuum from the CDUs is pre-heated and then fed through reactor catalyst beds in a hydrogen rich environment. The feed contaminants are converted under high temperature and pressure to compounds that can be removed downstream through conventional separation and absorption technology. The primary product of the ARDS is ARDS Resid (0.5wt % sulfur content), which is blended with atmospheric tower bottoms for producing 1 wt% Low Sulfur Fuel Oil (LSFO). This LSFO is normally pumped to Kuwait Ministry of Energy, Electricity and Water (MOE (E&W)). There are also nominal quantities of middle distillate products from ARDS that are sent downstream for further processing in the refinery.


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Units 03, 13 and 23 – Diesel Hydrotreating Units (DHTU) Each of the three DHTUs will treat 410.72 Sm3/h (62,000 BPSD) of distillate produced in the CDU and ARDS to produce Ultra Low Sulfur Diesel, ULSD (10 ppm sulfur content). The DHTU is also designed to meet Cold Filter Plug Point (CFPP) specification of maximum -5oC during summer operation and maximum -20oC during winter operation when processing Light Straight Run Diesel from CDU and ARDS distillate. The primary product, ULSD, is stored prior to export. There are also small quantities of naphtha and LPG products that are sent for further processing in the refinery. Units 04 and 14 – Naphtha Hydrotreating Units (NHTU) Each of the two NHTUs will treat 120.57 Sm3/h (18,200 BPSD) straight run naphtha produced in the CDUs to produce a naphtha product with low sulfur and non-detectable metals content suitable for use as hydrogen plant feedstock. The NHTU will process all Eocene naphtha supplemented by naphtha from other CDUs. Each NHTU will also be capable of processing high nitrogen content naphtha from the ARDS Units, although this mode of operation is not foreseen. The primary product, treated naphtha, is consumed by the Hydrogen Production Units. Units 05 and 25 – Kero Hydrotreating Units (KHTU) Each of the two KHTUs will treat 351.1 Sm3/h (53,000 BPSD) of kerosene produced in the CDUs to produce low sulfur, high quality Dual Purpose Kerosene (DPK) and Aviation Turbine Fuel (ATF). The feedstock is hydro-treated for sulfur removal and smoke point improvement. The primary products, DPK and ATF, are stored prior to export. Unit 34 - Saturated Gas Units (SGU) The SGU consists of two identical 100% plants. During normal operation, both plants are expected to be in operation, each plant processing 50% of the total feed. The SGU processes the offgas streams and wild naphtha produced in the CDU; as well as the sour LPG produced by the naphtha stabilizers in the CDU. In addition, imported fuel gas is also treated in the SGU prior to being delivered to the refinery fuel gas system. The SGU produces refinery fuel gas, LPG product, and naphtha product of petrochemical grade. Full-range sweetened LPG is routed via pipeline to the MAA Refinery for further processing. If the LPG cannot be routed through the pipeline, it will be vaporized, mixed with the other fuel gas components and sent to the refinery fuel gas system


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Unit 06 – Heavy Oil Cooling (HOC) Unit The HOC consists of a bank of common/dedicated shell and tube heat exchangers for cooling the ARDS Resid (0.5 wt% Sulfur FO) product from the three ARDS Units and the Atmospheric Residue product from the three CDU Units. The main cooling is done by a tempered circulating diesel coolant. The same banks of HOC exchangers are also used to cool the crude oil circulation during the CDU startup and shutdown. The cold ARDS Resid and the cold Atmospheric Residue products are blended in an inline mixer to produce 1.0 wt% LSFO product. A small quantity of ARDS Resid will be used as fuel oil for the refinery BRIEF DESCRIPTION OF PROCESS PLANT PACKAGE # 2 - SCOPE OF WORK

The Process Plant Package 2 Scope of Work consists of the following major Work Units: Work Unit 31 – Hydrogen Recovery Unit (HR)* Work Unit 32 – Hyrdrogen Compression Unit (HC)* Work Unit 33 – Hyrogen Production Units (HPU)* Work Unit 35 – Sour Water Stripper Unit (SWS)* Work Unit 39 – Amine Regeneration Unit (ARU)* Work Unit 43 – Sulfur Recovery Units (SRU) and Tail Gas Treating Unit (TGTU)* Work Unit 75 – Flare* Work Unit 86 - Sulfur Pelletizing / Conveying * Work Unit 92 – Acid Gas Flare* Work Unit 96 - Sulfur Storage Area * Additional Unit specific details are as follows.

Unit 31 – Hydrogen Recovery (HR) Unit In the HR Unit, amine treats ARDS cold low pressure separator off-gas and hydrogen is recovered through a dedicated Pressure Swing Adsorption (PSA) package. Although normally no flow, DHTU and KHTU reactor loop purges also route into the HR feed header. The PSA package recovery is 87%, minimum. This vendor package includes feed gas knockout drum, absorbers, product gas filters, purge gas drum, tail gas compression system, and tail gas cooler.


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Unit 32 – Hydrogen Compression (HC) Unit The HC Unit serves as a central compression facility serving the ARDS, DHTU, and KHTU hydrogen demands by compressing high purity hydrogen streams from the Hydrogen Production Units (HPU)into nominal 100barg and 200barg supply headers. Utilizing parallel multi-stage compression trains plus a spare train, the compressor load management and spillback systems satisfy hydrogen demand fluctuations due to hydrotreater catalyst cycles and maintenance requirements. The required number of compressor trains will be determined by the Vendor. FEED phase design basis assumes 6 operating plus 1 spare compressor trains at unit rated capacity. Unit 33 – Hydrogen Production Units (HPU) To meet the hydrogen needs of the ARDS and other hydrotreaters, facilities are provided to generate high purity hydrogen. The HPU consist of four identical 161,863Nm3/h (145 MMSCFD) trains that use steam reforming processes to generate Hydrogen. Feeds to the HPU will be mainly the hydrotreated naphtha from the NHTU and the supplementary ARDS membrane tail gas. The HPU are also designed to operate on 100% imported fuel gas feed in future. A pressure swing adsorption (PSA) package takes the raw product stream and removes most of the impurities to yield a minimum 99.8% purity hydrogen product. The HPU is designed to normally operate during power failure and generate high pressure steam to support the refinery steam system. Various provisions have been incorporated for this operation. The hydrogen product will be flared and part of the PSA feed gas will go to the Reformer heater fuel. Unit 35 – Sour Water Stripper (SWS) Unit The SWS Unit consists of three 50% parallel plants. This configuration allows for maintenance of one plant while still providing 100% processing capacity. During normal operation, all three plants are expected to be in operation. The SWS Unit removes hydrogen sulfide (H 2 S) and ammonia (NH 3 ) from the sour water streams generated by various process units in the refinery by stripping in a column using steam heated reboilers. The stripped H 2 S and NH 3 are sent to the Sulfur Recovery Unit, where H 2 S is converted to elemental sulfur and the NH 3 is converted to N 2 . The stripped sour water is cooled and the majority sent to the hot stripped sour water header for reuse by the various process units as wash water or make-up water. The remaining portion is sent to the Wastewater Treatment Facility.


