QATAR GENERAL PETROLEUM CORPORATION

PRE-FEASIBILITY STUDY
FOR AN ALUMINIUM SMELTER
IN QATAR
(Technical Proposal)







Contents


1. SOFRESID'S UNDERSTANDING OF THE QGPC INQUIRY
1.1. OBJECTIVES OF THE PRE-FEASIBILITY STUDY
1.2. KEY INFORMATION TO BE PROVIDED
1.3. TECHNICAL DESCRIPTION AND IMPLEMENTATION SCHEDULE
2. BRIEF DESCRIPTION OF THE PROPOSED PLANT
2.1. POWER PLANT
2.2. ALUMINIUM SMELTER AND PORT FACILITIES
2.3. BATTERY LIMITS
3. TECHNICAL PROPOSAL FOR THE PRE-FEASIBILITY STUDY
3.1. SCOPE OF SERVICES
3.2. PLAN OF EXECUTION FOR THE CAPITAL COST ESTIMATE
3.3. SOFRESID'S STRENGTH
3.4. ORGANIZATION CHART
3.5. SCHEDULE OF ACTIVITIES
4. INFORMATION AND DATA TO BE SUPPLIED BY QGPC AND AP
4.1. DATA TO BE PROVIDED BY QGPC
4.2. DATA TO BE PROVIDED BY AP
5. OUTLINE FOR THE IMPLEMENTATION OF THE PROJECT
5.1. SCOPE OF SERVICES
5.2. ORGANIZATION CHARTS
6. CURRICULUM VITAE OF KEY PERSONNEL
6.1. SOFRESID
6.2. GEC ALSTHOM

1. SOFRESID'S UNDERSTANDING OF THE QGPC INQUIRY

The pre-feasibility study requested by QGPC concerns a smelter producing 25 kg aluminium ingots with an annual production capacity of 240,000-250,000 metric tonnes. The smelter will be based on ALUMINIUM PECHINEY AP 30 technology. It will be associated, on the same site, with a gas-fired power station capable of meeting the electric power requirements of the various units of the plant and of the related ancillary general services and utilities.
The smelter is to be built in UMN SAID, in the port area near other industrial units.
The pre-feasibility study is to be made in co-operation with QGPC. QGPC's approval shall be obtained by SOFRESID for all major assumptions adopted in the course of the study.

1.1. OBJECTIVES OF THE PRE-FEASIBILITY STUDY


· Provide QGPC with full information to assess the technical cost of the project i.e.
¨ the capital cost of power station and aluminium smelter,
¨ the production costs of electric power and aluminium ingots.
· After obtaining supplementary marketing and financial inputs, provide a reputed banking institution with appropriate information to enable project financing.


1.2. KEY INFORMATION TO BE PROVIDED


1.2.1. CAPITAL COST ESTIMATE (* 15% ACCURACY)


Summary of 500/600 items for the smelter and 200/250 items for the power plant.

1.2.2. BREAKDOWN OF CAPITAL COST BY CURRENCY



(*) Calculated on the basis of exchange rates prevailing in the 1st quarter of 1996, to be agreed with QGPC.
1.2.3. CAPITAL COST EXPENDITURE SCHEDULE
Breakdown of expenditure month by month and by currency.

1.2.4. PRODUCTION COSTS (* 15% ACCURACY)


Power plant : in mills US $/kWh
Smelter : in US $/t aluminium metal

1.3. TECHNICAL DESCRIPTION AND MPLEMENTATION SCHEDULE

The key information described above will be supported by a technical description in addition to the process description provided by AP for the aluminium smelter.
As regards the electric power station, EGT (European Gas Turbines) subsidiary of GEC Alsthom, acting as sub?contractor to SOFRESID, will provide a detailed technical description and a technical memorandum justifying the configuration adopted (number of turbines, unit power, etc...), to satisfy the various operating possibilities.
A project implementation schedule will complete the study.

2. BRIEF DESCRIPTION OF THE PROPOSED PLANT


2.1. POWER PLANT


2.1.1. GENERAL


EGT, subsidiary of GEC Alsthom will prepare the power plant pre-feasibility study.
EGT provides to the world the most comprehensive range of high efficiency industrial, aeroderivative and heavy duty gas turbines, from 1.6 MW to 226 MW. Used for simple and combined cycle power generation, cogeneration and mechanical drive applications, every EGT product is specifically designed to meet power and environmental requirements world-wide. With more than 3 850 gas turbines operating in 104 countries, they represent a total generating capacity of over 50 000 MW.
A number of important design philosophies have enabled to develop superior products. A major element is the evolutionary approach of designs. It has resulted from improved components and materials which have been applied prudently and carefully, to increase power and thermal efficiency.
A second, highly successful principle has been the geometric scaling of both compressors and turbines, allowing maximum utilisation of available experience.
A third element of the design philosophy is thorough development involving design analysis, quality manufacturing, testing and feed?back from field experience.

