XX煤气化项目EPC总承包实施策略投标文件（技术标）.doc

for yueyang-jv epc projectyueyang sinopec-shell coal gasification project 岳阳中石化壳牌煤气化项目epc contract execution strategyepc 总承包实施策略sinopec e&c management dept.sinopec, lanzhou design institute 中国石化集团公司工程建设管理部中国石化集团兰州设计院september 20,2002 2002年9月20日content 目录section 1. general 项目概况1.1 interpretation of this project 对本项目的理解1.2 recommendation of ldi to be the epc contractorldi实施对本项目epc总承包1.3 project objective项目目标1.3.1 safety 安全性1.3.2 quality 质量1.3.3 schedule 进度1.3.4 budget 预算1.3.5 turn-over and plant start-up 移交和装置开车1.3.6 minimum impact on the adjacent facilities 对邻近设施的影响最小化1.3.7 the ldis office activities ldi的办公室活动1.3.8 the site project activities 现场设计活动section 2. scope of work工作范围2.1 the relationship between bdep contractor and epc contractor bdep承包方和epc总承包方的关系2.2 bbe internals bbe内件部分的规定2.3 phase 1detailed engineering design 阶段1详细设计2.4 phase 2procurement 阶段2采购2.5 phase3 construction 阶段3施工2.6phase 4 pre-commissioning 阶段4试车准备2.7phase5 commissioning assistance 阶段5试车协助section 3. organization and human resource 组织机构和人力资源3.1 general 概述3.2 request of jv board of directors 董事会的要求3.3 proposed project organization 中石化建议的项目组织机构3.4 project organization项目组织机构3.5 accountabilities of the position 岗位和人员职责3.6approximate number and category of personnel for each project项目各阶段动员的人员种类和数量section 4. project execution strategy项目实施策略4.1 project organization 项目组织4.2 project management 项目管理4.3 engineering 工程设计4.4 procurement management 采购管理4.5 construction management 施工管理4.6 commissioning assistance 试车协助section 5. hse plan hse计划5.1 ldis hse goal and management ldi的hse目标和管理5.2 principles 原则5.3 strategy 策略5.4 key processes 关键过程section 6. quality guidelines and execution strategy 质量方针和实施策略6.1 ldi qa/qc system兰州设计院的质量保证体系6.2 project qa/qc organization项目的质量保证/质量控制组织6.3 project quality plan项目质量计划6.4 material testing and inspection at vendor workshops在制造商现场的检验和试验6.5 material testing and inspection at site现场的检验和试验6.6 interface with the government quality agency与政府质量管理机构的接口section 7project it management 项目it管理section 8preliminary project schedule初步的项目进度计划8.1 interpretation of preliminary project schedule初步的项目进度计划说明8.1.1 interpretation of the drawing-up编制说明8.1.2 schedule briefs进度计划简介8.1.3 proposals建议8.2 preliminary project schedule初步的项目进度计划setion 9. choice for construction sub-contractor施工分包商的选择9.1 general 概述9.2 tendering policy 招标策略9.3 type of sub-contractor 分包合同的类型 section 1 general 项目概况 101for yueyang-jv epc projectsection 1. general 项目概况1.1. interpretation of the project 对本项目的理解1.1.1. significance 项目意义it is the first jv project between shell and sinopec, of which the successful cooperation will extend the business market of shell in china and improve the benefit of fertilizer of sinopec as well.该项目是shell和sinopec合资的第一个项目，具有示范意义。成功的合作有利于 shell扩大在华市场份额，有利于sinopec提高化肥市场的赢利能力。1.1.2. new technology技术新the main technology adopted in this project is shell coal powder gasification technology, which is the most advanced one at present from technical point of view. the powder treatment technology and control system are new. so its very important to study its design philosophy for the plant design and safe operation.该项目的主要技术煤气化采用壳牌煤粉气化技术，从技术指标来看，该技术是目前工业化的煤气化技术中最先进的，尤其粉体处理技术和控制系统均有全新的设计理念，充分消化和吸收其设计思想，对于装置的设计和安全操作极为重要。1.1.3. large capacity能力大the gasification plant of this project is capable of producing 142,000nm3/h synthetic gas (co+h2) from 2,000 tons of coal, equivalent to synthetic ammonia 1550ton/day. the plant with such huge capacity is the first in china. the yield of crude syn-gas is equivalent to that of 1.5 sets of 300,000tons synthetic ammonia plant with coal as fuel and that of 2 sets of synthetic ammonia plant with natural gas as fuel.该项目煤气化装置日处理煤2000吨，生产合成气（一氧化碳氢气）142000nm3/h，相当于合成氨1550吨/日。该装置的规模在国内是空前的，其粗合成气的产量相当于1.5套以煤为原料的30万吨合成氨装置，相当于2套以天然气为原料的合成氨装置。1.1.4. high quality requirements质量要求高shell and sinopec are very strict in quality management. and sinopec has comparatively strict qa/qc system.shell及sinopec均对质量管理的要求十分严格，sinopec有较为严密的质量保证体系。