CSP20 Testing Precommissioning and Commissioning Guideline - Full Compilation

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 1

Document Authorisation Document Title

Testing, Pre-Commissioning & Commissioning Guideline

Document ID

CSP-20

Document Version

Revision 1.0

Version Date:

JUNE 2014

Document Status:

Approved for Execution

Document Revision History

Rev Date:

Version:

Summary of Changes:

Revised by:

JUNE 2014

1.0

Additional sub-subsystems, updates on existing info and format modification.

Department of Commissioning, Construction (DCC), P&E, PCSB

Document Classification

SECRET or RAHSIA CONFIDENTIAL or SULIT INTERNAL USE or UNTUK DALAMAN OPEN or TERBUKA

√

ALL DOCUMENTS MUST BE CLASSIFIED BY THE LEVEL OF SENSITIVITY ACCORDING TO THE DOCUMENT SECURITY CLASSIFICATION SCHEME AS DETAILED IN APPENDIX V OF THE PETRONAS RECORDS MANAGEMENT GUIDELINES FOR ACTIVE RECORDS.



Acknowledgment This is dedicated especially to those who have shared their materials from various Departments and those who have participated and supported the development and review of this document. The individuals have shown commitments and continuous support throughout the whole process from inception to final issuance of this guideline. The constructive and comprehensive contributions to the content of the guideline have been proven invaluable in the process of developing and completing the guideline.

No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Name Ir. Akbal B Abu Alfredo P. Vicente M Zhafri B Nasarudin Muhamad Muaz B Azman Nur Shairah Bt Ahmad Ho Joon Heng Dhandi Wijaya A. Murali Krishna Kumar Sanjay Kumar Singh M Hussain B M Salleh Mohammad Firoz Alam Siamak Alaee Shahid M Siddiquee Lim Chui Yean Filomeno Fernandez Valencia Jr Steven Hammond M Nur Iman B Zahari Nazihah Bt Abdullah M Helmi B A Malek Mohd. B Ludin M Fauzi B Awang Khamis B A Kadir Latifah Rohaniah Bt Selamat Siti Nur Khatiejah Bt Salahuddin Pang Wan Sin M Akhmal B Ahmad Daud Rarichan Joseph Viresh Kumar Bodhram Kartina Wati Bt Arbi Leong Chai Yin

Department DCC (Advisor) DCC (Team Leader) DCC (Co-Team Leader) DCC (Co-Team Leader) DCC (Technical Writer) DCC (Technical Writer) DCC DCC DCC DCC DCC DCC DCC DCF DCF DESE DESE DEME DEME DEME DEIC DEIC DEIC DEIC DEIC DEIC DEEE DEPE DSE DSE



TABLE OF CONTENTS 1.0

PURPOSE .................................................................................................................................................... 8

2.0

ABBREVIATION &DEFINITION ..................................................................................................................... 9

2.1 2.2 3.0

ABBREVIATIONS ................................................................................................................................................ 9 DEFINITIONS..................................................................................................................................................... 9 SCOPE ...................................................................................................................................................... 11

3.1 SYSTEM DEFINITION......................................................................................................................................... 11 3.2 SYSTEM DESCRIPTION AND SCOPE OF WORKS ....................................................................................................... 32 3.3 TESTING AND PRE-COMMISSIONING COMMON SCOPE OF WORK .............................................................................. 33 3.3.1 General ................................................................................................................................................... 33 3.3.2 Piping ..................................................................................................................................................... 34 3.3.3 Mechanical ............................................................................................................................................. 37 3.3.4 Electrical ................................................................................................................................................. 40 3.3.5 Instrumentation& Telecommunication .................................................................................................. 40 3.4 COMMISSIONING ............................................................................................................................................ 43 3.5 COMMISSIONING AND START-UP PROCEDURE ....................................................................................................... 45 3.6 SYSTEM BY SYSTEM SCOPE OF WORK .................................................................................................................. 45 3.6.1 100 – PROCESS ....................................................................................................................................... 46 3.6.1.1 3.6.1.2 3.6.1.3 3.6.1.4 3.6.1.5 3.6.1.6 3.6.1.7 3.6.1.8

3.6.2

200 – PROCESSUTILITIES ...................................................................................................................... 106

3.6.2.1 3.6.2.2 3.6.2.3 3.6.2.4 3.6.2.5 3.6.2.6 3.6.2.7

3.6.3

210 – UTILITY GAS ........................................................................................................................................ 106 220 – INERT GAS .......................................................................................................................................... 110 230 – VENTING ............................................................................................................................................. 113 240 – PRODUCED WATER ............................................................................................................................ 117 250 – DRAIN ................................................................................................................................................. 120 260 – PROCESS HEATING ............................................................................................................................. 127 270 – CHEMICAL (DOSING) INJECTION/TREATMENT ................................................................................... 131

300 – GENERAL UTILITIES ..................................................................................................................... 145

3.6.3.1 3.6.3.2 3.6.3.3 3.6.3.4 3.6.3.5 3.6.3.6 3.6.3.7

3.6.4

110 – FULL WELL STREAM.............................................................................................................................. 46 120 – PROCESS LIQUID (PL) ............................................................................................................................ 54 130 – PROCESS GAS (PG)................................................................................................................................ 66 140 – GAS COMPRESSION .............................................................................................................................. 71 150 – GAS DEWPOINTING .............................................................................................................................. 81 160 – WATER INJECTION ................................................................................................................................ 90 170 – ACID GAS REMOVAL ........................................................................................................................... 100 180 – CONTAMINANT REMOVAL ................................................................................................................. 102

310 – FUEL AND LUBRICATION .................................................................................................................... 145 320 – COMPRESSED AIR ............................................................................................................................... 150 330 – WATER................................................................................................................................................ 155 340 – STEAM ................................................................................................................................................ 163 350 – HEATING, VENTILATION AND AIR-CONDITIONING ............................................................................. 167 360 – HYDRAULICS ....................................................................................................................................... 172 370 – MARINE SYSTEM ................................................................................................................................ 173

400 – SAFETY ........................................................................................................................................ 178

3.6.4.1 3.6.4.2

410 – FIRE FIGHTING .................................................................................................................................... 178 420 – LIFESAVING EQUIPMENT .................................................................................................................... 183

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.5

4.1 4.2 4.3 4.4 5.0

710 – MAIN BACKBONE LINK ....................................................................................................................... 256 720 – RADIO COMMUNICATIONS SYSTEM .................................................................................................. 261 730 – VOICE AND DATA COMMUNICATION................................................................................................. 267 740 – SURVEILLANCE AND SAFETY SYSTEM ................................................................................................. 271 750 – COMMUNICATIONS EQUIPMENT ....................................................................................................... 275

800 – MISCELLANEOUS ........................................................................................................................ 276

3.6.8.1 3.6.8.2 3.6.8.3 3.6.8.4 3.6.8.5 3.6.8.6

4.0

610 – PROCESS CONTROLS........................................................................................................................... 228 620 – SAFEGUARDING SYSTEM .................................................................................................................... 241

700 – TELECOMMUNICATION .............................................................................................................. 256

3.6.7.1 3.6.7.2 3.6.7.3 3.6.7.4 3.6.7.5

3.6.8

510 – POWER GENERATION/SUPPLY ........................................................................................................... 188 520 – DISTRIBUTION .................................................................................................................................... 197 530 – UNINTERRUPTIBLE POWER SUPPLY ................................................................................................... 209 540 – SMALL POWER AND LIGHTING ........................................................................................................... 213 550 – EARTHING & LIGHTNING PROTECTION .............................................................................................. 216 560 – DRIVES AND CONTROLLERS................................................................................................................ 219 570 – CONSUMERS ...................................................................................................................................... 222

600 – CONTROL AND SAFEGUARDING ................................................................................................. 228

3.6.6.1 3.6.6.2

3.6.7

REVISION : 01 PAGE : 4

500 – POWER ....................................................................................................................................... 188

3.6.5.1 3.6.5.2 3.6.5.3 3.6.5.4 3.6.5.5 3.6.5.6 3.6.5.7

3.6.6

PROCEDURE NO: CSP-20

810 – MATERIAL HANDLING ........................................................................................................................ 276 820 – FURNITURE/APPLIANCES.................................................................................................................... 284 830 – AVIATION ........................................................................................................................................... 289 840 – MARINE AND CORROSION PROTECTION ............................................................................................ 291 850 – STRUCTURAL ...................................................................................................................................... 295 860 – CIVIL ................................................................................................................................................... 300

REFERENCES ........................................................................................................................................... 304 CODES AND STANDARDS ................................................................................................................................. 304 CONSTRUCTION DRAWINGS............................................................................................................................. 305 CARIGALI STANDARD PROCEDURE (CSP) ......................................................................................................... 305 PETRONAS TECHNICAL SPECIFICATION ............................................................................................................ 305 PROCEDURES ......................................................................................................................................... 307

5.1 MECHANICAL AND PIPING PRE-COMMISSIONING PROCEDURE ................................................................................ 308 5.1.1 Turbine Driven Generators ................................................................................................................... 308 5.1.2 Diesel Engine and Gas Engine Driven Generators ................................................................................ 310 5.1.3 Diesel Engine Driven Firewater Pumps................................................................................................. 312 5.1.4 Electric Motor Driven Submersible Pumps ........................................................................................... 314 5.1.5 Diesel-Engine-Driven Start Air Compressors ........................................................................................ 315 5.1.6 Electric-Motor-Driven Air Compressors ................................................................................................ 317 5.1.7 Diesel-Engine-Driven Survival Crafts (Life Boat) ................................................................................... 318 5.1.8 Heating, Ventilation and Air Conditioning ........................................................................................... 320 5.1.9 Pedestal Cranes .................................................................................................................................... 323 5.1.10 Vapour Compression Type Water Makers ....................................................................................... 326 5.1.11 Wellhead Diesel Injection Pumps ..................................................................................................... 328 5.1.12 Electric-Motor-Driven Centrifugal Pump ......................................................................................... 329 5.1.13 Gas- And Diesel-Engine-Driven Centrifugal Pumps .......................................................................... 330 5.1.14 Gas-Engine-Driven Reciprocating Gas Compressors ........................................................................ 332 5.1.15 Turbine-Driven Centrifugal Compressors ......................................................................................... 335 5.1.16 Reinstatement Leak Test Procedure ................................................................................................ 336



5.1.17 Electro-Chlorinators ......................................................................................................................... 339 5.1.18 Nitrogen Gas Generators ................................................................................................................. 341 5.1.19 Standard Alignment Procedure ....................................................................................................... 342 5.1.20 Nitrogen Purging Procedure ............................................................................................................ 346 5.2 ELECTRICAL PRE-COMMISSIONING PROCEDURES.................................................................................................. 348 5.2.1 Insulation Resistance Test Procedure ................................................................................................... 348 5.2.2 Turbine-Driven Main Power Generator ................................................................................................ 348 5.2.3 Diesel-Engine or Gas-Engine-Driven Generators .................................................................................. 353 5.2.4 High Voltage Motor Control Center and Switchgear ........................................................................... 359 5.2.5 Low Voltage Motor Control Center and Switchgear ............................................................................ 361 5.2.6 Transformers ........................................................................................................................................ 363 5.2.7 Batteries and Battery Charger ............................................................................................................. 364 5.2.8 Uninterruptible Power Supply .............................................................................................................. 365 5.2.9 Navigational Aids ................................................................................................................................. 367 5.2.10 Small Power and Lightings............................................................................................................... 368 5.2.11 Earthing and Lighting Protection ..................................................................................................... 369 5.2.12 Heat Tracing .................................................................................................................................... 370 5.2.13 Un-coupled and Coupled Run Test of Electric Motors...................................................................... 373 5.2.14 Heater Control Panels and Heaters ................................................................................................. 376 5.3 INSTRUMENTATION PRE-COMMISSIONING PROCEDURES ....................................................................................... 379 5.3.1 General Construction Verification ........................................................................................................ 379 5.3.2 Loop Test of Pressure Instrument......................................................................................................... 379 5.3.3 Loop Test of Level Instruments............................................................................................................. 384 5.3.4 Loop Test of Temperature Instruments ................................................................................................ 392 5.3.5 Loop Test of Flow Instruments ............................................................................................................. 394 5.3.6 Loop Test Final Control Instruments .................................................................................................... 400 5.3.7 Loop Test Rotating Equipment Monitoring System ............................................................................. 407 5.3.8 Process Monitoring Control System (PMCS)......................................................................................... 412 5.3.9 Safety Instrumented System (SIS) (LAT) ............................................................................................... 416 5.3.10 Fire and Gas System (FGS) ............................................................................................................... 419 5.3.11 Pneumatic Instrument Control Panel ............................................................................................... 428 5.3.12 Wellhead Control Panel(WHCP) ....................................................................................................... 433 5.3.13 Fusible Plug Loop ............................................................................................................................. 440 5.3.14 Test of Pressure Safety Valve (PSV) ................................................................................................. 441 5.3.15 Test of Analyzer ............................................................................................................................... 441 6.0

GENERAL REQUIREMENTS ...................................................................................................................... 442

6.1 ORGANIZATION ............................................................................................................................................. 442 6.1.1 Organization Chart ............................................................................................................................... 442 6.1.2 Individual Roles and Functions ............................................................................................................. 443 6.2 TESTING AND PRE-COMMISSIONING SEQUENCE................................................................................................... 452 6.2.1 Flowchart ............................................................................................................................................. 452 6.2.2 Preparation Activities ........................................................................................................................... 464 6.2.3 Critical Path Network ........................................................................................................................... 466 6.2.4 Bar chart .............................................................................................................................................. 467 6.2.5 Manpower Histogram .......................................................................................................................... 468 6.2.6 Jobcards ............................................................................................................................................... 470



6.3 SAFETY ........................................................................................................................................................ 471 6.3.1 Pre-cautions ......................................................................................................................................... 471 6.3.1.1 6.3.1.2 6.3.1.3 6.3.1.4

General ........................................................................................................................................................ 471 Rotating Equipment ..................................................................................................................................... 471 Electrical Equipment .................................................................................................................................... 472 Pressurized Equipment ................................................................................................................................ 474

6.4 PUNCHLIST ................................................................................................................................................... 475 6.5 FINAL DOCUMENTATION................................................................................................................................. 478 6.6 COMMISSIONING AND OPERATING SPARES......................................................................................................... 479 6.7 SHIPLOOSE MATERIALS................................................................................................................................... 480 6.8 PRESERVATION ............................................................................................................................................. 481 6.9 TOOLS AND EQUIPMENT ................................................................................................................................. 482 6.9.1 Mechanical ........................................................................................................................................... 482 6.9.2 HVAC .................................................................................................................................................... 484 6.9.3 Piping ................................................................................................................................................... 485 6.9.4 Electrical ............................................................................................................................................... 487 6.9.5 Instrumentation ................................................................................................................................... 489 6.10 CONSUMABLES ............................................................................................................................................. 491 6.10.1 Preservative Lubricants .................................................................................................................... 491 6.10.2 Lubricants ........................................................................................................................................ 492 6.10.3 Miscellaneous .................................................................................................................................. 493 6.10.4 Others .............................................................................................................................................. 494 7.0

RECORDS ................................................................................................................................................ 495

7.1 ITR LISTING ................................................................................................................................................. 496 7.1.1 Architectural ........................................................................................................................................ 496 7.1.2 Civil ....................................................................................................................................................... 497 7.1.3 Electrical ............................................................................................................................................... 498 7.1.4 HVAC .................................................................................................................................................... 500 7.1.5 Instrumentation ................................................................................................................................... 501 7.1.6 Mechanical ........................................................................................................................................... 503 7.1.7 Piping ................................................................................................................................................... 505 7.1.8 Safety ................................................................................................................................................... 506 7.1.9 Structural ............................................................................................................................................. 507 7.1.10 Telecommunication ......................................................................................................................... 508 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10

APPENDIX I: ITR – A (CONSTRUCTION) ................................................................................................... 509 APPENDIX I-I: ARCHITECTURE (A) .................................................................................................................. 509 APPENDIX I-II: CIVIL (C) .............................................................................................................................. 509 APPENDIX I-III: ELECTRICAL (E) ..................................................................................................................... 509 APPENDIX I-IV: HVAC (H)........................................................................................................................... 509 APPENDIX I-V: INSTRUMENTATION (I) ............................................................................................................ 509 APPENDIX I-VI: MECHANICAL (M)................................................................................................................. 509 APPENDIX I-VII: PIPING (P) .......................................................................................................................... 509 APPENDIX I-VIII: SAFETY (S)......................................................................................................................... 509 APPENDIX I-IX: STRUCTURAL (ST) ................................................................................................................. 509 APPENDIX I-X: TELECOMMUNICATION (T) ....................................................................................................... 509

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 9.0


APPENDIX II: ITR – B (PRE-COMMISSIONING) ......................................................................................... 510

9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 10.0


APPENDIX II-I: ARCHITECTURE (A)- NA .......................................................................................................... 510 APPENDIX II-II: CIVIL (C)- NA ....................................................................................................................... 510 APPENDIX II-III: ELECTRICAL (E) .................................................................................................................... 510 APPENDIX II-IV: HVAC (H).......................................................................................................................... 510 APPENDIX II-V: INSTRUMENTATION (I) ........................................................................................................... 510 APPENDIX II-VI: MECHANICAL (M)................................................................................................................ 510 APPENDIX II-VII: PIPING (P) ......................................................................................................................... 510 APPENDIX II-VIII: SAFETY (S)........................................................................................................................ 510 APPENDIX II-IX: STRUCTURAL (ST)- NA ......................................................................................................... 510 APPENDIX II-X: TELECOMMUNICATION (T) ...................................................................................................... 510 APPENDIX III: ITR- C (COMMISSIONING) ................................................................................................. 511

10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10

APPENDIX III-I: ARCHITECTURE (A)- NA ......................................................................................................... 511 APPENDIX III-II: CIVIL (C)- NA ...................................................................................................................... 511 APPENDIX III-III: ELECTRICAL (E) ................................................................................................................... 511 APPENDIX III-IV: HVAC (H)......................................................................................................................... 511 APPENDIX III-V: INSTRUMENTATION (I) .......................................................................................................... 511 APPENDIX III-VI: MECHANICAL (M)............................................................................................................... 511 APPENDIX III-VII: PIPING (P) ........................................................................................................................ 511 APPENDIX III-VIII: SAFETY (S)....................................................................................................................... 511 APPENDIX III-IX: STRUCTURAL (ST)- NA ........................................................................................................ 511 APPENDIX III-X: TELECOMMUNICATION (T)................................................................................................. 511

11.0

APPENDIX IV: ITR OVERVIEW ................................................................................................................. 512

12.0

APPENDIX V: OVERALL SYSTEM DESCRIPTION ........................................................................................ 513

13.0

APPENDIX VI: ENDURANCE & PERFORMANCE TESTING CRITICAL PARAMETERS .................................... 514

14.0 APPENDIX VII: SAMPLE TABLE OF CONTENT (TOC) FOR OVERALL DETAILED TESTING, PRECOMMISSIONING AND COMMISSIONING PROCEDURE. ..................................................................................... 521 END OF DOCUMENT ........................................................................................................................................... 522



PURPOSE

The Testing, Pre-commissioning and Commissioning Guideline is prepared for use as a minimum requirement in performing testing, pre-commissioning and commissioning activities at the fabrication yard and offshore/onshore installation. It is CARIGALI's intention to ensure all systems are fully tested, pre-commissioned and commissioned in the fabrication yard to the maximum extent possible followed by final commissioning at site. The guideline is also intended to better define the workscope between fabrications, hookup and commissioning stages thus improving area of responsibilities for the personnel. The intent of onshore/offshore testing, pre-commissioning and commissioning are to: i)

verify all equipment are installed in accordance to Approved For Construction As-Built drawings and manuals,

ii) prove equipment is able to function according to its design specifications and intentions, iii) minimize problems during Start-up iv) identify equipment shortfalls and deficiencies so that corrective actions could be carried before Start-up, v) compile test data and results with all other documents into a complete equipment final documentation, vi) pre-determine outstanding activities (punchlist)



ABBREVIATION &DEFINITION

2.1

2.2

Abbreviations Term CSP ESD HUC ITR DMC RFC NDT PSV SDV BDV DBB PT AGRU MRU GTG GTC CEM FAT SAT EDG HVAC PCHE ICE EM

Definition Carigali Standard Procedure Emergency Shut Down Hook-up and Commissioning Inspection Test Records Discipline Mechanical Completion Ready for Commissioning Non-Destructive Testing Process Safety Valve Shut Down Valve Blow Down Valve Double Block and Bleed Valve Performance Test Acid Gas Removal Unit Mercury Removal Unit Gas Turbine Generator Gas Turbine Compressor Cause & Effects Matrix Factory Acceptance Test Site Acceptance Test Emergency Diesel Generator Heating, Ventilation & Air Conditioning Printed Circuit Heat Exchanger Internal Combustion Engine Electric Motor

Definitions 2.2.1

Testing An act of examination, trial or proof to prove and validate the correct and complete execution of the WORKS.

