Overview:  Palm Oil Mill Services
    

Service  Overview

PALM OIL MILL -

CONSTRUCTION,  COMMISSIONING  &  CONSULTANCY SERVICES

 

ARAB's Consultant Engineers and its Associate Companies have acquired vast experience and expertise in the design, construction, commissioning and operation of palm oil mills.

We can bring this to work for your plantation business should your company be considering building a palm oil mill in your estate(s).

 

Specialist services that we are able to provide are:-

 

New Plants

Project feasibility studies to determine the appropriate size and location of the processing plant.

Obtaining the required regulatory approvals for the plant.

The optimum design concept with regards to the levels of automation required, materials used and provision for future expansion.

Preparing the tender specification, evaluation of tender bids and advising the merits and demerits of bidders.

Construction Management and Quality Assurance during project implementation.

Commissioning and conducting the acceptance tests and performance tests on the plant to ensure compliance with contractual requirements.

Training of Operation and Maintenance Personnel.

 

Existing Plants

Improvement in mill throughput and processing efficiency

Reduction in oil and kernel losses

Reduction in mill operating costs

Automation of various stages of the process

Reducing environmental pollution through innovative technology and thus creating a better working environment for operations.

Utilisation of waste products or energy sources through innovative technology.

Modernisation of various stages of the process using state-of-the-art controls and automation.

 

 

CONSTRUCTION  SERVICES,    CONTRACT  MANAGEMENT  &  QUALITY  ASSURANCE

 

OVERVIEW

A substantial input that we are able to provide for any development project is in the fields of construction management and quality assurance. This section details some of the specific areas of expertise in this very important aspect of effective project implementation.

 

CONTRACT   DOCUMENTATION    AND    TENDER  ANALYSIS

Our capabilities encompass all aspects of contract documentation and tender analysis.
These capabilities have been developed in large and small-scale engineering projects.

 

They cover:-

Pre qualification of tenderers

Preparation of tender documents

Analysis and reporting on tenders received

Preparation of the contract documents

Our capabilities also encompass the planning and construction phases of projects and include:

Planning and programming

Estimating

Construction management

Claims management

Quality assurance

 

PRE-QUALIFICATION   OF   TENDERERS

Subject to the requirements of the owner and the funding agency, we can arrange for the complete pre qualification of tenderers for a contract. Services provided by us include preparation of brochure giving key project information, advertising for registration, preparation of appropriate questionnaires on applicants’ experience and financial standing, receipt, analysis and clarification of applications and preparation of recommendations to the owner.

 

PREPARATION  OF  TENDER DOCUMENTS

We prepare and issue tender documents, which normally include instructions to tenderers, general and special conditions of contract, specifications, bill of quantities, drawings and reference information. The actual makeup of the documents varies with the nature of the contract and with the particular needs of the owner and, in the case of internationally funded projects, with the particular requirements of funding agencies. Where possible, standardised forms of contract are adopted, subject to the agreement of the owner/client. Site visits by potential tenderers are arranged as necessary.

 

TENDER  ANALYSIS

Our analysis of tenders includes examination of tenders received by the owner, review of proposals for construction methods, program and cash flow, clarification discussions with higher ranked tenderers and submission of reports and recommendations to the owner.

 

CONTRACT   DOCUMENTS

Upon award of contract, our services commonly include preparation of formal contract documents incorporating the tender and any clarification of documents, together with completed schedules and forms for execution by the parties.

 

PLANNING   AND   PROGRAMMING

Preliminary project schedules are prepared during the feasibility phase, schedules for alternative project layouts compared, milestone dates defined and resources estimated.

As the project proceeds into detailed design, master schedule preparation is followed by preparation of sub-networks for features of the project, and progress is monitored according to the schedule.

For the construction phase, the contractor’s construction program for time, cash flow and resource allocation can be monitored, delays and time extensions quantified, and alternative construction procedures examined.

 

ESTIMATING

Using practical estimates of historical and current costs, productivity, plant and equipment costs, and labour rates, we are able to provide a range of estimate types to suit the owner’s needs.

At the feasibility stage indicative budget costs can be provided, alternative schemes ranked in cost order with comparative costs and major feature costs estimated.

As the project proceeds into the design phase, more accurate cost estimates are derived, based on the quality requirements; quantities and layouts provided by the design engineers. This function proceeds up to the stage where an Engineer’s Estimate can be developed as the basis for comparison of tenders.

During construction, we advise upon claimed construction costs and productivity for variation analysis, variation valuation, and provide estimates for costs to completion.

 

 

CONSTRUCTION   MANAGEMENT

Following the award of a contact by the owner, we include the provision of the full range of services necessary to ensure that the contract is completed according to time, cost and quality criteria.

On-site supervision can be provided to administer the contract and to inspect the works as they are constructed. Such services include the measurement of work completed, processing of regular progress payments, management of claims, reporting on progress and cost, attendance at meetings, reviewing contractors programs and proposals and administering inspection staff.