2.1.2. DESCRIPTION


The pre-feasibility will cover complete design, manufacture, delivery, and construction. It will include all associated civil works and commissioning on turnkey basis, together with all necessary plant and equipment, to complete a gas turbine generating station of approximately 420 MW total capacity at 50ºC ambient in Qatar.
The study will take into account the following:
· N turbines installed of which N?1 in service (1 turbine in stand by or maintenance),
· de?rated operations with N?2 turbines (breakdown of 1 turbine with another one in maintenance),
· connection to the electric grid of Qatar to enable sales of surplus power produced,
· possibilities of extension are provided in the design,
· optimisation of operation with local conditions (price of gas, selling price of energy on the national grid, climatic conditions i.e. temperature, marine environment, presence of sand, etc...).
The study will cover N gas turbines at site conditions operating in open cycle mode and housed in the turbine hall. The study will encompass all necessary auxiliaries for their safe, efficient and reliable operation, associated civil works, 132 kV generator transformers, and connection to the GIS substation, fire protection, control buildings, roads, earthing and low and medium voltage electrical systems as well as all services and facilities for the power station.
The proposed site layout shall take into account future conversion to a combined cycle operation and a further development of additional gas turbines and combined cycle plant at a later date; such items as an extension to the control building and cables trenches, etc... shall be designed to accommodate this.

As far as practical, the Gas Turbine Generators shall be independent of each other and shall be arranged in blocks of two units, each block being housed in a separate turbine hall.
The Power Station shall be designed with primary consideration for reliability and ease of operation and with future extensions in mind.
The main equipment concerned are:
· N Gas Turbine Generators together with all necessary plant and equipment for their safe, efficient and reliable operation. The exhaust ducting of each Gas Turbine Generator shall incorporate a blast stack.
· All necessary interconnecting pipework and valves for gas, fuel oil, lubricating oil, control oil, raw water, demineralized water, water cooling, control air, service air, etc...
· Three phases enclosed generators arranged for air/water cooler duty.
· Exhaust gas ducting including expansion joints, access doors, safety devices, silencers, lagging and cladding. No internal insulation shall be used throughout the exhaust system.
· Sets of coolers and heat exchangers complete with all the necessary pumps, piping, valves and fittings.
· Turbine control cubicles and control equipment including sequence starting equipment, comprehensive alarms, indication and controls.
· Turbine generator control cubicles and equipment which shall be located in the Central Control Room.
· Sets of generator neutral earthing equipment including transformer, neutral earthing resistor and connections.
· Complete station earthing grid systems.
· Complete pipework, valves, tanks, foundation bolts and plates, anchors, structural steelwork, stairways, walkways, ladders, hand rails and sundries.

· Outdoor core type oil immersed, three phase, 3 winding air cooled (ONAN/ONAF) generator transformers each continuously rated to match the peak output of the associated generators at all site ambient conditions and transform the generator voltage to 132 kV with on load tap changers.
· Outdoor core type oil immersed, three phase, air cooled (ONAN) unit and unit/station transformers to transform the generator voltage.
· Sets of phase isolated connections in continuous bus-ducting between the generator, the generator transformer and unit transformers complete with all necessary auxiliary equipment and supports.
· A generator circuit breaker, isolation and earthing switches located in the run of the main phase isolated connections between the generator and generator transformer.
· Unit electrical systems including auxiliary transformers, switchgear, batteries, secure a/c. supply systems, electrical protection earthing.
· Fire protection and detection systems including buried hydrant system, double hydrant outlets, transformers deluge water spray system, hose reel and equipment cabinets and alarm panel.
· 132 kV interconnecting bus duct/cables for connection to the 132 kV substation.
· Necessary fuel gas pipeline including hot tap connection, between the Gas Pressure Reducing Stations and the natural gas main adjacent to the site.
· All required Control and Instrumentation for the safe, reliable and efficient operation of the Plant.

2.2. ALUMINIUM SMELTER AND PORT FACILITIES


The planned aluminium smelter will include the following: (numbers refer to AP/SOFRESID's coding system).

2.2.1. SITE PREPARATION (004)


It includes (without limitation) the following activities :
· grading, levelling, general earthmoving,
· drainage, sewerage,
· fencing,
· roads and parking lot,
· landscaping,
· solid and liquid effluents treatment and disposal,
· connection of utilities to the site.

2.2.2. SUBSTATION (310)


The substation will meet AP requirements with respect to feeding the potline and all the auxiliaries of the entire plant.
· Power supply: the substation will be energised directly from the dedicated power plant installed on site,
· It will include :
¨ a high / medium voltage section,
¨ a section for main auxiliaries distribution,
¨ a conversion section,
¨ monitoring and control sections.