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Unit 39- Amine Regeneration Unit (ARU) The ARU consists of three 50% plants. This configuration allows for maintenance of one plant while still providing 100% processing capacity. During normal operation, all three plants are expected to be in operation. In the process of refining crude oil to make low sulfur refined products, the H 2 S is removed from various refinery gas and product streams using a circulating lean amine solution. The H 2 S rich solution is returned to the ARU as rich amine. In the ARU, the H 2 S is stripped out from the rich amine, and the solution returned to the users as lean amine. The concentrated acid gas stream from the ARU is routed to the Sulfur Recovery Unit (SRU). The aqueous amine solution used in the ARU is 45 weight percent MDEA (methyldiethanolamine). The ARU is designed to keep the lean amine acid gas at or below 0.01 mol H 2 S/mol amine. Unit 43 - Sulfur Recovery Units (SRU) and Tail Gas Treating Unit (TGTU) The acid gas generated in the SWS and ARU will be sent to SRU/TGTU for destruction of ammonia, extraction of elemental sulfur from the H 2 S, and oxidation of remaining contaminants. The NRP will utilize three 1000 MT/D Claus SRU with TGTU plants. During normal operation, all three plants are expected to be in operation, each plant processing one third of the total feed. When one plant is out of service for scheduled turnaround or maintenance, two plants will be operating at design capacity. Unit 75 – Flare The NRP will include a plant-wide flare system for hydrocarbon releases. The acid gas flare is a separate system, Unit 92. The hydrocarbon flare system has independent high and low pressure networks. The collected releases will be directed to flare tips for safe disposal via combustion. The hydrocarbon flare is a multi-point ground flare (MPGF) design split into three separate flare fields. Each flare field is enclosed within a radiation fence and contains both LP and HP stages/burners. Each flare field is capable of handling 50% of the total flare design capacity. This would allow one field to be maintained with no reduction in refinery throughput. Additionally, the hydrocarbon flare system will include a flare gas recovery unit (FGRU) designed to recover the combined purge/vent flow from each flare header.


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Unit 86 - Sulfur Pelletizing/Conveying Unit 86 includes four (4) sulfur pelletizing packages, two circular storage tanks, and sulfur conveying systems between the pelletizing packages and storage. Two parallel circular stores, 86-A-0401 A/B, are employed, each of 75,000 MT capacity, for stockpiling of pelletized sulfur within a protected storage environment. Together, the two circular stores provide storage of one shipping parcel (60,000 MT) and 21 days sulfur production at full rate. A dedicated conveying system will transfer sulfur pellets from Unit 86 onshore to a traveling ship loader located on the pier head. The conveyor, turning towers, and traveling loader systems shall be provided with specific safety and environmental control features to minimize of loss of product, provide for dust reduction and containment, fire detection and suppression, and static electricity suppression. Unit 92 – Acid Gas Flare The NRP will include two (2) 100% Acid Gas Flares. The Acid Gas flare system is mainly used for collection of the releases from process units in the Sulfur block. These collected releases will be directed to flare tips for safe disposal via combustion. Unit 96 - Sulfur Storage Area The liquid sulfur system contains four tanks, one of which is an operating spare. The four independently operating 10,500 metric ton (38,400 BBL) storage tanks provide a total of fourteen (14) Days storage. The liquid sulfur tanks provide both surge and holdup capacity to dampen the effects of process upsets and equipment service outages. Tank vents are sized to allow temporary degassing facilities when the SRU sulfur pits are upset. Two liquid sulfur transfer pumps, one operating and one 100% spare, are provided to send the liquid sulfur to the sulfur pelletizing unit. BRIEF DESCRIPTION OF UTILITIES AND OFFSITES PACKAGE # 3 - SCOPE OF WORK

The Utilities and Offsites Package 3 Scope of Work consists of the following major Work Units: Work Unit 60 – Steam Generation Unit* Work Unit 61 - Air Systems*


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Work Unit 62 – Water Systems* Work Unit 63 – Cooling Water Unit* Work Unit 70/71 – EICS & ICSS Work Unit 73 – HV Substations Work Unit 74 - Interconnecting Piperack

Work Unit 76 – Wastewater Treating* Work Unit 78 – Building

* Additional Unit specific details provided are as follows. Unit 60 - Steam Generation Unit The NRP requires steam for turbine drive pumps and compressors and for process heating and process feed. The steam requirements for the NRP include High Pressure (SH), Medium Pressure (SM), Intermediate Pressure (SI), and Low Pressure (SL) steam. This steam will be generated from a combination of utility boilers and process steam generation. The Unit consists of the following three (3) major components. a) Deaerators The treated make-up water and returned steam condensate will be stripped of dissolved oxygen and carbon dioxide with SL steam in the deaerators. The deaerated water will then be chemically treated prior to pumping to the boilers, as well as to other steam generators within the plant. A phosphate-free, side-stream of boiler feed water is distributed as needed for desuperheating needs throughout the plant. b) Boiler Feed Water (BFW) Boiler Feed Water will be produced in two variants - low pressure and high pressure. Low pressure BFW is fed to process steam utility (SI and SL) generation. High pressure BFW will be fed to the boilers to maintain the SH header operating conditions. It is also fed to the process units for SH or SM steam production. Desuperheating water is used for pressure letdown temperature control. c) Boilers The BFW will be fed to six boilers for generation of SH steam. Each boiler will include continuous pilots and burners, a superheater with attemperator, a steam drum, an economizer, a forced draft fan, flue gas stack, soot-blowers and associated ducting, piping, and controls. The boiler water quality will be maintained by continuous and intermittent blowdown. The controls for the boilers are in four categories – combustion controls, steam drum water level controls, steam temperature control, and burner management control. All


