CONSOLIDATED CONTRACTORS COMPANY
Transcription
CONSOLIDATED CONTRACTORS COMPANY
The BULLETIN is a publication issued at CCC in Athens by volunteer staff. All opinions stated herein are the contributors’ own. Submissions (announcements, stories, artwork, etc.) are welcome. CCC BULLETIN P.O. Box 61092 Editors Samer Khoury Zuhair Haddad Nafez Husseini Damon Morrison Public Relations Samir Sabbagh Maroussi 151 10 Fax (30-210) 618-2199 or [email protected] see The BULLETIN on line at www.ccc.gr - News - Quarterly Bulletin Bulletin October 2011 Issue No. 99 Production Jeannette Arduino Nick Goulas Georgia Giannias Alex Khoury Contents FROM THE DESK OF....................................Samer Khoury EDITOR’S VIEW...............................................................…1 MAIL BAG - Letter from Fehied F. Alshareef..................…1 RECENT AWARDS.......................................................……2 Quality Management - Quality Management Systems Overview Mounir Soufyan….......…..4 PROJECT PROFILE: Princess Noura University for Women - Inauguration - Hassan Moghrabi…................................8 - The Tunnel - Haitham Khader Msaeed ….......................9 Feature: Pipeline Projects - The Pipeline Enterprise - Rashid Shuhaiber….........14 - Australia Pacific LNG Upstream Project Phase 1 - Pipelines Zahi Ghantous…..…..16 - Pipeline Estimation - Hisham Kawash…......................18 - SAS FFD Project - Bassam Addada….........................20 - The Challenges of the Malagasy Experience Marwan Anas…...........22 Area News - Qatar: 30 M w/o LTI at Ras Laffan Port Expansion Project Buks Beukes….24 - Qatar: TR3/4 Shutdown - Rabi Rouwadi…............…..25 - Palestine: Bethlehem Centre - Samer Khoury….........26 - Switzerland: Palestine Heads the WFEO Fadi Raffoul.....26 Health, Safety & Environment - World Environmental Day - Belal Kayyali…............…..27 Corporate Social Responsibility - CSR News Report - Tony Awad…..........................…..28 - Special Olympics - Tony Awad….............................…..30 - Summer Trainees 2011 - Ramsay Khoury................…..31 - Helping the Local Community in Cairo Dina Farid and Ahmed Refai…..........32 - Indoor Plants Initiative, Egypt - Adrian Crowley…....33 Milestones - Announcements….....................................................…..34 - Letter from P.V. Veeraraghavan...............................…..35 Reflections - Trust Is the Difference Maker - Dr. Riad Elhaj.......…..37 Pipelines CONSOLIDATED CONTRACTORS COMPANY Reflections Trust Is the Difference Maker Trust is the foundation of leadership. It is an attitude that is earned and not acquired. It is earned in the process of overlapping our character and competence. From the Desk Of... Diversity, Flexibility and Social Responsibility I believe CCC’s strength lies in our ability to execute different kinds of projects from buildings, roads and harbours to more complex oil, gas and power projects like the EPC pipelines featured in this issue of the Bulletin. This type of diversity is not present in many companies and is one of our key strengths. A few years ago, our revenue was dominated by oil and gas projects whereas today civil projects constitute the majority of our work, yet we have maintained the same organizational structure, management and profitability. Again, this flexibility is unique in our industry and is another important factor which contributes to our success. CCC’s ‘Family Culture’ which has been inherited from our founders, has embedded in it the culture of giving back to our society which is another name for Corporate Social Responsibility. This human trail is seen throughout CCC’s staff and projects and some examples are included in this Bulletin. Again, we are among the few companies of this caliber who care about others. We, in our homes, and at our work, build the trust daily and reflect it to those around us, who in turn become the mirror that reflect it back to us. People around us are drawn to those who trust them and make them feel important. The people around us will trust us when they see many of the ingredients (in our character and competence) shown in the model. Trust is a must for all managers at all levels. It will act as emotional glue holding managers and others together. It gives meaning and value to all relationships with everyone, especially with the client / engineer. While there is risk in trusting others, the risk is much greater in not trusting them. When there is no trust friction arises; hidden agendas, conflicts and a win-lose environment is created. Low trust will slow every decision, every relation and every interaction. Low trust will slow everything in our life and in our work. Trust impacts the three major variables of productivity, namely: time, cost and quality. When trust is high, the cost and the time needed to do things go down and quality goes up. Trust is built gradually over many years of daily investments in our interactions and relations. However, it is fragile. It can break in no time, especially when some practices abound such as: breaking promise, holding information, being double-faced and gossiping. Trust is a major value in the bedrock on which our CCC culture was built. It is the value that gives the meaning to other CCC values. This value of trust must be emphasized, enhanced, exercised and maintained by everyone in order to continue as a difference maker in serving our culture and maintaining the family spirit and how others will see us. I am confident that given our continuous diversity, flexibility and social responsibility, CCC will continue to grow and remain strong. Samer Khoury President (Engineering & Construction) Dr. Riad Elhaj Bulletin Issue 99 / October 2011 37 Editor’s View Pipelines, pipelines and pipelines are the feature of this issue and there have been linearly consistent sales in this segment just like the pipeline construction sequences. I wish you an enjoyable reading of that. Moreover, I am very pleased to report to our readership that we have had an extremely good set of responses to the 60th Anniversary Logo design …. and yes we have finally chosen. 1st Prize Dear Bulletin Readers: • The first prize goes to Haitham Khader (Riyadh Office in KSA): his design will be used as the official logo throughout 2012. • The third prize goes to Mounzer Belly Soufi (QFIS project in Qatar) and his design will be used as a decoration sticker. • An honorable mention also goes to Sunil Machado (HAB5 Project in UAE) with a stamp design that we may want to consider as a postage stamp on our outgoing hard-copy letters and emails. 2nd Prize • The second prize to goes to Julius Lacea (QUS Project in UAE), whose design will be used for the web-site. Our 60th anniversary will be recognized group-wide with a branded and coherent message. It will be a centrally coordinated effort by MOA to produce the following: CONSOLIDATED CONTRACTOR COMPANY 1. A special video recorded message from Mr. Said Khoury. c 3. A 2011 Q4 Bulletin featuring the 60 years theme. 4. A special marketing video of 7-10 minutes. 5. Windshield sticker banners to be placed on all company cars in visible but nonobstructive and safe places. c th 3rd Prize 2. An updated website with special marketing pitches. c ANNIVERSARY We expect to have these ready for distribution in December 2011. Nafez Husseini 4th Prize Let us all help celebrate this event because 60 years is no small feat. Mail Bag Mr. Mohammad A. Al-Haj Business Development Consultant Consolidated Contractors Co. WLL Riyadh, Saudi Arabia 24 August 2011 Dear Mr. Al-Haj, I would like to thank you for sending me the CCC Bulletin June 2011 Issue No. 98. The information on Renewable Energy and Sustainability is worth going through. The Saline Water Conversion Corporation (SWCC), a government corporation, is a provider of desalinated water and electric power in the Kingdom of Saudi Arabia. The company, through more than 30 plants located in the East and Westcoast of the country, is the main supplier of desalinated water throughout Saudi Arabia and is also the second largest electric power producer in the country. Bulletin Issue 99 / October 2011 Best regards, Fehied F. Alshareef Governor Saline Water Conversion Corporation (SWCC) 1 Recent Awards Barzan Onshore Facilities Qatar The Barzan Project is located in Ras Laffan City, 80km north east of Doha. This initial phase will supply domestic gas to meet the State of Qatar’s infrastructure and industry growth. This will be done via processing a total feed gas quantity of 1.9 billion SCFD. The output of the gas processing is sales gas, liquid sulphur and gas condensate. The project’s facilities comprise: • gas receiving and condensate stabilization unit. • acid gas removal unit (two trains). • dehydration and mercury removal unit (two trains). • mercaptan removal unit (two trains). • NGL recovery/N2 rejection unit (two trains). • sulfur recovery unit (two trains). CCC’s scope of work is limited to construction of the process plant area (Area A000). CCC’s construction works are related to piping fabrication and erection, civil works, buildings EPC works, steel structure erection, equipment erection, electrical and instrumentation installations painting, insulation and common scaffolding for the process plant area (A000). The EPC buildings are mainly process buildings to support the process plant requirement, and are comprised of: • five substations. • three satellite instrument houses and • five free-standing toilets, Totaling 8,150m2 of built-up area. CCC was awarded the above-mentioned project in August 2011. The client is Qatar Petroleum Company and Exxon Mobil and the main (EPC) contractor is Japan Gas Company (JGC). The construction works duration is 34 months; the construction start date is September 2011, while the mechanical completion is scheduled for June 2014. APLNG Pipelines. Queensland Australia This job is in the Queensland area, 300km west of Brisbane and the scope of works involves engineering, procurement and construction of: • 42” ND main pipeline coal seam gas pipeline 360km in length. • 24” ND Spring Gully 2 to Reedy Hub (via Taloona) lateral pipeline coal seam gas pipeline 71.4km in length. • 18” ND Fairview CS3 to Spring Gully coal seam gas pipeline 27.3km in length. • 18” ND Spring Gully to Taloona coal seam gas pipeline 12.2km in length. • Four main line valve stations, 13 scraper stations and various facilities for each pipeline. CCC is part of the MC Joint Venture with McConnellDowell for the procurement and construction execution while KBR is the subcontractor for performing the engineering works. The owner is Australia Pacific LNG Pty Limited “APLNG”, a joint venture between Origin Energy and ConocoPhillips. Main construction activities are expected to start in May 2012 with completion in March 2014. Multipurpose Real Property Complex in Staoueli, Forum El Djazair, Zone 1, Residential Buildings Project Algeria The Forum El Djazair is located in the town of Staoueli, 15km west of the capital Algiers, on the Mediterranean Sea. The general scope of works requires the supply, installation, construction, testing and commissioning of Zone 1 of the project, inclusive of all the structural, civil, architectural, electromechanical works, external works, utilities, landscaping and exclusive of piling, shoring and excavation works. Zone 1 of the project consists of four residential highrise buildings, each comprising three basements + Ground + Mezzanine + 22 floors + saloon terrace and each high rise building comprising of 124 apartments. The total built up area is 211,960 m². The Client is Société Algéro-Emiratie de Promotion Immobilière and the consultant will be appointed in due course. DSC (Drake and Scull)/CCC Joint Venture was formed in September 2011 for the purpose of performing the works for the Forum al Djazair with respective participating interests of 50% and where DSC are the Leaders. The award was made in July 2011. However, the contract start date will be December 2011 and the duration is 30 months. • 36” ND Condabri lateral coal seam gas pipeline 78km in length. • 30” ND Woleebee lateral coal seam gas pipeline 92km in length. 2 Bulletin Issue 99 / October 2011 Recent Awards Sheikh Khalifa Bin Zayed Specialized Medical Centre, Casablanca * 60km of 14” Condensate Export pipeline from BS - 171 to AGRP at MAA. Morocco * 15km of 8” liquid disposal pipeline from the new intermediate slug catcher unit near GC-19 to AGRP at MAA. HH. Sheik Khalifa Bin Zayed Al Nahayan Specialized Medical Centre is located on Boulevard de la Prefecture, Commune de Hay Hassani, in the city of Casablanca, Morocco. The scope of work includes the supply, installation, construction, testing and commissioning of the main building and external works inclusive of all civil, structural, architectural, electromechanical works and all services and utilities. The building will be a modern medical facility comprising 133 beds (108 single bed rooms and 8 suites in wards, 17 patient bed rooms in ICU and CCU), 8 operating theatres with support areas and other specialized departments distributed on four floors (basement, ground, first and second) with a total built-up area of 41,000 m². The client is the Khalifa Bin Zayed Al Nahyan Foundation, Abu Dhabi, UAE. The client’s representative, appointed as the project manager, is Cyril Sweett International. The project was awarded in July 2011, the contract will start in October 2011 and the duration is 22 months. • Tie-ins of the new pipelines with the existing pipelines. • All associated civil and structural works including but not limited to field soil investigations, topographical survey, slit trenching, geotechnical investigation, earth works, valve pits, pipe supports and pipe sleeves, foundations for pig launchers/receivers, jib cranes and all other equipment, sump pits, burn pits, anchor blocks, fencing, pipe line markers, platforms and crossovers. • All electrical works and electrical equipment related to MOV’s cathodic protection, lighting and cable laying. The client is Kuwait Oil Company K.S.C. (KOC). The project duration is 24 months. Engineering activities will be performed over a period of 8-10 months and the construction and commissioning assistance over a period of 14-16 months. Eocene and chemical storage tanks at MGC KOC Construction of New Transit Pipeline from BS-171 to MAA Kuwait Kuwait Detailed design and engineering, procurement, construction, inspection, testing and commissioning of one 100,000 barrels stock tank with gas boot, one 50,000 barrels free water knockout tank with gas boot and two 25,000 US gallons capacity chemical storage tanks with a new control system. On August 25, 2011 CCC was awarded this major EPC project. The pipeline project runs from the Gas Booster Station 171 (BS-171) in West Kuwait to Acid Gas Removal Plant (AGRP) in Mina Al Ahmadi (MAA). The purpose of the project is to transfer sour gas and condensate from BS-171 to the acid gas removal plant in Mina Al Ahmadi via a gas export pipeline and a condensate pipeline including interconnections with the existing gas pipeline network at TP1, and