2.2.3. REDUCTION (320)


The reduction area comprises two potrooms equipped with a total of 288 pots, Pechiney AP30 technology.
Each building accommodates 144 pots arranged side by side in one row.
Potroom ventilation uses natural ventilation.
The pots are prebaked type with a continuous point feeding system and a computerized process control system.
Aluminium busbars provide the necessary DC current to all pots.
Each pot is equipped with 20 anode assemblies.
Alumina is fed to the pot by a Hyperdense Phase System (HDPS).
Multipurpose overhead travelling cranes called Pot Tending Assemblies (PTA) perform all necessary operations on the pots :
· replacement of spent anodes,
· metal and bath tapping,
· anode beam raising,
· miscellaneous operations.
A Cathode Transport Crane (CTC) is used for transferring used cathodes to the relining shop and bring-in newly lined cathodes.
The potline is also equipped with operating equipment such as anode transport vehicles, metal and bath ladles and metal transport vehicles.
A control room will accommodate the central computer system for both the potline and the pot gas treatment centre.

2.2.4. RAW MATERIAL FACILITIES IN REDUCTION AREA (324 TO 328)


Raw material facilities covers the following sections :
· fluorinated alumina facilities : the fluorinated alumina coming from the gas treatment centre is used for feeding the potline,
· crushed bath facilities : the recycled bath is used for anode covering in the pots,
· fresh alumina facilities : fresh alumina coming from the main site silos is stored in the potline in day silos in order to ensure the proper feeding of the Gas Treatment Centre (GTC).

2.2.5. POT GAS COLLECTION AND TREATMENT (330)


Gas evolved from the pots and collected by the hooding system are treated for cleaning by dry processing in two Gas Treatment Centres.

2.2.6. POTLINE SERVICES (340)


Potline services accommodate the following facilities :
· cathode sealing shop,
· lining-delining shop,
· lining paste heating shop,
· ladle and tapping tube cleaning shop,
· PTA maintenance shop,
· potline maintenance shop.

2.2.7. CASTHOUSE (350)


The casthouse will include the following sections :
· metal preparation with weighing of the liquid metal, skimming and stirring of liquid metal and holding furnaces,
· metal casting including ingot casting machines for 25 kg aluminium ingots and ingot stacking,
· dross treatment,
· industrial water network for metal cooling,
· outside storage and truck loading facilities.

2.2.8. GREEN ANODE PRODUCTION (360)


The green anode production section includes the following shops :
· anode paste plant where petroleum coke grains and recycled anode butts are ground and agglomerated by means of coal-tar pitch. It includes proportioning, preheating, mixing, forming cooling phases and fume and dust collection,
· anode handling and storage shop.

2.2.9. ANODE BAKING (370)


Before being used in the pots, green anodes must be baked to calcine the binding pitch.
It is achieved in an "open" type anode baking furnace.
The baking furnace is fired with gas.
The baking is controlled by a fully automated system.
Handling of anodes is carried out by means of Furnace Tending Assemblies (FTA).
Fumes collected by the exhaust manifolds are sent to a Fume Treatment Centre (FTC) using a dry process system similar to the GTC.

2.2.10. ANODE ASSEMBLY RECYCLING (380)


The recycling of anode assemblies is performed in dedicated shops as follows:
· anode assemblies cooling and storage shop,
· anode rodding shop where stems are separated from anode butts then recycled so that new anodes can be attached to it by means of cast iron. Bath crusts and carbon butts are conveyed to dedicated shops for recycling,
· Stems and brackets repair shop,
· Bath recycling shop,
· Carbon recycling shop.

2.2.11. GENERAL SERVICES (600)


It includes (with no limitation) the following facilities for the project :
· maintenance shops : central workshop and area workshop,
· main warehouse,
· laboratory,
· management and main offices,
· cloakroom, washroom, cafeteria, mosque,
· gasoline station.

2.2.12. UTILITIES (700)


It includes (with no limitation) the following facilities for the project :
· electrical power loop. A medium voltage network supplies power to the various shops in the plant. Distribution stations are located close to the consumers,
· fire fighting network,
· drinking water network,
· industrial water network,
· gas network,
· compressed air production and distribution,
· plant information system including :
¨ industrial computers covering the real time supervision shop and sector technical management of each process facility,
¨ business and management computers with office automation systems covering procurement, maintenance, human resources and corporate,
¨ plant wide computer network.

2.2.13. RAW MATERIAL FACILITIES ON SITE (800)


This chapter concerns the storage and handling of raw materials, namely :
· alumina,
· coke,
· fluorinated products,
· pitch.
Capacities of sufficient volume are installed on site as to cope with raw material deliveries (capacity of ships and different origins).
Handling is insured by means of belt conveyors.

