Gulf Oil and Gas accountACCOUNT
Equipment Strategy Continuous Improvement Project
Maintenance and Repair
Reference ITT/RG16/S014/12
Date 4/1/2012
Location Middle East
Scope 1.0 Introduction
The Company has developed world class facilities for the extraction, storage, processing and export of LNG. The Company currently operates seven LNG trains with more than 37 million tonnes of LNG per annum of production capacity. The Company also operates two sales gas trains which supply gas to local industries.

2.0 Preamble
The Company’s Operations mission statement is to operate and maintain the company assets in a safe, reliable, cost effective and environmentally friendly manner which meets customers’ expectations. To achieve this, obtaining the optimum plant reliability is a must. Implementation of best practices in operations, maintenance and spare parts availability is paramount. Development and Implementation of Equipment Strategies has a significant function in supporting the safe and efficient operation of the plants in terms of increasing Reliability. The lack of Equipment Strategies will have a direct impact on the plants’ availability, reliability and safety. This project requires the Services of a specialized Contractor, proficient and experienced in the Oil and Gas Industry with specific expertise in Criticality Analysis, Equipment Strategies development and Asset Verification preparation of base maintenance data in SAP compatible formats for the identified maintainable equipment. Company operates Meridium and SAP as its Asset Management and Work Management Solutions.

The Contractor shall have an effective and certified Quality Management System. The Services must be performed effectively, efficiently, accurately and safely with minimum tolerable disruption to the overall operation. As a significant portion of the Services detailed in this Contract is on site work, Company requires the Contractor to provide the Services with a high level of professionalism and in strict compliance with Company’s SHE&Q.

3.0 Project Objectives
The objectives of the Project are:
3.1 Complete Criticality Analysis for approximately 120,000 piece of equipment (tags).
3.2 Identify Equipment Strategies for maintainable equipment.
3.3 Complete Asset Verification and Work Pack development for Equipment Strategy implementation.
3.4 Support the Equipment Strategy implementation in SAP.
3.5 Facilitation and/ or addressing feedback after Implementation.
3.6 Perform Database quality checks.

4.0 Project Deliverables
The overall programme deliverables of this Statement of Service shall include but not limited to the following;
4.1 List of specified equipment with associated Criticality Level.
4.2 List of identified A, B and C Critical Equipment with existing approved Equipment Strategy (i.e. maintenance and inspection plan).
4.3 A complete field information document containing resources and plant conditions required for executing the Preventive Maintenance tasks on equipment.
4.4 Complete Work Packs that will support planning and execution of the Preventive Maintenance tasks.
4.5 Data elements collected from the field implemented in SAP. Deliverables are explained in more detail in sections 6.1 to 6.4.

5.0 Location of Work
Contractor shall be required to perform Onsite Service at the Company’s Onsite facility. Portions of this Service can be completed Offsite at Contractor’s premises. Contractor should minimise the Onsite work to that which is necessary, however validation and final results must be presented to Company at Onsite facility.

6.0 Contractor Scope of Service
Contractor Scope of Services shall include but not be limited to the following. Company reserves the right to amend the Scope of Service to include or exclude present, future or new activities as deemed necessary during the duration of the Contract

6.1 Phase I - Criticality Analysis
Contractor Scope of Service for approximately 120,000 equipment (tags) shall include but not be limited to the following:

6.1.1 Verify equipment type as specified in the list with technical documents.

Table below, provides an approximate count of equipment by discipline.

Discipline: Instrument, 76%
Discipline: Safety, 2%
Discipline: Static, 14%
Discipline: Machinery, 4%
Discipline: Electrical, 4%

6.1.2 Define Criticality Level based on the company Criticality Procedure and the company Typical Criticality Guideline (to be provided after the Contract Award).

6.1.3 The information pertaining to equipment (Tags) shall be provided in two (2) batches. First batch shall comprise of 90,000 tags to be followed within 2 months of Effective Date the Second batch of 30,000 tags shall be provided.

6.1.4 Document Business and/or SHE Criticality basis and any additional justifications or details.

6.1.5 For Equipment Types not covered under the company Typical Criticality Guideline, Criticality Level must be analysed with Company’s Operations and Technical Department at Company’s facility.

6.1.6 Criticality Assessment can be done primarily as an Offsite work from Contractor’s office, with only the requirement of a monthly site visit or as requested by the company, to validate results and review progress.

6.1.7 Contractor to submit a detail Progress Report on monthly basis to the Company

6.1.8 Total number of engineers required to complete the services is at the Contractor’s discretion, but the Company requires a minimum of 4 reliability engineers.

6.1.9 Timeline for completion:
a) Batch 1 of 90,000 tags - 4 months from the Effective Date of the Contract.
b) Batch 2 of 30,000 tags – 3 months from the date of receipt of information from
Company.
c) Within 5 months of the Effective Date of Contract, Phase I shall be completed.