existing condensate pipeline network at TP2 at AGRP in Mina Al Ahmadi. The scope includes the related piping, fire fighting, pumps, civil, electrical and instrumentation works. The client is Joint Operations (Saudi Arabian Chevron Inc. & Kuwait Gulf Oil Company), the award was made in July 2011 and the total duration is 730 calendar days. The new transit pipeline project involves the following works: • Design and detailed engineering. • Hazard & Operability (HAZOP) Study, Environmental Impact Assessment (EIA), Project Health, Safety & environment Reviews (PHSER) and Quantitative Risk Assessment (QRA). • Procurement of all permanent materials including line pipe, main valves (MOV’s), piping, etc. • Installation, testing, pre-commissioning and commissioning assistance of: * 60km of 24” sour service Gas Export pipeline from BS-171 to AGRP at MAA. Bulletin Issue 99 / October 2011 3 Quality Management Quality Management Systems Overview Introduction Throughout the industrial period of the 20th century organizations have been motivated to produce a quality product in order to serve the society and to ensure a competitive position in the market place. Initially, motivation was only driven by financial figures, for this reason many great companies ceased to exist. However, at a certain stage the whole attitude of businesses changed, organizations realized that financial figures are not enough to sustain a business. As companies grew many management styles were introduced starting with the army style management, a process of command and orders (Deming called it Soldiering). Army style management resulted in killing motivation and creativity of employees, therefore, this style could not survive. Other management styles were introduced to motivate employees and to give them more freedom in order to release their personal skills and creativity for the benefit of the organization. Many organizations realized that the learning process in the organization should be both ways: employees should learn from their managers and at the same time managers should learn from their employees. Therefore, the learning process does not end with the university degree, on the contrary; it should start at the time engineers obtain their degree. We have to realize that the learning process has no end. The time we stop learning, it is the time our creativity and innovation reach an end and we become a robot of a daily routine. I am in business to teach engineers about management, however, in this process I also learn a lot from them and also about myself. W. Deming (American statistician, professor, author, lecturer and consultant.) management in order to lead the organization toward improved performance. The following items represent the philosophy and basic principles used for development of quality management system ISO 9001-2008: • Customer Focus. • Leadership. • Involvement of People. • Process Approach. • System Approach to management. • Continual Improvement. • Factual Approach to Decision Making. • Mutually Beneficial Supplier Relationships. This article gives an overview of quality management principles and basic philosophy for improvement including development process, the requirements of applicable codes and standards and major impact on the organization. Quality Management Principles Quality Management is a Process Approach to Management involves the Methods and Techniques of Management of overall business processes that contribute to Customer Satisfaction with major emphasis on Quality & Continual Improvement. Eight quality management principles (chart 01) have been identified that can be used by top 4 Chart 01 Bulletin Issue 99 / October 2011 Quality Management ...Quality Management Systems Overview ...Text Main Processes The ISO 9001: 2008 standard has four main processes: Chart 02 • Management Responsibility. • Resource Management. • Product Realization. • Measurement, Analysis and Improvement. The above processes are based on PDCA cycle (plando-check-act), and represent management commitment in providing adequate resources for doing the expected work, and conducting measurement and analysis for the purpose of continual improvement. Market Directives European Union The European Union “EU” imposed two conditions on products and services made within the boundary of the EU, or purchased from outside to be used in the EU. Organizations must have a quality management system in line with ISO 9001 standard, and products must be certified to a national or international standard such as ASME, CSA, ULC, UL, etc. National Standard Organization National standard organizations have adopted ISO 9001 standard for local market and for supplies from international market. Market Directive Under the direction of government institutions and major corporations: “Organizations are required to implement ISO 9001 standard as a condition for prequalification.” able target “Joseph Juran”(1), this is illustrated in chart 03. Objectives of Quality Management System The objectives of quality management system can be summarized in the following: Customer • Meet quality requirements. • Ensure satisfaction. • Increase confidence. • Gain Commitment. Performance Performance can be measured as providing quality product and service that meet specified requirements on time and within budget. Nobody appreciates quality delivered two years late, and beyond the agreed budget. “These factors must be in balance: any neglect of any one will have a corresponding negative effect upon the other two - chart 02”. The Cost of Poor Quality The cost of poor quality is decreased with the introduction of appraisal and preventive measures. With the improvement of technology and introduction of new control measures zero defects is an achiev- Bulletin Issue 99 / October 2011 Chart 03 5 Quality Management ... Quality Management Systems Overview Product/Service • Prevent errors. Chart 04 • Prevent delivery delay. • Increase reliability. • Contribute to business success. Cost • Reduce cost of operation. • Increase productivity. Personnel • Increase employee morale. • Increase confidence. Market • Provide competitive edge in the market place. Quality Management Structure In previous bulletins we have presented the structure of the quality management system with ISO 9001:2008 as a basic guideline. We need to shift our thinking and restructure our quality management system to be business oriented in line with ISO 9001:2008 standard, not the other way around. The pyramid in chart 04 shows the structure based on system / process approach to management. This is the first step in continual improvement. Major Changes in the Quality Management System • Introduction of system approach to management. • Moving from a procedure based systems to process based systems. • Introduction of continual improvement requirement. • More emphasis on customer satisfaction. • Moving from conformance to performance. • Moving from control based systems to management based systems. • Review and approval of documents on a periodic basis. Codes and Standards We have always to remember that the core of our operation is the applicable codes and standards. We can’t build a process piping system without the application of B31.3 or a pressure vessel without the application of ASME section VIII (or equivalent standard). Implementation of quality management is an additional requirement used to organize our operation and to increase the level of confidence of our customers. This is illustrated in the chart 05 where total quality management is introduced in the outer circle. Involvement of People To involve people, top management should create an environment where authority is delegated so that people are empowered and accept responsibility to identify opportunities where the organization can improve its performance. This can be achieved by activities such as: • Setting of objectives for people, projects and organization. • Benchmarking competitors’ performance and best practice. • Recognition and reward for achievement of improvement. • Suggestion schemes including timely reaction by management. Major Impact The major impact of system approach to management can be summarized in the following items: • Identify processes needed for the business. • Determine sequence and interaction of these processes. 6 Bulletin Issue 99 / October 2011 Quality Management ...Quality Management Systems Overview ...Text • Determine methods of control of these processes. Chart 05 • Ensure availability of resources and information required to support the operation and monitor the processes. • Monitor, measure and analyze these processes. • Implement action to achieve the planned results. • Implement action to achieve continual improvement of processes. • Identify the method of control of outsource processes. The biggest impact is restructuring the system into series of processes, and using them to generate performance improvement. Also the organization may take the opportunity to reevaluate its processes and remove activities with no added values. Mounir Soufyan Abbreviation: MAI=Measurement, Analysis & Improvement TQM=Total Quality Management (1) Joseph Juran was a 20th century management consultant; he founded the Juran Institute in the USA providing training and consulting services in quality improvement and lean management as well as 6-sigma certification. Juran was the author of many books on quality management among them “Quality Control Handbook” and “Quality Planning and Analysis”. Bulletin Issue 99 / October 2011 7 Project Profile The Princess Noura University for Women The PNUFW is a state-of-the-art twenty-first century educational facility located in Riyadh, Saudi Arabia, close to the airport road. It is the largest women-only university in the world and it is recognized as one of the world’s few mega projects. The facility is surrounded by a 4m high boundary wall which encloses 8,000,000 square metres, on the outskirts of Riyadh and includes academic buildings, administration buildings, a hospital, research centres, staff and student housing, schools, sports facilities, plant and utility buildings and a 5km long utility tunnel. The university has been designed to cater for 40,000 students and 4,000 employees at peak attendance. The university contract was awarded on 25 January, 2009. The project was principally split into four different work packages: Package 1 to be carried out by Saudi Oger; Package 2 by the Saudi Bin Laden Group; Package 3 by the ESEC-CCC Joint Venture and Package 4 again by the Saudi Bin Laden Group. Package 3, the main civil works undertaken by the ESEC-CCC JV was comprised of the construction of sixteen utility buildings with a covered area of over 228,000m2; six bridges and three flyovers; over 1,500,000m2 of asphalting; over 600,000m3 of concrete; a utility tunnel in excess of 5km running through the centre of the project, 12m wide and 6m high; the planting of 30,000 palm and shade trees and 800,000m2 of grass and shrubs; 870,000m2 of pavement interlock, tiles and granite; over 10 million cubic metres of earthwork cut and fill and fabrication; laying and testing of 550,000 meters of underground noncarbon steel piping. The main electromechanical installations were an electrical power system with total connected load normal 233MVA, emergency 38MVA, connected load of major substation 145MVA. The number of substations is 182. Major: 17 at distribution and generator plant, minor: 90 located in different buildings and 75 packaged sub-stations and laying of 3200km of cables LV, MV, HV and fiber optic. A chiller Plant with 26 centrifugal chillers and seven screw chillers with a total of 57,150TR cooling capacity and 2 x 25,000m3 chilled water thermal storage tanks. A boiler house with eight Hurst package boilers 64,000KW heating capacity and generator house with eight Caterpillar generators each 13.8KV, 5MVA. A solar heating system of 36,000m2, 3,600 collectors mounted on the roof of the warehouse with 17MW instantaneous peak power output, 28,000MWH yearly yield and district cooling and heating site networks with 240km carbon steel pre-insulated pipes, motorized isolation valves, pressure and flow control valves and other hydronic controls. A central BMS for the university building and networks with 20,000 connected points for P3 package with servers to cater for the 250,000 points of the whole university. A SCADA system for monitoring and control of the medium voltage power distribution system and low current systems including: data communication, IP telephony, CCTV, access control, fire alarm and real time location, complete with network facilities. A data centre for IT and low current integration with a 3.3 Penta-byte Tier 3 facility for data processing and storage, complete with a structured cabling system linking the different buildings to the application and storage servers of the data centre. The installation of over 320 pumps starting from 1,750HP down to 1HP and fabrication and installation of 1,700 tons of pipe supports and 12,000 tons of structural steel for the chiller building, the warehouse, platforms, rails and ladders. Some of the enormous challenges faced were procurement of three million metres of cable, 900,000 meters of piping, 239,000 fittings, over 3,000 units of equipment and 36,000 valves, completing of Package 3 in 24 months, mobilizing and maintaining a camp to cater for 16,000 people, mobilizing and providing a maintenance facility for over 2,300 items of plant and equipment, interfacing with the other packages 2, 3 & 4 works, drilling wells to source sufficient irrigation water to provide 15,000m3 per day. On Sunday, 15 May, 2011 we witnessed the ceremonial inauguration of the Princess Noura University by HRH King Abdullah bin Abdulaziz Al Saud. King Abdullah officially opened the university less than three years after laying the foundation stone. During the opening of the university, King Abdullah rode the train which links major sectors of the campus and toured the facilities. The opening ceremony was an impressive event and was received with great enthusiasm by all attendees from the government, diplomats, representatives of all companies involved and future students and university staff. The university inauguration was welcomed by the Saudi community at all levels. The inauguration marked the exceptional achievement of all involved, resulting in a world-class university, realized within a remarkably short time period. Hassan Moghrabi Project Manager, Control A water supply pumping station for potable, drinking, irrigation and fire fighting water with 63,000m3 capacity and 610km piping networks and drainage systems with storm and waste water site networks and 10,400m3 per day sewage treatment plant. 