2.2.14. PORT AND TRANSPORT FACILITIES (900)


A dedicated berth is used for raw materials unloading.
It is assumed that an existing berth with sufficient draught can be used.
Port and transport facilities will mainly concern :
· Materials unloading systems using vacuum process it to be installed on the jetty,
· loading facilities for aluminium products,
· transport equipment between plant and port.
2.3. BATTERY LIMITS
The present pre-feasibility study takes into account the following aspects:
· the power plant and smelter are located on the same site,
· the port is located at about 2 km from the site,
· natural gas is available at the battery limits of the site,
· roads and communication facilities are available at the battery limits of the site,
· no desalination of sea water is considered.

3. TECHNICAL PROPOSAL FOR THE PRE-FEASIBILITY STUDY


3.1. SCOPE OF SERVICES


3.1.1. GENERAL


To undertake the pre-feasibility study, SOFRESID will involve a team of engineers specialised in the following fields:
· project management,
· cost estimations,
· scheduling,
· general techniques.
and specialists of GEC Alsthom for the electric power plant.
As for general techniques, there will be different specialists in:
· civil works and structurals,
· vessels,
· buildings,
· fluids,
· mechanical,
· lifting, handling and transport,
· electrical, instrumentation and automation.
The main purpose of involving specialists of general techniques will be to find, on the basis of AP's process data and considering site conditions, the best technical and cost solutions for building the project. In particular:

· Civil works
SOFRESID will investigate the type of foundations which are the most appropriate to the characteristics of the soil, as a function of the type of building and forces applied.
In the absence of precise data on the site selected, SOFRESID can achieve a good approach of the problem by using information on a nearby site (QAPCO). Indeed, this site is well known to SOFRESID because it participated to studies for extensions.
Moreover, SOFRESID is well aware of the particular problems of design of concrete structures related to local conditions (temperatures, maritime environment, etc...), and of the possibilities of local supplies in the region (capacity, characteristics, rebars, with or without linings, etc...).
· Metallic structures and vessels
During the pre?feasibility stage, SOFRESID will consider the design of structures taking into account:
¨ the regulatory constraints,
¨ process constraints,
¨ consistency with the various other disciplines (e.g. civil, roofing, cladding, lighting, etc...) and the choice of materials,
¨ local climatic conditions (insulation, protection, ventilation, etc...),
¨ consistency with the construction modes and the problems of supply and erection.
This work is conducted in close co-operation with the specialists of civil works, in order to achieve optimal technical and economic definition of the set foundations?structures.

· Mechanical, lifting, handling, transport
SOFRESID will take climatic conditions into account, for the design of all installations in order to avoid the problems related with the presence of sand and with maritime environment.
Particular attention will be given to the protection of mechanisms, to the selection of transport modes and to the definition of storage areas particularly in view of the relative long distance of the port to the site.
· Electrical and automation
SOFRESID will take climatic conditions into consideration, for selecting the technology of equipment, in order to avoid problems related with:
¨ high ambient temperature,
¨ maritime environment,
¨ presence of sand.
which are important points likely to affect the good operation of switching equipment (switch?gear, circuit?breakers) and electronic components.
SOFRESID will take advantage of experience gathered in the construction of previous projects in the fields of oil and gas.
In particular, SOFRESID will co-ordinate and manage the inter?faces between the different sub?assemblies related with the production and the distribution of energy, automation, transmissions and telecommunications.
Finally and more generally:
· SOFRESID will optimise the integration of both the Power Plant and Smelter on the site.
· SOFRESID will optimise the definition of all civil works, buildings, utilities, and maintenance shops, taking into account already at pre-feasibility stage the data provided by AP and QGPC and the possibility of obtaining local labour and/or local sub?contractors.

3.1.2. SERVICES TO BE PROVIDED


Within the framework of the pre-feasibility study, SOFRESID services will be as follows:

3.1.2.1. GENERAL


· Mobilisation of a team of specialists in the various disciplines involved:
· Preparation of a project kick-off meeting to be held in DOHA (issuance of a questionnaire),
· Collection of basic data from QGPC and AP,
· Analysis of the basic data supplied and of the information received at site.

3.1.2.2. DIRECT CAPITAL COST ESTIMATE


· Review of local contractors likely to undertake part of the fabrication and construction work, visits to their workshops and assessment of their capabilities.
· Preparation of, and invitation to submit, prequalification bids by selected local contractors.
· Definition of the roads and miscellaneous networks, utilities, general services depending on requirements, existing situation and background.
· Definition of the harbour facilities (unloading, storage, traffic, loading) required for the project and the possible extensions envisaged.
· Expert evaluation and undertaking of topographical surveys of the site considered by QGPC for the construction of both the smelter and electric power station.
· Definition of the type of foundations to be adopted, depending on soil quality data provided by QGPC.
· Sizing of the different process, support and office buildings, depending on AP's technical data and local climatic conditions.
· Assessment of quantities involved (tonnage and volumes), in the various disciplines.