1.1.5. compact schedule进度紧the project schedule is compact for the new technology, long pfd/pid, numerous heavy equipment, complicate domestic and international purchase of equipment and late start-up of design.由于项目技术新、工艺流程长、装置大型化，国内外设备定货复杂，设计启动较晚，致使项目进度紧。1.1.6. difficult engineering工程设计有难度here is only one same-size industrial plant adopted this technology in the netherlands at present. but its operation pressure is only 3.0 mpa. the gasification plant of this project is the first synthetic ammonia plant adopted this technology in the world. that most of the equipment is to be purchased within china brings about much difference from the original design. it is difficult for the engineering to meet the requirements of operation, safety and maintenance.目前该套技术仅在荷兰有一套同等规模的工业化装置，但其操作压力仅为3.0mpa。岳阳中石化壳牌煤气化有限公司的煤气化装置是全世界范围内采用该技术的第一套合成氨装置。而且绝大多数的设备将采用国产化设备，由于国产化设备在其实现方式和功能上与壳牌的原设计思路有一定的差别，这就要求在工程设计阶段将二者有机地结合起来，以满足装置操作、安全和检修、维修的需要。1.1.7. heavy purchase采购量大there are 320 equipment for gasification section and 20 equipment except cooler for air separation unit based on the preliminary statistics. besides so, there are many equipment for utility and safe system. large number of equipment with different type purchased from various places, oversized and overweight equipment and strict international purchase with high price brings about much challenge to the purchase of this project.根据目前的初步统计，煤气化部分共有各类设备320台，空分装置除冷箱成套供货外，尚有各类设备近20台。除此之外，还有共用工程系统、安全系统等各类设备。这些设备数量多、品种杂、供货渠道各不相同。超限设备不但数量较多，而且超限和超重较多，国外采购设备要求高、价格高。这给采购带来了挑战。1.1.8. climate effect气候影响it is difficult for site construction for its rainy weather of yueyang. and the shipment of large equipment will be affected by the dry and flood season of yangzi river. strict construction management with detail construction scheme of epc contractor will ensure the safe and smooth site construction.洞氮厂地处长江沿岸，周围的现场情况复杂，长江水运受枯水期和汛期的限制，给大件运输造成一定的困难。岳阳地区为多雨地区，将给现场施工带来了一定的困难。epc总承包商将根据气候影响制定详细计划，确保项目在合同期限内完成。1.2. recommendation of ldi to be the epc contractorldi实施对本项目epc总承包sinopec e&c recommends ldi to be the epc contractor.中石化集团公司工程建设管理部推荐ldi实施对本项目epc总承包.1.2.1. ldi is experienced in the design of fertilizer plant and has deep understanding of gasification process with different fuel. ldi has the experience of the engineering of similar plant as they have done the design and the technical revamp of shell residue gasification plant. ldi will form a technical team to solve the technical issues of this project.兰州院长期从事化肥装置设计，对不同原料的气化工艺均有一定的认识，曾承担壳牌渣油气化装置的设计，并对壳牌渣油气化装置进行油改气和油改油气混烧的技术改造，有一定的同类装置工程设计经验。在该项目中，兰州院将组织技术力量对该技术进行重点消化。1.2.2. ldi has undertaken the design, expansion and site service of 300,000tons synthetic ammonia plant several times. ldi will study carefully to avoid the problems arising from the scale expansion of equipment, piping and system.兰州院曾多次承担30万吨合成氨装置的设计和现场服务工作，并有对30万吨大化肥装置进行改扩建的经验。在该项目中，兰州院将对设备、管道和系统在大型化中可能发生的情况进行认真分析，逐一落实，切实作好装置大型化的工作。1.2.3. ldi will get further understanding of shell original design philosophy during engineering phase. ldi will prepare several schemes for selection and cooperate closely with manufactures to reduce the risk to the minimum in consideration of the domesticalization and industrialization of the plant.兰州院将在工程设计阶段深入了解壳牌的原设计思想，并从多方面进行国产化和工程化考虑，通过与有关制造商的密切配合，通过进行多方案的论证，将该项目工程化的风险降到最低。1.2.4. ldi will put much effort on the present preliminary design to speed up the whole project to create favorable conditions for the detail design and the purchase of long-term equipment. project planning and schedule control is to be prepared, in particular, the key control points which affect project schedule greatly.兰州院将努力推动项目进展，首先是抓紧现阶段的初步设计工作，将初步设计工作做扎实，进行方案优化；其次，为详细设计和长周期设备的订货创造条件；此外，需作好项目计划和进度控制工作，特别是对项目进度影响较大的关键控制点。1.2.5. ldi will prepare a detailed purchase scheme and provide sufficient personnel. tendering for purchase is to be adopted with support from sinopec e&c department, sinopec international and sinopec material and equipment department. strict construction management with detail construction scheme will ensure the safe and smooth site construction.