8 Bulletin Issue 99 / October 2011 Project Profile ...The Princess Noura University for Women ...Text Mechanical Works at the Tunnel Overview The Princess Noura University for Women is the world’s largest women-only university undergoing a transformation to become the first green campus in Saudi Arabia covering eight million square metres with an overall cost of $11.5 billion, a project which is expected to accommodate over 40,000 students and will feature 13 campuses, including those for medicine, dentistry, nursing, naturopathy, IT, languages, instant translation and pharmacy. The entire university project includes an administration building; a central library; conference centres; buildings for 15 academic faculties; several laboratories; a 700-bed hospital equipped with state-of-the-art facilities; housing for university staff; mosques; a kindergarten school, and exclusive amusement centres for families and students. this main tunnel were connected to the basement of several buildings in the project. The services linked through these branches reach the following: • Basement of colleges and researches centres. • Hospital and medical centres. • Connections with outside networks serving different types of facilities. All pipes branched from the service utility tunnel were directly buried underground while all chilled and heating water pipes are pre-insulated with leak detection system connected to project BMS systems. The services running in the utility tunnel are as follows: • Main chilled water pipes supply and return, supplied by a chiller plant having 54,000TR cooling capacity and 2 x 25,000 m3 chilled water thermal storage PNUW Project Architectural Schematic Plan The project was divided into four packages: Packages 1 and 2 include the buildings, colleges and the accommodation facility; Package 3 includes the infrastructure works utility buildings and roads while Package 4 includes the installation of a 15km high elevated train. CCC’s Scope of Work As a joint venture with El Seif Engineering Contracting Company Ltd , CCC executed all works under Package 3 which include 18 utility buildings, bridges, hard and soft landscaping, a 6km utility tunnel, fly-over bridges, a centralized chiller plant, a boiler plant, a generator plant, an SWT plant and the laying of 800,000 metres of a utilities piping network all over the whole area of the project. The Utility Tunnel Totalling six km in length, it is considered one of the biggest built to serve a university in the world and runs from the central utility plant buildings up to the different university faculties under the main spine area. Branches from Bulletin Issue 99 / October 2011 tanks. (CS pipes vary from 46” to 16”.) • Main heating water pipes supply and return. Supplied from boiler house having 32,000KW heating capacity (sizes for the main line vary from 24” to 12”.) • Internal fire system (12” ductile pipe). • External fire systems (8” ductile pipe). • Drinking water system (8” ductile pipe). • Domestic water system (24” ductile pipe). • Irrigation system (12” ductile pipe). • Electrical cable: high, medium and low voltage. • Telecommunication cables. • BMS cables. • SCADA cables. • CCTV cables. 9 Project Profile ...The Princess Noura University for Women Mechanical Works and A Tight Schedule Due to the great importance of this tunnel to the project and being crucial in achieving a time milestone set by the owner, the project management took all necessary steps along with our regional support departments and MOA to build the tunnel accordingly. We started by commissioning all the facilities required to meet this essential signpost: the manpower needed, the detailing of design drawings along with expediting delivery of all long lead material and equipment at the earliest possible time. The construction of the tunnel with the installation of all the mechanical works was scheduled to be completed within a period of 13 months. The table (opposite page) shows the quantities and the tight schedule to complete each mechanical activity. Piping Installation Challenges It did not take our management long to realize that the schedule would not be met without adopting extraordinary efforts and deep brain storming. Considering the tunnel’s size and scale, the quantities to be installed within a short time, the incomplete design drawings, the narrow space to work in, the difficulty of access of a construction location where many disciplines and other contractors were working all at the same time. Consequently, potential construction challenges and issues were reviewed and discussed with our construction manager. Each activity was deliberated over separately and listed with highlighted points as below. Supports Installation As a fact at the early stage, delivery time of material together with achieving of supports installation as per schedule will be a key to attain this milestone in a project, subsequently points were devised and agreed upon to be implemented. Tunnel Cross Section View Piping Installation Far from the oil and gas project execution of works, it was a new experience for most of our team having such type of construction, dealing with ductile pipes lock type installation, big pre-insulated pipes installation and being in such an extremely narrow working environment, next to that steps to find the solution are usually listed as, • Keeping our workers aware of ductile pipes installation procedure and related fittings all of time during a construction phase, as of avoiding any repair works and leaks later on. • Define the tools and process to install supports in line with walls cast at the field, embedded plates gathered with structural supports were a solution that make it faster and open a lot of fronts later on for piping installation. • Complete a comprehensive field investigation, considering all of factors around will possibly stop or delay our work scheme later on and report it back immediately to the concerns. • State a clear procedure in a field with survey team to lay out supports location as maximum accuracy could be achieved to assure later on supreme pipes alignments. • Keeping a maximum level of coordination with civil team about the interfaces points and delivery of embedded plate should they use to cast it in walls. 10 Excavation Work at the Beginning Bulletin Issue 99 / October 2011 Project Profile ...The Princess Noura University for Women ...Text Activity Scope Duration Supports installation ~ 4900 pieces ( Tonnage) 11 00 20 weeks Ductile Piping installation and testing ( Liner Meter ) 22 000 45 weeks Carbon Steel Piping installation and testing (Liner meter ) 21 000 29 weeks 23 6 weeks 1400 15 weeks Submersible Pumps (Pieces) Valves and expansion installation (Pieces) • Requesting all of the equipment adhered to such type of construction early e.g. side forklifts, electrical forklifts, portable welding machines and so on. • Arranging weekly meeting with civil team about the accessible areas for both pipes offloading and workers entrances. • Creating adequate tools to transfer the pipes and materials inside the tunnel. Hydro Testing and Flushing Due to the narrow space of work and delay in design of submersible pump connections with the outside network, it was strong-willed to hydro test each system in tunnel separately as one line in a one test pack starting from beginning of the tunnel till the end, this create us a biggest and most risky challenge during construction of tunnel all over. • Utilizing the roof opening as much as possible before being cast on the site. Finally and after deep brain storming we ended up with four test packs each one of them has length varies from 6 to 8 km with testing pressure about 25 bar. • From a constructability point of view, it was compulsory to keep the installation of the pipes there in a sequence from top till down. Preparing previously maximum precautions at the time of each test by: • Reviewing with material department the quantities and permanent material approved to be purchased to avoid any uncertainty afterwards. • Coordinating with the Procurement Departments the arrival dates of the lead material and notifying the civil team the priority areas we should work in accordingly. • Making sure that all valves, blinds and flanged connections are well tight and torque as per specifications. • Identifying clearly the access areas on case of emergencies. • Notifying all parties working in the tunnel about this event a week beforehand. • Conducting weekly meeting with the Engineering Department as of reviewing the drawings issued for the construction and feed them back with all predicaments, as built and corrections. • Conducting many walkthroughs with safety and our QC team prior a test’s time assuring that all of punch items already closed, the tests are ready and safe as maximum. By having completed the fabrication of spools and installation all of supports on the field, the team had another massive challenge and short time to focus, that was how to recover the lost progress affected by late material deliveries (CS material and valves). • Prepare the sucking pumps, temporary hoses and connect them to nearest outside manholes. Getting to the tunnel’s access point to offload the material and for our team to move was getting so difficult while the existence of many disciplines working at their peak time also make it harder. But even so with all of the above, neither a congested place nor a short span to finish could stop us to see a light at the end of the tunnel and stop enthusiastic team from achieving the challenging targets. With the installation of both supports and lines complete 11 days ahead of time, the preparation for the next challenging target (hydro testing) was made easier. Bulletin Issue 99 / October 2011 • Difficulty of communications inside the tunnel due to the lack of mobile telephone signals compelled us to keep a watchman every 100 metres in order to ensure a fast response in case of emergencies. On 30 September, 2010 a prime project milestone was accomplished with finishing a chemical cleaning and major reinstatement works inside the tunnel, with a wise leadership of our management, strict control and site team well planning, CCC proved to all that it can do a job as per time scheduled and as per highest quality could be delivered. As of consultant point of view, we were a sign of proud, extremist sample of high quality and hard working for everyone in project. We wait 5 months more until got first requisition from other packages to connect their college’s lines with ours ready on the tunnel. 11 Project Profile ... The Princess Noura University for Women Achievements After all preceding challenges had been conquered with a lot of efforts and persistence of a dedicated team that worked inexorably to meet the set targets; finally we reach with such remarkable achievements that: 1. As of being in line with them all of time, we finished all of mechanical work’s installation at the same time civil finish their work in tunnel. 2. Installation of the 22,000 liner metre of ductile pipes without having any damages or leaks at the installation and testing stage (it was a case study for manufacturer delivered us the pipes and the fittings). 3. Installation of 1.100 tonnage of supports 1 month ahead of schedule. 4. With all hard conditions inside the tunnel and difficulties during the erection phase, we completed the whole tunnel construction, commissioning without any LTI or any serious injuries. 5. In spite of overcrowded area, all preinstalled pipes were handled efficiently with maximum care to result by the end with 20,000 liner metre installation without any major insulation or pipe’s damages. 6. We completed the setting up of all major activities in the tunnel without even lose single bolt or asking for any additional material. 7. Testing of four carbon steel systems, with total liner metre for each 7,000 metre as one line without having any leaks, slippage or defects. 8. Successfully pre and commission all of the lines without having any major neither a minor problems and as per settled time. Supports Configuration Drawing strict follow up, our mechanical construction manager was a major key factor for initiating a work in there and solving ahead any problem might be revealed during the construction. 2. Timely and perfect completion of supports fabrication at the project Fabshop. 3. Posting on the tunnel wall the installation procedure during a construction phase along with assigning a twice week site meeting to recover progress and functioning backlog. 4. Early collective of the data linked with each construction activity on the tunnel before getting to start e.g. lessons learned from similar projects, manufacturer specifications and his customer’s feedback about the same material, best practices and so on. 9. Work has been done efficiently with minimum number of manpower (208 labourers at the peak time) and minimum amount of equipments. As result of that a tunnel productivity factor was the best among all of the activities in the project till the end. 10.Successfully implement a new piping 3D modelling system in a construction. Astonishing reward we had a side of above, that we got a satisfaction and contentment of the both client and project consultant as of our high quality of work and devoting our maximum, day and night to finish on the time. There were many ministry witnesses visit for the project and in every time a tunnel was sign of admiration and appreciations by in related witnesses. Key Factors of Success 1. With his wide experience, working in similar type of construction, his ultimate support and 12 Congested working space Bulletin Issue 99 / October 2011 Project Profile ...The Princess Noura University for Women ...Text 5. Coordination weekly meeting with Civil, Engineering and Procurement Departments allied all of interfaces point. 6. Accurate and perfect reporting systems, rather than using a zones criteria in reporting (1 km each zone) our C.M was made a decision earlier to divide tunnel into 69 main areas; defined later as MT; each MT has 50 m length. This helped us to track each problem or any activity in the tunnel easily with high performance. 7. Specially made SIDE forklifts and chargeable MINI forklifts that requested formerly by our management, find a solutions for a lot of critical problems faced later during the installation. 8. Many erection methods were developed on the site field helping us to move in faster in progress and do it as per highest quality of work, especially during supports and ductile piping installation. 9. Look ahead planning, and study well all of our demands antecedent to avoid any unheralded surprises could affect our progress. 10.Fast recovery plans settled out by our construction manager to mitigate the delays in engineering and materials delivery by highlighting all defects and embark on corrective actions accordingly. 11.Excellent safety team we had and their awareness all of the time there by work we do and steps shall keep our workers always with maximum precautions. 