· Requests for preliminary bidding documents by manufacturers for the supply of major equipment packages and/or specific smelter plant and equipment e.g.:
¨ main substation,
¨ alumina unloader,
¨ specific handling equipment,
¨ pot shells,
¨ super structures,
¨ pot gas treatment centres,
¨ refractories for the potline and the anode baking furnace,
¨ PTA, Furnace Tending Assemblies (FTA), Cathode Transport Crane (CTC) servicing machines,
¨ cathode block sealing machine,
¨ lining machines,
¨ standard overhead cranes,
¨ anode paste tower,
¨ casthouse cleaning, skimming and stirring machine,
¨ holding furnaces,
¨ ingot manufacturing lines,
¨ anode storage and reclaiming cranes,
¨ anode rodding line,
¨ anode and ladle transport vehicles, etc...
N.B. List of suppliers consulted will be prepared in agreement with QGPC and AP, in particular for all equipment items specific to the process.
· Assessment of the cost of the other items of equipment on the basis of recent project implementations, the data gathered from local contractors and SOFRESID's database.
· Assessment of the cost of the electric power station on the basis of the information supplied by GEC ALSTHOM.

· Detailed cost data provided by GEC?Alsthom, will be analysed by SOFRESID, in particular those data which concern concrete works, metallic structures and utilities, in order to homogenise them with those adopted for the cost estimations of the smelter.
· Determination of local and foreign cost components.

3.1.2.3. TECHNICAL DESCRIPTION


On the basis of the technical information supplied by AP and of the preliminary studies undertaken by SOFRESID and GEC?Alsthom, as described here?above, SOFRESID will establish a technical description; this will mainly cover the following:
· a general technical description of both the smelter and the power station.
· a memorandum justifying the configuration adopted for the power station.
· a memorandum describing the power station operation.

3.1.2.4. EPCM AND TEMPARY FACILITIES ESTIMATE


Assessment of the costs of the other services related with the project implementation:

· EPCM costs
¨ Direction of the project,
¨ Social relations,
¨ Accounts, cash,
¨ project control, scheduling, cost,
¨ engineering,
¨ procurement,
¨ contruction management,
¨ quality assurance,
¨ pre?operating testing.

· Miscellaneous costs and temporary installations
¨ local offices,
¨ temporary installations on site,
¨ ware housing,
¨ travel and catering of personnel moved from headquarters to site,
¨ local transport costs,
¨ telecommunications,
¨ document reproduction,
¨ computer, data processing and CAD.

3.1.2.5. START UP COST


Start-up costs will be estimated in agreement with AP and QGPC.

3.1.2.6. WORKING CAPITAL


Working capital will be estimated in agreement with AP and QGPC.

3.1.2.7. IMPLEMENTATION SCHEDULE


SOFRESID will draw up the preliminary schedule for the project implementation (engineering, procurement, construction, testing) accounting for :
· its own experience,
· the technical characteristics of the present project,
· the impact of equipment (transport and customs clearance duration)
· the local labour resources (working time, shift work schedules) and their related costs.

3.1.2.8. CAPITAL EXPENDITURE SCHEDULE


SOFRESID will draw up the capital expenditure schedule for each currency.

3.1.2.9. OPERATION COST


Assessment of the various costs related with the operation of the power plant and the smelter plant, including :
· management costs,
· labour costs,
· raw materials,
· power supply,
· spare parts,
· consumables.

3.1.2.10. REPORTS


· SOFRESID will draw up the pre-feasibility study dossier, on the basis of the above-mentioned data (10 copies).
· SOFRESID will draw up an Executive Report.

3.2. PLAN OF EXECUTION FOR THE CAPITAL COST ESTIMATE


To determine the investment cost which is the main purpose of the studies specified in the previous section, SOFRESID proposes to operate as follows:
· As soon as the team of specialists assigned to the project is formed, SOFRESID will investigate sub-contracting possibilities and the cost of services in the Gulf region. In this connection SOFRESID will:
¨ draw a list of firms capable of supplying equipment or carrying out erection work on the basis of :
- data already available at the Head-office from previous projects carried out in the region,
- data secured from QGPC,
- information collected from French organisations or local trade representatives or TRAFALGAR HOUSE COMPANIES,
- information collected from big French companies with local representatives, with which SOFRESID usually collaborates for big projects.
¨ audit a number of these companies so as to assess their capabilities (manpower and equipment resources, availability, type of services, etc...).
¨ prepare a preliminary call for bid dossier, for each speciality involved, on the basis of its experience in the aluminium and the technical information gathered with QGPC and AP, with a view to obtaining the costs of local contractor services.
¨ launch the prequalification calls for bids with the preselected local contractors.
¨ analyse the replies to said calls for bids and, for each speciality, work out a table of correspondence of local costs with the costs currently in force in France.
· After having analysed the basic data supplied by QGPC and AP, SOFRESID will:
¨ draw up call for bids documents for the usual bidders for the supply of the above-mentioned large and/or specific equipment.
¨ launch said preliminary calls for bids.