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controls are on the Uninterruptible Power System (UPS) ensuring steam production after power failure. The Hydrogen Production Unit has been designed to operate during a power failure and will generate high pressure steam to support the refinery steam system. Refer to Unit 33 for details. Unit 61 - Air Systems The air systems planned for the NRP consist of Plant Air (AP), Instrument Air (AI), and Nitrogen (N). a) Plant and Instrument Air AP and AI will be supplied by compressors common to both systems. To ensure reliability for the instrument air, process controls will be developed to prioritize the AI system. Ambient air after passing through the inlet filters/silencers is compressed in three-stage, inter-cooled centrifugal air compressors that are driven by a combination of electric and steam turbine drivers. The compressed air is cooled by an after-cooler prior to entering the wet air receiver, which then charges the distribution header for the refinery AP system. A separate stream of air flows through the instrument air dryer package and then on to the instrument air receiver prior to charge to the AI distribution system. b) Nitrogen A Nitrogen Generation System will provide nitrogen for normal process and utility needs for inert gas throughout NRP. The generator will use air supplied by the AP System. Additional nitrogen will be supplied to the plant (via 6 tube trailers located in Unit 61) to serve startup/shutdown requirements. Unit 62 - Water Systems The water systems planned for the NRP include the following: a) Desalinated Water Desalinated water is received from MOE (E&W) and fed into a pair of underground sumps. From there it is pumped to the Desalinated Water Tanks and the Cooling Tower basin. Two Desalinated Water Tanks are sized for three (3) Days allocation from MOE (E&W). b) Polished Water


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The desalinated water supplied from MOE (E&W) will be demineralized, mixed with returned steam condensate and fed to a mixed bed polisher for treatment prior to sending to the steam system. The polished water will be inventoried in storage to provide three (3) Days of hold-up to accommodate operational upsets in the treating system. The demineralized water is used primarily as make-up to the Condensate Polisher, but is also distributed to process and utility units. Two demineralized water tanks are sized for a combined storage time of one hour. c) Potable Water Fresh water is received from MOE (E&W) and fed into a pair of underground sumps. From there it is pumped to the Fresh Water Tanks and the Cooling Tower basin. Fresh water is chlorinated for domestic use and stored in two tanks sized for three days allocation. This water is chilled or heated as needed, and used in eye washes and safety showers and supplied from one centralized system. Potable water to buildings is chilled. d) Condensate Condensates returned from the steam systems are treated and stored in two Clean Condensate Tanks each sized for a working volume of approximately four hours storage. e) Acid and Caustic System A Caustic Storage Tank will be sized based on monthly consumption requirement. A 50% caustic will be delivered in trucks. A Sulfuric Acid Storage Tank will be sized based on monthly consumption requirement. A 98% sulfuric acid will be delivered in trucks. f) Firewater Treated effluent waste water is stored as the primary supply of firewater to the NRP firefighting system. The firewater is supplied to a plant-wide underground ring main system through diesel-driven pumps during a significant fire event. Electric motor-driven jockey pumps will be provided for general maintenance of system pressure. The capacity of the firewater system will be designed to handle the largest single fire contingency for the NRP facility. Fire protection in the plant will be provided by a combination of hydrants, hoses, monitors, and tank foam systems. Four firewater tanks are sized based on the Shell DEPs, in conjunction with NFPA requirements.


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Each diesel-driven FW pump is provided in its own package, including a day tank, filters, and instrumentation. Unit 63 - Cooling Water Unit A Cooling Tower with desalinated water makeup will cool the NRP cooling water to 36°C. Steam-driven pumps will normally maintain water circulation including in the event of a power failure. The cooling tower basin will be sized to contain sufficient water to optimize the flare system size. Make-up water to the cooling tower will be desalinated water or treated effluent from WWTP. Unit 73 – HV Substations Electric power to the NRP will be supplied by the national utility Ministry of Electricity and Water (MEW), at 275 kV from the nearby Al-Zour South Power Station (AZPS). At the NRP’s Main Intake Substations, 73-MIS-01 & 73-MIS-02, 275kV is stepped down to 132 kV for further distribution to 132 kV Hydrogen Compression Substation and Main Distribution Substations and constitutes the High Voltage Intake & Distribution System for the New Refinery Project (NRP). Unit 74 - Interconnecting Piperack Unit 74 consists of all interconnecting piping required to supply and/or transfer raw materials, products, and utilities to/from various units within the NRP Complex. Underground piping for cooling water, firewater, Accidentally Oil Contaminated (AOC) and Continuously Oil Contaminated (COC) sewers, etc. are also included in Unit 74. Unit 76 - Wastewater Treating The Wastewater Treatment Plant collects the various wastewater streams into one of the following six classifications. Each classification of wastewater receives different approaches to treatment depending on the type and levels of contamination. After treatment, the various segregated effluents will be evaluated for reuse in order to minimize effluent discharges. a) Accidentally Oil Contaminated Sewer System (AOC System) The AOC system collects and treats general surface area runoff, firewater, misc. utility systems blowdown (i.e. cooling water blowdown and sample cooler cooling water discharges) and other normally oil free and pH neutral waste streams from within and around the individual units. The system includes dry weather flow pumps with an oil-water analyzer specifically to monitor for any free oil that may have accidentally entered into the above streams. The AOC System also includes impoundment basins for first flush and peak


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flow diversion. Should the AOC dry weather flow contain unacceptable levels of hydrocarbon, water will be diverted into either the COC or High BOD systems via automated switching valves. Should the AOC flow exceed the pumping capacity of the system (i.e. during a storm or fire event), then water will automatically divert into these basins. Impounded water will subsequently be evaluated for contamination and, if needed, transferred to the appropriate treatment system prior to discharge. b) Continuously Oil Contaminated Sewer System (COC System) This system collects and treats oily water streams with low levels of soluble organic components (Streams with low BOD). This system includes treatment to remove both free and emulsified oil from the water. The streams normally sent to this system are maintenance oily water drains, crude and products tank bottom drains, and utility area oily water drains. c) High BOD Continuously Oil Contaminated Sewer System (High BOD) The High BOD system collects and treats water streams that are contaminated with oil and/or organics that require removal via biological treatment. The system consists of neutralization, followed by H2S oxidation, oil removal, biological treatment, clarification and filtration. The streams normally sent to this system are crude oil desalter water and stripped sour water. d) Sludge Collection and Treatment System The sludge collection and treatment system collects and stores sludge from the various pieces of wastewater treatment equipment. These various sludge streams are transferred to aerated tanks where the contents are continuously suspended and prevented from becoming septic. The contents of this tank are dewatered using centrifuges. The sludge collection system shall also be equipped with a vacuum truck disposal system consisting of vibrating screens with roll-off box for the oversized material, liquid storage and pumping to the sludge collection tank. Water recovered from the sludge collection system will be returned to the front end of the High BOD System. Separated oil will be sent to the wet slops system. e) Sanitary Waste A separate sanitary wastewater sewer system complete with lift stations will be used to convey sanitary wastewater to the wastewater treatment plant. Sanitary waste facilities will be included in several buildings. Sanitary wastewater will include its own separate biological treatment system with treated effluent being used for irrigation purposes. f) Zero Liquid Discharge (ZLD) System