12.Ultimate cooperation of project’s consultant and his subordinates by speeding up all of the RFI’s or site clarification requests issued under tunnel’s name. In addition to the above, facing the challenges, successful plans and adapting the instructions would not have been valid without having such a well experienced management team before us and amazing CCC heroes on the site field had a lot of elbow grease and persistence, worked relentlessly to meet this remarkable milestone on time and creating another successful story for our beloved CCC. Haitham Khader Msaeed Section Engineer Mechanical Bulletin Issue 99 / October 2011 13 Feature The Pipeline Enterprise between Iran, Iraq and Syria, and the European Blue Stream and Green Stream Pipelines. Although energy transmission lines have been in operation for about a century, they still have a bright future ahead. Increasing energy demand, utilization of non-conventional energy sources such as shale gas in North America and coal seam gas in Australia, the discovery and development of more oil and gas basins around the world in areas outside the historical energy regions, and the rise of new potent energy players such as Russia and Brazil mean pipeline construction is destined for more prominence in the immediate future. With potential plans to shut down nuclear plants in Japan and Europe following the Fukushima disaster earlier this year, nuclear power is now a less favourable energy option, and this is more good news for pipelines. From pure cross-country transmission systems, pipelines have evolved into strategic geopolitical and economic tools that help shape the future of the world. Pipelines have impacts that extend to whole regions and present investment and development opportunities for countries and societies alike. The Caspian countries could not have made use of their new sources of wealth had their oil and gas not reached the markets in a feasible manner. On the other hand, Georgia and Ukraine benefit from their being transit countries to have their cut. Pipelines have become so significant in our modern era that world leaders often get directly involved in strategic pipelines decisions, forcing re-routing in some cases, promoting peace or even severing ties in others. But politics and engineering are not the lone driving forces in pipelines. Pipelines have always been considered one of the cleanest means of energy transportation, yet they can still leave a considerable environmental footprint, especially during their construction phase. With the level of awareness of sensitive environmental issues quickly gaining momentum and spreading from the developed to the developing countries, more environmental legislations are being put into place; mitigation measures now start from the design board and do not finish with reinstatement. And the social impact these pipelines leave in their path is also scrutinized; the well-being of all affected societies and stakeholders weighs in immensely on crucial pipeline decisions. But energy is not the only driver for pipelines. Water has and will always be the source of life; it is the oil of the future. Transporting it allowed Roman cities to grow and prosper, and water pipelines are bound to play an equally important role in the future. Within CCC, the Pipeline Department followed a different school of operation than the traditional location or function-based schools, employing the matrix structure concept whereby operation goes hand in hand with the area management. This organization ensured continued leadership, proper logistic support and sustained technical expertise, and ultimately guaranteed the smooth operation of projects. We approached our projects from a much broader perspective, building up - brick by brick our capabilities to meet much bigger challenges. Gearing up with the right know-how, technology, and resources, we were able to undertake bigger and longer pipelines worldwide. These efforts were strengthened by the introduction of pipeline engineering capabilities within the CCC group, and by establishing Sicon O&G in Milan. From pipeline constructors in our traditional areas, CCC Pipelines are expected to spread wealth by investing in the communities along the route, be it by adding job opportunities, teaching local manpower, establishing trade training and education facilities, and setting up health plans and medical centers. In short, the pipeline has to disseminate higher standards of life. This political and economic persona of pipelines is even reflected sometimes in their naming such as the proposed Peace Pipeline in South Asia, the Islamic Pipeline 14 Bulletin Issue 99 / October 2011 Feature ...The Pipeline Enterprise ...Text has now emerged as a Global EPC Pipeline Contractor. The Pipeline Department is evolving to meet this growth and is in the process of becoming an established business unit within the Group. Our pipeline projects opened up new frontiers for the whole of CCC, well beyond our MENA backyard. Having strong capabilities paved the road to penetrate previously unchartered territories. We have successfully built difficult projects in remote areas including the Botswana North-South Carrier pipeline, the Karachaganak pipeline in Kazakhstan, the Mozambique-to-South Africa GLMC pipeline, the BTC/SCP pipelines Azerbaijani sections, the Madagascar Ambatovy NickelSlurry pipeline, and more recently the Australian coal seam gas pipelines APLNG and QCLNG. Our direct relations with major international energy operators such as BP, BG, Conoco Philips, and ADNOC, and partnerships with renowned international contractors, vendors, and service providers have enriched our portfolio and exposure, and made the CCC brand an international name in the pipeline industry. Our reputation as a reliable EPC contractor built up throughout the years is now paying off very well. Australia will not be the last continent we invade. Latin America will likely be our next target; Brazil is calling us with its very rich offshore fields. We are continually looking at ways to improve the business by taking further steps through the introduction of more concepts and technologies to our operations. In the early nineties, CCC managed to introduce the first pipeline computerized automatic welding crew in the region in Kuwait. Other improvements included the successful introduction of several joint coating application methodologies, mechanized double jointing facilities, automated pipeline monitoring solutions, computerized nondestructive testing, specialized pipe laying and welding equipment, and specialized crossing technologies including HDD and micro-tunneling. These developments and Bulletin Issue 99 / October 2011 the efficient provisions in terms of logistics and resources within CCC have boosted our competences and enabled us to undertake sizable pipeline projects in the non-traditional geographical areas, and even beyond the pipeline sector. When we did not succeed in getting a pipeline in PNG, we still managed to get a good slice of the job with the award of the associated airport and a sizeable portion of the LNG plant! Continuous research and study of the latest trends in the pipeline industry sector remains one of our major goals. Using modern technologies is the only way forward for CCC. This translates into higher environmental protection, enhanced quality and cheaper costs, yielding benefits to all stakeholders including pipeline owners, contractors, and communities. Nevertheless, CCC’s best assets remain our dedicated staff and workforce who have always delivered in the most challenging conditions, never letting the CCC family down. Rashid Shuhaiber Executive Director Business Unit (Pipelines) 15 Feature Australia Pacific LNG Upstream Project Phase 1 - Pipelines, August 2011 Australia Pacific LNG is a joint venture between Origin, ConocoPhillips and Sinopec. The Australia Pacific LNG project includes the development of Australia Pacific LNG’s substantial coal seam gas resources in the Surat and Bowen Basins over a 30-year period, a 520km transmission pipeline, and a multi-train LNG facility on Curtis Island, near Gladstone, Queensland, Australia. Australia Pacific LNG announced on the 4 August that MCJV was awarded the multi-million dollar contract to deliver the main gas export pipeline for the project and provide more than 1,000 construction jobs to the region. This contract win demonstrates MCJV’s ability as leaders in helping to shape the future of Australia’s resources industry by delivering on one of the largest LNG projects in Queensland. The delivery of the 30”, 36” and 42” diameter gas pipeline and associated facilities, follows MCJV’s completion of the Front End Engineering Design (FEED) and early works contract awarded in December 2009 by Australian Pacific LNG. Left to right: Page Maxson (Australia Pacific LNG), Mark Twycross (McConnell Dowell), Jodie Buckle (Origin), Moujally Jabara (CCC), Janet Hann (Origin) On the same day, CCC and McConnell Dowell signed the Execution Phase Joint Venture Agreement. This agreement gives continuity to the joint venture relationship already established between the two companies during the early works phase. This essentially is the commitment of both organisations to now jointly deliver the pipelines component of the Australia Pacific LNG Project. MCJV has been heavily involved in the early works of the Australia Pacific LNG pipelines project, working in an integrated team with Australia Pacific LNG for the delivery of the Project Front End Engineering Design (FEED) comprising: • Review of all pre-FEED documentation. • Completed and delivered FEED. • Project planning and procurement assistance (Free Issue Material). Left to right: Zahi Ghantous, Mark Twycross, Moujally Jabara, Mark Barrows • Participation in pre-qualification process of and site visits to pipe mills. • Design input into route selection and alignment sheets. • Survey and preliminary geotechnical and LiDAR studies. • Execution of early works scope and contractual deliverables. • Preparation of pricing package and scope definition for main piplines EPC, High Pressure Gas Network and Water lines. • Completion of EPC risk allocation for lump sum price for the MCJV scope on an open book basis. With Notice to Proceed expected to be issued to MCJV at the end of August, the pipelines project moves into full execution phase. Having already worked under the early works contract, this further milestone positions MCJV 16 Left to right: Subhi Khoury, Zahi Ghantous, Fiorenzo Mastromattei, Moujally Jabara, Mark Barrows, Ramzi Jabara Bulletin Issue 99 / October 2011 Feature ...Australia Pacific LNG Upstream Project Phase 1 - Pipelines, August...Text 2011 to ramp up activity on various fronts. The detailed design commenced in November 2010, with the team now working towards the finalisation and completion of detailed engineering by the end of March 2012. Construction commenced on the Callide Rail Siding in mid-August, in conjunction with Queensland Rail National. This rail siding will be commissioned at the end of October 2011. The first pipe is scheduled for delivery in January 2012 and will be stored in the adjacent laydown area. The decision to utilise rail and hence the need for the rail siding for the haulage of pipe came from the recommendations of the Environmental Impact Study (EIS) and the Queensland Coordinator General’s conditions for the project. This initiative will ensure community and personnel safety by the removal of haul trucks and preservation of local roads, and will also minimise traffic movements around the port of Gladstone. The major milestones to ensure 1st gas is delivered on schedule are: • Laydown areas and camps - Oct 2011. • Survey Works - March/April 2012. • Main line Welding - June 2012. • Substantial completion - December 2013. • Final Mechanical Completion - April 2014. • First LNG Shipment - 2015. MCJV has contracted with the local training facility run by Gladstone Area Group Apprentices Limited (GAGAL): this organisation provides the local community with indigenous employment and pre-employment training programmes. The project team is currently refurbishing the second floor of the facility in Biloela, Central Queensland. On completion, the facility will boast seven offices, two fully equipped training rooms, 18 workstations and amenities. MCJV will also lease the space for the two year period during project construction. This initiative provides a project office for MCJV and Australia Pacific LNG during the construction of the pipeline and the development will leave the legacy of a modern training facility for the community. MCJV will work closely with GAGAL to provide valuable ‘real life’ experiences for apprentices and trainees on the job, where possible. Ultimately, MCJV will provide the community with Bulletin Issue 99 / October 2011 a highly skilled workforce for the future, while ensuring its own workforce during construction. The Brisbane Project Office is residence to both the MCJV and Australia Pacific LNG representatives for the pipelines component of the project. This building provides the opportunity for a multi-faceted delivery team, promoting ‘best for project’ outcomes for both MCJV and Australia Pacific LNG. The capacity of the building is for about 170 people and will accommodate the project team until the end of construction and asset handover. With the construction phase fast approaching on the Australia Pacific LNG pipelines project, this is an opportunity for CCC to be involved in a world-class project and be at the forefront of the Australian LNG Industry. CCC will see new opportunities open up within the South West Pacific Region as a result of this valuable experience in a new market. Zahi Ghantous CCC’s project Manager APLNG Pipelines Project 17 Feature Pipeline Estimation At the time I decided to sit and write this article, the brilliant news of CCC and our partners, McConnell-Dowell, signing the APLNG Pipeline contract arrived from Australia, marking once more a prestigious milestone in the global pipeline industry. Despite the world recession of the past few years, demand for new pipelines has not decreased, making their construction one of the most vibrant, dynamic and competitive markets in the oil and gas industry. It is foreseen that around the world there is approximately 200,000 km of pipelines currently being planned and under construction. Of these, approximately 140,000 km represent projects in the planning and design phase while 60,000 km reflect pipelines in various stages of construction. Hence considering the significant volume of future pipeline projects to come, CCC is certainly keen to be part of this huge worldwide development. In the past ten years CCC has become a major international EPC Contractor for cross-country pipelines having already constructed pipelines of an accumulated distance of 1.75 times the circumference of the moon: this achievement has not happened by accident. Having said that, it becomes apparent that CCC is certainly ready to tackle the huge volume of bids to come, develop competitive and comprehensive proposals, and accordingly build the awarded pipelines. This readiness is obvious with the presence of a dedicated, talented, efficient and professional proposal team of Civil, Mechanical and Electrical disciplines, who with their tremendous effort have achieved putting the Pipeline Sales Estimation & Proposals Business Department at the core of CCC’s business. I think that everyone in the company is by now aware that Sales Estimation & Proposals for EPC