2.2.2

Pre-commissioning An act of ensuring that the functions and operations of system/ sub-systems are in accordance to the designed purpose and intended services and meet all applicable specifications, regulations, codes and standards. On successful completion of the activity the system/sub-systems shall be ready for commissioning activities.

2.2.3

Commissioning Act of putting certain items into active service for the first time as intended by



design and specifications. It includes dynamic functional testing and documentation of an assembly, system or sub-system independently or together with associated systems and facilities to ensure that it fulfils its designed purpose and services. 2.2.4

Verify To determine or test the accuracy of, as by comparison, investigation or reference.

2.2.5

Perform To begin and carry through to completion.

2.2.6

Check Supervise control, as of accuracy or efficiency.

2.2.7

Performance Test-Run (PTR) An act to prove and demonstrate overall plant reliability and operability, in accordance with agreed Performance Test Procedure which shall be depend on available throughput but not lower than plant turndown ratio.

2.2.8

No-Load Test A trial or proof as to the way in which individual machinery functions without load.

2.2.9

Load Test A trial or proof as to the way in which individual machinery functions with design load.

2.2.10 Endurance Test A trial of proof as to the ability to carry on through, usually for a specific period of time. 2.2.11 Mechanical Completion The checking and testing of equipment and construction to confirm that the installation is in accordance with drawings & specifications and ready for commissioning in a safe manner and in accordance with project requirements.



SCOPE

3.1

System Definition

3.1.1

All facilities and equipment are categorized into a specific system. A system is defined as a configuration of pipeworks and/or equipment that fall within the same process medium. OR SYSTEM is the first level of breakdown, being either process or utility that performs an overall operational function of a facility or plant.

3.1.2

A system is identifiable from the Piping and Instrumentation Diagram (P&ID) drawings.

3.1.3

Systems are broken down into two more categories; Subsystem and SubSubsystems. Each subsequent category identifies the relevant system in more detail.  Sub-system is a major subdivision of the system that performs a Major operational function of the facility or plant.  Sub-subsystem is a part of the sub-systemthat performs a given partial operational function,with minimum interference from the other subsubsystems and can be completed and commissioned as a separate entity.

3.1.4

CONTRACTOR shall identify and select only the relevant systems applicable to the Works. CONTRACTOR shall be responsible to identify and develop new systems should additional systems be applicable.

3.1.5

A chart showing the list of most identifiable systems at the different levels are shown in the subsequent pages.

3.1.6

Sub-system can be further breakdown into level 4 category for ease of handover to Operations. For example, the flowline for a cluster of Wellhead to be systemized at level 4 category to enable the Operations to start with the minimum throughput. Thus, every project is unique- a mix and match to tailor the process is required for handover to take place.



Sub-Subsystem limitation Rules: 1) Process/Utility; A) General rule: i)

Boundary limits of process / utility pipework should be an isolation valve, or spade, allocated to the Sub-subsystem that has the highest priority, and will be commissioned first.

ii)

Where the blind is necessary, the limit will be most suitable flange

Described Sub-subsystem Other Sub-subsystem Figure 3.1-1:

Example System Boundaries of a Sub-subsystem for Process/Utilities

B) Flare/Vent Sub-subsystems limit will be Downstream of: i) Safety valves ii) Pressure control valves iii) Blow down valves iv) Choke valves v) Isolation valves.



Flare/Vent Sub-subsystem Other Sub-subsystem Figure 3.1-2:

Example System Boundaries of a Sub-subsystem for Flare/Vent

C) Closed drain Sub-subsystem limit will be down stream of: 1- Safety Drain valves 2- Level control valves 3- Blow down valves and will be down stream of first valve of double isolation valves.

Close

Closed Drain Sub-subsystem Other Sub-subsystem Figure 3.1-3:

Example System Boundaries of a Sub-subsystem for Closed Drain

D) Fuel gas Sub-subsystemslimit will be Up stream of the last manual supply isolation valve. E) Nitrogen Sub-subsystem Limit will be Up stream of the last double manual supply isolation valves.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE


CARIGALI STANDARD PROCEDURE

Nitrogen/Fuel Sub-subsystem Other Sub-subsystem

Figure 3.1-4:

Example System Boundaries of a Sub-subsystem for Nitrogen/Fuel

F) Chemical injection Sub-subsystems Limit will be Upstream of the supply isolation valve for eachInjection point into the process line. G) Fuel and Lubricant Sub-subsystemsLimit will be Upstream of the first supply isolation valveto each user. H) ExchangersBoundaryLimit will be down stream of the Utility supply isolation valve.

TC

To and From Utility Systems Such as: Steam, Hot Oil, Cooling Water…

Utility Sub-subsystem Exchanger Boundary Figure 3.1-5:

I)

Example System Boundaries of a Sub-subsystem

Instrument Air / Utility Air / Black start Air Limit is Upstream of the final piping isolating valves and before the items of Equipment being supplied.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE CV

BD V


ESD

INSTRUMENT AIR

HVAC FIRE DAMPER 1-

AIR OPERATED PUMPS

Instrument Sub-subsystem Exchanger Boundary Figure 3.1-6:

Example System Boundaries of a Sub-subsystem for Instrument Air



2) Instrument Sub-subsystems A) The measuring devices (instrument device and Local Panel) are a part of process or utility Sub- subsystem. B) DCS is a standalone Sub-subsystem from the input/output racks (Cabling, JB, DCS Panel and Marshaling Panel). Outgoing wiring to individual loops will be allocated to process Sub-subsystem as either open or closed loops.

SIS/FGS EFFECT FEEDBACK TO DCS

INST. DEVICES

LOCAL

FIELD

DCS

DCS

MARSHALLING

PANEL

IJB

FIELD

CABINET

SIS

PANEL

SIS

MARSHALLING

SJB

CABINET

Process/Utility Sub-subsystem DCS Sub-subsystem SIS Sub-subsystem FGS Sub-subsystem

Figure 3.1-7:

Example System Boundaries of a Sub-subsystem

PANEL

SIS /F GS CA US E FE ED BA CK TO DC S


DCS SUB-SUBSYSTEM


PROCESS/UTILITY SUB-SUBSYSTEM

DCS

ESD

JB

LOCAL PANEL

OUTPUT MARSHAL ING

BDV ESD

CABINET

JB

LOCAL PANEL

BDV

DCS PANEL FT

JB

DCS

LOCAL PANEL

LT

PT

INPUT MARSHAL ING CABINET JB

Figure 3.1-8:

LOCAL PANEL

LT

Interface of DCS and PROCESS/UTILITY Sub-subsystems

C) SIS Programmable Logic Controller (PLC) based system will stand alone as a Subsubsystem, from the Input/Output racks as for Distributed Control Systems. Input/Output loops will be classified as open loops and allocated to Subsubsystems as the outgoing/incoming wiring of distribution control systems. D) FGS Programmable Logic Controller (PLC) based system will stand alone as a Sub-subsystem, from the Input/Output racks. Loops will be classified as open loops and that allocated to FGS Sub-subsystems with the exception that these Sub-subsystems will be based on designated FGS Zones.




Note: Zone A: Process Unit Zone B: Utility Unit

Figure 3.1-9:

Interfaces of FGS Sub-subsystems




Figure 3.1-10: Interfaces of SIS Sub-subsystems and also between SIS and FGS

3) Electrical Sub-subsystems



A) An Electrical Sub-subsystem will contain all items relative to the distribution network (LV or HV) but excluding all starters, contactors, switch-fuse, etc., where the electrically powered device is allocated to a Process or Utility Sub-subsystem. B) Switchboards and Distribution Boards are dedicated to one service and this form the basis of an Electrical Sub-subsystem. C)

Depending on the complexity of the distribution network then these base Subsubsystems will be further sub-divided to suit the Project requirements.

D) Some important sub-subsystem need to use uninterrupted power and also to be alive during total power shutdown like as DCS, FGS, Process/Utility Local Panel, EG Control Panel, Telecom that the power will be supplied by AC/DC UPS System.

Note: For the UPS Sub-subsystemscertain large machines have Uninterrupted Power Supplies which are dedicated to that machine only (for example Compressor).In this instance the Uninterrupted Power Supply (UPS) system and distribution will be allocated to that Vendor package equipment sub-subsystem


Figure 3.1-11: Electrical Sub-subsystems

4) Mechanical Equipment




A) Items of Mechanical Equipment will fall completely within the limits of a Process or Utility Sub-subsystems. In certain instances, Stand-by and/or Parallel equipment, which are often complete VENDOR Packages, may also be designated as complete Sub-subsystems. This will match the initial Start-up philosophy, in order to achieve, for example, early Oil & Gas production. Typical examples: 1) Main Oil Pump 2) Gas Compressor 3) Main Generator 4) Pedestal Crane…

Figure 3.1-12: Interfaces of Sub-subsystems

B)

HVAC systems are normally dedicated to a specific building or area. Some designs will consist of individually controlled systems, each with their own air handling unit and control panel. In this case, each system will probably be allocated its own Sub-subsystem number. It is also possible for a number of areas to be controlled from a central control panel. In this case, the need to divide the system into Subsubsystems will probably be dictated by start-up constraints.

Note: In the case of individual systems, all ductwork, dampers, grills, sensors, heaters etc. will be included in the same Sub-subsystem as the air handling unit and control panel. Common or shared utilities, such as cooling water and boilers should be placed in separate Sub-subsystems. If these utilities are dedicated to



HVAC systems, and are required to be commissioned at the same time, they could be included in the same Sub-subsystem.

Figure 3.1-13: HVAC Systems

5) Telecommunication A) Telecommunication systems tend to be custom designed for each project, and the technologies for these systems is constantly changing. As a general rule, the systems listed will each have their own Sub-subsystem. Sub-subsystem boundaries will include all field equipment up to the outgoing terminals of the control console or distribution rack. The rack control consoles or distribution racks should be included in the Sub-subsystem of the equipment that will be commissioned first.

SYSTEM

SUBSYSTEM

100

110

SUB-SUBSYSTEM 111

WELLHEADS (DRY X-MAS TREES)

P&ID Number 01,02,03



CARIGALI STANDARD PROCEDURE FULL WELL STREAM 120 PROCESS LIQUID (PL)

130 PROCESS GAS (PG)

140

GAS COMPRESSION

112 113

WELLHEADS (WET TREES) WELL TESTING

121 122 123 124 125 126

PL COLLECTION AND RECEIVING PL SEPARATION (OIL FACILITIES) CRUDE OIL STABILISATION CONDENSATE STABILISATION PL TRANSFER / STORAGE SYSTEM PL METERING AND EXPORT / OFFLOADING

34 13 13, 33

131 132

PG COLLECTION AND RECEIVING PG SEPARATION (GAS FACILITIES)

04 20

133

PG METERING

26

SUCTION MANIFOLD OFF GAS COMPRESSOR COMPRESSOR TRAIN (BOOSTER/ EXPORT/GAS 143 LIFT/GAS INJECTION) 144 DISCHARGE MANIFOLD 145 EXPORT / DOWNHOLE INJECTION 151 152

GAS DEW POINTING

153 154

160

WATER INJECTION

161 162 163 164 165

170 ACID GAS REMOVAL

180 CONTAMINANT REMOVAL

04 10

141 142

PROCESS 150


24,25

07

GAS DEHYDRATION TRAIN (WATER DEW POINT) ADSORPTION (WATER DEW POINT) TURBO EXPANDER (HYDROCARBON DEW POINT) DIRECT COOLING (HYDROCARBON DEW POINT)

21, 22,23

SEAWATER INTAKE FILTRATION DEAERATION TREATED WATER PUMPING TREATED WATER EXPORT / DOWNHOLE INJECTION

96

171

ACID GAS REMOVAL UNIT

181

MERCURY REMOVAL UNIT(ADSORPTION)

182

MERCAPTAN REMOVAL UNIT(ADSORPTION)

21, 22,23 21, 22,23 21, 22,23

09 09

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 200

210 UTILITY GAS

211 212


FUEL GAS SYSTEM INSTRUMENT GAS

60 58

220

221

INERT GAS

222

NITROGEN (NITROGEN GENERATION & NITROGEN BOTTLES) SPENT/FLUE GAS

230

231 232 233

ATMOSPHERIC VENT HP FLARE LP FLARE

95 63 62

240 PRODUCED WATER

241 242

PRODUCED WATER SYSTEM DISCHARGED WATER TREATMENT

40,41,42 40,41,42

250

251 252 253 254

OPEN DRAIN (NON-HAZARDOUS) HAZARDOUS DRAIN CLOSED DRAIN SEWAGE

65 65 64 57

261

WASTE HEAT RECOVERY

PROCESS HEATING

262 263

HOT OIL WARM OIL

270

271 272 273 274 275 276 277 278 279-1 279-2 279-3 279-4 279-5

SODIUM HYPOCHLORITE POLYELECTROLYTE COROSSION INHIBITOR DIESEL GLYCOL ANTIFOAM SCALE INHIBITOR DEMULSIFIER REVERSE DEMULSIFIER PH MODIFIER BIOCIDE METHANOL POUR POINT DEPRESSANT (PPD)

88 68 68 68 68 68 68 68 68 68 68 68 68

310 FUEL AND LUBRICATION

311 312 313

DIESEL FUEL JET FUEL LUBRICATION OIL

67 66

320 COMPRESSED AIR

321 322

INSTRUMENT AIR UTILITY AIR

54 55

VENTING

DRAIN

59

PROCESS UTILITIES 260

CHEMICAL (DOSING) INJECTION/TREAT MENT

300

GENERAL UTILITIES




330

WATER

340 STEAM 350 HEATING, VENTILATION AND AIRCONDITIONING (HVAC) 360 HYDRAULICS 370 MARINE SYSTEM

400

410 FIREFIGHTING


323

BLACK START/STARTING AIR

331 332 333 334 335 336

SERVICE WATER FRESH AND DISTILL WATER FEED WATER POTABLE WATER HOT WATER COOLING WATER

341 342 343

STEAM GENERATION STEAM DISTRIBUTION STEAM CONDENSATE

351 352

DIRECT EXPANSION UNIT CHILLED WATER UNIT

50 50

353

AIR HANDLING/ VENTILATION UNIT

50

361

HYDRAULICS POWER UNIT (HPU)

371 372 373 374

BALLAST BILGE AND SLUDGE WATERTIGHT DOOR TURRET & MOORING

411 412

FIREWATER DELUGE AND SPRINKLER TOTAL FLOODING FIRE SUPRESSION & FIRE EXTINGUISHER

53 86 86/84

413

51

52 69

77

SAFETY

500

420 LIFESAVING EQUIPMENT

421 422 423

LIFERAFTS SURVIVAL CRAFTS ESCAPE AND RESCUE EQUIPMENT

82 82 82

510

511 512

MAIN POWER GENERATION EMERGENCY POWER GENERATION ELECTRICAL NETWORK MONITORING SYSTEM / POWER MANAGEMENT SYSTEM (ENMC / PMS)

75 75

TRANSFORMERS HIGH VOLTAGE SWITCHGEAR AND MOTOR CONTROL CENTER

76 76

POWER GENERATION/ SUPPLY

513

POWER 520

521

DISTRIBUTION

522




525 526

LOW VOLTAGE SWITCHGEAR AND MOTOR CONTROL CENTER INTEGRATED MOTOR CONTROL SYSTEM (IMCS) OVERHEAD LINE / CABLE CAPACITOR / REACTOR

530 UNINTERRUPTIBLE POWER SUPPLY

531 532 533

AC UPS SYSTEM DC UPS SYSTEM ELECTRICAL POWER UNIT (EPU)

540

541

EMERGENCY DISTRIBUTION BOARD

SMALL POWER AND LIGHTING

542

NORMAL DISTRIBUTION BOARD

543

NAVIGATION AID

550 EARTHING & LIGHTNING PROTECTION

551

EARTHING

552

LIGHTNING PROTECTION

560 DRIVES AND CONTROLLERS

561

VARIABLE SPEED DRIVE (VSD)

562

HEATER CONTROL SYSTEM

570

571 572 573

575 576

ELECTRIC HEATERS HEAT TRACING SYSTEM AUX DISTRIBUTION IMPRESSED CURRENT CATHODIC PROTECTION (ICCP) SYSTEM LIGHTING SOCKETS

611

DISTRIBUTED CONTROL SYSTEM (DCS)

523 524

CONSUMERS CONTROLLER

600

CONTROL AND SAFEGUARDING


610 PROCESS CONTROLS

620

574

613 614

SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) INFORMATION MANAGEMENT SYSTEM (IMS) SUBSEA CONTROL

621

SAFETY INSTRUMENTED SYSTEM (SIS)

612

76 76 76 76

89




SAFEGUARDING SYSTEM

622

FIRE AND GAS SYSTEM (FGS)