6.1.10 Phase I Deliverables:
a) List of equipment for each batch with associated Criticality Level including basis for Criticality and reference documents used to be provided in Company’s format.

b) List of equipment for each batch wherein Criticality level cannot be defined using Company’s Typical Criticality Guideline (to be provided after the Contract Award), including reason(s) for exclusion and requirements to define Criticality. Report for each batch to be provided in Company format.

c) Reports in (a) and (b) above, shall be submitted in Draft for the Company’s review and comments. All comments and observations shall be resolved to the satisfaction of the Company before Final Reports are submitted.

6.2 Phase II - Equipment Strategy Identification
Contractor’s scope of Service for approximately 50,000 equipment (Tags) shall include
but not be limited to the following;

6.2.1 Assign existing approved Equipment Strategies as A, B and C Critical using Company Equipment Strategies Library. Detailed Equipment Strategy to be provided after the Contract Award.

6.2.2 Document all findings, basis and results in Company Formats.

6.2.3 For Equipment not covered under the company Equipment Strategies Library, Equipment Strategy must be developed with Operations and Technical Department at the Company’s facility (this part of Service shall be considered as part of section 6.4 below.)

6.2.4 Equipment Strategy assignment can be done primarily as an offsite work from Contractor’s home office, with only the requirement of a monthly site visit or as requested by the Company to validate results and review progress.

6.2.5 Total number of engineers required to complete the services is at the Contractor’s discretion, but the Company requires a minimum of 4 reliability engineers.

6.2.6 Timeline for completion:
a) As evident from 6.1.9 above, information from the Company shall be provided in batches. However, it is expected, as and when the Contractor receives approval from the Company refer 6.1.10 (a) above, the Services under Section 6.2 shall commence.

b) Within 6 months from the completion of batch 1, as identified under 6.1.9.1 above, Services for Phase II shall be completed.

6.2.7 Phase II Deliverables:
a) List of equipment with associated Equipment Strategy Number including basis for Equipment Strategy selection to be provided in Company’s format.

b) List of equipment wherein Equipment Strategy cannot be defined using Company’s Equipment Strategy Library, including reason(s) for exclusion and requirements to define Equipment Strategy. Report to be provided in Company’s format.

c) Reports in (a) and (b) above, shall be submitted in Draft for the Company’s review and comments. All comments and observations shall be resolved to the satisfaction of the Company before Final Reports are submitted.

6.3 Phase III - Asset Verification and work pack development for SAP
Implementation
The main objective of this section is to convert the Equipment Strategy into executable WOs using SAP as CMMS. This scope is divided in three main sections:

6.3.1 Part A - Field Verification and Data Collection
The scope of this activity is intended to collect all relevant and necessary data from field to make the Equipment Strategy into an executable Work Package. The Service shall include activities carried out at Company’s Onsite facility & Contractor’s home office.

6.3.1.1 Conduct visual inspection of the Equipment for data collection, ensuring physical availability and tag number confirmation. The asset verification is expected to provide the basis for following deliverables:

- Physical presence & tag number of the equipment.
- Do-ability of the tasks as defined in the approved Equipment Strategy by the Company.
- Man hours and discipline skills required for each task identified in the Equipment Strategy document. Identify resources (Production Resource Tools) requirements such as scaffolding, cranes, special tools, etc.
- Identify Pre and post maintenance works for major Planned Preventive Maintenance activities such as vessel inspections, equipment overhauls etc.
- Identify routes to group objects in the same work order.
Table below, provides an approximate count of equipment by discipline. However, for the Field Verification and Data Collection purposes, the final total count may vary by +20%:

Discipline Tags
Discipline: Electrical , Tags: 2,500
Discipline: Emergency Management , Tags: 300
Discipline: HVAC 600
Discipline: Instrument, Tags: 17,500
Discipline: Lifting, Tags: 50
Discipline: Metering, Tags: 50
Discipline: Rotating: Tags: 1,200
Discipline: Static, Tags: 4,500
Discipline: Telecom, Tags: 300
Discipline; Piping, Tags: 23,000
Discipline: Approximately Total, Tags 50,000

6.3.1.2 Prior to initiation of the activities, it is important to set up the data collection and file format (porting formats) to be used by the Contractor detailing the attributes required to be sourced. Data fields and structure will be proposed by Contractor and finalised in consultation with the Company along with all the necessary completion rules and standards.

Data formats once finalised shall form the basis for collection and population of data; hard copy print outs of these formats shall be carried to site for filling in the necessary information. These data shall be converted into electronic format for the next stage activities. It is expected that the porting formats shall be in either MS Excel or MS Access. Porting format shall define the number of fields covered and level of details required for data.