Pipelines is not just crunching numbers and compiling figures to reach the right price. The first thing every one of us should have in mind is that the pipeline industry is a very competitive environment. As such, it requires thorough reading and analytical minds for proper evaluation of the market, identification of the right partners, establishing the best strategies and execution plans and sizing up the competition through commitment, clarity in communication and awareness of the market. Formulating the execution strategy for a pipeline job is a crucial key for success. Yet many variables and challenges need to be taken into consideration, some of which 18 are the remoteness of the location, the nature of the terrain, the complexity of the logistics, pipeline route obstructions, dealing with local communities, environmental constraints, just to name a few. It is also worth mentioning that most oil and gas pipeline projects are built in very remote and harsh areas, uninhabited land, often located in non-traditional countries for CCC. This fact introduces countless unknown parameters which the proposal team needs to address right away, reflect them in the proposal and bring these crucial issues to the attention of CCC executives for their counsel. When tackling CCC non-traditional areas of operation, the proposal team would start by conducting a country survey and site visits, identifying potential local suppliers and subcontractors, availability and level of skill of local labour and trades in addition to legal issues, taxation, political issues, security, and so on. Market investigation and survey for procurement and manpower opportunities Bulletin Issue 99 / October 2011 Feature ...Pipeline Estimation ...Text with major oil and gas players such as Exxon Mobil, BP, BG, Shell, ADNOC, PDO, GASCO, ADCO, Sasol, Origin, ConocoPhillips, and many others, is an art in itself which requires the full dedication of the area management, hard work and executive management commitment. This will be achieved through lengthy and vigorous meetings to reach a win-win situation that will please the client and meet CCC requirements. It is worth mentioning that the Sales, Estimation & Proposals Department’s responsibility begins at the stage of identifying the tender and is completed at the award phase. (Keep in mind that most of the time this department is requested to handle the first phase of the project in terms of controls, subcontracting and so on.) are followed by internal workshops between various CCC departments that will eventually lead to the formation of the successful execution strategy to be followed. This will be achieved only with the dedication and full support of CCC area management, internal departments, and in particular the Plant Department. Yet another critical issue is identifying all associated project risks involved and to reach decisions on how to mitigate those risks. After all of the above have been well studied, the EPC proposal team will ensure the agreed principles are reflected in the bid, including the number of spreads, camp requirements and all execution details, accordingly starting to put together the technical and commercial proposal for submission to the client, paying special attention to the health, safety, environmental and quality aspects of the project. Submission of the proposal is normally followed by the fierce negotiation stage for all technical, commercial and contractual conditions. Being successful in negotiations Bulletin Issue 99 / October 2011 Moreover, dealing with partners in different types of contractual agreement such as consortium, joint venture or subcontract basis requires lots of effort, coordination and skill. Understanding each partner’s work ethics, culture, systems, work process and mentality requires us to be flexible, open-minded and straightforward to be able to achieve a win-win situation for both parties, committing ourselves to the principle of the famous statement “two cultures as one team”. For a partnership to be successful, it is crucial to build one team working together to achieve a common goal, implementing a small-sized steering committee to ensure a quick decision-making process. Both parties need to complement each other, with one leader and sit in front of the client as such. In order to achieve this one team approach, communication and trust between the partners is a key factor that can open the doors for successful team building. In conclusion, it is proven that the Sales, Estimation & Proposals for Pipelines Department’s performance is key to the continuation of CCC’s success in the EPC business. Rest assured that our proposal team will exert all efforts, knowledge, skills and dedication to meet all concerns and expectations in a very competitive environment. Finally, I must say well done to our partners and proposal team, and offer my gratitude to our management for their trust and commitment, as without this seamless interaction, success would not have been possible to achieve. Hisham Kawash Manager, Estimation & Proposals 19 Feature SAS FFD Project: Another Major Development by ADCO The overall Sahil-Asab-Shah Full Field Development Project (referred to as SAS FFDP) is one of the major projects undertaken by ADCO in the western region of Abu Dhabi with an initial investment value that exceeds US$5 billion. The aim of this project is to boost oil gathering at these three fields ahead of transmitting the crude to Ruwais for further processing and exporting. In early 2009, ADCO awarded their prestigious project for Sahil and Shah Full Field development to the consortium of Tecnicas Reunidas (TR) and CCC. TR is the responsible party for the overall engineering and procurement and CCC is responsible for construction and the EPC for buildings and the two main oil lines from Sahil and Shah to Asab. The project objective of this section of the overall development was to raise the current production level from 55/50 Kbopd in Sahil and Shah respectively to 100/70 Kbopd. One of the main project challenges is the remoteness of the Shah area (260km from Abu Dhabi towards the empty quarter of Saudi Arabia) which necessitates a major road development to access the project site. The amount of soil to be cut and filled remains a major undertaking in the project scope. The scope of work for this project ranges from upgrading existing facilities and new installations at five locations of degassing stations (central and remote), development of several wells and associated flowlines, water and gas injections lines and two main oil lines connecting Sahil and Shah central degassing stations with Asab central degassing station. An excess of around 340km of flowlines and 110km of main oil lines will be laid by CCC for this project. The feature of this bulletin issue is about pipelines, so the details provided hereafter will focus on CCC’s scope in the EPC of the two main oil lines (MOLs). The detailed scope of work for the two MOLs in terms of numbers is as per the chart. out at NPCC yard in Musaffah. Purchase orders for all other material and equipment have been already placed and delivery to site commenced back in 2010. The project logistics are quite complex. CCC has conducted two workshops for constructability and SIMOPS which were quite essential for availability of several contractors within the vicinity of the project sites. This matter has necessitated conducting as well dedicated interface management sessions that are currently being carried out with several contractors on a weekly basis. As mentioned earlier, being one of the major challenges in the project, both pipelines traverse massive sand dune desert areas which necessitated utilization of a huge The detailed engineering and procurement services for MOLs have been carried out by CCC EPSO in Musaffah including all related stress calculations. The hydraulic studies were carried out by TR being part of the overall hydraulic scheme for the project. CCC EPSO actively participated in TR engineering sessions and workshops for EIA/EBS, HAZOP, SIL, ENVID, HAZID, Noise Study, HSEIA, QRA, and PHSER. Seamless line pipe for the main oil lines was procured from Tinaris Dalmene in Italy and the 3-layer polypropylene coating was carried Description 20 Qty. 1 Total length of the two 3LPP MOLs 110 kms 2 Diameter of both MOLs 3 Total number of launchers and receivers 4 4 Total number of valve stations 3 5 Total number of crossings including 1 HDD 6 Total length of FOC laid across MOLs 16” 210 172 kms Bulletin Issue 99 / October 2011 Feature ...SAS FFD Project: Another Major Development by ADCO ...Text Scope ROW Stringing Welding FJC Lowering Backfilling Hydro testing Meters Meters Meters Meters Meters Meters Meters Meters SAHIL MOL 48,000 45,943 39,734 36,663 23,986 23,963 23,802 0 SHAH MOL 62,000 61,474 59,387 56,329 40,076 31,261 23,523 0 Overall 110,000 107,417 99,121 92,992 64,062 55,224 47,325 97.65% 90.11% 84.54% 58.24% 50.20% 43.02% Area (%) 0.00% fleet of earth moving equipment to construct the ROW. ADCO has implemented unprecedented very stringent HSE regulations and work permit system in this project. However, The ROW construction was completed according to the plan and to the full satisfaction of ADCO. As most suitable gatch burrow pits in the vicinity of the pipelines ROW were depleted, the construction team faced difficulties in finding alternative sources and was forced to import gatch from about 100-120km away from pipeline routes. Several water wells were drilled to secure water supply for earthworks. The Main Oil Line Welding Procedure Specifications were successfully qualified on 27 July 2010 and the pipeline laying and welding activities commenced on 6 October 2010. The welding activities started with a high repair rate which was analyzed in detail, controlled and brought down to acceptable levels. Most of the weld repairs were resulting from Elongated Slag Inclusion (ESI) and Lack of Fusion (LF) as shown in the charts. The current overall weld repair rate is below 3% which considered quite well for manual pipeline welding. 2 QMS audits were jointly conducted by MOA and TR Corporate QA Teams. Both audit results were rated good. The total number of RFI’s issued is 8,630 and the number of NCR received is four yielding a ratio of pipeline NCRs to total number of RFIs attended of just 0.05%. Currently construction has progressed significantly and it is expected that most MOL activities will wrap up by year-end. The table summarizes the current achievement at end of August 2011. Hydrotesting procedures and profile have been completed and the activity is planned to commence shortly. The two main oil lines will join a common corridor of Asab central degassing station in the last 6km approaching CDS. This matter is being coordinated with Asab project contractor. CCC will carry out construction of the receiving stations for both MOLs in Asab CDS including the tie-in of the FOC’s. This matter has been continuously discussed in the weekly interface meeting with the Asab contractor. The overall project execution has completed an excess of 15 million man-hours without LTI which is considered a record by ADCO for a huge and diverse worksite where CCC crews are working at more than 20 locations simultaneously. SAS project management is quite confident for accomplishing all project targets related to the EPC work for MOLs, marking another major achievement for CCC in this field. Moreover, this matter was recognized and highly praised by ADCO’s senior management, making it an example for other contractors to follow. Bassam Addada SAS Project Director Bulletin Issue 99 / October 2011 21 Feature The Challenges of the Malagasy Experience Pipeline projects have taken us into many distinguished areas around the globe, but few have been as intriguing and challenging as the Madagascar pipeline, both on and off the job. For most of us with the Gulf working background, the Malagasy experience started even before we landed at the small airport of Antananarivo. Trying to pronounce the name of the Malagasy capital was our first ordeal; luckily the locals call it “Tana” so we could save ourselves the babbly embarrassment. But as the plane landed in the realm of King Julien and his aide Maurice (ask your children about these furry primates), the windows revealed vast areas of mountainous nature and thick vegetation that seemed infinite, in contrast to sand dunes and desert plains. Green overwhelms the view so much that one feels Madagascar is the proverbial definition of the colour itself; but Madagascar is much more colourful. The “Red Island” as it is called due to the colour of its soil, is a nature-lover’s paradise; an amazing wealth of flora and fauna lies in between the green and red. In fact, the island has the world highest number of endemic species (almost 80%). It is home to the famed lemur and fossa (pronounced foossa!), and has a very rich marine life as well; some of us even enjoyed close encounters with dolphins and whales on the Indian Ocean coast. But beyond the native colours lies a different tale. Taking the short flight from Tana to Tamatave, the port city where our project offices were established, was quite pleasant and fortunate. However, the sole road connecting these two cities and in effect the project locations was a narrow, mountainous, and curvy road (literally nauseating) with regular congestions due to the heavy truck traffic and the numerous villages that have mushroomed chaotically along it. Further frustration builds up virtually all the time, as endless traffic jams occur after traffic accidents and side collapses. baths and for washing clothes, and the grassy sides of the road are the natural dryers! Sometimes you feel that the twentieth century has stopped short of going there. Along with poverty come the usual suspects including ignorance, crime, theft (diesel being the favourite), corruption, and child abuse. Yet although the vast majority of the population is illiterate, it was nicely surprising to see kids walking to schools everywhere, in the most unexpected locations, in their tidy uniforms but bare feet! The population, although mostly Catholic, has its own version of mixing traditional beliefs with the teachings of the church; sacred trees and stones abound, the elderly are very much respected and their blessing had to be sought before enter- Distances in Madagascar are measured in hours, not kilometers. One can imagine the internal logistic hardships that come along. Like many African countries, poverty is predominant in Madagascar, in some areas to a level that we cannot conceive living in our dainty villages and concrete cities back home. Villages are literally clusters of power-less water-less wooden huts; nature is the native restroom, rivers are used as communal 22 Bulletin Issue 99 / October 2011 Feature ...The Challenges of the Malagasy Experience ...Text rivers, wetlands and swamps all compounded the complexity of construction. Add to that several ecologically and environmentally sensitive areas; human activities were already destroying this natural beauty so we had to have the