· Concurrently with the above-mentioned operations, SOFRESID will proceed, by speciality, to an assessment of the quantities to be implemented depending on the project specific features, especially in connection with:
¨ civil work, according to soil data,
¨ structures, wall siding and covering, according to climatic conditions and building sizes,
¨ roads and miscellaneous networks and utilities, according to requirements and the outside connecting points,
¨ electric power, according to regional standards.
· On the basis of:
¨ the economic and technical data supplied by QGPC and AP, in connection with the production units and operating conditions,
¨ its own knowledge,
¨ the data gathered with the various bidders,
¨ the evaluation of the quantities to be implemented,
SOFRESID will draw up a budget of investment:
¨ broken down into zones, units and specialities,
¨ specifying the parts supplied by local or foreign contractors,
¨ using the codes usually used by AP.

3.3. SOFRESID'S STRENGTH


Apart from its size (2 500 employees) and its experience of managing large international projects (40 years) in such fields as metallurgy, oil and gas, petro?chemicals and fertilisers, SOFRESID brings the following pluses to the project:

· It is independent from any manufacturer or supplier of process,
· It belongs to a big financial and industrial, international group of companies with which it can collaborate if necessary,
· It has the assistance of a local "branch office" (SOFRESID GULF),
· It has good knowledge of the region and of the site because it has participated to the implementation of projects in the region,
· It has good knowledge of the process because it was involved in the implementation of the aluminium plant of Dunkirk which uses the same AP 30 technology,
· It has the participation of GEC Alsthom for the electric power plant. This internationally known company has a lot of experience in the type of power plant that is required as well as in big international projects, particularly in the Gulf region,
· It is accustomed with working on big projects with process technology suppliers, particularly with the different entities of AP,
· It has acquired numerous experiences in other industrial fields,
· It has proven its capability to optimise equipment in conformity with the requirements of the process as well as all ancillary equipment and services.


3.4. ORGANIZATION CHART


The organisation that SOFRESID intends to set up for carrying out the pre-feasibility study is shown on the organisation chart as indicated in APPENDIX 1.

The various specialists required will work under the control of a project manager who will be charged of the project organisation and co-ordination. He will be QGPC's counterpart.

3.5. SCHEDULE OF ACTIVITIES


SOFRESID anticipates that the pre-feasibility study will be performed in compliance with the schedule as indicated in APPENDIX 2, i.e. over a maximum of 6?months, from the putting into force of the contract to the mailing of the final report to QGPC.
Also, the schedule provides that apart from the first meeting (kick-off meeting), two other meetings will take place in DOHA with the following objectives:
· 2nd meeting - after 2.5 months approx.:
¨ to review the progress of the studies,
¨ to supply QGPC with the early information resulting from local calls for bids,
¨ to show the early technical and economic trends.
· 3rd meeting - After 5 months approx.:
¨ to provide QGPC with the various components of the dossier,
¨ to gather their comments with a view to preparing the final report.

APPENDIX 1

APPENDIX 2

4. INFORMATION AND DATA TO BE SUPPLIED BY QGPC AND AP


4.1. DATA TO BE PROVIDED BY QGPC


During the kick-off meeting in DOHA, QGPC will provide the following data/information to SOFRESID:
· Subsoil investigation report.
· Geographical plan of the area showing access to the site, location of gas supply / water supply, and access to the area for port facilities.
· Plot plan of the site area with exact dimensions and location with regard to power plant and smelter(Location of the smelter as well as ventilation needs to be verified by appropriate studies).
· Climatic conditions.
· Information relating to the supply of gas, point of supply, quality, heat value.
· Information relating to the water supply, availability, quality, price.
· Information relating to the national power grid, point of connection, voltage etc... (in case of a possibility of exporting power to the national grid).
· Manpower and staff cost elements.
· Elements of social policy with respect to shift work, offices, etc....
· Environmental regulations and requirements.
· Specific constraints linked with the use of the proposed area.

4.2. DATA TO BE PROVIDED BY AP


During the kick-off meeting, AP will provide the following data/information to SOFRESID:
· Proposed basic data list and power requirement.
· Proposed lay-out of the smelter.

Within two weeks after the kick-off meeting, these documents will be formally finalised.
Within two months after the effective date of the study, AP will provide the following data/information related to the smelter and the port unloading facilities :
· Project general definition.
· Shops process description, schematic lay-out, process block diagrams.
· Main process equipment general definition and list.
· Detailed list and quantities for specific items such as busbars, potlining, bake oven refractories.
· Utilities Consumption.
· Electrical main single line diagram.
· List of suppliers for main process equipment.
· Within three months after the effective date, AP will provide the following data / information related to the smelter and the port unloading facilities :
· Work organisation, plant manning.
· Raw material consumption.
· Raw material prices.
· Consumable and other cost items.
· Working capital, including raw materials, anode storage, spare parts, materials in process, final products.
· Start-up costs, including consumables, operating personnel before start-up, personnel training, technical assistance, overheads.