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The ZLD system is used to remove contaminants from the WWTP making the recovered water suitable for cooling tower make-up and as a feed stream to the condensate polishing system. The ZLD consists of GAC filters and associated regeneration equipment for the removal of residual organics followed by Microfiltration, three trains of 3 stage Reverse Osmosis and 2 Brine concentrators. The ZLD system is designed to handle the normal refinery flow plus a contingency that is specific for each subsystem. g) Clean Storm Water (CSW) The Clean Strom Water is an underground drainage system to handle clean runoff from non-process areas such as roads & graveled area. The water will be impounded and will overflow by gravity to the sea. h) Emergency Outfall Line. A reinforced concrete emergency outfall line is included in the WWT system to route the excess water to sea. BRIEF DESCRIPTION OF TANKAGE PACKAGE # 4 SCOPE OF WORK

The Tankage Package 4 Scope of Work consists of the following major Work Units: Work Unit 67 – Storage - Tankage / Piping / Underground * Work Unit 69 – Plant Fuel Oil and Slop Tankage* Work Unit 84 – Inter-refinery Pipelines*

* Additional Unit specific details are as follows. Unit 67 - Storage Unit - Tankage/Piping Connecting piping and instrumentation inside the NRP fence line for inter-refinery transfer pipelines are provided for the following services: • • • • •

LSFO to MAA LSFO to Al-Zour Power Plants LPG to MAA Low Sulfur Diesel (LSD) to MAA Low Sulfur Diesel (LSD) to Al-Zour Power Plant


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• • • • •

KEC crude from KOC KHC crude from KOC Eocene crude from KOC LF crude from KOC Fuel Gas from KOC

NRP Scraper launcher and receiver facilities are provided by KOC for the following pipelines: • • •

LSFO to MAA LPG to MAA Low Sulfur Diesel (LSD) to MAA

KOC will also provide any required launcher/receiver stations for their three incoming crude pipelines, outside of the main NRP fence.

Storage in NRP will consist of the following services and its associated support systems, such as transfer pumps, tank gauging, etc: • • •

Crude Tankage Intermediate Tankage Finished Product Tankage

The tankage requirements are based on required duration of storage and the required flexibility in receiving, transferring, shipping and switching of different storage products. Pumps will be located in common pump houses, instead of at their respective tanks within the diked area. a)

Crude Storage

The function of crude storage is to receive crude via pipelines from KOC, and store it before being transferred to the Crude Distillation Unit. Minimum one (1) Day crude storage will be provided. Per Company standard practice, the Crude storage tanks will float with in and out flows without any provision for settling and draining water. Based on four grades of crude, five crude storage tanks are considered. Two crude storage tanks are dedicated for KEC, one tank each is dedicated for KHC, Eocene and Lower Fars. With one tank down for maintenance, a minimum volume of 95,392 m3 (600,000 BBL) storage will be provided. Crude storage tanks are floating roof type to allow for higher vapor pressure of the crude minimizing loss of crude inventory.


Page 20


A total of eight, 100% crude transfer pumps are provided, two for each crude service. b)

Intermediate Tanks

Number and capacity of Charge and Intermediate Storage tanks will be based on inventory buildup of intermediate streams during planned shutdown of the units. Intermediate tankage consists of the following: •

•

ARDS Feed Raw Kerosene NHTU Feed Raw Diesel HPU Feed

c)

Finished Product Storage Tanks

• • •

1. Aviation Turbine Fuel (ATF), Dual Purpose Kerosene (DPK) - ATF, DPK product storage will be based on the maximum shipping parcel size plus seven (7) Days productionof approximately 211,930 m3 (1,333,000 BBL) in five floating roof tanks. Four, 33% pumps will be used for shipping pumps. Tank to tank transfer is provided. A total of seven, 33% pumps will be considered for ATF/DPK and ULSD services combined. 2. Ultra Low Sulfur Diesel (ULSD) - Diesel product storage will be based on the maximum shipping parcel size plus seven (7) Days productionof approximately 317,656 m3 (1,998,000 BBL) in eight fixed-roof tanks. Each tank is provided with a mixer to homogenize the product prior to dispatch. Three 33% pumps are provided. A common spare pump is provided for ATF/DPK and ULSD. Two Low Sulfur Diesel (LSD) storage tanks identical to the eight ULSD product tanks are provided to store off spec diesel prior to pumping via pipeline to the MAA Refinery and to Al Zour South Power Plant. Each tank is provided with a mixer to homogenize the product prior to dispatch. ATF/DPK/ULSD pump will be used to transfer to MAA. New LSD pump will be used to transfer to Al Zour South Power Plant. 3. Low Sulfur Fuel Oil (LSFO) - Low-Sulfur Fuel Oil product storage will be provided for a total of 1,213,073 m3 (7,630,000 BBL) of fuel oil. 186,015 m3 (1,170,000 BBL) of fuel oil storage is currently available at the MAA Refinery. Remaining fuel oil storage of 1,027,535 m3 (6,463,000 BBL) will be provided in NRP by a total of 15 fixed roof type tanks. Four, 33% LSFO pumps will be used for shipping pumps. Two 100% pumps will be used to provide LSFO to the Al Zour Power Plant.