consciousness to minimize our own footprint. Try fitting all that into an already tight schedule of a high profile project. ing village lands, normally followed by a drinking feast. The challenge of constructing a pipeline through these regions was an extraordinarily enriching human experience indeed, where our crews and staff had to adapt to the rules of surrounding societies, many of whom were actually employed on the job. The Madagascar climate as well was very different from what we were used to. Here it either rains continuously or rains continually (work that out English language buffs!); the rainfall in the driest month by far exceeds that of London’s wettest! Cyclones are frequent, a minimum of three major ones yearly, and some of which had devastating effects. Unusual site conditions including muddy and slippery rights of way, rock mountains, dense tropical forests, It is in this challenging environment that we had to build our project: 216km of cross country slurry pipeline and 65km of tailing lines. Nothing here was on our side. Getting through the harsh and rugged terrains was a feat on its own. The red soil, after the slightest rain, was muddy for several days, preventing access to the jobsites. The gravity-driven design of the pipeline necessitated deep cuts into the mountains, often exceeding 80M or a 30-storey building, and a huge amount of earthworks totalling almost 10 million m3. The restrictions impeded the construction of reasonable pre-welded pipeline strings and the majority of the pipeline had to be welded in short sections with excessive cold bends. The noncontinuous access to sites also restricted the maneuver and logistics of resources which resulted in forming mini projects along each access. And although we had experienced other challenges while constructing pipelines in desert terrain, sand dunes, sand storms, in sun, in heat and humid weather conditions, working on the ASPI project posed a series of extraordinary challenges. In fact, the project was an unconventional pipeline necessitating unconventional execution strategies. Nevertheless, we made it. We persevered in the most difficult conditions; we went through a serious political unrest period; we overcame the French language barrier. These obstacles only served to empower our dedicated teams and we delivered. In short, Madagascar was a true outof-this-world challenge, and a unique pipeline experience. Marwan Anas Project Sponsor (ASPI) Bulletin Issue 99 / October 2011 23 Area News Qatar Ras Laffan Port Expansion Project Celebration CCC/TCC JV has once again proved its effective delivery of strategic management in terms of executing construction works and enforcement of safety conduct as it celebrated its achievement of 30 million man-hours without lost time incident at the Ras Laffan Port Expansion Project on 30 May 2011. This also marked the first time in the client’s (Qatar Petroleum) history to record such a milestone. With the combined efforts of CCC/TCC RLPEP Management in conjunction with the cooperation of the construction group, the Administration Department and the entire HSE Team, the attainment of this success of the project really proves that it is not far and impossible. In recognition of this momentous occasion, two separate celebrations were organized. A special dinner was given to all the personnel as well as to the subcontractors residing at the RLP Camp on 5 June. On 16 June, a special lunch was arranged at the RLP Camp Senior Mess Hall which was attended by CCC/ TCC and QP management and staff. Various dishes and refreshments were especially prepared and served to the guests by the Shaqab Abella Catering made possible with the support of the Camp Manager Ihsan Chayeb. A short programme was conducted during the celebration. Imad Khaled welcomed the guests and thanked everyone. QP Project Manager Nabeel Mohammed Ali Alrashid Al-Buenain graced the occasion and expressed his appreciation of CCC/TCC’s safe work and team effort. The undersigned, as project HSE Manager, thanked each and every employee, subcontractors and client for their contribution towards achieving 30 million manhours without LTI. (See the letter of thanks.) Buks Beukes Project HSE Manager LETTER OF THANKS Dear ALL, Today, Monday 30th May 2011, the RLEP Project has reached yet another RECORD MILESTONE by achieving 30 MILLION MAN-HOURS without a LOST TIME ACCIDENT. It took hours and hours of coordination and communication to make it all happen safely. We have hundreds of people involved on site, facing each other day to day. The hard work and desire to make it happen safely has paid off with the reduced number of people injured on the worksite. As I write this we have completed 286 days without a recordable injury on the Project, This is something we have NOT accomplished for quite some time, Many, many families should be thankful that their loved ones has not been injured on the project. This has been accomplished because we have many tools in our SAFETY TOOLBOX which are being refined and used in better fashions each day and every week. Some of these Safety Tools are the Start Cards in the mornings, The Special Safety Stand downs, Work permits, JSA‘s, Safety Rules, Safety Meetings and Regulations and our Training Programs on Awareness Training and Hazard Hunting. Each of these tools plays its own part in protecting our workers from harm and injury. By achieving 30 million man-hours without a LTI we are setting records in milestones, but remember these records reflect that we are setting records in hurting fewer and fewer people on our project, and that is something to be proud of. Each and every one of you is on the brink of being the ELITE in Performance here on the RLEP Project. Each injury we prevent brings us closer and closer to new records of NOT injuring our people-our friends and colleagues. Remember we CAN go farther, We CAN reach new milestones in Safety, We CAN improve on the great performance we have now. Most of all, We CAN prevent many more injuries on the Project. All it takes is HARD WORK. In conclusion, I again want to express my sincere gratitude for each and every member of the RLEP Project including our CLIENT and Sub Contractors for their dedication, hard work and care for our workers and their colleagues. Regards Buks Beukes 24 Bulletin Issue 99 / October 2011 Area News Qatar LNG Plant Shutdown Projects in Ras Gas, Qatar Following the completion of the RGX 6/7 and AKG2 Projects, our RGX team has been executing brown field (live plant) projects in Ras Gas for Chiyoda Technip JV (CTJV) and Chiyoda AlMana Engineering Limited (CAEL), including LNG trains 1/2/3/4/6/7 shutdown related works. Plant shutdown projects are extremely challenging in the following aspects: • Timely mobilization of trained and experienced manpower; safety training; and qualification. • Timely inspection and mobilization of equipment. • Timely completion of pre-shutdown related works, including availability of project deliverables, material procurement, readiness of required special tools or specialized contractors and the establishment of communication channels. • Preparation of shutdown packages including clear scope definition, hourly based schedule preparation and resolution of activity clashes with other parties. ager H. Al Muhannadi during the celebration which was held on 21 June at the Four Season Hotel in Doha. This was a token of appreciation from Ras Gas for the remarkable work carried out by our RGX team on both critical path projects RGP328 (TR3 GT’S DLN retrofit) and RGP403 (Demisters replacement of suction drums 36/46-V007/010) which were safely executed in 28 days; LNG Trains 3/4 shutdowns from 13 May to 9 June with 560,280 man-hours without LTI and completed ahead of schedule. Rabih Rouwadi Construction Manager •Logistics to cover for the 24/7 work scheme during plant shutdown window, including transportation, messing and communication. • Close monitoring of daily activities as per schedule, and schedule updating every shift (12 hours). • Close communication with all stakeholders through daily meetings and site walks. • Raising the team’s spirit and motivating the team by creating win-win situations with clearly defined targets and goals to meet the challenging shutdown schedule. A memento and certificate of appreciation were presented to CCC by RG Operations Group Man- Bulletin Issue 99 / October 2011 from left to right: Hamad Al-Muhavvadi, Rabih Rouwadi, Fahad Al-Khater 25 Area News Palestine The Exhibition Centre in Bethlehem In early June CCC Chairman Said Khoury hosted a luncheon at the Exhibition Centre in Bethlehem. itual leaders in Palestine. There were seven heads of different churches as well as the head of the Islamic faith. Also attending were several Palestinian ministers and other officials. This venue is owned by CCC and the Palestine Investment Fund and the luncheon was in honour of all the spir- Samer Khoury President (Engineering & Construction) Switzerland Palestine Heads the WFEO At the World Engineers’ Convention 2011 in Geneva, Eng. Marwan Abdel Hamid (President of the General Union of Palestinian Engineers) was elected the new President of the World Federation of Engineering Organizations (WFEO). CCC, one of the main sponsors of WEC2011, was represented by Suheil Sabbagh who made an impressive speech and handed over the Hassib Sabbagh for Engineering Construction Excellence in Innovative Solar Power Award to Eng. Riad Zakhem, Ph.d.-PE for his successful photovoltaic (PV) projects in Colorado, USA. During the convention, we had the opportunity to meet representatives from all over the world and we felt proud that the name Hassib Sabbagh and the CCC legacy were familiar to all of them. Marwan Abdel Hamid (left) and Suheil Sabbagh Fadi Raffoul, PE-PMP Senior Design Project Coordinator 26 Bulletin Issue 99 / October 2011 Health, Safety & Environment World Environmental Day On 5 June, 2011, World Environmental Day (as part of Earth Week) was celebrated in many countries. This special day was founded by US Senator Gaylord Nelson about forty years ago. Our environment is important not only for us but for future generations and hence it is our responsibility to maintain its sustainability, safeguard its elements and natural balance as “we do not inherit the earth from our ancestors; we borrow it from our children.” Therefore, we should all contribute to the reduction of emissions into the environment in order to ensure environmental sustainability and a decent environment for our children and grandchildren. 7. Before throwing away a piece of paper, see if you can use the back of the paper to plan, make casual notes or write things to do. 8. Most of the time, an air conditioner can be set to a notch warmer after it has cooled the room. 9. Computers and other electronic devices can be turned off during the night or when you will not be using them for a long time. 10.Reuse plastic bags until they are worn out before discarding, plastic take away boxes for leftover food or lunches, both sides of office paper before recycling 11.Reduce the amount of time you spend in the shower. Based on the above, we would like to share with you below the simple actions that can be taken on a personal level which will have a great positive impact on the environment: 12.Reduce car use. Almost 60% of car trips are less than 10 km and 25% are less than 3.5 km. Therefore, walking or bicycling can be an alternative for short car trips. 1. Switch off a light and see if you can still work comfortably. Most of the time we have too many lights on in our offices and homes. 13.Recycle household waste plastic, paper, glass, wood: donate old clothes, books, toys, furniture to charity. 2. Take out from the plug, all battery chargers and mobile chargers and such when they are not in use. 3. Switch off your car while you wait (at least if it will take a minute or longer) at the red lights. 4. Switch to CFL’s. They last longer and use less power. 5. If you can, stop buying the newspaper and read the e-paper instead. If you can, join a library rather than buying books. 6. Use the fastest and paperless way to mail documents: email. Bulletin Issue 99 / October 2011 14.Repair leaky faucets and always turn off your taps tightly so they don’t drip. A tap leaking a drop of water per second wastes over 25 litres of water in a day. 15.Stub the butt. Over 4,000 chemicals go into making a cigarette. Tobacco smoke produces fine particulate matter, which is the most dangerous element of air pollution for health, 10 times greater than diesel car exhaust. Save your lungs and save the environment. Belal Kayyali Vice President Health, Safety and Environment 27 Corporate Social Responsibility CSR News Report Contribution to CSR Initiative CCC Staff are encouraged to come up with ideas and activities related to CCC’s CSR Initiatives including Going Green and community involvement events. Please send your ideas, initiatives and achievements to “CSR-CCC” email address [email protected] . CSR “Open-Box” In line with Corporate Social Responsibility Initiatives, the “OPEN-BOX” campaign was launched for the purpose of providing an open channel to the employees to freely express and convey their ideas, suggestions and comments, in full confidentiality, to top management regarding issues that would contribute positively to the general welfare of the company and the employees. Greece Nigeria DUAR Beach & Shower Area First Aid Refresher Course Based on the success of the First Aid Training Course that was conducted last year, MOA CSR Committee organized First Aid Refresher Training sessions last June for the employees and family members which concentrated on summer emergencies and CPR. Nursery Schools MOA CSR Committee has arranged and secured special discounted rates from a couple of daycare/nursery schools in the vicinity of the office to help working mothers be close to their children during the day. Other discounted rates are also offered to CCC parents. Kazakhstan Donation to Inder Region Following up the DUAR Project’s CSR activities, a beach and shower area below the newly constructed Ossisa Bridge (which forms part of the project) has been designed and put into operation. Oman Third Blood Donation Day Continuing with the spirit of CCC’s Corporate Social Responsibility and successful blood donation activities, a third campaign was held in July by the ASCS Contract 5B Management in collaboration with the local Blood Donation Bank, which turned out to be another successful CSR event. The campaign was appreciated by all includ- In line with the CCC CSR initiative and as part of Kazakhstan’s programme for supporting the Kazakh community, the CSR team has made a donation to the residents of Inder village, 250 km from Atyrau city. The donation comprised food parcels for 60 disadvantaged families in the region. Iftar for Orphans On the occasion of Holy Ramadan, Kazakhstan’s CSR team invited 50 children from the Atyrau Orphanage to have Iftar at our camp canteen. 