623

FUSIBLE PLUG LOOPS HIGH INTEGRITY PRESSURE PROTECTION SYSTEM (HIPPS) WELLHEAD CONTROL PANEL (WHCP) INSTRUMENT CONTROL PANEL

624 625 626

700

710

711

713 714 715

DIGITAL MICROWAVE RADIO (DMR) SYSTEM VERY SMALL APERTURE TERMINAL (VSAT) SATELITE SYSTEM FIBRE OPTIC TRANSMISSION SYSTEM UHF RADIO LINK TROPOSCATTER RADIO SYSTEM

721 722 723 724 725 726

VHF/FM (MARINE COMMUNICATION) VHF/AM (AVIONICS COMMUNICATION) HF/SSB RADIO SYSTEM NON-DIRECTIONAL BEACON (NDB) SYSTEM DIGITAL TRUNK RADIO WIRELESS SYSTEM

712 MAIN BACKBONE LINK

720 RADIO COMMUNICATIONS SYSTEM

730 TELECOMMUNICA TION

800 MISCELLANEOUS

VOICE AND DATA COMMUNICATION


731 732 733 734

PABX AND TELEPHONE SYSTEM (ANALOG & DIGITAL) LOCAL AREA NETWORK (LAN)/WIDE AREA NETWORK (WAN) NETWORK MANAGEMENT SYSTEM (NMS) MOBILE BROADBAND

740

741

SURVEILLANCE AND SAFETY SYSTEM

742

PUBLIC ADDRESS GENERAL ALARM (PAGA) SYSTEM CCTV AND INTRUSION SYSTEM

743

METEOROGICAL SYSTEM

750 COMMUNICATIONS EQUIPMENT

751

ENTERTAINMENT SYSTEMS

810 MATERIAL HANDLING

811 812 813

PEDESTAL CRANE GANTRY/BRIDGE/JIB CRANE MONORAIL / TROLLEY HOIST

80,81,83, 85



814

ELEVATORS

821 822 823 824 825

GENERAL ACCOMODATION SPACES GALLEY / MESS HALL OFFICES COLD ROOM SICKBAY

830 AVIATION

831 832

HELIDECK AVIATION REFUELLING

840 MARINE AND CORROSSION PROTECTION

841 842

SACRIFICAL ANODE CATHODIC PROTECTION MARINE GROWTH PREVENTION

843

DE-HUMIDIFIER SYSTEM

850

851 852 853 854 855

TOPSIDE JACKET LIVING QUARTERS (LQ) BRIDGES TELECOM TOWER

861

PROCESS AREA (INSIDE BATTERY LIMIT) NON PROCESS AREA (OUTSIDE BATTERY LIMIT) RECEIVING AREA LAUNCHING/EXPORT AREA

820 ARCHITECTURAL

STRUCTURAL

860

862 CIVIL

863 864

Figure 3.1-14: Overview of Systems, Subsystems &Sub-subsystems


Figure 3.1-15: Level 1 Commissioning & Start-up Sequence



Figure 3.1-16: Level 2 Commissioning & Start-up Sequence




System Description and Scope of Works 3.2.1

System description provides, to some extent, information on the processes, the system point of origin and ending, the equipment involved and other pertinent facts.

3.2.2

Scope of Works depicts activities required to be performed by CONTRACTOR during Testing, Pre-commissioning and Commissioning stage. Activities described with words like verify, check or ensure mean the tasks should have been completed by Fabrication Team and only to be checked by Testing, Precommissioning and Commissioning Team using the relevant documentation. Should there be a need to re-perform any of the completed activity on the basis of equipment or material flaw or failure; this shall be executed upon concurrence by CARIGALI.

3.2.3

Activities described with the word perform mean the tasks to be executed by Testing, Pre-commissioning and Commissioning Team only. This includes start-up and vendor representative supervision.

3.2.4

Activities identified in the Scope of Works listed in subsequent pages are in no means final. CONTRACTOR is advised to elaborate further using the documentation provided i.e. vendor data, in determining the actual extent of work required.

3.2.5

CONTRACTOR shall be responsible for identifying and developing Scope of Works that are not depicted in this section.

3.2.6

Contractor shall obtain manufacturer's (vendor) assistance to ensure satisfactory installation of equipment.

3.2.7

Contractor shall obtain manufacturer's (vendor) warranty service if outlined in contract documents.



Testing and Pre-commissioning Common Scope of Work Many activities are repetitive in many systems or subsystems as it is common for a specific task performed on certain equipment in a particular system or subsystem may also be required for similar equipment under a different system or subsystem. For example, an electric-motor-driven pump testing and pre-commissioning activities are essentially the same for all such pumps be it in a liquid metering system or a compression system. A standard and common Scope of Works is therefore readily identifiable as depicted in the following subsections. Should a specific system require additional activities, then the relevant activities would be stated under the respective system by discipline.

3.3.1

General

3.3.1.1

Verify equipment manuals, reference drawings, factory calibration certificates, test reports and test certificates are available.

3.3.1.2

Verify equipment skid structure and on-skid items are free of any damage.

3.3.1.3

Verify nameplate data for all items are as per datasheet and specification.

3.3.1.4

Verify tagging and numbering for all items are correct.

3.3.1.5

Verify equipment temporary shipping braces, stoppers and other protective structures are removed.

3.3.1.6

All test/calibration equipment shall have a valid calibration certificate from the manufacturer or certified by authorized third party.



Piping

3.3.2.1

Verify conformity line checking against IFC Instrumentation Diagram (P&ID) drawings as follows:

Process and

i)

Verify valves, flanges, blind flanges and piping items were properly installed and tightened

ii)

Verify gaskets plusbolts & nuts installed are of the right specification

iii)

Verify the flow direction of check valves, globe valves, Restriction Orifices, and other inline instruments

iv)

Verify pipeworks were adequately supported as per drawings.

v)

Verify the accessibility and operability of manual valves and all of instrument indicators

vi)

Verify all process pipes, process equipment and line instrument plus isolation valves has been leak tested

vii)

Verify color coding, line numbering and directional arrow are provided correctly

viii)

Verify functional test of all manually-operated, isolation and block valves

3.3.2.2

Verify flushing had been completed which shall be referred to CSP-22 Flushing/ Hydrotest Procedure and Paragraph 6.2.1 Piping Matrix for guideline.

3.3.2.3

Verify hydrotesting had been completed which shall include the following activities: i)

FAT and Valve leak test has been done based on acceptance criteria on API 6D and BS 5351 Codes and Standards

ii)

Non-return valves and swing check valves shall be returned to its original position after completion of hydrotesting

iii)

Temporary spade and blinds were removed after hydrotesting



iv)

Pipeworks are drained and blown with dry air once hydrotesting completed

v)

All instruments and relief valves which are removed during test shall be reinstated back to its original location

vi)

Refer to CSP-22 Flushing/Hydrotest Procedure for detailed hydrotest procedure

3.3.2.4

Verify the internal chemical cleaning for piping system as per para 6.2.1 Piping Matrix chemical cleaning

3.3.2.5

The flange management shall be performed prior to Re-instatement Leak Testwhich consist of :

3.3.2.6

a)

Flanges alignment to ensure the correctness of flange to flange alignment, gaskets, cleanliness flanges facing,

b)

Bolt tensioning/tourqing as per approved procedure to ensure the tightness of stud bolt with correct tension/ torque value including the correctness of stud bolt installation.

Perform reinstatement leak test which shall include the following activities (refer to Section 5.1.16 for details): i)

Perform internal inspection and verify cleaning of vessels is completed and "Final Closure Certificates" have been issued

ii)

Gross leak test with 7 bar compressed air may be required prior to Reinstatement leak test to ensure the early detection of the major leaking point and then to avoid any wastage of Nitrogen consumable. However the Gross Leak test (with compressed air) is not allowed for existing facilities.

iii)

Verify test instruments used have a range of fifty (50) percent higher than the test pressure. Test instrument validity period do not exceed six (6) months after certification or re-calibration by third party.

iv)

Upon completion of Re-instatement Leak test the system shall be preserved by 1 bar nitrogen.



3.3.2.7

For general utilities (as per para 6.2.1 Piping Matrix), service test is to be carried out in lieu of Reinstatement Leak Test. Test pressure shall be operating pressure.

3.3.2.8

Verify insulation and claddings are conformed to specification and drawings.

3.3.2.9

Verify pipework(as per para 6.2.1 Piping Matrix)is adequately supported, internally cleaned and preservation applied after pickling or acid cleaning.

3.3.2.10

Verify the systems (as per para 6.2.1 Piping Matrix) have been purged with nitrogen and achieved below 4% oxygen content.

3.3.2.11

Verify the Base Line Survey on the basis of Corrosion Risk Assessment for corrosion management of piping system.



Mechanical Rotating Equipment

3.3.3.1

Verify hold down bolts and vibration dampeners (if any) has been adequately installed and tightened.

3.3.3.2

Verify skid and equipment levelness as recommended by manufacturer or vendor. Should grouting is applied; Vendor Representative’sconcurrence may be required during inspections.

3.3.3.3

Verify alignment of suction/discharge piping flange, driver and driven equipment i.e. motor to pump, motor to gearbox, turbine to gearbox, accessory drive to turbine, etc., is completed and the values are within vendor acceptable values.

3.3.3.4

Verify Lube Oil flushing has been completed as per vendor recommendation

3.3.3.5

Check air, fuel and lube oil filters for cleanliness and replace as necessary.

3.3.3.6

Check lubrication or greasing of all external bearings and check lube oil for contamination, replace if necessary

3.3.3.7

Check cooling system and ensure coolant and corrosion inhibitor are added.

3.3.3.8

Perform no-load test of critical rotating equipment such as compressor, engine, etc.

3.3.3.9

Secure and preserve equipment after pre-commissioning for sea transportation.

Note: Vendor Representative’s assistance and concurrence may be required.



Static Equipment

3.3.3.10

Verify hold down bolts have been adequately installed and tightened.

3.3.3.11

Verify Equipment as-built drawings, test reports and Certificates are available.

3.3.3.12

Verify tagging and nameplates data for equipmentas per Fabrication drawing/PID.

3.3.3.13

Verify equipment temporary shipping braces,stoppers and other protective structures have been removed.

3.3.3.14

Performinternal and external installation and inspection and verify cleaning of vessels and tanks have been completed and issue Final Closure Certificates.

3.3.3.15

Verify equipment manuals reference drawings; factory calibration certificates;test reports and test certificates are available.

3.3.3.16

Verify all of flanges and stud bolt for man hole, hand hole and all of nozzles have been aligned and tightened.

3.3.3.17

Baseline thickness measurement for static equipment. This shall be carried out prior to commissioning at selected test points to facilitate future real time corrosion rate.

3.3.3.18

Baseline measurements to be included in the Equipment Record Cards if any.

3.3.3.19

A check of record of all manufacturing data books, shop inspection reports, and manufacturer inspection and test reports should be kept in the equipment file. This information shall be recorded in Equipment Record Card, which shall be completed before COMMISSIONING.

3.3.3.20

To check correct Installation of Equipment (ex: sliding saddle movement for expansion; bolts to be loose).

3.3.3.21

Check whether special (maintenance) tools and inspection manuals have been supplied.

3.3.3.22

Check that test holes in Reinforcement Pads are open (filling hard grease). Shall not be plugged with metal plugs).



3.3.3.23

For air-coolers, check that the fan rotation and blade setting are correct.

3.3.3.24

Check accessibility of manhole covers, davits, valves, gauges.


3.3.5


Electrical

3.3.4.1

Inspect and verify all electrical equipment supplied and installed are as per the specification.

3.3.4.2

Verify nameplate data, tagging and numbering of cables, relays, devices.

3.3.4.3

Verify electrical cables are installed correctly, continuity checked and insulation resistance tested.

3.3.4.4

Verify electrical junction box installations and power cable terminations are completed as per specification.

3.3.4.5

Verify all earthing connections are terminated.

3.3.4.6

Perform inspection and function test of motor RTU. Hand-off-auto and ammeter function.

3.3.4.7

Perform uncoupled/solo run test of electric motors and record direct of rotation after motor windings and space heaters are insulation tested. Confirm that all motors are rotating in correct direction as per vendor datasheet and marked direction of rotation.

3.3.4.8

Perform coupled run test of electric-motor-driven equipment.

3.3.4.9

Perform start-stop function test.

3.3.4.10

De-energize subsystems after completion of pre-commissioning activities.

3.3.4.11

Perform visual inspection of battery condition.

3.3.4.12

Perform visual inspection and functional test for UPS system.

3.3.4.13

Perform visual inspection and functional test for the batteries and solar panel/charger for the navigational aid system.

Instrumentation& Telecommunication

3.3.5.1

Verify all individual instruments comply withCARIGALI specifications prior to calibration by comparing instrument name tags and datasheets to the specifications.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.3.5.2


Verify all instruments on skid and off skid installation, testing and calibration are completed and recorded on standard forms and ITRs.

Note: Completion of these activities shall be clearly indicated by attaching colour-coded labels or stickers to each instrument or instrument system.

3.3.5.3

Verify calibration and pop test certificates of all relief valves are valid.Relief valve should have a minimum certificates validity of 6 months upon RFSU.

3.3.5.4

Verify that all field instruments including skid mounted instruments should have a minimum certificates validity of 6 months upon RFSU.

3.3.5.5

Verify FGS field devices installation; testing and calibration are completed and recorded on standard ITR form and checklist.

3.3.5.6

Verify that all tubing for primary process, impulse line, signal line, instrument air supply, sample lines and hydraulic lines are correctly installed and are leak/pressure tested to the specification requirements (see instrumentation pre-commissioning procedure under Section 5.3).

Note: The tubing needs to be purged before leak/pressure test

3.3.5.7

Verify instrumentation isolation valves and manifold valves could be opened and closed easily.

3.3.5.8

That all instrument junction box installations and cable terminations (including Fibre Optic) are correctly installed as per in engineering drawing.

3.3.5.9

Verify completion of instrument and control cable insulation resistance checks and continuity checks. All thermocouples and RTDs signal and control wirings shall be checked for polarity and continuity, including external power if required.

3.3.5.10

Perform loop checking of all field instruments (indication, control, alarm and shutdown) to control Process Monitoring and Control System, Safeguarding System, Unit/Local Control Panel, Turbine Control Panel, telecommunication, etc.). This includes stroking of valves i.e. shutdown valves, blowdown valves, control valves, etc. and function testing of local control panel.



3.3.5.11

Perform alarm and shutdown test of system (Safety Instrumented System, Fire and Gas System, etc.)by simulating abnormal/tripcondition at the primary element. It shall be ensured that the correct operational sequence and action of all components are as per specifications.

3.3.5.12

Perform function testing for all control panels (Process Monitoring and Control System, Unit/Local Control Panel, Turbine Control Panel, telecommunication, etc.)

3.3.5.13

Perform Instrument Earth, Safety Earth and I.S. Earth Checks within Control Panel.

3.3.5.14

Verify instrumentation isolation valves and manifold valves could be opened and closed easily and sight glasses are not obstructed with paint, etc.

3.3.5.15

Verify wire terminals for solid and clean connections.

3.3.5.16

Check all lugs and connectors (electric, pneumatic, hydraulic) for correct tagging and numbering

3.3.5.17

In case of field bus installations, verify loop resistance, cable capacitance, inductance values and provision of end resistance as applicable.

3.3.5.18

Verify connections of proper wire terminals.



Commissioning

3.4.1

Detail Commissioning & Start-Up procedure shall be crossed reference to CSP-21 for minimum requirement and Contractor shall develop Project Specific Testing, Pre-Commissioning &Commissioning procedure at each stage of the project (live documents which will be continuously updated throughout project).

3.4.2

Commissioning Common Scope of Works i)

Ensure that all pre-commissioning activities are complete andReady for Commissioning (RFC) certificates signed off.

ii)

Line-up/ open isolation valve per P& ID

iii)

Purge the piping with N2 before allowing hydrocarbon into it, applicable for hydrocarbon systems.

iv)

Keep the loop under positive nitrogen pressure.

v)

Allow the process liquid into the system slowly and replace the nitrogen

vi)

Check and monitor for any leakage during gas-in and pressurization of line.

vii)

Carry out equipment and its control system tuning until achieving the desired operating conditions.

viii)

The system shall achieve the product specifications as described in P&ID specifications and DBM.

ix)

Carry out endurance test for: 1. Continuously running equipment (72 hours); 2. Non-continuous running equipment (4 hours)

x)

Ensure all the parameters shall be within the safe operating limit as per P&ID/ equipment specifications, such as: a. Level b. Pressure c. Flowrate d. Temperature e. Vibration f. Noise Level

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE xi)


Refer to vendor Site Acceptance Test (SAT) procedure and relevant ITR-C.


3.6


Commissioning and Start-up Procedure 3.5.1

Run the system continuously for duration of recommended hour(s) based on the system requirement. Necessary adjustment for temperature, pressurization, air flow, etc. at system is to be made (if required).

3.5.2

Check for all parameters and characteristic stated inside manual are correct.

3.5.3

Record performance and other critical parameters

3.5.4

Ensure that all necessary documentation is available and attached to the report.

System by System Scope of Work The subsequent page illustrates the detailed Scope of Works for the pre-determined systems. Illustrations to depict the mentioned systems/subsystems are also included for reference only. CONTRACTOR shall utilize the particular project Piping and Instrumentation Diagram drawings for accurate details. CONTRACTOR shall review the content against other relevant documentation such as vendor manuals and drawings to acquire a more complete Scope of Works.



3.6.1

100 – PROCESS

3.6.1.1

110 – FULL WELL STREAM

3.6.1.1.1

111 – PROCESS | FULL WELL STREAM | WELLHEAD (DRY TREES)

111.1

System Description A Wellhead is the component at the surface of an oil or gas well that provides the structural and pressure-containing interface for the drilling and production equipment. Christmas (X-mas) tree is an assembly of valves, spools, and fittings used for an oil well, gas well, water injection well, water disposal well, gas injection well, condensate well and other types of wells. Dry X-mas trees are installed on the surface. Offshore, where a wellhead is located on the production platform it is called a surface wellhead, and if located beneath the water then it is referred to as a subsea wellhead or mudline wellhead.Process controls is classified separately under SubSubsystem 625 - Wellhead Control Panel (WHCP).

The major components covered by Topside Contractor are:     

Flowline from X-mas Tree up to the Production/Test Header High Integrity Pressure Protection System (HIPPS) Production Choke Valve (PCV) Position Transducer (ZT) Downstream Pressure/ Temperature (DPT)

The major components covered by Drilling Contractor  Annulus Master Valve (AMV)  Annulus Access Valve (AAV)  Chemical Injection Valve (CIV)  Production Master Valve (PMV)  Production Wing Valve (PWV)  Downhole Pressure /Temperature Gauge (DHPTG)  Annulus Pressure/Temperature (APT)  Upstream Pressure/ Temperature (UPT)

111.2

Pre-commissioning Scope of Works i)

Piping Refer to Section 3.3.2 - Common Piping Scope of Works.