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4. Petrochemical Naphtha (PCN) - PCN product storage will be based on the maximum parcel size plus seven (7) Days production of 260,739 m3 (1,640,000 BBL) in 5 fixed-roof type tanks. Five, 25% pumps are used for shipping PCN. Unit 69 - Plant Fuel Oil and Slop Tankage The Plant Fuel Oil and Slop Tankage Unit include the following systems: a) Dry Slop Two Dry Slop tanks sized for a total 31,797 m3 (200,000 BBL) capacity are provided to receive Dry Slops (DS) from OSBL and Process Units. Dry slop is sent to the CDU for reprocessing. b) Wet Slop Two Wet Slop tanks sized for a total 10,652 m3 (67,000 BBL) capacity are provided to receive wet slops from Waste Water Treatment Plant and the Oil Drips System (ODS) in the Process Units. Dewatered slop is sent to the Dry Slop Tank for reprocessing in the CDU. Water (oily water) is sent to SWS. c) Plant Fuel Oil The plant fuel oil tanks are sized to provide seven (7) Days consumption of fuel oil in the refinery with a total working volume of 15899 m3 (100,000 BBL) The plant fuel oil will be provided to the steam boilers, CDU furnaces, and ARDS Fractionator furnaces by a closed loop in continuous circulation. Diesel fuel will be provided via trucks to inventory the diesel day tanks at diesel driven equipment such as the firewater pumps and the emergency generators. d) Continuous Flushing Oil Continuous flushing oil tanks are sized for 1590 m3 (10,000 BBL). One, 100% motor-driven and one, 100% steam-driven continuous flushing oil pumps are provided. e) Intermittent Flushing/ARDS Sulfiding Intermittent flushing oil tank is sized for 7949 m3 (50,000 BBL). One, 100% motor driven and one, 100% steam driven intermittent flushing oil pumps are provided. This system is also used to provide sulfiding oil to the ARDS Unit.


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Unit 84 - Inter-refinery Transfer Pipelines The Inter-refinery Transfer Pipelines are routed in a 200 meter wide Right of Way (ROW) being provided by KOC, which include the following services. •

Four crude pipelines one each for KEC, KHC, Eocene and Lower Fars will be provided by KOC up to the NRP fence line.

•

Two imported fuel gas lines are brought to the NRP fence line by KOC from Mina AlAhmadi (MAA) Refinery.

•

Two (2) new LSFO lines with launchers from NRP to MAA Refinery will be provided by KOC.

•

A new LPG line with launcher from NRP to MAA Refinery will be provided by KOC.

•

A new Low Sulfur Diesel (LSD) line from NRP to MAA Refinery will be provided by KOC.

•

Future Vacuum Gas Oil (VGO) pipeline and future Hydrocracker Bleed Oil pipeline will be in the same corridor/row as the KOC crude lines.

In addition, a new LSFO line and a new LSD line, not in the KOC Right Of Way, will be routed to Al-Zour South Power Plant by NRP. The NRP scope for KOC pipelines is mainly to provide the connecting components between the refinery fence and the associated pieces of equipment.

BRIEF DESCRIPTION OF MARINE PACKAGE # 5 SCOPE OF WORK

The Marine Package 5 Scope of Work consists of the following Work Units: Work Unit 85 - Soldis Pier * Work Unit 86 - Sulfur Pelletizing/Conveying Work Unit 88 - Subsea Outfall Lines * Work Unit 90 - Construction Dock * Work Unit 93 - Offshore (Sea Island) * Work Unit 98 - Small Boat Harbor * * Additional Unit specific details are as follows.


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Unit 85 - Solids Pier The Solids Pier is a shore-connected marine structure that shall facilitate safe and reliable mooring and loading of solid product to ocean going bulk carriers. This facility shall provide space and support for ship loading equipment, conveyors, auxiliary equipment, utilities, equipment for control of loading and shipping operations, and access to these same facilities. The Solids Pier is a pile supported structure for berthing of a single vessel and is connected to shore via a piled approach trestle. The approach trestle departs transitions offshore through the Small Boat Harbor via the northern breakwater and travels seaward to a point east-northeast roughly 3 kilometers from shore along the 10-meter depth contour. The required water depth is 14.5-meters. Therefore, Contractor shall be required to dredge the approach channel, turning area, and berthing area for this pier. The approach trestle will carry the conveyor, roadway, utilities and other infrastructure required for transfer and loading operations. A service platform near the intersection of the approach and pier head will provide for conveyor turning tower, utility equipment, electrical substation, field auxiliary room, and other infrastructure. The approach trestle and pier shall be provided to accommodate for future export of petroleum coke. The pier head shall be configured by Contractor to accommodate two (2) traveling ship loaders, although only one (1) ship loading system will be installed by Contractor. Unit 86 - Sulfur Pelletizing/Conveying The system includes packaged sulfur pelletizing systems, two circular storage tanks, and sulfur conveying systems to the solids pier. Covered stockpiles (circular stores) are utilized for storage of pelletized sulfur produced by the sulfur pelletizers. Two parallel units, 86-A-0401 A/B, are employed, each of 75,000 tonne capacity. The two circular store systems are designed for the stockpiling of pelletized sulfur within a protected storage environment. Together, the two circular stores provide storage of one shipping parcel (60,000 tonnes) and twenty on (21) days sulfur production at full rate. The main conveyor up to Unit-86 from Solid Pier is by EPC 5 while EPC 2 shall install conveyors from Pelletizer units till the first transfer towers. EPC 5 will install Air Compressor and Drier system to cater to the Plant and Instrument Air requirements of Unit-86 of EPC 2 in addition to their own requirement. Unit 88 - Subsea Outfall Line A subsea outfall line will be provided to discharge the treated waste water effluent. This is a buried pipeline that extends offshore through the southern breakwater of Small Boat Harbor and discharges approximately 500 meters from shore.


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Unit 90 - Construction Dock The use of a construction dock for offloading of heavy lift items only Unit 93 - Offshore (Sea Island) The Sea Island is a free-standing piled structure capable of berthing four (4) liquid tankers and loading liquid product via marine loading arms. The Sea Island will be totally self-sufficient for continuous manned operation and consists of ship loading and product metering systems, PCN vapor recovery system, power and utility generation, crew accommodations, control, and observation building, mooring and navigation monitoring systems, communications systems, small boat landing, helipad, emergency escape craft, and all other infrastructure as described. The liquid products shall be transferred to the Sea Island via marine pipelines originating from shore for export. The Sea Island is located at a natural water depth of 20 meters approximately 17.5 kilometers from shore. The water depth required for the largest vessel is 19 meters. The liquid products will be supplied to the Sea Island via marine pipelines. The pipelines will originate at scraper launcher stations onshore and travel underground through a corridor near the southern boundary of the Small Boat Harbor and shore area. The lines will remain buried as transition is made to marine conditions via a crossing through the shore and surf zone and then out to suitable water depth where burial may no longer be required. Contractor shall demonstrate by design all associated pipeline parameters (e.g. line sizing, weight coating, onbottom stability, surf zone stability, pipeline expansion, hydraulics and dynamics including surge protection). The pipelines will traverse on-bottom to risers located at the Sea Island. There are five (5) marine pipelines that consist of 4 main product lines and a ship slop return line to shore. Unit 98 – Small Boat Harbor The Small Boat Harbor consists of a harbor with a sheltered approach, berthing areas for support craft (tugs, mooring line boats, etc.), fueling depot, and other infrastructure as required for operation of this facility. The harbor is accessed from the sea via an approach channel and is sheltered from surrounding sea states by breakwaters on the northern and southern end of the harbor. The harbor area must achieve a water depth of 7 meters with the approach channel maintained to this same depth. The harbor will require dredging and the approach will require dredging up to the point where the depth can be achieved naturally. The harbor and breakwaters must be armored