28 Bulletin Issue 99 / October 2011 Corporate Social Responsibility ...CSR News Report ...Text ing the Department of Blood Services, Directorate General of Health Services, Ministry of Health. Out of the 48 volunteers, 39 were cleared to donate blood. Papua New Guinea playgrounds of Al Itifaq Sports Club in Khobar. The CCC team came in at third place. Congratulations and good luck for future games! Iftar for Khobar Office Employees Children’s Open Heart Operation Trust In line with their CSR support to their local community, CCC PNG made an appreciable donation towards the Children’s Open Heart Operation Trust which was accepted and appreciated by officials from the trust. Saudi Arabia Khobar Office Social Activities during Ramadan 2011 Employee of the Month At the invitation of the CCC-KSA Area Management, employees at the Khobar office, White Camp, Rashid Office and the PMV Office gathered for Iftar on Sunday, 14 August 2011. All attendees had a good time and expressed their appreciation and thanks and wished CCC’s owners, management and colleagues all the best and good luck. Turkmenistan Five were selected as top performers for their good work, dedication and punctuality and above all for their excellent relations with everyone. In a very close competition, Taher Khan came out top of the five. Certificates and presents were handed over to the role model staff in a very nice warm atmosphere. Congratulations and good luck to the other members. Greco-Roman & Freestyle Wrestling Championship for the President’s Cup 5th Annual Football Tournament Part of CCC’s CSR activities in Saudi Arabia, CCC participated in the 5th Annual Football Tournament in memory of the late Abdullah Dabal, a prominent figure in Saudi football. CCC sponsored a team of fifteen players, all students at King Fahd University of Petroleum and Minerals (KFUPM). The games were played at the Bulletin Issue 99 / October 2011 CCC Turkmenistan sponsored an event devoted to the Greco-Roman and Freestyle Wrestling Championship for the President’s Cup, which took place on 29 June in Ashgabat city. The championship was organized by the National Wrestling Sports Centre of Turkmenistan and CCC being the sponsor of the event presented prizes to the winners and their teachers to express our adherence to the ideas of sport and healthy living in Turkmenistan and all over the world. Tony Awad Group Corporate Social Responsibility Officer 29 Corporate Social Responsibility Special Olympics World Summer Games “Let me win! But if I cannot win, let me be brave in the attempt.” Special Olympics Slogan The Special Olympics were held in Athens from 25 June to 4 July and CCC management is very proud of the fact that 16 employees were volunteers at this event. Our volunteers were among the 25,000 who assisted the 7,000 athletes with intellectual disabilities and their family members and made sure that the 21 sports at 30 venues went smoothly and to the joy and satisfaction of all who participated. Those who participated were: • Antoinette Mansour • Maria Chrysoudakis • Omar Alfatyan • Sue Lazariotou • Elias Najem • Valia Saba • Houneida Rechrech • Jeannette Arduino • Fadi Raffoul • Dimitri Regoukos 30 The Emblem of the Special Olympics World Summer Games ATHENS 2011 is a radiant sun, the source of life that underlines the excellence and power of the athlete that takes part in the Games. Excellence is depicted in the olive branch and power in the spiral form in the center of the sun. The colors reflect the Greek landscape and project emotions like passion for life in the warm red, optimism in the orange, determination in the blue, freedom in the light blue and hope in the green. • Katerina Koutsouki • Marwan Saca • Godfrey Soans • Samir Sabbagh • Ala Abu Ghazaleh • Tasos Konstantellos Congratulations to our volunteers and to Dimitra Ntalachani for efficiently coordinating their participation. Tony Awad Group Corporate Social Responsibility Officer Bulletin Issue 99 / October 2011 Corporate Social Responsibility Developing the Human Resource Foundations for the Construction Industry Summer Trainees 2011 training, they are also exposed to CCC’s culture, as well as site conditions thus giving them a realistic understanding of the construction industry. Trainees follow a formulated job rotation plan that should be signed off by each department to ensure that they have covered the set materials. Many trainees are required by their university to complete a report or dissertation of up to one hundred pages at the end of their training, describing CCC, the work experience, and the particulars of the project that they trained on. This forms an integral part of their education, and acts as a useful insight for CCC to ascertain the depth of the trainee’s exposure during their internship. This autumn concluded another successful year for CCC’s Summer Trainee Internship Programme, which under the stewardship of the HR-Training & Career Development Department at MOA has been developed in recent years to include a formalized rotational structure, and a thorough assessment of the trainees as well as the programme as a whole. The programme represents the opportunity given to students to apply their knowledge in a real work environment, giving them a true insight into company culture, and allowing them to test out diverse career paths. The benefits of the summer training programme include: (1) generating a candidate pool for future hiring by initiating high caliber graduate recruitment from an early stage; (2) helping to build good relations of mutual benefit with participating universities in terms of education and future employment; (3) providing students the opportunity to test their interest in a particular field; and (4) increasing students’ confidence and motivation in a work environment. Also students will be more prepared to enter into full-time employment in their area of specialization upon graduation. CCC endeavours to maintain close relations and build strong ties with numerous international universities and key education institutions. As a result of this, students were recruited from various universities across the Middle East, Europe and the American Continent. Through yearly university job fairs, CCC is also able to promote the company to interested students. In 2011, over one hundred and thirty summer trainees were selected after being interviewed, and placed across CCC’s project sites or area offices across the Middle East, Greece, the continent of Africa, and CIS countries. All of the trainees selected completed their training, which in most cases formed an important part of their accreditation for their university. Training typically lasts for 8 weeks and involves a combination of office experience, and ‘hands-on’ site experience for engineers. Not only do trainees receive technical Bulletin Issue 99 / October 2011 In line with CCC’s Corporate Social Responsibility policy to help local communities by recruiting residents, many students from local universities were selected and trained. In Greece, several Greek nationals were selected to take part in the internship programme. These trainees received training at MOA in office functions such as finance, administration and architecture, while others were sent to project offices in the UAE. Abu Dhabi area offices independently recruited students from local universities and placed them at project and area sites in the UAE. A number of students from Qatar University, College of Engineering received training at Projects in Qatar. Also in Oman, trainees were recruited locally, and trained at Oman projects. All universities involved have expressed gratitude for their student’s participation in the programme. Feedback from the trainees has been very positive, and many have reported through written and verbal feedback that they would feel privileged to be part of the CCC team in the future. To quote some trainees: “I enjoyed working in a friendly and professional environment…the training was excellent.” “Working here was a great experience… I really enjoyed working with people of different nationalities… I really look forward to coming back to this department.” “The work environment was professional and the employees were extremely helpful. I hope to accomplish all that I can while working alongside my co-workers.” “I would like to take the chance to thank you for giving me the chance to be part of the [CCC] family for a while. It was a nice experience that gave me many competencies and a good insight for my future life.” “Training with CCC has given me a great introduction to the construction industry. It has motivated me to work in this field in the future, and I would be honoured to work with this company.” Lastly, we would like to thank all CCC employees who have been involved with summer trainees. With your help and encouragement, trainees continue to receive first class training and a praiseworthy internship experience. We are certain that the Summer Training programme will continue to be successful in the future. Ramsay Khoury HR - MOA Training & Career Development 31 Corporate Social Responsibility CCC Egypt Helping the Local Community in Cairo At the end of January 2011, the whole world witnessed history as millions of Egyptians took to the streets in demonstrations. Unfortunately the civil unrest caused businesses to lay off large numbers of employees. This reflected negatively on society as many of these workers are the sole source of income that supports their entire families. most affected. CCC Egypt collected, from employees and managers from projects all around Egypt, EGP11,230 in donations. The company generously offered to match the donations increasing the sum to EGP22,460. This amount went to support approximately 150 families for an entire month. CCC Egypt’s CSR team acted quickly suggesting an initiative to help the families. After brainstorming different ideas and contacting different charity organizations, the CSR team decided that the best approach would be to start with the most basic need: food. The most effective way to make this idea a reality was by donating food packages containing necessities such as rice, sugar, oil, flour, salt and dried vegetables, to affected communities especially daily labour and their families as they were the most affected. With the help of Boraq, a local charity organization, the CSR team contacted The Egyptian Food Bank, an organization that specializes in food distribution to the poor. We needed their expertise and large database to insure that our donations reached people Finally we would like to thank all our staff for their generosity, the CSR team for their effort in making the initiative a success and the company for their continued support and contributions. 32 Bulletin Issue 99 / October 2011 Dina Farid and Ahmed Refai CSR Egypt Corporate Social Responsibility Indoor Plants for CCC Area Office Staff, Egypt The reason for this initiative is that employees can gain many benefits from indoor plants located beside their workplace. The mere presence of plants in our surroundings brings a feeling of refreshment. Plants are not just decorative items used to fill a vacant space. The most important benefit of indoor plants is their ability to absorb carbon dioxide. In return they emit oxygen into the surrounding office area. It helps in cleansing the air. They also absorb harmful chemicals and toxins (people get sick less and thus reduce potential absenteeism). The experiments conducted to test the absorption capacity of indoor plants have yielded excellent results. witnessed a drop in absenteeism and enhancement in the creativity of employees. The minor health problems like fatigue, headaches and so on could see a reduction to a considerable extent. The CSR Egypt team provided indoor plants to 71 employees for placing beside their workstations at CCC Egypt New Area Office on the 4th August 2011. The idea behind this was to enhance each employee’s work environment. Adrian Crowley CCC Build, Cairo Plants are also known to have de-stressing effects on the mind. The green colour that the plants possess relaxes the mind. Placing plants in offices has resulted in the rise in productivity of employees. According to studies conducted, the offices having enough plants in the premises have CSR task team members with senior management before distributing the plants, from left to right:Tarek Tantawi, Azzam Fedda, Ziad Taleb, Mohamed Farag, Adrian Crowley, Ehab El-Masry Bulletin Issue 99 / October 2011 33 Milestones Engagements & Marriages CCC Oman an congratulate th d especially the staff at DM ei IA Project married to Gra r colleague Charles Tanno us who got ce Haddad. T he wedding ce held on 2 July re 2011 in his ho me town, Tho mony was Lebanon. um-Batroun, El Nassar ivil) and Nour -C A O (M d ue il 2011. Ahmad El Mao ceremony in Dubai on 22 Apr ng had their weddi announce ar) is happy to place in at Q , ct je ro P took LPE Ihab Refai (R be married. The ceremony ce of family to en t es en pr m e ge th ga his en 2011 in gypt on 3 July Alexandria, E and friends. Births his wife Amani udi Arabia) and . Sa t, ec oj Pr FW baby girl, Bisan Baha Diek (RU e birth of their th ce un no an d to Diek are please 26 March 2011 in Palestine. on rn bo as w She Iyeke Oba’s (RLPEP, Qa happy to announce the bir tar) and his wife Tega are very th of their first child, a bo Oghenewuese Stephen . He was born on 13 Ap y called ril 2011 in Warri Delta State, Niger ia. a) and his t, Saudi Arabi s of the ec oj Pr FW U Qazi Iqbal (PN ppy to advise his colleague e is Afifa, are ha wife Tasmeen baby. It’s a girl and her nam st fir birth of the , Bihar, India. inia, Begusarai born in Lakhm Lila Nousia (PMV, Athen s) and her husband are to announce the birth of pleased their second child, a bab y boy. He was on on 28 July 2011 in Athens. any d his wife Am eer, Cairo) an by, a girl called in ng E IM (B Ibrahem Taha ce the birth of their first ba noun are happy to an born on 1 August 2011. as w e Mariem. Sh Saad Abu Naassi (SAS FFD Project, Abu Dhabi ) and his wife Iman Abo Khamis are happy to announce the birth of their son, Ahmad. He was born on 27 Septemb er 2011 in Sharjah, UAE. 34 Mahiuddin Goriya (DMI A-Oman) and his wife are extremely pleased Seema to announce the birth of their son Muhammad on 5 March 2011. Sister Samina and the entire family are very happy wi th the new arrival. af d his wife Rah PSO, UAE) an rth of their baby (E q le ha -K el Ehab Abd nounce the bi e very glad to an Abu Douleh ar June 2011 in Irbid, Jordan. girl Lama on 26 Ahmed Hassabu (DHP, Qatar) and his wife Nancy been blessed with a sec have ond son. His name is Na beel and he was born on 4 July 2011 . his wife Ghada ce, Athens) and eir first baby, ffi O g in ag an (M the birth of th Sami Al Saidi ed to announce date of their first wedding ht lig de e ar en (the Al D on 13 July 2011 . a girl (Salwa) an rd Jo , an Amm anniversary!) in Rahman Yaqub (PNUFW Project, Saudi Arabia) and his wife Zulekha Rahman wo of their second child, a gir uld like to announce the birth l named Shifa Noura. Sh e was born on 12 July 2011 in Chickmaglur, Karnataka, India. All the family are enamo ured of the new arrival. ubeena t, Oman) and R was ec oj Pr IA M (D She sain