兰州院将制订详细的采购计划，配备足够的采购专业人员，在工程管理部的支持下，与国际事业公司和物装公司密切合作，通过严格的招投标程序进行采购。并且将通过严格的施工管理，进行详细的施工规划，作好施工方案，确保施工安全，使现场施工顺利进行。1.3. project objectives 项目目标the project will be approached and managed in order to meet the following project objectives:本项目将努力达到下述项目目标。1.3.1 safety 安全性safety in the design for a safe, reliable, environmentally and operationally satisfactory facilities; execution of advanced hse management.注重设计的安全性、可靠性和环境要求，满足装置操作要求。执行先进的安全、环境和健康的管理方式。safety in the construction to meet the target of a zero lost time accident (lta) rate and a total recordable incident rate of less than 0.5.制定相应安全措施，施工安全要符合“lost time accident”事故率为零和可记录的事故率小于0.5的目标。1.3.2 quality 质量establish a complete qa/qc system to ensure and control the quality in the design, procurement and construction of the plant to meet the high quality requirements to strive for an excellent project.为满足高质量的要求，建立良好的质量保证体系，确保按照设计、采购和施工计划所制定的质量要求进行控制，达到全优工程的目标。1.3.3 schedule 进度overall control to ensure the schedule and completion of the facility within the contractual schedule to meet the planned intermediate milestones with particular reference to the turn over sequence of the various units based on the contract.按照合同规定，合理的总体统筹控制，保障在进度范围内完成工作，实施进度满足计划进度中中间节点和里程碑所涉及到的各单元交工顺序。 1.3.4 budget 投资breakdown cost based on contract price to achieve effective budget control and complete the works within the planned budget; assistance to jv to reduce the project cost.按照合同价进行分解，有效的进行费用控制，在计划的预算内高质量完成工作。同时协助jv尽可能降低工程造价。1.3.5 turn over and plant start-up 移交和装置开车design, procurement and construction activities will be focused on the objective to achieve a smooth and on schedule turn over sequence followed by a smooth plant start-up and early normal production and to assist the client pass the completion inspection smoothly.设计、采购和施工活动确保顺利和按计划实现，按计划移交、以及达到高标准中间交接，开车一次成功，考核标定一次合格，较早达到正常化生产的目标。协助业主一次完成国家竣工验收。 1.3.6 minimum impact on the adjacent facilities 对邻近设施的影响最小。great attention on the need to minimize the impact on the adjacent facilities will be paid during the design and construction stages. study of the best solutions will be put to achieve such goal. 在设计和施工阶段，需要对邻近设施的影响最小化予以极大关注，研究最佳解决方案以达到这样的目标。1.3.7 the ldis office activities ldi的办公室活动the project management group will draw out a detailed project execution plan specially for this project after the contract awarded. this plan will become the basic management document of the execution of the contract and guide line the following activities at ldis office.在赢得合同之后，项目管理组将制定一个专门用于本项目的详细实施计划。这个计划将成为合同执行的基本管理资料并编制ldi办公室活动的大纲。 to ensure the smooth execution of the contract, ldi will strengthen the resource of this project, for example human resource, facilities and offices and etc. 为确保执行合同，ldi将调动全部的资源，如人力、设备、办公室等，优先满足此项目的要求。 based on pds system, the detailed design and engineering work will be mobilized at this office.以pds系统为基础，详细设计工作将在这个办公室进行。 the procurement group will start work based on this office too. if needed, the office in shanghai is available.采购组也将在这个办公室进行工作。如果需要也可在上海的办公室进行。 the final as built drawings will be completed at this office based on the hand marked drawings provided by ldis site work group or construction contractor.基于ldi的现场工作组或施工承包商提供的有施工标记的图纸，ldi在本部办公室完成最终的竣工图。1.3.8 the site project activities 现场设计活动ldi will send sufficient discipline engineers and management personnel to form a site project team with the support from sinopec e&c. the site project team will start work in yueyang as soon as the contract is awarded.在中石化工程建设部的协助下，ldi将调集足够的工程师和管理人员组成现场项目组。合同签定后，ldi将在岳阳立即组建现场项目组。 site construction manager is in charge of the site project team.现场项目组将由项目施工经理直接领导和组织。 the site project team will be equipped with good office facilities and it system to keep contact with jv and ldi head office conveniently.现场项目组将具备良好的办公条件和it系统，随时保持与jv和 ldi本部以及全球的联络。 the site project team will try to finish the local investigation and the negotiation with local government and related organizations.现场项目组尽早完成当地的调查，并作好当地的公共关系工作。 