111.3


ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical If applicable, refer to Section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

Commissioning Scope of Works i)

Refer to Commissioning common scope of works (Section 3.4.2)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.1.2 112.1


112 – PROCESS | FULL WELL STREAM | WELLHEADS (WET TREES) System Description

The subsea X-mas tree sits on top of the subsea wellhead and provides a means to monitor and control oil or gas production from well, or injection of water or gas into a well. A subsea Xmas tree maybe a vertical type or a horizontal type depending on valve configuration. The major components are:                

Tubing Retrievable Surface Controlled Subsurface Safety Valve (TRSCSSV) / Surface Controlled Subsurface Safety Valve (SCSSV) Annulus Master Valve (AMV) Annulus Access Valve (CIV) Methanol Injection Valve (MIV) Crossover Valve (XOV) Production Master Valve (PMV) Production Wing Valve (PWV) Production Choke Valve (PCV) Downhole Pressure /Temperature Gauge (DHPTG) Annulus Pressure/Temperature (APT) Upstream Pressure/ Temperature (UPT) Subsea Multiphase/Wet Gas Flow Meter (MPFM/WGFM) Position Transducer (ZT) Downstream Pressure/Temperature (DPT) Acoustic Sand Detector (ASD) Subsea Control Module (SCM).

Other associated equipment for subsea production system (SPS) may include but not limited to:      

Jumper Manifold Pipeline End Termination (PLET)/Pipeline End Manifold (PLEM) Flowline Umbilical/Hydraulic Flying Leads (HFL)/Electrical Fling Leads (EFL) Subsea Umbilical Termination Assembly (SUTA)



112.2 Pre-commissioning Scope of Works Post installation testing of a subsea tree is normally undertaken by the drilling rig using an IWOCS (Intervention and Workover Control System). Pre-commissioning must wait until subsea hook-up is complete and is limited to testing from the topside to include:     

Communication tests Sensor checks (pressure, temp, sand rate, flow rate) Valve operations (excluding downhole safety valve) Choke operations Shutdown tests

112.3 Commissioning Scope of Works Commissioning is limited to testing and operating from the topside. Activities are the same as pre-commissioning except with the inclusion of opening the downholesafety valve.

Figure 3.6.1-1: Dual Cluster Manifold SPS


Figure 3.6.1-2: Simple & Generic SPS Flow Diagram




113 – PROCESS | FULL WELL STREAM | WELL TESTING System Description The Sub-Subsystem is generally associated with its boundaries defined from the Test headers to the well testing facilities. It includes equipment such as Test Separator, Multi Phase Flow Meter (MPFM) and Subsea MPFM Wet Gas Meter (WGM) for well testing which located at each individual flow line. Test separator is provided to enable well testing. The following is the basis of Test Separator operation: i.

The well testing is conducted for one well at any time.

ii.

Well to be tested is disconnected from the production header and then it is connected to test header.

iii.

The test separator measures the oil and gas flowrates, water cut and the GOR of the well fluid.

iv.

The oil, water and gas streams leaving the test separator are re-mixed and co-mingled into the production header to mix with the fluids from other wells.

Each of the Well flow lines is provided with a connection to Test header. During testing of a well, the corresponding flow line is opened into the Test separator via the test header and its connection to the production header is isolated. Only one flow line is opened into the Test separator at a time. The instruments on the Test Separator are level transmitters to control the flow rate of water and oil, pressure transmitter, local temperature gauge, level gauges and pressure gauges. 113.2



ii)


iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works.



CARIGALI STANDARD PROCEDURE iv)

113.3 i)


Commissioning Scope of Works Refer to Commissioning common scope of works (Section 3.4.2)

BDS

TEST SEPARATOR

FROM TEST MANIFOLD

SDV

PC

P-12

FI PCV

BDV

SDV

S

LC

TC

FI LCV

Figure 3.6.1-3: Well Testing Facilities Schematic

SDV

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE V-CONE TYPE

WCM

PT

TT

PDT

WET GAS METER COMPUTER (FMC) H FLA

L

Figure 3.6.1-4: Wet Gas Meter – V-cone Type

H FM

L

FQI

FT

PT

FT

TT

VENTURI TYPE FE

Figure 3.6.1-5: Wet Gas Meter – Venturi Type




3.6.1.2

120 – PROCESS LIQUID (PL)

3.6.1.2.1

121 – PROCESS | PROCESS LIQUID (PL) |PROCESS LIQUID (PL) COLLECTION AND RECEIVING

121.1

System Description This Sub-Subsystem is generally associated with process crude with its boundaries defined from the wellheads to the respective collection headers and/or from a receiving pipeline riser to the inlet of a separator vessel. Equipment in the Sub-Subsystem includes production headers, test headers, receiver, allocation metering, and production manifold. It also includes associated instruments such as pressure and temperature gauges and transmitters.

121.2

121.3



ii)


iii)


iv)


Commissioning Scope of Works i) Refer to Commissioning common scope of works (Section 3.4.2)


Figure 3.6.1-6: Liquid Collection and Receiving system


TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 3.6.1.2.2

122.1


122 – PROCESS | PROCESS LIQUID (PL) |PROCESS LIQUID (PL) SEPARATION (OIL FACILITIES) System Description Separation of incoming crude is common on most facilities. Separation vessels are equipped with internal weirs; baffle plates, etc. to segregate crude, gas and water. Gas being the lightest would be released at the top of the vessel whereas water and crude outlets are generally located at the bottom of the vessel. It comprises of several pressure vessels such as a High Pressure Separator (HP Separator), a Low Pressure Separator LP (Separator), a Test Separator, a Surge Vessel, relief valves and special items such as interlocks. It also involves associated instrumentations such as pressure and temperature gauges and transmitters, level indicators and flow elements, to mention a few. Free Water Knockout (FWKO) vessel is used to separate the gas and bulk of free water of the preheated crude oil coming from crude exchangers. The FWKO vessel has two main sections, the oily water separation section and the Oil collection section. The following are the design features and principles of the operation of FWKO vessel; i)

A distribution plate located at the immediate downstream of the inlet baffle distributes the oil and water phases uniformly across the vessel cross section.

ii)

Vertical plate coalesce pack section to enhance coalescing of the water droplets in the oil phase and for coalescing of the oil droplets in the oil phase and in the lower water phase.

iii)

The area downstream of the coalescing packs provides further residence time required for the settling of water droplets from oil phase into water phase and rising of oil droplets from water phase to mix into oil phase.

iv)

A weir plate at the downstream of the oil water separation section prevents flow of the bottom water layer into the oil compartment, and also prevents movement of sand particles into the oil section.

v)

Water is withdrawn from the bottom of the oil water separation section through a water level control valve. The flow rate of the water is controlled to maintain steady level of oil water interface.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE vi)

122.2

122.3


Oil is withdrawn from the bottom of the oil collection section through an oil level control valve.



ii)

Mechanical a)

Refer to Section 3.3.3 - Common Mechanical Scope of Works.

b)

Perform inspection of pressure vessels and its internals.

iii)


v)





Figure 3.6.1-7: Process Liquid Separation system



Figure 3.6.1-8: Process Liquid Separation system

Figure 3.6.1-1: Production Separator




CARIGALI STANDARD PROCEDURE 3.6.1.2.3

123.1


123 – PROCESS | PROCESS LIQUID (PL) |CRUDE OIL STABILISATION

System Description Crude oil received from Separator is fed to crude oil stabilization unit for removing the light gas along with hydrogen sulfide before the oil is stored and transporting for downstreamuses. The crude stabilization process sweetens the Sour crude and reduces the vapor pressure to make safe for shipments. Crude Stabilization system is comprises of Flash Drum, Desalter, Dehydration Vessel, Crude Stabilization Column, KettleReboiler, Pumps etc. It includes the extensive pipework and instruments like Shutdown valves, Control valves for various application, Analyzers, transmitters and indicators.

123.2

123.3


Piping Refer to Section 3.3.2 – Common Piping Scope of Work

ii)


iii)


iv)


Commissioning Scope of Work i)

Refer to Commissioning common scope of work (Section 3.4.2)



CARIGALI STANDARD PROCEDURE 3.6.1.2.4 124.1


124 – PROCESS | PROCESS LIQUID (PL) | CONDENSATE STABILISATION System Description Condensate received from slug catcher and Knockout drum is fed to stabilization unit to reach the required specification for transportation of condensate or for the use of the condensate in drown stream process. The stability is specified in True Vapor Pressure or Reid Vapor Pressure (TVP or RVP). Condensate stabilization unit is comprises of Surge Drum,Filter Coalescer, Stabilization column, Pumps, Exchangers and Re-boiler etc. It includes the extensive pipework and instruments like Shutdown valves, Control valves for various application, Analyzers, transmitters and indicators.

124.2

124.3



ii)


iii)


iv)





125.1


125– PROCESS | PROCESS LIQUID (PL) |PROCESS LIQUID (PL) TRANSFER / STORAGE System Description The cargo system associates with FPSO/FSO are FPS/Spar facilities normally consists of cargo tanks, cargo pumps, cargoeductors. It covers storage for crude oil, crude off loading/export, crude oil washing and crude stripping facilities. Crude oil washing system uses dry oil from cargo tank to clean and wash away sediment of other cargo tank and return back the washing to crude oil tank using eductor. It is normally done during the time between exports and during export operations. The COW operation is to be carried out with inert gas system fully functional due to the static electricity involvement. The cargo tanks are normally equipped with tank gauging using radar sensor/guided microwave sensor to monitor and analyze the level content of cargo oil tank and slop tank. It is also fitted with temperature sensors to monitor the fluid temperature.

125.2

125.3



ii)


iii)


iv)





126.1


126 – PROCESS | PROCESS LIQUID (PL) |PROCESS LIQUID(PL) METERING AND EXPORT / OFFLOADING System Description Liquid transfer and metering is an integration of several skid equipment originating from the discharge nozzle of a separator/surge vessel through a pumping subsystem and metering sub-subsystem before ending at the shutdown valve downstream of the scraper launcher. It comprises of an extensive array of pipeworks with Crude Oil Transfer Pump (COTP), metering runs, flow element (e.g. turbine, orifice), Meter Prover (if applicable), Auto Sampling Station (if applicable), Export Launcher, Heat Tracing/Exchanger/Heater. All signals are hardwired to its Metering Control System consisting flow computer(s) and supervisory computer(s). It also includes a variety of instruments like shutdown valves, control valves for various applications, transmitters and indicators. Several local control panels for individual equipment are also involved.

126.2



ii)


iii)


iv)

Instrumentation a)

Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

b)

Confirm all communication and hardwired signals to other systems e.g. PMCS, SIS etc. are established.

c)

Confirm Factory Acceptance Test (FAT) punchlist has been demonstrated cleared with relevant calibration certificates and test reports attached.



d)

Perform functional test of pump control panel including interfaces with other systems.

e)

Perform functional test of metering panel including interfaces with other systems.

f)

Perform functional test and loop checking of auto sampler, sampler pump (if applicable) and metering skid including interfaces with metering panel.

Note: Presence of vendor is required during functional test

126.3





Figure 3.6.1-9: Typical Process Liquid Metering and Export/Offloading Schematic



3.6.1.3

130 – PROCESS GAS (PG)

3.6.1.3.1

131 –PROCESS | PROCESS GAS (PG) |PROCESS GAS (PG) COLLECTION AND RECEIVING

131.1

System Description Process gas is collected and received in a manner identical to liquid collection and receiving system. It comprises of a gas header, a test header, flow lines from the gas producing wells, riser shutdown valve, scraper launcher and receiver, choke valves, associated piping and instrumentations.

131.2

Pre-commissioning Scope of Works Activities are similar to the listing stipulated under Sub-Subsystem 121.

131.3

Commissioning Scope of Works Activities are similar to the listing stipulated under Sub-Subsystem 121.


Figure 3.6.1-10:

PG Collection and Receiving system



132.1


132 – PROCESS | PROCESS GAS (PG) |PROCESS GAS SEPARATION (GAS FACILITIES) System Description Slugcatcher is used to remove liquid slug in the gas. As gas passes through the vessel, an arrangement of baffle plates reduces velocity of the incoming gas thus providing opportunity for the heavier hydrocarbon component to precipitate into liquid. This liquid is called condensate. There is also a possibility of other forms of liquid such as water to be present that requires removal as well. The Sub-Subsystem comprises of a knockout vessel called a Slugcatcher, a production separator, a surge vessel, a pressure relief subsystem, associated piping and instrumentations. This Sub-Subsystem is reflected as part of the process schematics in Figure 3.6.1-10shown under SubSubsystem 131.

132.2


132.3




133 – PROCESS | PROCESS GAS (PG) | PROCESS GAS METERING

133.1System Description On a gas processing facility, gas export Sub-Subsystem boundary begins from the discharge of a liquid knockout vessel or a separator to the riser shutdown valve at the export pipeline. However, on a gas compression facility the boundary for gas transfer and metering Sub-Subsystem is identified from the end of the discharge manifold system to the riser shutdown valve of the particular export pipeline. It comprises of an extensive array of pipework with Gas Metering runs, flow element (e.g. ultrasonic meter, orifice), Gas Chromatograph/Analyzer System (if applicable), Auto Sampling Station (if applicable), Export Launcher Heat Tracing/Exchanger/Heater. All signals are hardwired to its Metering Control System consisting flow computer(s) and supervisory computer(s). It also includes a variety of instruments like shutdown valves, control valves for various applications, transmitters and indicators. 133.2



ii)


iii)


iv)

Instrumentation a)


b)

Confirm all communication and hardwired signals to other systems e.g. PMCS, SIS etc. are established.

c)

Confirm Factory Acceptance Test (FAT) punchlist has been demonstrated cleared with relevant calibration certificates and test reports attached.

d)

Perform functional test of metering panel including interfaces with other systems.



CARIGALI STANDARD PROCEDURE e)

Perform functional test and loop checking of auto sampler and metering skid items including interfaces with metering panel.

f)

Verify the serial number of the calibration and carrier gas for the Gas Chromatograph (GC) as per approved datasheet/certificate.

Note: Presence of vendor is required during functional test

133.3


SSC


GAS SAMPLING AND ANALYZER CABINET (OFFSKID) MANUAL SPOT SAMPLING

SSC GC PRIMARY SAMPLE CONDITIONING SYSTEM

GC SECONDARY CONDITIONING SYSTEM

GAS CHROMATOGAR PH (PAY)

GC PRIMARY SAMPLE CONDITIONING SYSTEM

GC SECONDARY SAMPLE CONDITIONING SYSTEM

GAS CHROMATOGRA PH (CHECK)

MOISTURE ANALYZER

SSV M

M

M

M

M

FT

PT

QT

PG

TG

TT

TW M

M

M

M

M

M

M

M

M

FT

PT

QT

PG

TG

TT

TW

M

M

SSV

SSV

Figure 3.6.1-11:

FT

PT

QT

PG

TG

TT

TW

Typical Process Gas Metering Schematic


140 – GAS COMPRESSION

3.6.1.4.1

141 – PROCESS | GAS COMPRESSION |SUCTION MANIFOLD

141.1


System Description Suction manifold, also called suction header, is pipework from the gas outlet of separators or slug catchers to the inlet of a compressor train suction scrubber or a heat exchanger. Minimal equipment is involved; primarily the associated piping and instrumentations such as shutdown valves, gauges transmitters and indicators.

141.2

141.3



ii)

Mechanical - None.

iii)

Electrical - None.

v)



Refer to Commissioning scope of works (Section 3.4.2)



Figure 3.6.1-12: Process Schematics for Gas Compression consisting of Suction Manifold, Compression Train and Discharge Manifold Sub-Subsystem



142– PROCESS | GAS COMPRESSION |OFF GAS COMPRESSOR System Description The combined off gas streams from Crude/Condensate stabiliser, Surge Drum and acid gas of GSU are compressed by two stages centrifugal compressors. Off gas compressor are driven by fixed/variable speed motor. Each stage is equipped with its own Anti-surge/Recylce control valve designed for full flow condition. The main components of the system are shown in the Fig XX below. Off Gas Compressor train Sub-subsystem is divided into smaller components such as: i)

Prime movers for compressors is electric motor,

ii)

Speed reducing gearbox,

iii)

Centrifugal Compressors

iv)

Scrubber vessels,

v)

Control panels, and

vi)

Ancillary subsystems; for example Dry gas seal, fuel gas, diesel, air inlet filtration, start system, etc.

It also includes numerous instrumentations. Usually, a gas compression system is equipped with its own control system and it is linked to other control systems such as DCS, SIS and FGS. 142.2

Pre-commissioning Scope of Works. For the Compressor pre-commissioning activities, the vendor or supplier guidelines are to be followed strictly. Line cleaning, chemical cleaning activities, charging seal gas, lube oil circulation are few of the precommissioning activities. i)


ii)


iii)




CARIGALI STANDARD PROCEDURE vi)

142.3


Commissioning Scope of Works i) Refer to Commissioning scope of works (Section 3.4.2)

1st Stage

Figure 3.6.1-13:

2nd Stage

Off Gas Compressor




143.1


142– PROCESS | GAS COMPRESSION | COMPRESSION TRAIN (BOOSTER/EXPORT/GAS LIFT/GAS INJECTION) System Description Gas Compression is required to provide secondary recovery to a field in the form of gas lifting and gas injection. It is obtained through use of compression. A train is defined as a sequential arrangement of equipment that makes up one compression system (refer schematic in Figure 3.6.1-12 under Sub-Subsystem 141). A compression train Sub-Subsystem is divided into several smaller components such as: i)

Prime movers for compressors; for example a turbine, an internal combustion engine or an electric motor,

ii)

Speed reducing gearbox,

iii)

Compressors; either centrifugal or reciprocating, booster

iv)

Heat exchanger,

v)

Scrubber vessels,

vi)

Control panels, and

vii)

Ancillary subsystems; for example seal gas, fuel gas, diesel, air inlet filtration, start system, etc.

It includes where applicable of prime movers (Turbine or ICE or EM), Gearbox, compressor (Centrifugal or Reciprocating), booster compressor, heat exchanger, scrubber/vessels, control panels, and ancillary equipment. It also includes numerous instrumentations. Usually, a gas compression system is equipped with its own control system and it is linked to other control systems such as DCS, SIS and FGS. 143.2 Pre-commissioning Scope of Works. For the Compressor pre-commissioning activities, the vendor or supplier guidelines are to be followed strictly. Line cleaning, chemical cleaning activities, charging seal gas, lube oil circulation are few of the precommissioning activities. i)



143.3


ii)


iii)


vii)





144 – PROCESS | GAS COMPRESSION |DISCHARGE MANIFOLD System Description Discharge manifold Sub-Subsystem starts at the outlet of the discharge scrubber or a heat exchanger of the compression train and ends at the inlet nozzle to the lift gas distribution network. Minimal equipment is provided in this system; primarily the associated piping and instrumentations such as shutdown valves, gauges transmitters and indicators.