Mahmood Hus y parents of baby Shanum. pp ha e th a. e di ar In Begum erabad, er 2011 in Hyd born on 3 Octob Bulletin Issue 99 / October 2011 Milestones Farewell Letter Dear Colleagues, I am leaving the services of our illustrious company by 10 July 2011 to settle down at my home in India. By GOD’s grace, as on date I am keeping good health. I thought it will be nice to share few of my very important and profound experiences during my tenure in our illustrious company. I commenced my service with our company in Kuwait in 1982 in the Desalters Project construction for Kuwait Oil Company (KOC) at total four Gathering Centres. It was an EPC Project for Black Sivalls & Bryson Co, UK. My PM was Mr. Rashid Shuhaiber under whom I worked also in Yemen Messila Expansion Project (YMEP) during 1991and 1992 on the 24” Crude Oil Pipeline Project. During 1984 I was with Mr. Rashid in his office when one young gentleman came and joined us and enquired in detail about the Project, contract value, start and completion dates, progress as on date vis a vis planned progress, cost details, etc. Later I came to understand that the person was our President Operations on a vacation from his College. Even at that time he had so many searching queries and eagerness to know the details, problems, etc. During 1982 to 1987 CCC was constructing several Mechanical Projects mostly for KOC and Mr. Mattia Saad was Manager, Mechanical Projects guided Mr. Alfred Hubshen, AVP Mechanical. As several thousands of piping spools and heavy Structural steel columns, beams and trusses had to be fabricated CF Braun Inc who were the Project Manager on behalf of Kuwait Oil Company (KOC) for the major stations works at Gathering Centres (GC) 15 & 25 wanted CCC to put up a separate Fabrication Shop with all detailing, planning, materials handling, fabrication, sub arc welding, etc facilities. AVP Mechanical Mr. Alfred Hubshen went into top gear ordered for all required equipment; deployed Mr. Dmitri Economides and Dmitri Mavrikios from MOA for close follow up of all procurement, supply etc. and field erection under the Control of General Superintendent Mr. Mehran Gozibikian another legendary of CCC. Alfred Hubshen also brought in from some other company in KSA Mr. Walker Hunter to manage the Shop. I do not have to say that a state of the art Fabrication facility with all handling facilities came into being within about 5 to 6 months at Ahmadi in Kuwait to the great surprise of all including C.F. Braun Inc! Such is the prowess of CCC and the unflinching efforts of one and all right from the AVP to the last Helper! Bulletin Issue 99 / October 2011 After my stint at Kuwait during 1982 to 1988 I worked at Yemen Messila Export Project (YMEP). At YMEP I was working for the installation of 24” Crude Oil pipe line about 124 kms long from Central Plant Facility (CPF) to the Export Facility on the sea front. The YMEP Project is located in the biblical Hadramukh province of Yemen. The pipeline route from CPF over about 60 kms upto the cliff was very hard and rocky right from ground level giving least chance to a rock breaker thus an Excavator with rock breaker attachment will give an output of say 50 to 60 mts. Extensive dynamiting had to be resorted to achieve a progress of say about 250 to 300 mts per day! Another problem was soft said for bedding and padding of the pipeline. This had to be transported over 100 kms, screened near the ROW and used! After passing the hard & rocky route we reach the cliff which dropped over 700 mts within a distance of 2 kms, so steep! The route suggested was zig zag with great difficulty to haul the pipes without damaging the coating. Our PM Mr. Rashid Shuhaiber personally walked through and surveyed the Area. Then he saw to it that appropriately sloping ROW and pipe line route through the cliff was built specifically dynamiting wherever required. Thus it was possible to lay comfortably the 24” pipeline through the cliff. Also one can drive up or down the 35 Milestones ...Farewell Letter steep cliff, with utmost care of course, with a 4 wheel drive Land Cruiser. His dedicated efforts made possible a workable pipeline route through the cliff for the civil and pipe line construction personnel. His perseverance and untiring work to achieve the goal was a model for all of us. YMEP was followed with my working at Kuwait during 1993 to 1997. Then I came down to Habshan, UAE in1999 where I am continuing till date in various Projects, all pipeline projects. In GASCO (Atheer) OGD II Project, Habshan, UAE we faced (I was in charge during the last stage of the Project) “Black powder problems” in two pipe lines each about 121 kms long, one going to Ruwais and the other to Maqta. GASCO Consultant opined that the seawater that was used for hydro testing was not chemical treated adequately and the swabbing and drying after dewatering was not done correctly leaving patches of inadequately treated sea water and these gave rise to incubation during operation giving rise to black powder problem. CCC and Technip disagreed with this view and put forth many facts and recorded data from our old records. Finally Technip employed “Capcis, UK” to study the problem and submit their report, collected samples of black powder and got analysed in UK and submitted their report stating that the “black powder problem” must have arisen due to operational problems and not due to any water treatment of hydro test water or drying etc. This closed the subject due to our perseverance and proving our position. In this we had the full support of Technip, OGD II Project (Technip Bechtel J/V) with whom we had very good rapport at Project site level. This must be considered as a very important requisite in all our Projects and should be cultivated. During my tenure in UAE Pipelines Projects we had ADCO NEB Phase I Project. It involved laying about total 450 kms of various pipelines. As all of us know, CCC installs only “On shore pipelines” over dry and sabkha terrain and not on a terrain under water. But in this NEB Phase I Project we had to lay pipelines from mainland to three islands one beside the other with shallow water between the islands and the mainland. The distances between the mainland to the first island was 1.75 kms and from the first island to the second and second to the third were 0.85 km and 0.70 km respectively. Mr. Bassam Addada was our Project Manager. One river crossing expert Mr. Luigi Campagnolo was suggested. He came for a day from Doha, Qatar and explained regarding the pulling force calculation for shore pulls and left. We had to lay 6 pipelines (2 of 20”, 3 of 10” and 1 of 6”) between mainland and first island and over the other two islands 3 pipes (one each of 20”, 10” and 6”). ty electric motor driven winches with required large dia 2000 mts long wire ropes, pulling heads to enable pulling three pipes at a time, required capacity 200 floaters each with 1.3 tonnes buoyancy, etc. Also a Cat 325B/ Kori Pontoon Excavator which can dig maximum 21feet (6.4 mts) below ground level with amphibious under carriages designed for marsh conditions and stump studded swampy terrain was mobilized. Once all the calculations were made and all the required equipment and accessories were in place thanks to the undaunted efforts of our PM the laying of the pipelines went like clockwork and completed before time! It was all due to his attitude of never take a “no” for an answer to a problem! Please understand that we all started with no clues on laying of pipelines under shallow water. All through my voyage in our company CCC it was a continuous learning exercise for me. There were gaps in my service period arising out of the downturn immediately preceding and succeeding the invasion of Kuwait by Iraq and later collapse of the price of Crude to US$18 per barrel. Our EVP, Operations (now President, Operations) offered me positions in Station works at Yanbu, KSA and at Oman. All these positions involved piping and Equipment erection works. I politely declined due to my preference and fascination for pipelines jobs, of which I have been associated for total more than 3, 500 kms till date including the present ADCO BTG Project where I am now working. Why I mention this is to emphasize the empathy of our President and his concern to see that a CCC employee is as far as possible continuously employed. This humanistic approach is a great boon for us which we should all cherish. I depart from CCC family with a heavy heart. I take this opportunity to exhort upon all the CCC ites to be totally loyal to our company CCC, be sincere in all your efforts, be honest and transparent in all your dealings, appreciate the difficulties of the company in these very difficult times of near collapse of the Economy of many countries, be quality and HSE conscious and last but not least have a nice word for the good work done by your associates and junior colleagues. You will find the general morale shoot up and sky will be the limit for your as well as our Company CCC growth and achievements. There will be overall peace and happiness, after all that is the basic aim of all of us in our life. With my deep and sincere regards to all, yours truly. Thank you one and all, good bye! P. V. Veeraraghavan Project Control Manager BTG Project, Habshan, UAE Our PM Mr. Bassam Addada discussed with NPCC and calculated the capacity requirements of various equipments. Then he located 125, 75 and 50 tonnes capaci- 36 Bulletin Issue 99 / October 2011 Reflections Trust Is the Difference Maker Trust is the foundation of leadership. It is an attitude that is earned and not acquired. It is earned in the process of overlapping our character and competence. From the Desk Of... Diversity, Flexibility and Social Responsibility I believe CCC’s strength lies in our ability to execute different kinds of projects from buildings, roads and harbours to more complex oil, gas and power projects like the EPC pipelines featured in this issue of the Bulletin. This type of diversity is not present in many companies and is one of our key strengths. A few years ago, our revenue was dominated by oil and gas projects whereas today civil projects constitute the majority of our work, yet we have maintained the same organizational structure, management and profitability. Again, this flexibility is unique in our industry and is another important factor which contributes to our success. CCC’s ‘Family Culture’ which has been inherited from our founders, has embedded in it the culture of giving back to our society which is another name for Corporate Social Responsibility. This human trail is seen throughout CCC’s staff and projects and some examples are included in this Bulletin. Again, we are among the few companies of this caliber who care about others. We, in our homes, and at our work, build the trust daily and reflect it to those around us, who in turn become the mirror that reflect it back to us. People around us are drawn to those who trust them and make them feel important. The people around us will trust us when they see many of the ingredients (in our character and competence) shown in the model. Trust is a must for all managers at all levels. It will act as emotional glue holding managers and others together. It gives meaning and value to all relationships with everyone, especially with the client / engineer. While there is risk in trusting others, the risk is much greater in not trusting them. When there is no trust friction arises; hidden agendas, conflicts and a win-lose environment is created. Low trust will slow every decision, every relation and every interaction. Low trust will slow everything in our life and in our work. Trust impacts the three major variables of productivity, namely: time, cost and quality. When trust is high, the cost and the time needed to do things go down and quality goes up. Trust is built gradually over many years of daily investments in our interactions and relations. However, it is fragile. It can break in no time, especially when some practices abound such as: breaking promise, holding information, being double-faced and gossiping. Trust is a major value in the bedrock on which our CCC culture was built. It is the value that gives the meaning to other CCC values. This value of trust must be emphasized, enhanced, exercised and maintained by everyone in order to continue as a difference maker in serving our culture and maintaining the family spirit and how others will see us. I am confident that given our continuous diversity, flexibility and social responsibility, CCC will continue to grow and remain strong. Samer Khoury President (Engineering & Construction) Dr. Riad Elhaj Bulletin Issue 99 / October 2011 37 The BULLETIN is a publication issued at CCC in Athens by volunteer staff. All opinions stated herein are the contributors’ own. Submissions (announcements, stories, artwork, etc.) are welcome. CCC BULLETIN P.O. Box 61092 Editors Samer Khoury Zuhair Haddad Nafez Husseini Damon Morrison Public Relations Samir Sabbagh Maroussi 151 10 Fax (30-210) 618-2199 or [email protected] see The BULLETIN on line at www.ccc.gr - News - Quarterly Bulletin Bulletin October 2011 Issue No. 99 Production Jeannette Arduino Nick Goulas Georgia Giannias Alex Khoury Contents FROM THE DESK OF....................................Samer Khoury EDITOR’S VIEW...............................................................…1 MAIL BAG - Letter from Fehied F. Alshareef..................…1 RECENT AWARDS.......................................................……2 Quality Management - Quality Management Systems Overview Mounir Soufyan….......…..4 PROJECT PROFILE: Princess Noura University for Women - Inauguration - Hassan Moghrabi…................................8 - The Tunnel - Haitham Khader Msaeed ….......................9 Feature: Pipeline Projects - The Pipeline Enterprise - Rashid Shuhaiber….........14 - Australia Pacific LNG Upstream Project Phase 1 - Pipelines Zahi Ghantous…..…..16 - Pipeline Estimation - Hisham Kawash…......................18 - SAS FFD Project - Bassam Addada….........................20 - The Challenges of the Malagasy Experience Marwan Anas…...........22 Area News - Qatar: 30 M w/o LTI at Ras Laffan Port Expansion Project Buks Beukes….24 - Qatar: TR3/4 Shutdown - Rabi Rouwadi…............…..25 - Palestine: Bethlehem Centre - Samer Khoury….........26 - Switzerland: Palestine Heads the WFEO Fadi Raffoul.....26 Health, Safety & Environment - World Environmental Day - Belal Kayyali…............…..27 Corporate Social Responsibility - CSR News Report - Tony Awad…..........................…..28 - Special Olympics - Tony Awad….............................…..30 - Summer Trainees 2011 - Ramsay Khoury................…..31 - Helping the Local Community in Cairo Dina Farid and Ahmed Refai…..........32 - Indoor Plants Initiative, Egypt - Adrian Crowley…....33 Milestones - Announcements….....................................................…..34 - Letter from P.V. Veeraraghavan...............................…..35 Reflections - Trust Is the Difference Maker - Dr. Riad Elhaj.......…..37 Pipelines CONSOLIDATED CONTRACTORS COMPANY