the site project team is capable to solve the technical problems during construction and will get support from ldi head office and sinopec e&c.现场项目组将有足够的能力解决施工过程中的技术问题，并能够随时得到ldi本部的支持和中石化工程部的指导。 section 2 scope of work 工作范围 section 2. scope of work 工作范围2.1. the relationship between bdep contractor and epc contractorbdep承包方和epc总承包方的关系bdep and epc are two inseparable parts of a project. as the bdep contractor, sgsi is the partner of ldi, which is the epc contractor. sinopec e&c department proposes that bdep contractor and epc contractor shall sign a link agreement based on the contract with jv.bdep（基础设计）和epc是完成整个项目建设过程中的两个不可分割的阶段，作为bdep承包商的sgsi有责任完成与jv签定的合同中载明的事项，作为epc总承包商的兰州院有责任完成与jv签定的合同中载明的事项，故sgsi和兰州院应是合作伙伴关系。bdep承包商和epc总承包商应在与jv签定的合同的基础上签定相关联结协议。2.2. bbe internals bbe内件部分bbe internal is out of the scope of epc contract. sinopec e&c department proposes to keep this part outside the epc scope. the internals shall be delivered to shanghai port by cif. and other work shall be within epc contractor scope of work.中石化工程部提议把bbe内件部分划在总承包合同之外。内件将以到岸价运抵上海码头，随后的工作列入epc合同范围。2.3. general epc承包总说明as epc contractor of yueyangjv plant, ldis obligations and rights shall be detailed and strictly described and specified in the overall contract between yueyangjv and ldi.the scope of work described here is in brief.scope of work specified in epc overall contract includes engineering design, equipment and material purchasing and construction fabrication . overall work scope shall start from detailed design till mechanical completion including pre-commissioning work of the plant.ldi作为岳阳煤气化有限公司的epc承包商，它的责任和权利将在岳阳煤气化有限公司和ldi的总承包合同中进行详尽和严格的描述和规定。这里工作范围的描述是简要的。epc总承包合同规定的工作范围包括了工程设计、设备和材料的采购和施工建设。整个工作范围的从详细设计开始，直到装置的机械完工(包括予试车阶段的工作)为止。following up, test-running ,commissioning and performance test shall be carried out by the client, who is in charge of the organization of related personnel while ldi provide technical support and service and create favorable conditions for the participation of jv.随后进行的联动试车、投料以及性能考核等工作，将由业主组织有关人员进行，ldi以技术支持服务方式参与工作。ldi将尽可能早的为jv的介入创造条件。work for ldi, can be divided into following phases： ldi所承担的工作，可以大致分为如下几个阶段：2.4. phase 1detailed engineering design 阶段1详细设计the detatiled design of all the plant in the contract based on the bed to be approved by the owner. 基于业主批准的基础设计（初步设计），承担合同装置的所有工程设计工作。2.5. phase 2procurement 阶段2采购2.5.1. the procurement activities includes: procurement management, purchasing, expediting, inspection and testing, transportation and services.采购活动包括：采购管理、采买、催交、检查和试验、运输和服务。2.5.2. work out the procurement planning, which includes: 编制采购计划，包括：(1) purchasing plan 采买计划(2) expediting plan 催交计划，(3) inspection and testing plan 检查和试验计划(4) shipping plan 运输计划(5) sub-contracting plan (if any) 分包计划（如果有的话）2.5.3. a procurement status report is produced at the desired frequency.按照要求的时间做出采购状态报告。2.5.4. monitor the procurement development in dynamic state.动态监控采购进展。2.6. phase3 construction 阶段3施工4.1.1. scopes 范围ldi shall carry out the whole construction and management work during the construction stage, including selecting construction subcontractors. ldi将完成施工阶段的全部施工和施工管理工作，包括选择施工分包商。l selecting construction subcontractors, and instructing subcontractors to carry out the whole construction work.选择施工分包商，并指导其完成全部施工工作。l carrying out the management of construction of the plant to meet the cost, program, quality and hse objectives of the project.完成装置的施工管理，以满足项目的费用、进度、质量和hse目标。l explaining the drawings and documents that ldi provided, and solving the mismatch incurred on the site.解释ldi提供的图纸和文件，解决由其导致的现场问题。during site construction, contractors management and supervision will monitor all activities to ensure that the required safety, quality and progress requirements are met by site subcontractors.在现场施工期间，承包商的管理和监督将对所有活动进行监控，以保证分包商满足必要的安全、质量和进度要求。4.1.2. programs 进度计划ldi shall provide a detailed construction programs in accordance with the project milestone requirements. ldi将提供一个与项目里程碑要求一致的详细施工进度计划。4.1.3. documentation 文件ldi shall provide documentation required by the contract in accord