At the conclusion of a contract, final reports summarising the construction phase are normally submitted and complete inspection and photographic records handed over to the owner.

 

 

QUALITY   ASSURANCE

During the implementation phase of a project we give particular attention to ensuring that the contract works are executed in accordance with -the appropriate quality requirements.

Quality control and assurance services cover the detailed inspection of the work to predetermined guidelines and standards, the carrying out of specified tests, the analysis and reporting of test results and the verification of compliance with design requirements.

Detailed Quality Manuals for quality assurance at the manufacturing works, quality assurance at site works and quality acceptance criteria of completed works can be provided. Tests on completion to ensure that performance of machinery such as boilers, steam turbines, gas turbines are acceptable and can be carried out in conformance with internationally acceptable standards.

 

ISO 9000 CERTIFICATION

We have the expertise to organise documentation of all activities in any production plant and prepare it for I.S.O. certification.

 

 

PROJECT   MANAGEMENT

We are able to offer complete project management services for many projects. Our personnel have developed expertise in this field through extensive practical experience on many projects of various sizes and types that they have managed.

In any economic environment, it is critical that a project be completed on schedule, within budget and to the highest quality standards if it is to meet the owner’s short term and long term needs. Owners are therefore increasingly turning to the use of project management systems, such as those offered by us, to ensure that cost, program, function and quality objectives are met.

At the commencement of any project management assignment, we set up a multidisciplinary team under the direction of an experienced project manager. All team members will have had extensive practical experience in their relevant fields and, in particular, the project manager will have the necessary skills and experience to ensure the successful implementation of the project. If requested by the owner, maximum use is made of either the owner’s staff and resources or, where appropriate, the staff and resources of other professional organisations nominated by the owner.

Our project management staff are highly skilled professionals who are experienced in the use of advanced computer technology to establish management reporting systems and to control and monitor the progress of a project.

The project team is fully backed by our resources and a specially nominated member of our top management who will overview the project.

Each project has unique characteristics and objectives and normally requires the establishment of specialised management systems. Specific services that are available under these systems through the various phases of a project are set out below:

 

INCEPTION   PHASE

Project identification studies

Feasibility studies

Appraisal of potential sites and geo-technical investigations

Environmental studies

Preliminary layouts and designs

Preliminary implementation programs

Preliminary cost estimates

Liaison with government, commercial and community organisations.

 

DESIGN   PHASE

Detailed planning

Detailed site investigations

Preparation of detailed layouts, designs and specifications

Tender documentation

Calling of tenders

Tender evaluation and recommendations

Detailed estimates

Detailed programs

Detailed budget and cash flow forecast

 

CONSTRUCTION   PHASE

Preparation of master schedules incorporating individual construction programs

Supervision of construction

Contract administration

Quality assurance on-site and off-site

Construction records

Payments to contractors

Cost control

Updated cash flow forecasts

Financial, progress and technical reports to owner

Liaison with government, commercial and community organisations

Materials and equipment procurement and expediting

Site safety and industrial relations

Site security

 

PROJECT   FINALISATION

Scheduling and supervision of commissioning and handover

Operation and maintenance manuals.

Completion reports

Resolution and assessment of contractual claims

Contract finalisation

Ongoing surveillance and inspection.

 

 

ELECTRICAL   &   MECHANICAL  ENGINEERING

 

OVERVIEW

Our Electrical and Mechanical Engineering expertise has been developed over many years from the power supply industry, the palm oil processing industry as well as projects with Government agencies and private sector clients.

 

Our areas of expertise include:

Boiler inspection services

Electrical installation services

Water supply projects

High voltage transmission systems

Low voltage distribution systems

Automatic control and protection systems

Ventilation and air-conditioning systems

Maintenance management

 

Within these fields, the services, which we offer and in which our personnel are experienced, include:

Project identification and feasibility studies

Plant parameter determination

Equipment cost estimation

Design and specification

Tender evaluation

Contract administration and project management

Factory test and progress inspection

Erection and commissioning supervision

Project reports and O&M manuals

Personnel training

Contract and finance packaging

In addition to the planning and implementation of new facilities, we undertake technical and economic analyses of existing installations. Such analyses provide the basis for upgrading obsolete equipment to improve operational flexibility and overall plant reliability.

 

The various types of projects for which we are able to provide electrical and mechanical services include:

 

POWER  PLANT  PROJECTS

Electrical: generators, transformers, switchgear, excitation systems and auxiliary equipment;

Mechanical: gas turbine plants, (open and combined cycle), steam turbine plants, pumps, compressor systems, co- generation systems and auxiliary equipment.

 

INFRASTRUCTURE   DEVELOPMENT

Water supply and drainage systems for commercial, industrial and municipal installations

Fire fighting and protection systems

Industrial lifts and escalators

Materials handling

Cranes and hoists

 

VENTILATION   AND   AIR-CONDITIONING  SYSTEMS

Industrial, ventilation systems for power stations, workshop complexes, transport tunnels, carparks and large building complexes;

Industrial and commercial air-conditioning systems.