144.2


144.3



Figure 3.6.1-14:

Discharge Manifold System




145 – PROCESS | GAS COMPRESSION |EXPORT/DOWNHOLE INJECTION System Description Every installation after processing of oil or gas is required to be exported to next user. Oil and/or gas are exported through long pipelines from offshore installation to onshore plant. Pipelines are normally provided with pig launcher in this case called Export Launcher. Oil can be exported to oil tankers also. In case of FPSO, after processing oil is stored in the hull of FPSO and transferred to shuttle tankers. Shuttle tankers take oil to onshore for offloading. For the reservoir maintenance and ultimate more oil recovery, reservoir is flooded with gas or water. Thus water or gas is injected in the reservoir. The injection is done through X-mas trees. Normally X-mas tree is on the surface but water or gas through X-mas tree is injected in the reservoir and sometimes called downhole injection.

145.2



ii)


iii)


viii)

Instrumentation Refer to Section 3.3.5 -Common Instrumentation Scope of Works.







3.6.1.5

150 – GAS DEWPOINTING

3.6.1.5.1

151 – PROCESS | GAS DEWPOINTING | GAS DEHYDRATION TRAIN(WATER DEW POINT)

151.1

System Description Removing water vapor from the gas is important because it prevents hydrates from forming when the gas is cooled in the transmission and distribution systems and prevents water vapor from condensing that create corrosion problem. Glycol contactor is a pressure vessel used in gas dehydration process. It is a vertical vessel equipped with several trays of small outlets that are methodically situated. Instead of trays Glycol Contactor can have structured packing also. As wet gas or gas laden with water vapor travels from bottom of the vessel upwards, it meets with the glycol that is sprayed from the top. As glycol has a very high affinity for water, water vapor is extracted from the gas thus making the gas dry. The major equipment are Glycol contactor, glycol/gas heat exchanger, glycol storage vessel, glycol transfer pumps, complete glycol regeneration package (re-boiler, skimmer vessel, charcoal/glycol filters, heat exchangers, glycol trim cooler/fan and electrical motor drivers etc.), anti-foam chemical injection system, local control panel, thyristor control panel, dew point analyzer and all associated piping, valves, instrumentation, moisture analyzer, tubing, instrument/electrical cabling and junction boxes. The Sub-Subsystem comprises of a contactor vessel and regeneration skid and its associated piping and instrumentation.

151.2



ii)


iii)


TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE v)



Figure 3.6.1-15:

Gas Dehydration system




Figure 3.6.1-16:

Gas Dehydration system




152 – PROCESS | GAS DEWPOINTING |ADSORPTION(WATER DEW POINT) System Description Adsorption is the adhesion of water molecules from a gas, liquid, or dissolved solid to a surface. This process creates a film of the adsorbate on the surface of the adsorbent. Note that adsorption is a surface-based process while absorption involves the whole volume of the material. Solid desiccants, Molecular sieves used as adsorbents. Major equipment involved are Adsorption bed, Regeneration unit, heat exchanger, cooler, LCP, Dew point analyzer and all associated piping, valves, instruments, moisture analyzer, tubing, electrical cabling and JB.

152.2



ii)


ii)


vi)


Figure 3.6.1-17:

152.3

Adsorption system

Commissioning Scope of Works

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE i)






153.1


PROCESS | GAS DEWPOINTING |TURBO EXPANDER AND RECOMPRESSION (HYDROCARBON DEW POINT) System Description The turbo expander with compressor unit is used to provide refrigeration for the sales gas purification/treatment process in a hydrocarbon processing plant.It is representative of a natural gas dew pointcontrol process where the low pressure ratio expander cools thegas only enough to lower the hydrocarbon dew point to beappropriate for pipeline transmission of the gas. Expander outletliquid fractions are usually in the range of 2 to 8% by weight. The expansion turbine is of the radial inflow type with advanced aerodynamic design maximizing the isentropic efficiency. The machine is of a proven cartridge concept which allows a quick replacement of the machinery capsule including rotating parts without interference with expander process pipes. A high efficiency compressor wheel is utilized as a loading device, recovering the mechanical energy from the expander. A vane diffuser ensures optimum efficiency and head flow characteristic. Turbo expanderand re-compression is equipped with following: i) Quick Shut off Valve ii) Joule-Thompson Control Valve iii) Anti-Surge Controller iv) Variable guide Vane v) Dry Gas Seal vi) Active Magnetic Bearing(AMB) vii) Automatic Thrust Balancing Unit viii) Cold Vessel Recovery Unit ix) Suction and Discharge Knockout Drums x) Magnetic Bearing Control System

153.2



ii) Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works.



iii) Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works. iv) Instrumentation Refer to Section 3.3.5 -Common Instrumentation Scope of Works.

153.3 Commissioning Scope of Works i)


Figure 3.6.1-18:

Turbo Expander




153.1


154 – PROCESS | GAS DEWPOINTING |DIRECT COOLING (HYDROCARBON DEW POINT) System Description Hydrocarbon Dew Point system is designed to inhibit the formation of solid hydrates in the gas stream i.e. to perform a level of dehydration. The major equipment are Refrigeration Compression package, Dew point control package. The system includes the refrigeration system. This is achieved through the injection of a liquid agent directly into the gas stream. The liquid agent is selected based on low viscosity and low freezing temperature rather than dehydration ability.

153.2

153.3



ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works

iii)


vii)





Figure 3.6.1-19:

Cooling system




CARIGALI STANDARD PROCEDURE 3.6.1.6

160 – WATER INJECTION

3.6.1.6.1

161 – PROCESS | WATER INJECTION | SEAWATER INTAKE

161.1


System Description Normally found only on water injection facilities, seawater intake SubSubsystem starts from the submersible "lift" pump to the inlet of a coarse filtration unit. Installation of the pumps are frequently performed offshore as it requires pre-installation of its "caissons"; tubular structures where the pumps are protected from the surrounding oceanic environment. However, the respective discharge piping and control instrumentation are preinstalled in the fabrication yard. The Sub-Subsystem includes one or more electric-motor-driven submerged centrifugal pumps, vacuum relief valves, discharge pipings, Sea Water Lift Pump (SWLP), Electro- chlorination package and associated instrumentations.

161.2

161.3



ii)

Mechanical Refer to Section 3.3.3- Common Mechanical Scope of work

iii)


iv)




–


Figure 3.6.1-20:

Seawater Intake system




162 – PROCESS | WATER INJECTION | FILTRATION System Description There are two types of filtration equipment provided for in this SubSubsystem. One is called "coarse" filtration and the other "fine" filtration (refer to attached process schematics in Figure 3.6.1-21). Coarse filters are essentially vessels equipped with internal elements that provide filtration of particles of 100 microns or more. The filter elements are rotated with the assistance of an electric motor to shake the trapped particles out of the elements whereby the particles are then released into the drain. This sequence is called a "backwash". In the fine filtration equipment, filter vessels are filled with different layers of filter media. The media are normally made of garnet and anthracite. As dirty water flows through the media from the top, particles bigger than 2 microns are trapped thus provided very clean water. Unlike coarse filters, trapped particles are removed on a fixed period by reversing the flow. This process is also helpful in restoring the media fluffiness for another cycle of filtration. The Sub-Subsystem starts at the inlets of the coarse filters and ends at the outlet of the fine filters. It comprises of pressure vessels, motor-driven mixers and blowers, butterfly valves, control valves and other associated piping and instrumentations. The major equipmentare injection pumps and all associated drive equipment and accessories and local control panels. All conditioning equipment, including suction filters and dedicated chemical injection systems, all suction and discharge piping and headers, valves, instrumentation, tubing and any electrical/instrument cabling and junction boxes.

162.2



ii)



162.3


iii)


v)




Figure 3.6.1-21:

Filtration system



163 – PROCESS | WATER INJECTION | DEAERATION System Description Deaeration is a process of oxygen removal from the water. It is mostly achievable through two processes; gas stripping and vacuum. Under gas stripping, process gas passes through water droplets and "strips" the oxygen from the water molecules. Under vacuum, separate equipment is required to create the necessary vacuum thus allowing the oxygen molecules to separate from the water molecules. The whole process occurs in a tower vessel called a "deaerator tower". Inside a deaerator tower, packings are randomly arranged with the sole purpose of increasing the contact between two phases i.e. water and gas, thus removing oxygen under vacuum condition. The Sub-Subsystem includes a pressure vessel, electric-motor-driven pumps, vacuum ejector sets, control valves and other associated piping and instrumentation.

163.2

163.3



ii)


iii)

Electrical Refer to Section 3.3.4 -Common Electrical Scope of Works.

iv)





Figure 3.6.1-22:

Deaeration system






164 – PROCESS | WATER INJECTION | TREATED WATER PUMPING System Description Treated water pressure is increased prior to injection into the wells by employing different sets of pumps. For low pressure requirements, a 'booster" pump is sufficient to meet the needs. It is used to maintain inlet suction pressure for the high pressure pump. It is normally a single-stage centrifugal pump driven by an electric motor. The major equipment are low pressure booster pump, high pressure multistage pump (turbine or diesel /gas engine drive) ancillary equipment. Shutdown valves control valves, blowdown valves, gauges and transmitters

164.2

164.3



ii)


iii)


v)





Figure 3.6.1-23:

Treated Water Pumping system



165.1


165 – PROCESS | WATER INJECTION | TREATED WATER EXPORT/DOWNHOLE INJECTION System Description The Sub-Subsystem starts from the discharge of the injection pump and ends at the gate valves to the water injection wells. It includes discharge manifold, riser shutdown valves, scraper launcher and receiver, injection water header, flowlines to water injection wells, associated piping and instrumentations.

165.2



ii)


iii)

Electrical - None.

v)

165.3





Figure 3.6.1-1:

Treated Water Export / Downhole Injection system




3.6.1.7

170 – ACID GAS REMOVAL

3.6.1.7.1

171 – PROCESS | ACID GAS REMOVAL | ACID GAS REMOVAL UNIT

171.1

System Description In case of high H2S, where it may not be suitable to re-inject or flare the acid gas, further treatment would be required by introducing acid gas to Acid Gas Enrichment Unit (AGEU) to selectively remove H2S over CO2 in order to produce an acid gas composition which enables acceptable operating conditions for Sulphur Recovery Unit (SRU). The Sulphur Recovery Unit consists of modified Claus Units with catalytic stages with common degasser and incinerator where acid gas is pre-heated to around 195 °C. Elemental sulphur is produced which is routed to sulphur blocking area and the tail gas routed to incinerator to convert remaining sulphur species to SO2. This is also known as gas sweetening and acid gas removal in downstream plants referring to processes that use aqueous solutions of various amines to remove H2S and CO2 from gases. Main equipment involved are Absorber, tanks and vessels, reboiler, pumps, reflux drum, associated piping and instruments.

171.2

171.3



ii)


iii)


ix)





Figure 3.6.1-24:

Acid Gas Removal system




3.6.1.8

180 – CONTAMINANT REMOVAL

3.6.1.8.1

181 – PROCESS | CONTAMINANT REMOVAL | MERCURY REMOVAL UNIT(ADSORPTION)

181.1

System Description Also known as de-mercurization in downstream plants found after the dehydration process where mercury is removed from gas by adsorption using activated carbon beds or other technology such as silver-doped molecular sieve, sulfur impregnated carbon, copper sulfide and the like. Major equipment involved is Packed Bed columns, Tanks, vessels and associated piping & instrumentation.

181.2

181.3



ii)


iii)


iv)


v)

Catalyst Loading by Specialized Subcontractor



Figure 3.6.1-25:

Mercury Removal system



182.1


182 – PROCESS | CONTAMINANT REMOVAL | MERCAPTAN REMOVAL UNIT(ADSORPTION) System Description Natural gas having contaminants Mercaptans which is a sulphur-containing compounddefined as RSH where R represents radical, and having an extremely offensive, garlicky odor. Dewpoint Gas is feed to the unit from the Mercury Removal Bed. The incoming gas is first cooled in the Mecaptan Unit Gas/Gas Exchanger and then by the Chiller Package. It is then feed into the Molecular Sieve Vessels. Two (2) out of the three (3) Molecular Sieve Vessels will be online at any one time. The vessels have a duty time of 16 hours before entering an eight (8) hour regeneration cycle. The regeneration cycles are staggered to ensure two (2) vessels are always online. The conditioned gas exits the Molecular Sieve Vessels with a total sulphur content of <5mgS/Nm³. The stream passes through the Molecular Sieve after Filter and onto the Mercaptan Unit Gas/Gas Exchanger to cool incoming gas from the Mercury Removal Bed. The gas stream then flows to the pipeline for export. After 16 hours of online duty time, the Molecular Sieve Vessel enters a regeneration cycle. In this cycle, the bed is heated to 300ºC to regenerate the desiccant. The Mecaptans Removal Unit consists of: i) Mercaptan Unit Gas/Gas Exchanger ii) Molesieve Chiller Package, iii) Three (3) Molecular Sieve Vessels iv) Molecular Sieve After Filter v) Regeneration Gas Heater vi) Regeneration Gas Cooler vii) Regeneration Gas Filter

182.2



ii)





182.3


iii)


iv)


v)

Molecular sieve loading by Specialized Subcontractor



Figure 3.6.1-26:

Simplified Quick-cycle PFD



CARIGALI STANDARD PROCEDURE 3.6.2

200 – PROCESSUTILITIES

3.6.2.1

210 – UTILITY GAS

3.6.2.1.1

211 – PROCESS UTILITIES | UTILITY GAS |FUEL GAS SYSTEM

211.1


System Description Fuel gas system will provide for gas driven prime movers such as Gas Turbine Generator to drive Gas Compressor and other miscellaneous load such as compressor seal gas requirement and vessel blanketing. Inclusive where applicable of Fuel gas scrubbers, filters/scrubbers, preheaters, superheaters and all associated level control systems and pressure control valves, control panels, thyristor panels and all line piping, headers, valves and instrumentation, tubing and any electrical /instrument cabling and junction boxes

211.2


Piping Refer to Section 3.3.2 - Common Piping Scope of Works

ii)


iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works

v) Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works

211.3




Figure 3.6.2-1:

Fuel Gas system A



Figure 3.6.2-2:

Fuel Gas system B




212 –PROCESS UTILITIES | UTILITY GAS |INSTRUMENT GAS System Description The gas extracted from the wellfluid for use as instrument supply medium is inherently wet such that this has to go through a system to slightly enhance the quality of gas to be used for instrumentation. Major equipment involved are gas scrubbers, filters and associated level control systems, pressure monitoring loop, control valves, all line piping, tubing, headers, valves and other associated instrumentation.

212.2

212.3



ii)

Mechanical Refer to Section 3.3.3 - Common Piping Scope of Works.

iii)


v)






3.6.2.2

220 – INERT GAS

3.6.2.2.1

221 – PROCESS UTILITIES | INERT GAS |NITROGEN (NITROGEN GENERATION & NITROGEN BOTTLES)

221.1

System Description Inert gas such as nitrogen which contains low oxygen is admitted into process system to make the atmosphere in the tanks inert so that explosive environment may not occur even if any ignition source is generated. Nitrogen bottle is normally provided as back-up for purging and blanketing where it distributed to the FG system, HP/LP flare, produce water degasser, stripping and blanket gas to glycol flash vessel. The major equipment are generator, absorption vessels, receivers, distribution header & control panels

221.2



ii)


iii)


iv)





Figure 3.6.2-3:

Nitrogen System

The nitrogen system is usually supplied by the Vendor. For Commissioning, the vendor supplied guidelines shall be adhered. Before commissioning, ensure that the battery limit valves are closed.



222 – PROCESS UTILITIES | INERT GAS |SPENT/FLUE GAS System Description One method to get the spent gas source is from flue gas taken from the boiler uptake after it is washed, cleaned and cooled. The boiler provides a plentiful supply of flue gas and the only additional equipment required is that associated with processing of the gas before it is delivered to the cargo tanks. The major equipment are fan, scrubber and instrument control.

222.2

222.3



ii)


iii)


iv)





230 – VENTING

3.6.2.3.1

231 – PROCESS UTILITIES | VENTING | ATMOSPHERIC VENT

231.1


System Description Atmospheric vent system or low pressure vent generally implies venting of gas or pneumatic air to the atmosphere. The system starts at the discharge of particular equipment like a compressor or a vessel such as a knockout drum. It comprises of pipeworks and minimal equipment like flame arrestors and rupture disks. The major equipment are discharge outlet of equipment, knockout drum, flame arrestors and rupture disks.

231.2


Piping a)

Refer to section 3.3.2 - Common Piping Scope of Works. Note: This is an open-ended Sub-Subsystem, therefore reinstatement is not possible.

231.3

ii)

Mechanical - None.

iii)

Electrical - None.

iv)

Instrumentations Refer to section 3.3.5 - Common instrumentation Scope of Works.





232 – PROCESS UTILITIES | VENTING | FLARE System Description Thepurpose of the Flare and Vent Systems is toprovide safe discharge and disposal of gasesand liquids resulting from different systems handling oil and gas. The systems are typically divided into a High Pressure (HP) Flare and a LowPressure (LP) flare system. The LP system is operated marginally above atmosphericpressure to prevent atmospheric gases such as Oxygen to flow back into the vent andflare system and generate a combustible mixture. With low gas flow, inert gas isinjected at the flare nozzle to prevent air ingress. The flare system consists of flare header and sub headers, flare KO drums and pumps, smokeless flare stack with ignition panel, velocity seal and air blowers. The major equipment are liquid knock-out drums, flame arrestors, molecular seals, flare tips and any associated piping valves, instrumentation and flare gas meter.

232.2



ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works. Perform internal inspection on the knockout vessel.

iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works

iv)

Instrumentations Refer to Section 3.3.5 - Common Instrumentation Scope of Works.



Figure 3.6.2-4: Flare system

232.3

Commissioning Scope of Works Ensure that the following systems/subsystems to be confirmed for readiness: 

Plant air system



Instrument air system



Safety and fire protection system

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 

Diesel storage and handling system



Fuel gas distribution subsystem


Since flare system is open-ended at the flare tip, air ingress can be expected any time. It is best to purge sub headers, header and flare KOD in sections. Ensure that the entire Flare system is purged with nitrogen (allowable oxygen concentration is less than 4%). Drain accumulated liquid from the base of the flare stack if stack has been provided with drain pot. Purge gas (fuel gas) needs to be admitted in the system when oxygen level is achieved before nitrogen flow is stopped. Commissioning Sequence: Admit Fuel gas to the flare pilot by lining up the required isolation valves using the fuel gas, air-fuel mixture and flame front generator flare stack can be lighted up. For keeping the flare live, fuel gas will be admitted continuously. Fuel gas and other hydrocarbon lines are under nitrogen pressure, so care should be taken while lining up these lines to flare system, as it may extinguish the pilot. Clearance can be given to line up relief / blow down lines from various systems as required. Reinstate all PSV downstream valves in LOCK OPEN position as per P&ID and register in Mechanical isolation register.