6.3.1.3 Data fields and structure will be formulated based on the equipment type. Asset validation is carried on the basis of the baseline data provided by the Company using documents such as P&IDs, PFDs, ES, (to be provided after the Contract Award) etc.

6.3.1.4 Exception/discrepancies identified during the field verification process must be reported to the Company for resolution. Where required, advance information will be provided to the company for initiating necessary changes. Typical discrepancies could be (but are not limited) to:
- ES task not applicable to the equipment;
- Equipment not located at site; and
- Equipment not accessible to do the task.

The list of possible discrepancies should be mutually agreed prior to initiating the field verification activities. If any changes are required to the agreed list during the Field Verification, the changes can be included after mutual discussion and approval.

6.3.1.5 Data submission will be on a periodic basis, in the format (refer Section 6.3.1.2) that has been agreed upfront. The submissions will purely cover the data that has been captured on the strength and validation of the site visits and on site discussions..

6.3.1.6 Company can reject any submission if this is not aligned with the requirements. Contractor shall fix the rejected submission prior to submitting a revised one.

6.3.1.7 In order to align the deliverables to the requirements of the Company and meet its expectations, a pilot data for a specific plant or unit shall be submitted for review and acceptance. The plant and the extent of data submission for the pilot shall be mutually agreed upon between Parties.

6.3.1.8 Total number of personal required to complete the services is at the Contractor’s discretion, but the Company requires a minimum of 10 Field Verification Technicians.

6.3.1.9 Timeline completion for Phase III Part A:
a) It is expected that upon completion of Phase II, the Company may take up to 3 months to finalize the list of total count of equipment to be part of Phase III scope.
b) The Company shall also endeavour to provide any variation up to +20% in total count of equipment, while the Field Verification and Data Collection is being carried out by the Contractor.
c) Services for the Phase III Part A shall be completed within 6 months from the receipt of the list of total count (refer 6.3.2.1 above) including any variation (refer 6.3.2.2 above) on the total count from the Company.

6.3.1.10 Phase III Part A Deliverables:
a) List of equipment with associated Field Verification and Data Collection to be provided in the format agreed in section 6.3.1.2
b) Reports shall be submitted in Draft for the Company’s review and comments. All comments and observations shall be resolved to the satisfaction of the Company before Final Reports are submitted.

6.3.2 Part B - Work Package Development
The scope of this section is intended to develop Work Package for selected equipment. The task shall include activities carried out at Contractor’s home office.

6.3.2.1 Once the data collection is finalized the Contractor will develop the electronic work packs which is a compilation of the resources identified and relevant documents that can support the execution of the Maintenance activity in a specific equipment. This information must be provided to each equipment identified in a limited scope; this scope will be defined based on equipment types. Typically the equipment types expected to be part of this limited scope are: PRVs, ESDVs, Vessels, Columns, Heat Exchangers, Electrical Substations equipment, Compressors, Turbines, (Motors and Pumps with overhaul tasks).

Following an approximate of Work pack count by discipline:
Discipline Tags
Discipline: Electrical, Tags: 2,500
Discipline: Instrument, Tags: 17,500
Discipline: Lifting, Tags: 50
Discipline: Metering, Tags: 50
Discipline: Rotating, Tags: 1,200
Discipline: Static, Tags: 4,500
Discipline: Approximate Total, Tags: 25,800

6.3.2.2 Prior initiation of the activities, the format to be used for preparing the Work Package shall be specified by the Company (to be submitted after Contract Award). Typical the Work Package shall include the following:

- Cover sheet with summary of all relevant information.
- Detailed activity list (Includes all scope of work with estimated resources).
- P&IDs or Electrical online diagrams.
- Equipment Data Sheet.

6.3.2.3 Work Package shall be prepared based on the System Condition to carry out the maintenance. System Condition reports shall be provided by the Company. If the Equipment Strategy for one equipment contains tasks to be done online and during facility shutdown two work packages are to be developed.

6.3.2.4 Total number of personal required to complete the services is at the Contractor’s discretion, but the Company requires a minimum of 5 Field Maintenance Technicians.

6.3.2.5 Timeline completion for Phase III Part B:
a) It is expected that once reports for Phase III Part A (refer 6.3.3 above) are being approved by the Company, tasks pertaining to Phase III Part B shall be initiated.
b) Services for the Phase III Part B shall be completed within 2 months from the completion of Phase III Part A.
6.3.2.6 Phase III Part B Deliverables:
a) Contractor shall submit two types of Work Package information per equipment to be provided in Company’s format as per section 6.3.2.2
b) Reports shall be submitted in Draft for the Company’s review and comments. All comments and observations shall be resolved to the satisfaction of the Company before Final Reports are submitted.