 

MAINTENANCE   MANAGEMENT

Hydraulic, mechanical and electrical plant overhauls and refurbishing;

Plant uprating;

Control and protection system modernisation;

Computer-aided maintenance management systems.

While we maintain complete capability in major project implementation, we appreciate the needs of smaller developments and provide services to any small to medium sized organisations.

 

 

ENVIRONMENTAL   ENGINEERING

 

WATER SUPPLY  AND  EFFLUENT TREATMENT

We have the capacity through both in-house resources and associate organisations to investigate, design and manage water supply and waste or effluent treatment schemes.

Upgrading and rehabilitation of existing schemes may be an economic alternative to new projects and we are able to provide the required advice and design capacity for such work.

 

AIR POLLUTION CONTROL

We have the capability to design air pollution control systems appropriate for the needs of various types of industries to meet the requirements of the Department of Environment.

Systems that we specialise in includes: -

Dust pollution control in industries

Boiler Flue Gas dry separation system.

Boiler Flue Gas venture wet scrubbing system.

 

NOISE POLLUTION CONTROL

An important area where we have developed expertise in is the design of noise control systems and design of simple innovative means of reducing noise levels of operating equipment within an industry.

 

 

TRAINING   &   EDUCATION

 

OVERVIEW

An area of expertise, which has been developed in parallel with the personnel’s engineering and project management experience, has been in the field of personnel training. Transfer of technology is an essential component of consultancies and we have actively developed this area of expertise as the means of passing on technical and management skills to counterpart staff. Technology transfer, has in fact now become an intergal component of our investigation, feasibility, design, and construction activities.

Our expertise covers all aspects of training and staff development, from the analysis and planning stages through to design, implementation and monitoring of projects. Training and technology transfer programs have involved specially designed seminars and on-the-job training. An important aspect of our programs is the transfer of training technology to personnel so that these personnel will be able to analyse, plan, design, implement and monitor their future programs with minimum dependence on external assistance.

Our experience on projects has proven that for training and staff development programs to be successful they must be based on the actual needs of the client organisation and its personnel. Accordingly formal development plans are prepared from project design document so that training and staff development can be effectively implemented and managed. The development of plans follows modern educational and training practices of identifying needs, determining objectives, selecting content and strategies and evaluating results.

Our training or staff development plan identifies:

The people to be trained – groups or individuals

Needs of the group or individuals

Suitable programs.

Resources required for the program

A schedule of activities.

Estimate of costs

Monitoring, evaluating and reporting procedures.

The formal plan then provides guidelines for the implementation of the programs and serves as a management tool for monitoring progress.

Senior personnel are involved in the planning processes.

 

DESIGN  OF PROGRAMS

It has been found that a mix of practical and formal training often achieves the most satisfactory results with program activities designed to meet the needs of individual personnel. The activities can emphasise ‘learning by-doing’ via on-the-job tutoring and practical training to develop job-specific skills, and/or formal courses in which relevant theoretical knowledge is gained depending again upon the needs of the individual personnel.

Training is primarily carried out on-site for operational personnel, supplemented by classroom lectures as appropriate, with formal lecture sessions followed by practical application of theory being mainly used for the development of more senior staff.

Typical on-site activities include:

On-the-job tutoring where project staff work under the guidance of specialists to gain experience in each of the elements of their job functions.

Practical training where brief lectures, group discussions and practical demonstrations are held at job-sites under actual working conditions.

Short formal classroom type courses on topics that relate to current job activities

Formal and practical courses conducted by visiting specialist trainers.

All on-site training is conducted by our staff or visiting specialists assisted by counterparts.

Staff development programs, which can be carried out:

Attachments for practical work-experience training

Study tours to discuss and observe appropriate technologies.

The use of appropriate training and staff development methods and resources is essential for successful results. Some typical training strategies and procedures employed by us are indicated below. These strategies and procedures can be altered to meet specific client requirements.

On-site training is conducted in the English language with counterpart staff translating throughout if necessary. This procedure develops the technical and training competencies of the counterpart staff so that specialist inputs are progressively reduced as training activities are repeated.

Our specialists who conduct the training are drawn from the work place so that a link between training and production is enhanced.

Use specialists and counterpart staff with a sound technical knowledge and skilled in modern training methods.

Instruction is conducted for short periods to facilitate learning and, where possible, the individual topics relate to current job activities.

‘Hand-on’ training is emphasised in both formal and practical sessions.

The materials utilise project specific examples and models

A high priority is given to training of selected staff to implement and manage the programs to ensure that a self-sustaining training capacity is developed.

 
 
Should you be interested in any of the above services, please contact us for further details. Thank you.
 

  

Agricultural  Research  &  Advisory  Bureau   [ARAB]
3.5 mls Kajang-Serdang Rd.
Selangor 43000, Malaysia.
Tel: (60 3) 8736-8490       Fax: (60 3) 8736-8491/92
Email: arabis@arabis.org          www.arabis.org
 


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