3.6.2.4

240 – PRODUCED WATER

3.6.2.4.1

241 –PROCESS UTILITIES | PRODUCED WATER |PRODUCED WATER/ WASTE WATER SYSTEM

241.1

System Description Produced Water from the separators / dehydrators/ cyclones is routed to a common header. This common header routes produced water from the trains to the Produced Water Skimming vessel. Skimmed oil Flow through the system is by gravity to avoid the formation of an emulsion. Oil recovered from the Produced Water Skimming vessel is routed to a common Oil Recovery Sump. The skimmed oil is returned to each of the production trains upstream of the Crude Heater via the Oil Recovery Pumps. It is inclusive where applicable of hydro cyclones,floatation unit, flash vessel, pumps and associated drive equipment and accessories and local control panels. All conditioning equipment, exchangers, vessels including pre-filters, filtration, oil analyzer and dedicated discharge system, all suction and discharge piping and headers, valves, instrumentation and associated tubing and any electrical/instrument cabling and junction boxes.

241.2

241.3



ii)

Mechanical Perform internal inspection on vessel.

iii)

Electrical - None

i)

Instrumentations Refer to Section 3.3.5 - Common Instrumentation Scope of Works




242.1


242 – PROCESS UTILITIES | PRODUCED WATER |EFFLUENT WATER TREATMENT System Description It treats the process effluent water to acceptable specification of the end user. Various methods deployed in treating the water such as hydrocyclones, gas floatation, corrugated plate interceptors, Reverse osmosis, Submerged Ultra Filtration, Bio-treating, etc.

242.2

242.3



ii)

Mechanical Perform internal inspection on the vessel.

ii)

Electrical Refer to Section 3.3.4 - Common Electrical of Works.

iv)





Figure 3.6.2-5:

Effluent Water Treatment system






3.6.2.5

250 – DRAIN

3.6.2.5.1

251 – PROCESS UTILITIES | DRAIN | OPEN DRAIN (NON-HAZARDOUS)

251.1

System Description Open drain system, sometimes called "non-hazardous drain", involves drainage of wastes overboard of the facility. A good example of an open drain is the "downcomer" line for disposal of drilling mud. Sometimes, it is synonymous with atmospheric or non-pressurised drain lines. This SubSubsystem is generally associated with pipeworks only. The major equipmentare drain sump, drain pump, open drain line & headers.

251.2

251.3



ii)

Mechanical - None

iii)

Electrical - None

iv)

Instrumentation - None




Figure 3.6.2-6:

Open Drain system




252 – PROCESS UTILITIES | DRAIN | OPEN DRAIN (HAZARDOUS) System Description The function of Hazardous Drain System is to collect hazardous liquid or waste media which could contaminate the environment. The system will collect from various area drain lines and headers from topside to hull/marine. The major parts are hazardous drain system and headers.

252.2

252.3


Piping Refer to Section 3.3.2 - Common Scope of Works.

ii)


iii)


iv)






253 –PROCESS UTILITIES | DRAIN | CLOSED DRAIN System Description Closed drain, sometimes called pressurized drain or hazardous drain, is meant to handle waste media which could contaminate the environment. A distinctive feature of the system is that it involves a waste collector called a "sump caisson". Pumping equipment called "sump pump" is provided to recycle hydrocarbon waste material back into the process system for further extraction. Closed drain system may contain equipment such as relief valves, a pump, a prime mover in the form of an electric or pneumatic motor. It also involves associated instrumentation including indicators.

253.2

253.3



ii)


iii)


iv)





Figure 3.6.2-7:

Closed Drain system




254 – PROCESS UTILITIES | DRAIN | SEWAGE System Description The sewage system is designed to treat the grey and black water. Black water from toilets, urinals and all discharged from living quarters, workshop, administration building will be treated in the biological type sewage treatment unit before disposal overboard. All toilets and other foul water drains, sewerage and sewage treatment systems including all pumps, drives, control panels, associated instrumentation and cabling. Also including compactor machines and all associated hydraulic systems and controls.

254.2

254.3



ii)


iii)


iv)





Figure 3.6.2-8:

Schematic of the Sewage Sub-subsystem




3.6.2.6

260 – PROCESS HEATING

3.6.2.6.1

261 – PROCESS UTILITIES | PROCESS HEATING | WASTE HEAT RECOVERY

261.1

System Description This is an energy recovery heat exchanger that recovers heat from hot streams with potential high energy content, such as hot flue gases from a diesel/gas turbine generator or other heat sources or exhaust units. The major equipment are heating coils, exhaust unit system of boiler or steam generator, associated piping and instrumentation.

261.2

261.3



ii)


iii)


iv)





Figure 3.6.2-9:


Process Schematic for Process Heating Subsystem consisting of Hot Oil and Warm Oil Sub-subsystem



262 – PROCESS UTILITIES | PROCESS HEATING | HOT OIL System Description Hot oil is used on facilities where continuous heating of the process crude to prevent it from hardening is necessary. Hot oil is circulated with the assistance of a pumping facility and distributed around pressure vessels and other users (refer to process schematics shown in Figure 3.6.2-9 shown under sub-subsystem 261)

262.2


Piping Refer to Section 2.3.2 – Common Piping Scope of Works.

ii) Mechanical Refer to Section 2.3.3 – Common Mechanical Scope of Works iii) Electrical Refer to Section 2.3.4 – Common Electrical Scope of Works iv) Instrumentation Refer to Section 2.3.5 – Common Electrical Scope of Works

262.3





263 – PROCESS UTILITIES | PROCESS HEATING | WARM OIL System Description Warm oil subsystem is tapped from the hot oil facilities and it is used for similar purposes in hot oil. Warm oil is circulated with the assistance of a pumping subsystem. The system consists of equipment such as electricmotor-driven centrifugal pumps for circulation, strainers, associated piping and instrumentations. Refer to attached schematics shown in Figure 3.6.2-9.

263.2

Pre-commissioning Scope of Works Activities are similar to the listing in sub-subsystem 261

263.3

Commissioning Scope of Works Activities are similar to item 261



3.6.2.7

270 – CHEMICAL (DOSING) INJECTION/TREATMENT

3.6.2.7.1

271 –PROCESS UTILITIES | CHEMICAL (DOSING) INJECTION/TREATMENT | SODIUM HYPOCHLORITE

271.1

System Description Hypochlorite is essentially pure chlorine. Hypochlorite (NaOCl) is obtained from the electrolysis of seawater (NaCl) into hypochlorite and hydrogen gas. It is colorless and corrosive in nature. The concentration of hypochlorite is proportional to the amount of electric current passing through the electrolysers or rectifiers. Hypochlorite is used in water treatment plant at lift pumps suction area to prevent ingress of sea growth, bacteria and unwanted water life which if not applied could cause clogging at the pump suction. The major equipment are hydrogen disengagement tank, motor-driven air blowers, motor-driven pumps, rectifiers, control panel and associated piping and instrumentations.

271.2

271.3



ii)


iii)


iv)





Figure 3.6.2-10:

Sodium Hypochlorite Schematics



272.1


272 – PROCESS UTILITIES | CHEMICAL (DOSING) INJECTION/TREATMENT | POLYELECTROLYTE System Description Polyelectrolyte is injected upstream of filters to assist removal of very small particles in water treatment plant. It is colorless, very viscous and corrosive in nature. When mixed with water, polyelectrolyte tends to settle at the bottom thus it appears to have higher density or "heavier" than water. It is normally diluted with water in a mixing tank to achieve the required concentration before it is injected into the process. The major equipment are chemical storage tank, a water tank, a mixing tank, dosing pumps, mixers, strainers, power cables, Hand-Off-Auto (HOA) switches and associated piping. It also includes instrumentations such as indicators, shutdown valves, control valves and transmitters.

272.2

272.3



ii)


iii)


iv)





Figure 3.6.2-11:

Polyelectrolyte schematics



273.1


273 – PROCESS UTILITIES | CHEMICAL (DOSING) INJECTION/TREATMENT | CORROSION INHIBITOR System Description Scale and corrosion inhibitors are injected to prevent formation of scales and to lessen the corrosion inside the piping. It commonly applied when carbon steel piping is specified for water treatment plant as carbon steel tends to corrode in seawater. The major equipment are storage tank, transfer pumps, calibration gauge, injection pumps and associated instruments.

273.2



ii)


iii)


iv)


273.3 i)

Commissioning Scope of Works Refer to Commissioning scope of works (Section 3.4.2)


Figure 3.6.2-12:

Corrosion Inhibitor schematics



274.1


274 – PROCESS UTILITIES | CHEMICAL (DOSING) INJECTION/TREATMENT | DIESEL SYSTEM System Description Diesel injection Sub-Subsystem contains of equipment such as injection pumps, electric motors and power cable and relief valves. The major equipment are storage tank, transfer pumps, calibration gauge, injection pumps and associated instruments.

274.2



ii)


iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works. v) Instrumentation Refer to Section 3.3.5 - Common Instrumentation Scope of Works.

274.3



Figure 3.6.2-13:

Diesel system





275.1


275 – PROCESS UTILITIES | CHEMICAL (DOSING) INJECTION/TREATMENT | GLYCOL System Description Glycol is injected at the compression recycle lines and upstream of pressure control valves to prevent hydrate formation when gas is recycled. This SubSubsystem contains equipment such as motor-driven injection pumps, calibration gauges, power cable, injection fittings and relief valves. The major equipmentare storage tank, transfer pumps, calibration gauge, injection pumps and associated instruments.

275.2



ii)


iii)


iii)

275.3



Refer to common scope for Commissioning (section 3.4.2)


Figure 3.6.2-1:

Glycol system





3.6.2.7.6

276.1


276 – PROCESS UTILITIES | CHEMICAL (DOSING) INJECTION/TREATMENT | ANTIFOAM System Description Antifoam is used to prevent the formation of foam during the preparation of a treatment fluid or slurries at surface. Excess foam created during the mixing process may cause handling and pumping difficulties and may interfere with the performance or quality control of the mixed fluid. Antifoam agents may also be used to break foams returned from the wellbore, following a treatment, in preparation for disposal of the fluids. The major equipment are storage tank, transfer pumps, calibration gauge, injection pumps and associated instruments.

276.2

276.3



ii)


iii)

Electrical - None.

iv)


Commissioning Scope of Works i) Refer to common scope for Commissioning (section 3.4.2) ii) Keep the injection rates as per specifications/P&ID.




277.1


277 – PROCESS UTILITIES | CHEMICAL (DOSING) INJECTION/TREATMENT | SCALE INHIBITOR System Description Scale Inhibitor is used to control or prevent scale deposition in the production conduit or completion system. The chemicals may be continuously injected through a downhole injection point in the completion, or periodic squeeze treatments may be undertaken to place the inhibitor in the reservoir matrix for subsequent commingling with produced fluids The major equipment are storage tank, transfer pumps, calibration gauge, injection pumps and associated instruments.

277.2

276.3


Piping - None.

ii)


iii)

Electrical - None.

iv)


Commissioning Scope of Works i) Refer to common scope for Commissioning (section 3.4.2)




278.1


278 – PROCESS UTILITIES | CHEMICAL (DOSING) INJECTION/TREATMENT | DEMULSIFIER System Description Demulsifier is used to enhance the separation of water from oil in the FWKO drums and heater treaters. It is used to neutralize the effect of emulsifying agent. It is injected to the crude upstream of the heat exchangers The major equipmentare storage tank, transfer pumps, calibration gauge, injection pumps and associated instruments.

278.2

278.3


Piping - None.

ii)


iii)

Electrical - None.

iv)



Refer to common scope for Commissioning (section 3.4.2)



279 – REVERSE DEMULSIFIER System Description Reverse Demulsifier is designed to separate oil emulsions into three phases: Oil Phase  Biological  Solid Without the use of Reverse Demulsifier, disposal of waste oil-in water emulsion would be environmentally unfriendly. Oil-in-water emulsion are treated at ambient temperature. Treatment should be added at a point of high turbulence for complete dispersion within the treatment tank. After dosing, all dosing and pumping equipment should be switched off to allow phase separation to take place in a turbulence free environment. The major equipmentare storage tank, transfer pumps, calibration gauge, injection pumps and associated instruments.

279.2

Pre-Commissioning Scope of Work, refer to Sub-system 278

279.3

Commissioning Scope of Work, refer to Sub-system 278



3.6.3

300 – GENERAL UTILITIES

3.6.3.1

310 – FUEL AND LUBRICATION

3.6.3.1.1

311 – GENERAL UTILITIES | FUEL AND LUBRICATION | DIESEL FUEL

311.1

System Description Diesel is used as backup fuel for equipment such as generators, compressor drivers, engine-driven pumps, etc. should fuel gas system malfunction or shutdown. The major equipment are diesel storage vessels, day tank, transfer pumps, filters, valves,associated piping, electrical and instrumentation.

311.2

311.3



ii)


iii)


iv)





Figure 3.6.3-1:

Diesel system




312– GENERAL UTILITIES | FUEL AND LUBRICATION | JET FUEL System Description Facilities that are frequently visited by helicopter may be equipped with refueling equipment. The major equipment are portable storage tank, fuel pumps, filter separators, monitors, dispensers, associated flexible hoses and valves.

312.2

312.3



ii)


iii)


iv)



Refer to common Commissioning scope of work (Section 3.4.2)





313– GENERAL UTILITIES | FUEL AND LUBRICATION | LUBRICATION OIL System Description Some facilities, several major equipment may share the same lubrication oil supply thus it requires a big volume of lubrication oil to be stored. Under such circumstances, a separate equipment skid facility may be provided to cater for the needs. Equipment would include oil storage tank, fill pumps and drivers, filters & valves, associated piping and instrumentation.

313.2

313.3


Piping Refer to section 3.3.2 - Common Piping Scope of Works.

ii)

Mechanical Refer to section 3.3.3 - Common Mechanical Scope of Works.

iii)

Electrical - None.

iv)


Commissioning Scope of Work Refer to common Commissioning scope of work (Section 3.4.2)


Figure 3.6.3-2:

Lubrication Oil system






3.6.3.2

320 – COMPRESSED AIR

3.6.3.2.1

321 – GENERAL UTILITIES | COMPRESSED AIR | INSTRUMENT AIR

321.1

System Description Compressed air for instrument and utility applications is provided by two (2) rotary-type screw compressors. The compressors are set up to operate one as a lead and the other as a standby unit. A dedicated controller is provided at each compressor for automatic loading and unloading. Another type of compressor is packaged integrally geared centrifugal air compressor. The major equipment includes air compressors and all associated drive equipment and accessories (including all on skid scrubbers, coolers and air intake equipment, etc.)and local control panel. Instrument air dryer and control panel, valves, moisture analyzer, and junction boxes.

321.2

321.3



ii)


iii)

Electrical Refer to section 3.3.4 - Common Electrical Scope of Works.

iv)

Instrumentation Refer to section 3.3.5 - Common Instrumentation Scope of Works.


Refer to common Commissioning scope of work (Section 3.4.2)


Figure 3.6.3-3:

Instrument Air system




322– GENERAL UTILITIES | COMPRESSED AIR | UTILITY AIR System Description Utility air is tapped from the Utility Air Receiver discharge without going through any filtration and drying. Utility air serves various users such as sump pump, maintenance tools and it also pressurizes starting air SubSubsystem. Self-actuated control valve ensures the air supply pressure is maintained i.e. the control valve would completely shut upstream pressure is lower than the pressure setting. This includes air compressors and all associated drive equipment and accessories (including all on skid scrubbers, coolers and air intake equipment, etc.)and local control panel. Instrument air dryer and control panel, valves, moisture analyzer, and junction boxes.

322.2



ii)

Mechanical – Refer to Section 3.3.3 – Common Mechanical Scope of Work

322.3

iii)

Electrical - None.

iv)


Commissioning Scope of Works Similar to commissioning work for Sub-Subsystem 321


323.1


323 – GENERALUTILITIES | COMPRESSED AIR | BLACK START/STARTING AIR System Description Starting air is used for equipment that is started up using pneumatic starters; for example starters on internal combustion engines. Starting air compressor is driven by a diesel engine which could be started manually or using hydraulic starter. During "black start", there is no compressed air from the utility header until power supply is available. Thus, start air provides for the required facility to start up the power generator. Start air could also be used as instrument air as the discharge piping is connected to the inlet of the air driers. The major equipment are starting air compressor (diesel engine driven), air intake filter.

323.2

Pre-commissioning Scope of Works Activities are similar to the listing under Sub-Subsystem 321.

323.3

Commissioning Scope of Works Similar to commissioning work for Sub-Subsystem 321


Figure 3.6.3-4:

Starting Air system



330 – WATER

3.6.3.3.1

331 – GENERALUTILITIES | WATER | SERVICE WATER

331.1


System Description Service water application is for cleaning of deck areas thus seawater is normally used. Seawater is pumped up from the ocean by the jockey pump (part of subsystem 411), routed into the RO Unit/Water Maker Unit and then stored in a water tank. When required, a dedicated service water pump would pressurize the service water system after the water has gone through some strainers to trap foreign particles and distribute the water for the required use. The rest of the system is only pipeworks. The major equipment are water cooler and water treatment skid consisting of filtration and chlorination units i.e. RO/Water Maker.

331.2



ii)

Mechanical a)

iii)

Electrical a)

iv)


Refer to Section 3.3.4 - Common Electrical Scope of Works.

Instrumentation– Refer to Section 3.3.5 – Common Instrumentation Scope of Works.

331.3

Commissioning Scope of Works i) Refer to Commissioning common scope of works - Section 3.4.2.


Figure 3.6.3-5:

Service Water system




3.6.3.3

330 – WATER

3.6.3.3.2

332– GENERAL UTILITIES | WATER | FRESH AND DISTILLED WATER

332.1

System Description Fresh water is generated by having fresh water generator where sea water is desalinated seawater (vapor compression) and distill water is formed. Fresh water is then generated from the distill water after gone thru chlorine dozing unit and re-hardening filter. Fresh water system will supply water to accommodation and input to feed water and potable water system. Fresh water to accommodation will further treated with hydrophore system. This includes fresh water generator, fresh/distill water tank and pump.

332.2

332.3



ii)


iii)

Electrical Refer to Section 3.3.4 - Common Electrical Scope of Works..

iv)

Instrumentation–Refer to Section 3.3.5.


Refer to Commissioning common scope of works (section 3.4.2)



333– GENERAL UTILITIES | WATER | FEED WATER System Description The function of feed water system is to supply feed water to boilers. This feed water is used by the boilers to generate steam. Condensate and distill water is the main source for feed water system. The major equipment are cascade tank with inspection/observation tank, transfer pumps and boiler chemical dosing unit.