Page 25


3.0

ENGINEERING, PROCUREMENT RESPONSIBILITIES

AND CONSTRUCTION (“CONTRACTOR”)

The CONTRACTOR’s scope of work for the Project shall be clearly stipulated in the Tender documents. However, in general the scope of work for CONTRACTOR shall include, but shall not be limited to the following: • Detailed engineering for the various process units and facility segments as listed above. • 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. • Engineering, procurement, inspection, supply, transportation, unloading at the Project site, 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. • 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. • Procurement, inspection, supply, transportation to the Project site, unloading of capital, operational and startup spares (to include the supply of spares and special tools for the construction, pre-commissioning and commissioning activities). • Liason with KNPC and Kuwait statutory authorities regarding obtaining any and all permits required in the execution of the Project. • Demolition of facilities including disposal of all debris and unusable materials • Full and complete erection / construction, testing / inspection, and mechanical completion of the plant.


Page 26


• Tie Ins to existing facilities, where required. • Preparation of the required detailed operating / technical manuals. • Supply and loading of first charge of calibration gases, oils, chemicals, adsorbents, molecular sieves and catalyst. • Implement a quality management program to provide procedures for engineering, procurement, construction and commissioning which meet the Project and ISO 9000 quality system requirements. • 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. • 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. • Conduct HAZOP and other similar studies for the projects in association with the chosen Licensors and Owner. • Implement and maintain an effective, well established and approved planning system for the control and scheduling of all activities and development of reports to Owner in accordance with the requirements of the Project. • Provide assistance and coordinate with Owner, Licensors, and Vendors during commissioning, start-up and performance testing of plant. • Provide required services of vendor representatives and specialists for critical or specialized activities during construction, precommissioning and commissioning as deemed necessary by Owner.


Page 27


• Carry out any warranty or guarantee obligations during the maintenance guarantee and / or warranty periods. • Provide Owner with all electronic files (computer files) of drawings and documents of the plant. • 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. 4.0

PRE-REQUISITE FOR PRE-QUALIFICATION 4.1

Only those contracting companies that have successfully executed Major Refinery, Petrochemical and Oil & Gas New/Upgrade/Revamp EPC Projects worldwide over the past fifteen (15) years shall be considered.

4.2

Any contracting company, joint venture (JV) or consortium wishing to be included on the QBL must be an established EPC CONTRACTOR/s with the relevant experience and capability to execute the work in which interest is indicated. Contractor is requested to fill Table-1 indicating its interest of participation in bidding. Specific qualification requirements for Joint Ventures and for JV Leader partner capabilities and experience are described in Exhibits A and B.

4.3

If CONTRACTORs are registering for prequalification for this project in the form of a consortium or joint venture, each party must define generally what scope of work each will execute in such an arrangement and demonstrate herein that each party is capable of performing that scope of work. Each party shall answer all questions herein and designate each parties’ response. Each party shall sign the prequalification documents. In such a case, proof of a joint venture / consortium must be submitted in the form of a draft agreement.


Page 28


4.4

All joint venture / consortium documentation shall be subject to KNPC approval and conditional to submittal of a legalized joint venture / consortium agreement (notarized copy) for KNPC review before final approval is granted to bid.

4.5

Joint venture / consortium documentation shall be evaluated on a single entity basis against capabilities and previous project experience. Preference shall be given to joint venture / consortium(s) with prior working experience. Newly established or specially formed joint venture / consortium(s) for this Project will be subject to additional reviews and bidder is advised to submit written justification why Owner should consider such a proposed new entity.

4.6

In addition to evaluating the JV or consortium as a single entity, the lead partner will be evaluated individually to determine if it has the systems, processes, engineering and project management capabilities to complete the work even if a junior partner needs to be replaced.

4.7

Joint ventures shall be formed during the prequalification stage. If a company is not qualified individually or as a lead JV partner, that company will not be allowed to attempt to qualify at a later time.

4.8

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.

5.0

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 CONTRACTORSs for the above


Page 29


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

with

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 if qualifying alone or by lead JV partner if qualifying as a JV. 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 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.


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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

Queries if any, regarding the New Refinery Project or other information given herein, shall be addressed to:

Chairman, PQ Committee Mina Abdullah Admin Building 3rd Floor, Room 333 P.O. Box 69, Safat Kuwait 13001 Email: [email protected]

5.11

Owner will require that twenty percent (20%) of the work (E, P or 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.

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. These must be returned


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in sealed envelopes, marked ”PREQUALIFICATION DOCUMENTS – KNPC NRP” and addressed and sent to:

ITC Reception Desk Room # 1A-046, 1st Floor, KNPC H.O., Ahmadi - Kuwait 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

CONTRACTOR

to

complete,

sign

and

submit

the

“CONTRACTOR

Declaration” on the following page. 5.17

CONTRACTOR to complete multiple questionnaires if submitting as a joint venture or consortium. One questionnaire to be completed for the combined JV and one questionnaire to be completed for each individual company participating as JV/consortium partner.

5.18

In the event CONTRACTOR is interested in prequalifying for more than one package, a separate set of pre-qualification documents will need to be submitted for each scope package.


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Pre-Qualification Questionnaire for CONTRACTOR CONTRACTOR DECLARATION TO:

Chairman, Prequalification Committee KNPC New Refinery Project

Full Name of Company:_______________________________________________ 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 after award of work. 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. 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.


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Name :

Signature and stamp:

Address : Tele. No.:


Page 34


Fact Sheet Notes: 1. Response to each question is mandatory. 2. Fact Sheet to be filled up by single contractor if qualifying alone or by lead JV partner if qualifying as JV.