5. OUTLINE FOR THE IMPLEMENTATION OF THE PROJECT


5.1. SCOPE OF SERVICES


For this implementation phase, SOFRESID has assumed that the project will be carried out as a standard Engineering, Procurement and Construction Management project (EPCM); however, it is take into account that, for a number of units, it is preferable to let the contractor be responsible for the definition, supply and installation, and therefore to place a turnkey contract (e.g. power plant, anode paste tower, gas treatment centre, etc...).
During the design stage, SOFRESID will endeavour to reach the best quality / cost ratio on the basis of its experience in major projects, while meeting the essential data of AP manufacturing process.
Thanks to its experience in managing and implementing big projects throughout the world, either in the form of EPCMs, or LUMP SUM TURN KEY contracts, SOFRESID's key staff are :
- directors and project managers permanently concerned with the objective of achieving the best quality and price,
- specialists capable of designing project facilities most suited to the processes and to local conditions,
- buyers with a perfect knowledge of international and local conditions in every industrial field, a feature which enables to select the best suppliers, in terms of prices, quality and after sales services,
- construction managers experimented in the co-ordination and supervision of work and tests in conformity with quality, safety, costs and contractual obligations of manufacturers.
computer systems enable the teams in charge of project management, to manage the project's costs and schedule in real time and thereby to avoid risks of uncontrolled deviations from set objectives.

In this perspective, SOFRESID will provide the following services:

5.1.1. MANAGEMENT, ADMINISTRATION AND CONTROL.


- Organise, monitor and control all aspects of the project.
- Prepare a Quality Assurance plan for the project.
- Prepare a manual of the project procedures covering all aspects of the project, including communications, control, and approval requirements by QGPC.
- Prepare the project baseline budget and cash flow schedules.
- Prepare the project baseline schedule and detailed schedules.
- Monitor the progress, performance and cost of the project, and present the pertinent reports to QGPC.
- Maintain records of all engineering, procurement and construction activities.
- Issue monthly progress reports.
- Draw up purchasing procedures and General Terms and Conditions for Contracts.
- Draw up accounting procedures and a chart accounts meeting QGPC present accounting procedures.
- Provide qualified staffing to perform the services in a timely manner as required by the project schedule.
- Prepare a final report.
5.1.2. PROJECT BASIC ENGINEERING
- Review with QGPC and AP the project concept and complete the basic engineering for the parts that are not covered by the process basic engineering delivered by AP.
- Prepare the project work plan including project/process criteria and submit it to QGPC for approval.
- In addition to the basic engineering provided by AP prepare all basic engineering drawings, including general arrangements, facility arrangements, process flow diagrams, one-line diagrams, plot plans, and other documents which will identify the project concepts, scope, and criteria.

5.1.3. PROJECT ENGINEERING


- Receive drawings
- Co-ordinate and interpret the information received from AP as it applies to the preparation of specifications and design and construction drawings.
- Prepare project criteria based upon those provided by AP.
- Prepare specifications for design, procurement and installation contracts, construction contracts and equipment purchases.
- Participate in prequalification of bidders.
- Prepare bid technical analysis.
- Conduct quality control monitoring of suppliers and contractors.
- Arrange for appropriate quality control and inspection services.
- Hold pre-award meetings with bidders to ensure bidder understanding of the scope of work, quality and schedule requirements.

5.1.4. DETAILED ENGINEERING


- Prepare drawing and specification schedules.
- Conduct the necessary information gathering at site.
- Prepare site specific design criteria.
- Prepare the appropriate basic and detail design and construction drawings.
- Prepare basic design and construction drawings for bid packages for design and installation contracts.
- Prepare technical construction specifications.
- Participate in bid evaluations.
- Prepare and maintain equipment lists.
- Prepare and maintain a motor list and an instrument list.
- Review equipment vendor's drawings.
- Review contractor drawings.
- Prepare " as built " drawings.

5.1.5. PROCUREMENT SERVICES


- Plan, administer and control the procurement programme.
- Plan, administer and control the contracts management programme.
- Co-ordinate procurement activities with engineering and construction.
- Prepare tender documents, including terms and conditions for international procurement of contracts for design, supply and supervision of erection, and equipment purchases.
- Prepare tender documents for tendering of contracts from GULF area and foreign contractors for site erection and civil works construction.
- Pre-qualify potential bidders for contracts.
- Prepare and present recommended lists of qualified bidders and contractors for the QGPC approval and selection.
- Prepare and issue requests for bids.
- Prepare commercial analysis of bids, with or without prices according to QGPC request.
- Conduct pre-award negotiations with selected bidders, recommend to QGPC award of purchase orders and construction contracts.
- Control contractors activities : quality control; time schedule.
- Monitor and expedite the procurement of certain equipment and materials.
- Assist contractors in planning, organising, directing and co-ordinating the transport of equipment and materials to the site.
- Approve progress payments on behalf of QGPC.