333.2

333.3



ii)


iii)


iv)






334– GENERAL UTILITIES | WATER | POTABLE WATER System Description Potable water is obtained from watermakers where seawater is desalinated into fresh water for use in living quarters and any other application that requires use of fresh water. Watermakers normally comes on a skid in the form of a vapor-compression type or a reverse osmosis. Both types require use of chemicals and the skid would include smaller items such as filters, pumps, some tanks and instrumentations. The major equipment are water maker skid (pumps, filters, tanks & instrumentation).

334.2

334.3



ii)


iii)


iv)





Figure 3.6.3-6:

Potable Water system




335– GENERALUTILITIES | WATER | HOT WATER System Description Hot water is required at accommodation for sinks, showers, washer, ice maker and etc. It is generated from fresh water via electric calorifier system. Input water comes from fresh water system and after being treated by fresh water hydrophore and de-chlorinator filter. The major equipmentarecalorifier/Heater, hot water tank &pump.

335.2

335.3 i)



ii)


iii)


iv)





336– GENERAL UTILITIES | WATER | COOLING WATER System Description Cooling water systems absorb heat from the processes they are designed to cool(Printed Circuit Heat Exchanger-PCHE). In HVAC systems, the condenser cooling water absorbs heat from the refrigerant through a heat exchanger. In process cooling water systems the cooling water absorbs heat from the process stream that needs cooling. The re-circulating water in cooling water systems is usually cooled by the evaporation of a small amount of the recirculating flow (typically 1-2%). This evaporation takes place as water flows over and through cooling towers, fluid coolers or evaporative condensers. The major equipmentincludeheat exchanger(PCHE),Chalorifier/Cool Water Tank,Pump.

336.2

336.3 i)



ii)


iii)


iv)




340 – STEAM

3.6.3.4.1

341 – GENERALUTILITIES | STEAM | STEAM GENERATION

341.1


System Description The steam generation can generally be classified into two principal type fired boiler system and waste heat system. The primarily purpose of steam generation is to generated steam under the conditions (Flow rate and pressures) required for systems and end-used requirement. The major equipments are boiler or heat source, steam drum heating coils, piping and associated instrumentation.

341.2

341.3



ii)


iii)


iv)





Figure 3.6.3-7:

Steam Generator




342– GENERAL UTILITIES | STEAM | STEAM DISTRIBUTION System Description The steam distribution system contributes the produced steam from steam generation system i.e. boiler and been distributed to each station including power generation and processing plant facilities. The major equipment includes piping, steam traps and associated instruments.

342.2

342.3



ii)


iii)


iv)






343– GENERAL UTILITIES | STEAM | STEAM CONDENSATE System Description The steam condensate system is the final stage of steam cycle. The condensate discharged from equipment will then be recycling to cascade tank. It is normally comes from all condensers and steam traps. This includes a steam condensate system (condensate receiving tank & condensate pumps).

343.2

343.3



ii)


iii)


iv)







350 – HEATING, VENTILATION AND AIR-CONDITIONING

3.6.3.5.1

351 – GENERALUTILITIES | HEATING, CONDITIONING | DIRECT EXPANSION UNIT

351.1


VENTILATION

AND

AIR-

System Description Direct expansion type air handling units with air cooled condensing unit maintain appropriate quality of air, room temperature and relative humidity to provide human comfort as well as to protect electronic and electrical equipment from excessive operating temperature and prevent corrosion and deterioration due to air contamination. It maintains positive pressure within the room to prevent ingress of flammable/toxic gasses and achieve non-hazardous area classification. The major equipment are air handling unit, compressor/condenser unit, HVAC Control panel & duct.

351.2

351.3 i)



ii)

Mechanical Refer to Section 3.3.3 - Common Mechanical Scope of Works

iii)


iv)




Figure 3.6.3-8:

HVAC Subsystems





352.1

352– GENERALUTILITIES | HEATING, CONDITIONING | CHILLED WATER UNIT


VENTILATION

AND

AIR-

System Description The condenser water absorbs heat from the refrigerant in the condenser barrel of the water chiller, and is then sent via return lines to a cooling tower, which is a heat exchange device used to transfer waste heat to the atmosphere. The extent to which the cooling tower decreases the temperature depends upon the outside temperature, the relative humidity and the atmospheric pressure. The water in the chilled water circuit will be lowered to the Wet-bulb temperature or dry-bulb temperature before proceeding to the water chiller, where it is cooled to between 4° and 7°C and pumped to the air handler, where the cycle is repeated. This is inclusive of chillers, cooling towers, pumps, electrical control equipment, instrumentation, associated piping and valves.

352.2

352.3 i)



ii)


iii)


iv)




Figure 3.6.3-9:

Chilled Water Unit





353.1


353– GENERALUTILITIES | HEATING, VENTILATION CONDITIONING | FORCED AIR VENTILATION UNIT

AND

AIR-

System Description The purpose of the system is to provide sufficient air ventilation to required room such as engine room, emergency generator room, fire pump room, steering gear engine room, purifier space and auxiliary machinery room. Types of ventilation are mushroom, gooseneck, storm hood and cowl head type. The equipment involved are supply fan and exhaust fan.

353.2

353.3



ii)


iii)


iv)






3.6.3.6

360 – HYDRAULICS

3.6.3.6.1

361 – GENERALUTILITIES | HYDRAULICS | HYDRAULICS POWER UNIT (HPU)

361.1

System Description The purpose of Hydraulics Power Unit (HPU) is to provide hydraulic power needed i.e. for subsea control system and subsea valve. The system operates using a liquid base biodegradable control fluid such as McDermidOcenic HW443 or Castrol Transaqua HT, at fluid cleanliness SAE AS4059 Class 6B-F or better. The major equipmentare HPU supply tank, return tank, pumps, valves and bulkhead connection to TUTU.

361.2

361.3



ii)


iii)


iv)





370 – MARINE SYSTEM

3.6.3.7.1

371 –GENERAL UTILITIES | MARINE SYSTEM | BALLAST

371.1


System Description The Ballast and Bilge systems are critical to safety and life and must function reliably over a broad range of environmental, global response and damage condition.The Ballast System is design to ballast, de-ballast and trim the vessel simultaneously over a wide range of vessel stability and trim conditions, and accommodate emergency bilge suctions.

371.2

371.3



ii)


iii)


iv)






372– GENERALUTILITIES | MARINE SYSTEM | BILGE AND SLUDGE System Description The purpose of the bilge system is to pump out bilge (water pounding or collected water) on all decks board, hull access and pump room or void compartment in the event of flooding. According to ABS Steel Vessel 2004 Part 4 mention that the bilge system is intended to dispose of water which may accumulate in space within the vessel due to condensation, leakage, washing, firefighting etc. it is to be capable of controlling flooding in the propulsion machinery space as a result of limited damage to piping system. It includes the bilge and sludge system.

372.2

372.3



ii)


iii)


iv)






373– GENERAL UTILITIES | MARINE SYSTEM | WATERTIGHT DOOR System Description Hull of a floating structure consists of various watertight doors or hatches that provide access into and out of various rooms and compartment while maintaining watertight integrity between them. The basic intent of the doors is to provide the means of access for personnel, but to prevent progressive flooding between rooms and compartments when they are not in use. Some of the watertight doors types are hydraulic operated sliding doors, manual hinged watertight doors, hydraulic assisted watertight hatches and manual watertight hatch.

373.2

373.3


Piping - None.

ii)


iii)


iv)

Instrumentation - None.







374– GENERAL UTILITIES | MARINE SYSTEM | TURRET & MOORING System Description A turret mooring system is composed of a fixed turret column supported by an internal or external vessel structure via a bearing arrangement. The vessel-bound components can therefore freely weather vane around the turret, which is fixed via a number of anchor lines to the seabed. This turret arrangement allows the FPSO to adopt the direction of the least resistance against waves, wind and currents. Toroidal swivels allows for the transfer of fluids across the rotary interface while the FPSO is weathervaning. Above deck level, located between the fixed turret column and the swivel stack, is a structure that supports the piping manifolds. These manifolds comingle the fluids (oil, gas, water, etc.) and thus reduce the number of fluid paths in the swivel stack. A turret mooring system consists of 5 main components:

374.2

1.

A number of anchor lines, to keep the vessel on station

2.

A turret column, to connect the anchor lines to the vessel

3.

A bearing arrangement, to allow the vessel to weather vane

4.

A vessel structure to support the bearing arrangement

5.

The fluid transfer system consisting of an underwater fluid transfer system, a manifold, a toroidalswivel stack, and vessel piping arrangement.


Piping - None.

ii)


iii)


iv)







400 – SAFETY

3.6.4.1

410 – FIRE FIGHTING

3.6.4.1.1

411 – SAFETY | FIRE FIGHTING | FIREWATER

411.1


System Description Inclusive where applicable of all fire water and all associated drive equipment and accessories including jockey pumps. All local control panels and instrumentation, electrical instrumentation cabling and all associated caissons, suction piping, discharge piping and fire mains, deluge system, valves, monitors, hoses and nozzles. All foam generation equipment. This Sub-Subsystem includes a diesel engine, a gearbox, ancillary equipment, copper nickel piping and associated instrumentations. It also includes fire monitors, fire hose reels and foam hose reel.

411.2

411.3



ii)


iii)

Electrical - None.

iv)





Figure 3.6.4-1:

Firewater system






412– SAFETY | FIRE FIGHTING | DELUGE AND SPRINKLER System Description For fighting fire outdoors around equipment areas such as compressor station, wellheads, launcher and receiver areas, pressure vessels etc., deluge or sprinkler is installed. This includes all deluge and sprinkler system and all associated drive equipment and accessories.

412.2

412.3 i)



ii)

Mechanical Verify panel structure and air accumulator tank are free of damage.

iii)

Electrical -None.

iv)

Instrumentation Refer to Section 3.3.5 – Common Instrumentations Scope of Works




413– SAFETY | FIRE FIGHTING | TOTAL FLOODING FIRE SUPPRESSION & FIRE EXTINGUISHER CO2 is now use in areas where fire suppression using water or Halon gas as medium is not permissible, CO2 discharge is triggered by fire and Gas Detection and also by manual operation. When fire is detected in a certain area, the sensor will send signal to the fire alarm panel which in turn would open the release valve. A timer delay is installed to allow for personnel inside the control room to leave the premises before the CO2 is release. This includes firefighting in the form of CO2 and associated equipment such as gas cylinders, storage cabinet, discharge manifold, release valve solenoid and discharge nozzles.

413.2

413.3



ii)

Mechanical Refer to Section 3.3.3 – Common Mechanical Scope of Works

iii)

Electrical -None.

iv)

Instrumentation Refer to Section 3.3.5 – Common Instrument Scope of Works.



Figure 3.6.4-2:

Fire Suppression System


Figure 3.6.4-3:

Fire Extinguisher



420 – LIFESAVING EQUIPMENT

3.6.4.2.1

421 – SAFETY | LIFESAVING EQUIPMENT | LIFE RAFTS

421.1


System Description Life rafts normally come in an enclosed and pressurized container whereby to release the life raft a tug line is pulled and the container would burst. The major equipment is life raft in an enclosed container.

421.2

421.3


Piping - None.

ii)

Mechanical Perform functional test for all rafts, if raft type could be reassembled.

iii)

Electrical - None.

iv)



Perform the test per vendor’s procedure.

Figure 3.6.4-4:

Life Raft





422– SAFETY | LIFESAVING EQUIPMENT | SURVIVAL CRAFTS

422.1

The most essential lifesaving equipment on any platform, survival crafts and the support frame are normally installed offshore. Survival crafts are driven by a diesel engine and the engine is usually air-started. A craft is equipped with survival kits, an air cylinder, a hand pump, safety belts and pneumatic or hydraulic controls, to mention a few. This includes survival craft engine driven and support frame.

422.2


Piping - None.

ii)

Mechanical a)

Verify quantity of rations and accessories provided are as per specification..

c)

Perform functional test of craft diesel engine.

d)

Verify air cylinder is fully charged.

e)

Verify hand pump is functioning properly.

f)

Verify no physical damages to the craft frame and body.

iii)

Electrical- refer to Electrical common scope of works (Section 3.3.4)

iv)

Instrumentation–refer to Instrumentation common scope of works (Section 3.3.5)





ii)

Refer to relevant ITR-C.

Figure 3.6.4-5:

Survival Craft





423– SAFETY | LIFESAVING EQUIPMENT | ESCAPE AND RESCUE System Description Other lifesaving equipment includes lifebuoys, Jacobs ladder, safety netting, lifejackets, fire blankets and portable fire extinguishers, to mention a few.

423.2

423.3 i) ii)


Piping - None.

ii)

Mechanical a)

Verify quantity supplied is as per specification.

b)

Verify portable fire extinguisher cylinders are fully charged.

c)

Verify the accessories such as water-operated lights, whistles, etc., for the lifebuoys and lifejackets are provided.

iii)

Electrical - None.

iv)


Commissioning Scope of Works Refer to Commissioning common scope of works (Section 3.4.2) Perform the test per vendor’s procedure.


Figure 3.6.4-6:

Escape and Rescue Equipment





500 – POWER

3.6.5.1

510 – POWER GENERATION/SUPPLY

3.6.5.1.1

511 – POWER GENERATION

511.1

|POWER

GENERATION/SUPPLY

|

MAIN

POWER

System Description Sub-Subsystem 511 consists of single/dual-fuel-fired turbine-driven generators and the turbine ancillaries such as electro-hydraulic starter motor, pre/post lube oil pump, backup direct current (DC) lube oil pump, diesel fuel pump motor, lube oil cooler fans and turbine enclosure fans. It also includes a control console consisting of a programmable-logic microprocessor-based control system, controls and indicators for turbine enclosure Fire and Gas detection and suppression system, a turbine local control panel, a voltage regulator panel, a vibration monitoring system and a circuit breaker panel. It also involves electrical power supply cables and main junction box, on-skid and off-skid instruments, turbine engine gage panel, turbine exhaust, turbine air intake, exhaust system, fuel system, valves and associated piping. For smaller systems, Micro Turbine Generators (MTG), Gas Engine Generators (GEG) or Diesel Engine Generators (DEG) may be used. In case of GEG and DEG, the pre-commissioning and commissioning requirements shall follow Sub-Subsystem 512 Emergency Power Generator Unit. As for the MTG, reference shall be made to specific vendor recommendations and the ITRs.



CARIGALI STANDARD PROCEDURE 511.2




ii)

Mechanical

iii)

a)

Refer to section 3.3.3 - Common Mechanical Scope of Works.

b)

Verify turbine lube oil system flushing had been completed.

c)

Verify turbine pre/post lube oil pump and backup DC lube oil pump are functioning correctly.

d)

Verify turbine fuel loading valves are functioning properly.

e)

Verify turbine air intake chamber is free of foreign particles.

f)

Verify turbine air intake filter elements are in good condition.

g)

Perform no-load test of turbine engine.

Electrical a)


b)

Verify Electrical inspection, checks and test of AC generator had been carried out.

c)

Perform full function checks of turbo-generator enclosure ventilation system.

d)

Refer 5.2.1 – for other pre-commissioning checks and tests.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE iv)


Instrumentation a)


b)

Perform simulated function testing of Turbo-generator including auto and manual start sequences, normal and emergency shutdown sequences, fire and gas detection and fire suppression systems.

Note: Vendor representative assistance may be required.


Figure 3.6.5-1:

Main Generator System




Commissioning Scope of Works Commissioning of the main power generation system shall include full site testing of the generating system. This shall include a load test using the actual fuel complete with load acceptance and rejection tests as required and detailed in the relevant commissioning ITRs. The commissioning tests shall be in line with vendor recommendations for the site acceptance tests and shall be witnessed by the vendor and the owner.




512.1


512– POWER |POWER GENERATION/SUPPLY | EMERGENCY POWER GENERATION System Description Sub-Subsystem 512 consists of gas or diesel fired engine driven generators and auxiliaries such as electric /hydraulic starters, enclosure fans, fuel system etc. It also includes a control console consisting of a programmable-logic microprocessor-based control system, controls and indicators for enclosure Fire and Gas detection and suppression system, an engine control panel, generator control panel and a voltage regulator. It also involves electrical power supply cables and main junction box, on-skid and off-skid instruments, engine gage panel, air intake and exhaust system, fuel system, valves and associated piping.

512.2



ii)

Mechanical

iii)

a)


b)

Verify turbine lube oil system flushing had been completed.

c)

Verify turbine pre/post lube oil pump and backup DC lube oil pump are functioning correctly.

d)

Verify turbine fuel loading valves are functioning properly.

e)

Verify turbine air intake chamber is free of foreign particles.

f)

Verify turbine air intake filter elements are in good condition.

g)

Perform no-load test of turbine engine.

Electrical a)


b)

Verify Electrical inspection, checks and test of AC generator had been carried out.


iv)


c)

Perform full function checks of enclosure ventilation system.

d)

Refer 5.2.2 – for other pre-commissioning checks and tests.

Instrumentation a)


b)

Perform simulated function testing of generator system including auto and manual start sequences, normal and emergency shutdown sequences, fire and gas detection and fire suppression systems.


512.3

Commissioning Scope of Works Commissioning of the emergency power generation system shall include full site testing of the generating system in accordance with 5.2.2.5. This shall include a load test using the actual fuel complete with load acceptance and rejection tests as required and detailed in the relevant commissioning ITRs (Load test at site may be waived, subject to approval from principal, provided full load test has been carried out during FAT using the actual fuel). The commissioning tests shall be in line with vendor recommendations for the site acceptance tests and shall be witnessed by the vendor and the owner.



513– POWER |POWER GENERATION/SUPPLY | ENMC/PMS System Description This covers the Electrical Network Monitoring and Control system covering load sharing/load shedding controls/Power management System etc. This usually is packaged together with the main generation package. It includes a control console consisting of programmable-logic microprocessor-based control systems, PC based network control systems, data acquisition systems, interface cabling and human machine interfaces.

513.2


Piping Not Applicable.

ii)

Mechanical Not Applicable.

iii)

Electrical

iv)

a)


b)

Perform full function checks of the ENMC system to satisfy the design functional specifications as per the commissioning ITRs in line with manufacturer recommendations.

Instrumentation a)


b)

Perform simulated function testing of generator system including auto and manual start sequences, normal and emergency shutdown sequences, fire and gas detection and fire suppression systems.




Commissioning Scope of Works Commissioning of the ENMC system shall be performed together with the overall power generation system commissioning.


520 – DISTRIBUTION

3.6.5.2.1

521 –POWER |DISTRIBUTION | TRANSFORMER

521.1


System Description This system covers all the power/distribution HV AND LV transformers (Except the main power transformer for grid intake/export), associated equipment and incoming cables/busducts to the transformers. It consists of power/distribution transformers, Neutral Earthing Resistors (NERs), On Load Tap Changers (OLTC), Remote Tap changing Cubicles (RTCC), local isolators and incoming cables/busducts.