A. Your willingness and ability, if you are selected to be a bidder, to submit a competitive proposal for this project in accordance with the bid basis set out above. Answer

Check one

Not willing and/or not able Willing and able B. Your willingness and ability to submit a proposal within the period discussed above for bidding. Answer

Check one

Not willing and/or not able Willing and able C. Your experience during the past five years with KNPC or affiliates. Please list the affiliate names and the scope of work performed.

D. Do you have experience in executing large jobs (greater than $ 300 MM) outside your home country during the past 15 years. Answer Yes No


Check one

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Please list the 3 largest contracts you have performed as a prime contractor in an EPC capacity, including the contract amount.

E. Your bonding ability. Please state the bonding capacity of your company. Answer Below $100 million $100 million and above

Check one

F. Indicate the maximum value, in US Dollars, of an EPC contract outside your home country that you are capable of executing, both alone and as a Joint Venture / Consortium. Answer $ 300 MM to $ 600 MM $ 600 MM to $ 1 Billion Over $ 1 Billion

Check one

G. 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

H. Your willingness to execute a Confidentiality Agreement regarding this work. Answer No Yes


Check one

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ATTACHMENT No. 1 Pre-Qualification Questionnaire for CONTRACTOR For NRP 1.0 1.1

CONTRACTOR Information Is CONTRACTOR company the Lead JV / Consortium partner ? Yes ________

1.2

No _________

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:

1.3.5

Telephone Number:


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1.4

Date of Business (Company) Establishment Day

1.5

1.6

Month

Year

Type of Business 1.5.1

Public, Private, Partnership, Limited Liability, Un-Limited Liability, etc. (Give Details)

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. If Joint Venture, provide these organization charts for each JV participant.

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”.


Page 39


1.8.4

Affiliates / Associates / Subsidiary Companies; provide details in the form of a graphic representation to clearly identify each of the CONTRACTORS’s Affiliates / Associates / Subsidiary Companies and their interrelation to one another.

1.8.5

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”.

1.8.6

Internet Website (if applicable)


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ATTACHMENT No. 2 Pre-Qualification Questionnaire for CONTRACTOR For NRP 2.0

Experience 2.1

Has the CONTRACTOR carried out full EPC scope contracts with a value over $400 million for Petrochemical, Refinery Projects worldwide (other than the Contractor’s home country) during the past the last fifteen (15) 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 Projects 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

Client References – CONTRACTOR shall submit Form 2, EPC Contractor Reference Inquiry, for five 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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Establishment 3.1

What is the total permanent manpower available within the CONTRACTOR’s organization for each of the following categories:

Category

Permanently Employed With CONTRACTOR Having Experience 20 10-20 < 10 Years Years Years

CORPORATE Management Administrative Financial Sales PROJECT Engineering - Process - Mechanical - Instrument - Electrical - Civil Project Control (Planning, Costing, Contracting, Procurement) CONSTRUCTION Constr. Manager Quality Control Quality Assurance Safety Administrative Field Engineering Field Procurement Constr. Supv.


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Contracted Manpower

TOTAL


Totals Note: Project and Construction personnel shall not be duplicated. 3.2

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”.

3.3

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

3.4

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.

3.5

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 2011 projected through year 2016 showing available manpower versus committed and projected.


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Current Engagements (Manpower Availability) No.

Project Name/Location

1 2 3 4 5 6 7 TOTAL

:

2012 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: Number of Project Name, Location and CONTRACTOR’s No Personnel Category Role (E/P/C) Assigned 1 2 3 4 5 6 7 8 9 10


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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

7 8

Description 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 & Gas Gross Profits before taxes Gross Profits after taxes


Page 45

2009(*)

2010(*)

2011(*)


9

Net profits

Note (*):

4.5

CONTRACTOR must indicate the end of financial year 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 $ 400 million). Project Name

Tender (Bid) Bond USD $

Performance Bond USD $

Contract Value in USD $

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.: Contact Name: (Repeat as required in case of additional auditors)


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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 Instrument Electrical Safety QA /QC All Site Preparation Civil / Structure Mechanical Electrical Instrument Inspection Safety Commissioning

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By CONTRACTOR

By Others


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

Activity

Main Office

Regional Office

Other Location

All Process Mechanical Civil 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.


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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 CONTRACTOR Refinery or Petrochemical or Oil & 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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Health Safety and Environment 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 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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ATTACHMENT No. 8

Pre-Qualification Questionnaire for CONTRACTOR For NRP 8.0

Construction and Procurement Strategies

8.1

Procurement / Expediting Strategy and Organization

8.2

i)

CONTRACTOR is requested to describe its strategy for the procurement of the main columns, vessels and other major equipment items.

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 - 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. pressure vessels, columns, reactors, compressors, etc.).

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.


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8.3

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).

8.4

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 Man-hours reflected in 8.3 above:

8.5

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).

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.


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(iii)

2)

Where Construction Work is Subcontracted to Others, Company Permanent Rigging Engineering Staff reviews and signs off on all lifts of _____Tons.

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 Projects:

Capacities Range 1) up to 100 Ton 2) 125-300 Ton 3) 350-500 Ton 4) Over 500 Ton 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 Largest Lifts (T-T (MT) Length/Diameter)


ATTACHMENT No. 9 Pre-Qualification Questionnaire for EPCs For NRP 9.0 Litigation / Arbitration / Disputes 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”.

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”.

9.3 CONTRACTOR is requested to inform if CONTRACTOR has ever had a contract terminated for default If so, kindly provide details and if not, please affirm by “NONE”.