6.4 Adhoc Services
6.4.1 SAP PM Technologist for SAP PM Data implementation The scope of this activity is focused on the SAP implementation of the intelligence collected from the field verification. This activity shall be under Company’s supervision at Company’s facilities. General activities to be covered under this service shall include but not limited to the following:

6.4.1.1 SAP PM Implementation covers the data preparation, transformation, upload and validation of all elements related to Task List, Maintenance Items and Maintenance Plans. This data must be reviewed and approved by the company prior SAP upload.

6.4.1.2 Work packs will be also implemented in SAP through Preventive Maintenance “PM” module.

6.4.1.3 SAP PM Technologist relevant experience and skill criteria required is described as follows.
a- Must have at least 5 years experience in SAP PM modules especially objects such as Task Lists, Maintenance Items, Maintenance Plans.
b- ust have at least 2 years Maintenance background in Process Industry.
c- Must be highly computer literate and have exposure to large scale databases with the ability to write simple queries.
d- Must be proficient in English both written and Oral.

6.4.2 Reliability Engineer for Criticality Analysis / Equipment Strategy Facilitation The objective of this activity is to identify Criticality Level and Equipment Strategy for list of equipment not covered under section 6.1 or 6.2, in which cases analysis shall be executed with Company’s Operations and Technical under Company’s supervision at \ Company’s facilities. General activities to be covered under this service shall include but not limited to the following:

6.4.2.1 Criticality Level definition following Company’s procedures.

6.4.2.2 Equipment Strategy development applying general principles of Reliability Centered Maintenance (RCM) and Failure Mode and Effect Analysis
(FMEA).

6.4.2.3 Provide technical support and identify suitable solution for Equipment Strategies Feedback Requests from field maintenance to resolve any ambiguities that would prevent their implementation.

6.4.2.4 Revision, validation and approval process of the Equipment Strategies developed will be under Company’s responsibility.

6.4.2.5 Contractor relevant experience and skill criteria required are described as follows.
a- Must have at least eight (8) years Oil & Gas or Petrochemical experience of which four (4) is in reliability engineering.
b.-Must have prior demonstrable leadership experience i.e. have lead small to medium sized Equipment Strategy reviews in a leadership or facilitation role.
c- Must have formal training in a reliability or risked based equipment strategy development methodology i.e. RCM-II, API Recommended Practice 580, Risk-Based Inspection.
d- Must have undertaken formal facilitation training e.g. 2 week RCM-II Facilitators course.
e- Must have knowledge of CMMS (SAP preferable) Planned Maintenance (PM) module.
f- Must be highly computer literate and have exposure to large scale databases with the ability to write simple SQL queries.
g- Must be proficient in English both written and Oral.
h- Must have excellent communication and presentation skills.
i- Must have coaching experience.
j- Preferable training and experience of Meridium™ Asset Performance
Management (APM) software solution;
k- Preferable Certified Maintenance and Reliability Professional (CMRP) certified by SMRP.

6.4.2.6 Engineering background will be required from disciplines such as Instrumentation, Rotating, Electrical or Static Equipment. Selected Engineer will be agreed with the Company based on requirement.

6.4.3 Database Quality Engineer for Data Quality Checks The scope of this activity is to provide assistance in maintaining the quality of data in Meridium. This activity shall be under Company’s supervision at Company’s facilities. General activities to be covered under this service shall include but not limited to the following:

6.4.3.1 Provide expertise and advice on monitoring the quality and fidelity of the Equipment Strategy data.

6.4.3.2 Lead data quality checks and resolve accordingly at Functional Location and Equipment Strategy Level (details of required checks to be submitted with Contract Award).

6.4.3.3 Contractor relevant experience and skill criteria required are described as follows.

a- Must have 5 years experience in extracting data from SAP PM & MM modules into various formats especially objects such as Functional Locations, Equipment Masters, Maintenance Plans, Task Lists, Material Masters, BOMs, PR, PO, Contracts and Info Records.

b- Must be highly computer literate and have exposure to large scale databases with the ability to write simple SQL queries.

c- Must be proficient in English both written and Oral.

6.5 Minimum Requirements
The Scope of Work and Contractor requirements previously mentioned in above Clauses 6.1 to 6.4 are identified by Company as a minimum requirement to fulfil the service requirements for this contract. It is the Contractor’s responsibility to advise Company in writing should Contractor envisage an amendment or otherwise being required. Only those tasks approved by Company in writing may be undertaken. Should Company agree to any such amendments and the compensation rates for these are not already included in Section 4.0 Compensation, these rates must be mutually agreed in writing between Company and Contractor prior to work commencing.

Bidding Information

Bid Bond US $ 240,000
Maintenance and Repair
Related Prooducts: Maintenance and Repair Consultancy Engineering FEED General Maintenance and Repair Process Technology Licensing Production Engineering Project & Resource Management
Related Tenders: Consultancy Engineering FEED General Maintenance and Repair Process Technology Licensing Production Engineering Project & Resource Management

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