5.1.6. CONSTRUCTION MANAGEMENT


Construction management for the project will be provided in two phases: pre-construction and construction.

The following is a proposed list of the construction management services that will be furnished during these two phases:
- Pre-construction services
¨ Work with the designers to provide constructibility reviews.
¨ Prepare construction managing procedures for use in the field.
¨ Obtain site data and conduct a site investigation programme.
¨ Develop a detailed construction work plan and procedure outline for the construction phase.
- Construction services
¨ Supply construction site offices.
¨ Hold pre-construction meetings with bidders to assure their understanding of the scope of work, site conditions, safety and other requirements.
¨ Participate in the review and recommendations for the award of construction contracts.
¨ Initiate and monitor (supervise) geo-technical site activities.
¨ Monitor, co-ordinate and control all construction activities.
¨ Monitor construction methods for adherence to drawings and specifications.
¨ Perform all field engineering services.
¨ Perform field inspection and quality control.
¨ Monitor and co-ordinate performance of survey work to be provided.
¨ Monitor and co-ordinate the sub-contracted laboratory test work for concrete, soils and welding.
¨ Administer construction contracts.
¨ Document all correspondence with contractors and service contracts.
¨ Perform all field purchasing.
¨ Maintain drawing register and records.
¨ Issue drawing revisions to contractors.
¨ Maintain daily job diaries of each contractor's activities.
¨ Prepare a start-up and commissioning plan.
¨ Establish and implement a jobsite safety programme.

¨ Monitor contractor's safety programmes.
¨ Maintain progress and record photographs at jobsite.
¨ Prepare and issue construction activity reports.
¨ Provide construction input to the project monthly progress/cost comparison report.
¨ Update construction schedules and monitor contractor progress review and revise schedules on a regular basis to reflect real progress.
¨ Check and approve progress payment requests and make recommendations for payments.
¨ Hold weekly meetings with contractors to review progress and co-ordinate future work.
¨ Initiate force majeure delay reports whenever required.
¨ Co-ordinate site off-loading, storage, and protection of certain owner-furnished equipment and materials.
¨ Monitor inspection of certain equipment upon jobsite arrival to assess possible shipping damage or missing parts.
¨ Arrange for storage of certain materials and equipment in a secure manner for issue to construction contractors.
¨ Review and evaluate change order requests from contractors, submit recommendations to QGPC for change orders, and progress accordingly.
¨ Participate in the settlement of disputes including any claim between QGPC and contractors/suppliers.
¨ Arrange for site security, first aid, and fire protection under subcontract.
¨ Co-ordinate testing and checkout of the completed facilities before plant start-up.
¨ Initiate completion and final acceptance procedure.
¨ Provide the field support necessary for load testing and start-up of the facilities.
¨ Provide as-built drawings, specifications and equipment list.
¨ Close out the activities in the field at completion of construction.
¨ Participate in the preparation of the final project report.

5.2. ORGANIZATION CHARTS


In the construction phase, SOFRESID will set up teams of specialists organised according to the organisation chart indicated in APPENDIX 3, i.e.
- Under the authority of a Project Director initially based in Paris, then on the site, there will be two project teams, one in Paris, the other one in Doha, each being managed by a Project Manager.
- Each team, in Paris and Doha, will have a similar structure so as to operate on a self-contained basis and to ensure full consistency at different for actions taken in Paris and actions taken or continued in Doha.
- There will be four project engineers as Deputy Project Managers. Each one will be in charge of the management and co-ordination of a zone. These project engineers are functional heads of the specialists of the various disciplines involved in their zone.
- In Paris, the structure (Appendix 3.1) will be organised so as to carry out the design work, procurement, invoice checking and project organisation and control.
- In Doha, the same functions will be filled plus the site safety management and administration (Appendix 3.2) on the one hand, and the management/co-ordination of construction work and equipment testing (Appendix 3.3) on the other hand.
SOFRESID Gulf will support SOFRESID in all aspects related to the expertise available locally in the fields of :
- engineering
- procurement
- construction

APPENDIX 3.1

APPENDIX 3.2

APPENDIX 3.3

6. CURRICULUM VITAE OF KEY PERSONNEL



6.1. SOFRESID


BOUCOU Robert
De La BROSSE Pierre
GAUVRIT Jacques
LABILLE Serge
LAURENCHET Pierre
PAGE Michel

6.2. GEC ALSTHOM


GRANACHET Bernard
WOLFARTH Charles