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ATTACHMENT No. 10 Pre-Qualification Questionnaire for CONTRACTOR For NRP 10. IT Support System. 10.1 CONTRACTOR is requested to list the planning and scheduling systems currently being used within its establishment. 10.2 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. 10.3 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. 10.4 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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FORM (1) Experience – World-Wide 1-

Project Name

2-

Owner Name

3-

Country & Location

4-

Legal Name of CONTRACTOR’s Entity Signing the Contract and Executing the Work

5-

Nature of Project Yes abcde-

6-

No

Grass Root Extension Revamp Debottle Neck Others (Specify)

Product Slate Product Name

Capacity KTPA

abcdef-


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FORM (1) Experience – World-Wide (continued) 7-

Licensed Technology Licensor Name

Process Unit

abcdef-

8-

Project Total Value

9-

CONTRACTOR Contract Value

US. $ EPC US. $

10- Other CONTRACTOR US. $ earned Values 11- Type of Contract Yes abcde-

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


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No


FORM (1) Experience – World-Wide (continued)

16- Number and type of Sub-Contracts No. abcdefgh-

Sub-Contractor’s Name

Scope of Service

17- Involvement in Licensed Technology License

CONTRACTOR’s Scope

abcdef-


Page 58

FORM (1.1)

Experience – Worldwide Summary

NO

1

2

3

4

…

PROJECT DESCRIPTION

OWNER NAME

LEGAL NAME OF CONTRACTOR’S ENTITY SIGNING THE CONTRACT & EXECUTING THE WORK

COUNTRY & LOCATION

PROJECT TOTAL VALUE

EPC CONTRACT VALUE

CONTRACT OR SCOPE (E/P/C)

DATES (FROM START TO FINISH)

SUBCONTRACTED SERVICES

FORM (2) Contractor Reference Inquiry

This section to be completed by EPC Contractor Regarding _______________, who is attempting to prequalify for work associated with the Kuwait National Petroleum Company’s New Refinery 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. 8. 9. 10. 11. 12. 13.

Was Contractor the Main Contractor or a subcontractor? Did the Contractor perform the major elements of the work without the use of subcontractors? If not, what was the volume of work subcontracted? Contract Type (i.e. Lump Sum, Unit Rate, Reimbursable etc.) Was the work performed by this Contractor on time, taking into account any awarded completion extensions? Did the Contractor implement satisfactory Quality Assurance and Control procedures? Did the Contractor implement satisfactory Safety Programs and Procedures? Would you consider awarding further work to this Contractor? Work Execution Quality of Workmanship Cooperation Management Quality Quality of Field Supervision Labor Quality Sufficiency

Good

Average

Poor


Labor Relations Safety Performance Reaction to Changes Planning Quality

14. Commercial Commercial Relationship Contractor attitude to claims Invoicing Quality

15.

Good

COMPANY NAME BY TITLE/POSITION DATE PHONE EMAIL

16. Completed forms should be sent to: Chairman, PQ Committee Mina Abdullah Admin Building 3rd Floor, Room 333 P.O. Box 69, Safat Kuwait 13001 Email: [email protected]


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Average

Poor


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.

2010

2009

Rate

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 Yes

2011

No No No

Rate

2011 No

Rate


c) Full time Job Safety/Health/Environment Officer 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

Yes

No

Yes

No

Yes

No

Yes Yes Yes Yes Yes

No No No No No

Do you have written programs for the following: a) Hearing Conservation b) Respiratory Protection Where applicable, have employees been: Trained Fit Tested Medically approved c) Hazard Communication 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

b) Describe how you will provide first aid and other Medical


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services for your employees while on site Specify who will provide these services : _________________

Yes

No

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

Frequency_____ Frequency_____ Frequency_____

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?

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 Yes eg? Lloyds BV etc

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

No

c) Do you maintain operating equipment in compliance with Regulatory requirement? d) Do

you

maintain

maintenance

the

applicable

Certification

records

inspection for

Yes

No

Yes Yes

No No

and

operating

equipment? Inspection and Audits a) Do you conduct Safety and Health Inspections?


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Yes

b) Do you conduct Safety and Health program audits?

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

Environments

the

regulatory

training

safety

requirements

health

and Yes

No

for

your Yes

No

Yes

No

Employees? b) Have your employees received the required Safety & Health and Environment training and retraining? c) Do you have as specific Safety & Health and


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Environment 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

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. What is the percentage towards Environmental expenses on your


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annual turnover?

Are you aware of the prevailing environmental regulations in the state of Kuwait? INFORMATION SUBMITTAL

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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TABLE (1) Contractor’s Interest

No.

EPC Package

1 2 3 4 5

NRP EPC Package 1 NRP EPC Package 2 NRP EPC Package 3 NRP EPC Package 4 NRP EPC Package 5

Rank Interest (1 to 5 – 1 being most favorable)

If qualified, indicate which package you would bid

Please indicate the maximum number of EPC Packages you are capable / interested to execute. ________________________


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EXHIBIT “A” Applicable to Packages 1 & 3

Minimum Pre-Qualification requirements for Bidder. (If Bidder is submitting application individually the limits apply to the individual organization. If Bidder is a JV, the limits in this Exhibit A applies to the JV combined capabilities) 

Total revenues no less than 5 billion USD per year



Experience of at least 7 major projects in the Petrochemical/Refining/Oil & Gas Industry



Experience of at least 5 Projects larger than 1 billion USD or its JV equivalent



Minimum 400 million USD in global design revenues



Net worth larger than 1.5 billion USD (Combined)



Leader in HS&E. LTR less than .50 per 200,000 hours



Workforce of at least 2,250 Engineers

(Revenues above shall be based on the highest revenue earned per year from amongst the last 5 years)


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EXHIBIT “A” Applicable to Package 2





Experience of at least 7 major project in the Petrochemical/Refining/Oil & Gas Industry


















Page 70


EXHIBIT “A” Applicable to Packages 4 or 5





Experience of at least 5 major marine facilities or tank farm projects related to Petrochemical/Refining/Oil & Gas Industry



Experience of at least 5 Projects larger than 250 million USD or its JV equivalent















Page 71


EXHIBIT “B” Applicable to Packages 1 & 3 Minimum Pre-Qualification requirements for JV Leader (In addition to have JV prequalified as a single entity, the JV Leader Partner must meet the following criteria)






Experience of at least 5 major projects in Petrochemical /Refining/Oil & Gas Industry









Net worth larger than 1 billion USD






Workforce of at least 1350 Engineers



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EXHIBIT “B” Applicable to Package 2 Minimum Pre-Qualification requirements for JV Leader (In addition to have JV prequalified as a single entity, the JV Leader Partner must meet the following criteria)






Experience of at least 5 major projects in Petrochemical /Refining/Oil & Gas Industry


















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EXHIBIT “B” Applicable to Packages 4 & 5 Minimum Pre-Qualification requirements for JV Leader (In addition to have JV prequalified as a single entity, the JV Leader Partner must meet the following criteria)



Total revenues no less than 1.5 billion USD per year



Experience of at least 5 major marine facilities or tank farm projects in Petrochemical /Refining/Oil & Gas Industry



Experience of at least 3 Projects larger than 250 million USD or its JV equivalent















Page 74

KNPC Refinery

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