521.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical a)


b)

Check transformer nameplate details.

c)

Inspect transformer assembly for levelness and foundation fixing details.

d)

Inspect all joints and bushing for leakage.

e)

Check transformer connection data to determine polarity of terminals and phase sequence.

f)

Check and inspect the tap settings to verify the various voltage transformation ratio.

g)

Verify calibration and current injection of Protection Relays, on transformer feeder cables.

h)

Verify complete testing of transformer cables on primary and secondary sides.

i)

Inspect transformer neutral connection.

j)

Verify high potential testing of transformer high voltage winding.


iv)


k)

Measure primary and secondary winding phase-to-phase and phase-to-earth insulation resistance.

l)

Functional test of transformer ancillaries such as oil pump motors, cooling fans and associated controls, temperature warning and tripping system.

m)

Perform functional test of trip signals on transformer primary and secondary side circuit breakers at respective high voltage and low voltage switchgears.

n)

For oil-immersed transformers, perform di-electric oil strength (breakdown) test on sample oil from each unit before energizing.

o)

Energize transformer and note the corresponding secondary voltage at no load based on the tap setting.


Figure 3.6.5-2: 521.3


Transformer schematic

Commissioning Scope of Works Commissioning of the transformers include a load test of the transformer in accordance with the ITRs. Full load test of the transformer may be waived, subject to approval of principal, provided a full load test and temperature rise test had been conducted during factory acceptance tests.



3.6.5.2

520 – DISTRIBUTION

3.6.5.2.2

522– POWER |DISTRIBUTION | HIGH VOLTAGE SWITCHGEAR AND MOTOR CONTROL CENTER

522.1

System Description This covers the high voltage switchgear and high voltage motor control centre up to the outgoing feeders. All incoming cables/busduct to the respective switchgear shall be part of this system. Sub-Subsystem 522 includes High Voltage Switchboard and a Motor Control Center which consist mainly of the main bus-bar, vacuum circuit breakers (VCB) or Gas insulated switchgear - GIS (e.g. SF6 circuit breakers) , distribution feeder, high voltage motor starter feeders, high voltage supply cables, control cables, protection relays, metering, potential and current transformers. A typical single line diagram is shown under Sub-Subsystem 522.

522.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical a)


b)

Inspect Switchgear / Motor Control Center assembly for alignment, levelness and foundation fixing details.

c)

Measure resistance of bolted connections by Ducter test. Retorque and mark bolts as required.

d)

Inspect and test switchboard anti-condensation space heaters.

e)

Calibrate and perform current injection tests of protection relays, voltage and current transformers, metering and circuit breakers as applicable.

f)

Perform high potential testing of all bus-bars and circuit breakers.

g)

Conduct functional test of electrical earthing system.


iv)


h)

Check polarity of direct current supply and energize the control circuit.

i)

Perform functional check of circuit breaker interlocking facilities such as electrical, key and mechanical interlocks i.e., trips or interlocks sent and received.

j)

Check operation of circuit breaker with the breaker In Isolated and In Service position at Local and Remote condition including indications.

k)

Check motor starter feeder and motor contactor control operation.

l)

All the relay settings shall be verified against the relay setting chart and relay calibration sticker shall be placed on all relays at the end of setting and calibration activities.



Figure 3.6.5-3:

High Voltage Switchgear and Motor Control





Piping - None.

ii)

Mechanical - None.

iii)

Electrical a)


b)

Measure resistance of bolted connections by Ducter test. Retorque and mark bolts as required.

c)

Conduct insulation resistance tests.

d)

Perform high potential testing of all bus-bars and circuit breakers.

e)

Check polarity of direct current supply and energize the control circuit.

f)

Energize the switchgear as per energization procedure. Refer 5.2.3 for detailed steps on energizing the switchboard.


523.1


523– POWER | DISTRIBUTION | LOW VOLTAGE SWITCHGEAR AND MOTOR CONTROL CENTER System Description This covers the low voltage switchgear and low voltage motor control centre up to the outgoing feeders. All incoming cables/busduct to the respective switchgear shall be part of this system. Sub-Subsystem 523 includes 415 volts Switchboard / Motor Control Center which consist mainly of a main bus-bar system, 415 volts utilization feeders, 415 volts motor starter feeders, supply cables, control cables, protection relays, metering, potential and current transformers.

523.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)

Similar activities as stipulated under 522.2 iii) items a) to l).

b)

Switchgear and Motor Control Center energization in accordance with Section 5.2.4 of the Precommissioning/commissioning Procedure.

Instrumentation – None.


Figure 3.6.5-4:

Low Voltage Motor Control Center and Switchgear





Electrical Similar activities as stipulated under 522.3 iii) items a) to e). Energize the switchgear as per energization procedure. Refer 5.2.4 for detailed steps on energizing the switchboard.


524.1


524– POWER |DISTRIBUTION | INTEGRATED MOTOR CONTROL SYSTEM (IMCS) System Description This system covers the IMCS panels, workstations, Human Machine Interfaces (HMIs) all interfaces between switchgear/DCS/PMCS/other package equipment and the IMCS including any fibre optic links. Sub-Subsystem 524 includes the intelligent electronic devices (IED) on all the switchgears, interface with third party systems including DCS/PMCS, all communication cabling and interfaces, Human Machine Interfaces (HMI), control/monitoring consoles, sequence of event recorders etc. as shown in the project functional schematic diagram.

524.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)

Perform full function checks of the IMCS to satisfy the design functional specifications as per the commissioning ITRs and in line with manufacturer recommendations. This shall include simulation of all control functions including the signals from DCS/PMCS.

Instrumentation a)


b)

Perform simulated function testing of all interfaces between instrument and IMCS including start/stop controls and redundant communication.



525– POWER |DISTRIBUTION | OVERHEAD LINE/CABLE System Description This system covers the Overhead line / cable for power intake from grid / export to grid. Sub-Subsystem 525 consists of all power transmission systems including transmission lines, transmission towers, lightning arrestors, power transmission cables (both land based and submarine) and associated termination arrangements.

525.2


Piping - None.

ii)

Mechanical - None.

iii)

Civil/Structural a)

iv)

v)

Checks on all foundation and steel structures as per civil/structure testing procedures.

Electrical a)

Conduct line joints integrity tests.

b)

Perform all tests and checks as per pre-commissioning ITRs.




526– POWER |DISTRIBUTION | CAPACITOR/REACTOR System Description This System covers the capacitor banks / Reactors for power quality improvement. Sub-Subsystem 526 consists of all power capacitors and reactors including the power factor correction relays, cabling and interconnecting cabling.

526.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)

Conduct insulation resistance tests.

b)

Perform all other tests and checks as per pre-commissioning ITRs.




3.6.5.3

530 – UNINTERRUPTIBLE POWER SUPPLY

3.6.5.3.1

531 – POWER |UNINTERRUPTIBLE POWER SUPPLY | AC UPS SYSTEM

531.1

System Description The AC UPS System provides a continuous, uninterruptible and clean alternating current (VAC) power supply to the AC UPS distribution board from the battery charger and also when charger is not in use, the distribution board is supplied through the isolation transformer. The purpose of onshore pre-commissioning and commissioning is to confirm that the system can operate to the desired design specification which involve electrical cable/control check and function/run test if required to demonstrate the system operation. The major components are rectifier/Inverter system, battery, battery isolators, distribution boards, cabling.

531.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical a)

iv) 531.3

Refer to Section 3.3.4 - Common Electrical Scope of Works and relevant pre-commissioning ITRs.


Commissioning Scope of Works a)

Refer to Section 3.3.4 - Common Electrical Scope of Works and relevant commissioning ITRs.


Figure 3.6.5-5:

ACUPS with Distribution Board System




532– POWER |UNINTERRUPTIBLE POWER SUPPLY | DC UPS SYSTEM System Description The DC UPS System provides a continuous, uninterruptible and clean direct current (VDC) power supply to the DC UPS Distribution Board. The DC UPS System consists of two (2) charges which are independent of each other that supply to a common distribution board. Since the two (2) charges/batteries are independent of each other, they are linked via the distribution board to the other. When normal mode, both charges will maintain the battery charge at float mode and will supply the distribution board. When at AC supply fail mode, if only one (1) charger fails, the other charger will continue to feed the load, but if both charger supplies fail, both chargers are stopped and the batteries will take over and feed the load. The purpose of onshore pre-commissioning and commissioning is to confirm that the system can operate to the desired design specification which involve electrical cable/control check and function/run test if required to demonstrate the system operation. The major components include chargers, battery, battery isolators, distribution boards, cabling.

532.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical a)

iv) 532.3

Refer to Section 3.3.4 - Common Electrical Scope of Worksand relevant pre-commissioning ITRs.

Instrument – None.




533.1


533– POWER |UNINTERRUPTIBLE POWER SUPPLY | ELECTRICAL POWER UNIT (EPU) System Description The Electrical Power Unit provides a continuous, uninterruptible and clean power supply to the various instrument loads for subsea control system. The EPU is a fully self-contained unit complete with the UPS, Battery, chargers, interconnecting cables etc. The purpose of onshore pre-commissioning and commissioning is to confirm that the system can operate to the desired design specification which involve electrical cable/control check and function/run test if required to demonstrate the system operation. The major components include EPU and associated cabling.

533.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical a)

iv) 533.3







3.6.5.4

540 – SMALL POWER AND LIGHTING

3.6.5.4.1

541 – POWER |SMALL POWER AND LIGHTING | EMERGENCY DISTRIBUTION BOARD

541.1

System Description The emergency small power and lighting distribution system consists of the emergency distribution boards for both small power and lighting, cabling from emergency MCC to emergency distribution boards and the outgoing circuits of the distribution boards. The major components include distribution boards and cables.

541.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical a)

iv) 541.3

Refer to Section 3.3.4 - Common Electrical Scope of Worksand relevant pre-commissioning ITRs.


Commissioning Scope of Works Refer to Section 3.3.4 - Common Electrical Scope of Works and relevant commissioning ITRs.


542.1


542– POWER |SMALL POWER AND LIGHTING | NORMAL DISTRIBUTION BOARD System Description The normal small power and lighting distribution system consists of the normal distribution boards for both small power and lighting, cabling from normal MCC to the normal distribution boards and the outgoing circuits of the distribution boards. The major components include distribution boards and cables.

542.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical a)

iv) 542.3






543 – POWER |SMALL POWER AND LIGHTING | NAVIGATIONAL AIDS System Description Sub-Subsystem 533 provides 24 volts of direct current (DC) power supply to navigational aids lanterns. The major components of the system are battery charger, battery bank, DC distribution board and power distribution cables. The battery charger derives its alternating current (AC) power from Low Voltage Motor Control Center and Switchgear. This includes navigational aids, batteries, solar panels and junction boxes.

543.2

Pre-commissioning Scope of Works Activities are similar to the listing under Sub-Subsystem 531.

543.3


Verify that all pre-commissioning activities are complete and signed off prior to starting any work.

b)

Perform the test per vendor’s procedure.

c)


Figure 3.6.5-6:

Navigational Aid



3.6.5.5

550 – EARTHING & LIGHTNING PROTECTION

3.6.5.5.1

551 –POWER | EARTHING & LIGHTNING PROTECTION | EARTHING

551.1

System Description This system covers the overall earthing of the plant/platform. However, individual equipment earthing shall be part of the respectieve equipment. Only the main earth grid and connections to the platform are considered as part of this system. Alternating current (AC) system neutrals for power generation and distribution systems (namely High Voltage and Low Voltage generators, transformers, reactors, switchboards, motors and Uninterruptible Power Supply unit) are connected to one common earth grid up to the jacket leg or as per design requirements. Equipments are bonded to the platform structure. Screens of signal cables which are connected to instrument earth and intrinsically safe earth maybe looped together to a common or separate earth grid and connected to the jacket leg or as per design requirements. Lightning conductor system complete with air termination are interconnected together to have a separate grid extending up to the jacket leg. Sub-Subsystem 551 consists of Earth Electrodes, earthing ring and branch conductors, earthing bar, earthing resistors, earthing boss, cable wire armour bonding and junction boxes. Steelworks of the structural legs which are buried into the seabed are considered to be the Earth Electrode for offshore platforms.

551.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical a)

Refer to section 3.3.4 - Common Electrical Scope of Works.

b)

Inspect and check earth cable lugs, earth boss stud diameter and welding, and earth resistor connections. Ensure that earthing layout and connections conform to the design.

c)

Inspect that all contacts are cleaned greased and bonded with denso tape where applicable.

d)

Check tightness of all earth connection.


iv) 543.3


e)

Check earth cable protection such as kick plate or kick pipes.

f)

Check that earth cable sizes are correct.

g)

Continuity and resistance checks on bonding of cable wire armour/braid, brass cable glands and equipment frame to earth, main earth resistance and earth loop resistance.

h)

Perform check, inspection and tests on Neutral Earthing Resistor such as measuring ohmic value, insulation resistance test and di-electric test.




552.1


552– POWER | EARTHING & LIGHTNING PROTECTION | LIGHTNING PROTECTION System Description This system consists of lightning protection system and bonding.Steelworks of the structural legs which are buried into the seabed are considered to be the Earth Electrode for offshore platforms. Sub-Subsystem 552 consists of Earth Electrodes and earthing ring. Lightning conductor system complete with air termination (where applicable) are interconnected together to have a separate grid.

552.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)

Ensure that lightning protection layout and connections conform to the design drawings.

c)

Inspect that all contacts are cleaned greased and bonded with denso tape where applicable. Check tightness of all earth connection).

d)

Check earth cable/down conductor protection such as kick plate or kick pipes.

e)


g)

Perform the lightning protection grid resistance when disconnected from the main plant earth grid (in case of onshore facilities).




3.6.5.6

560 – DRIVES AND CONTROLLERS

3.6.5.6.1

561 –POWER | DRIVES AND CONTROLLERS | VARIABLE SPEED DRIVE (VSD)

561.1

System Description This system covers the electrical system from incoming cable to the VSD upto the outgoing cable to the respective motor. Sub-Subsystem 561 includes the variable speed drive system for motor control consisting input/output transformers, variable speed drives, harmonic filters, Human Machine Interfaces (HMI) and all interconnecting power and control/communication cables.

561.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

561.3

a)


b)

Perform full function checks of the VSD to satisfy the design functional specifications as per the commissioning ITRs and in line with manufacturer recommendations. This shall include simulation of all control functions including the reference signals from DCS/PMCS and setting of parameters.

Instrumentation a)


b)

Perform simulated function testing of all interfaces between instrument and VSD including start/stop controls and speed set points.


Refer to Section 3.3.4 - Common Electrical Scope of Works and relevant commissioning ITRs. Commissioning of the VSD system shall be performed together with the commissioning of the related motor (i.e. during the mechanical test run of the corresponding driven machine).


Figure 3.6.5-7:

Variable Speed Drive




562– POWER | DRIVES AND CONTROLLERS | HEATER CONTROL SYSTEM System Description This system covers the electrical system from incoming cable to the heater control panel upto the outgoing cable to the electric heater. Sub-Subsystem 562 includes the thyristor based control system for heater control consisting input/output transformers, thyristor controllers, contactor controllers, harmonic filters, Human Machine Interfaces (HMI) and all interconnecting power and control/communication cables.

562.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

562.3

a)


b)

Perform full function checks of the heater control panel to satisfy the design functional specifications as per the commissioning ITRs and in line with manufacturer recommendations. This shall include simulation of all control functions including the temperature reference signals from DCS/PMCS and setting of parameters.

Instrumentation – a)


b)

Perform simulated function testing of all interfaces between instrument and the heater controller including start/stop controls and temperature set points.


Refer to Section 3.3.4 - Common Electrical Scope of Works and relevant commissioning ITRs. Commissioning of the heater control panel shall be performed together with the commissioning of the related electric heater when the medium is available.


570 – CONSUMERS

3.6.5.7.1

571– POWER |CONSUMERS| ELECTRIC HEATERS

571.1


System Description This covers the electric heater, RCU/Safety switch and the cables from MCC to Heater Panel/respective equipment/component of this system. The major components include electric heater, RCU, Safety switch, Power and control cables from heater panel upto the heater/RCU/Safety switch/Thermistor etc.

571.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv) 571.3

a)


b)

All tests and checks as required in relevant ITRs shall be performed.

Instrumentation – None


Refer to Section 3.3.4 - Common Electrical Scope of Works and relevant commissioning ITRs. Commissioning of the motors is to be performed together with the commissioning of the related driven machine (i.e. during the mechanical test run of the corresponding driven machine).



572– POWER |CONSUMERS | HEAT TRACING SYSTEM System Description This covers the heat tracing system from the incoming cabling to heat tracing panel upto the tracing tapes. The major components include heat tracing panels, distribution boards, junction boxes, heating tapes and all associated cabling.

572.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv) 572.3

a)


b)







573–POWER |CONSUMERS |AUX DISTRIBUTION System Description This covers the cables from the Auxiliary distribution board to the individual load (MOV/Level Gauge lighting/Auxiliary panels etc). The major components include power and control cables from the aux distribution board upto the respective auxiliary equipment (MOV/Level Gauge lighting/Auxiliary panels etc).

573.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv) 573.3

a)


b)






574.1


574 – POWER |CONSUMERS |IMPRESSED CURRENT CATHODIC PROTECTION (ICCP) SYSTEM System Description This covers the Impressed Current Cathodic Protection (ICCP) system from the incoming cabling to the cathodic protection distribution panel / transformer rectifier unit until the anodes. The major components include cathodicprotection distribution panel, transformer rectifier unit, anode and cathode junction boxes and all associated cabling.

574.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv) 574.3

a)


b)







575– POWER |CONSUMERS| LIGHTING System Description This covers the lighting circuits and fixtures (normal and emergency) from cabling from the DB up to individual lighting fixture. The major components include cabling, junction boxes, lighting fixtures.

575.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv) 575.3

a)


b)







576– POWER |CONSUMERS| SOCKETS System Description This covers the small power/welding socket circuits and sockets (welding/convenient/handlamp socket) from cabling from the DB up to individual socket. The major components include cabling, Junction boxes, socket outlets/plugs.

576.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv) 576.3

a)


b)








600 – CONTROL AND SAFEGUARDING

3.6.6.1

610 – PROCESS CONTROLS

3.6.6.1.1

611 – CONTROL AND SAFEGUARDING | PROCESS CONTROLS |DISTRIBUTED CONTROL SYSTEM

611.1


System Description This system consists of a microprocessor-based Distributed Control System (DCS) which utilizes distributed processors to perform loop and sequence controls, interfacing to input and output (I/O) points from field devices on local and remote location (platforms, sub-station). Also interface with third party systems (Safety Instrumented System, Telecommunication System, Fire and Gas System, etc) and Human Machine Interface. System Cabinets (includes controller, I/O cards, serial cards, communication card etc.), Marshalling Cabinets (includes field termination, barriers, etc.) and Human Machine Interface (HMI).

611.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical a)


b)

Perform energization of PMCS.


611.3


Instrumentation a)


b)

Refer to relevant ITR-B

c)

Verify the battery back-up (if required)

d)

Verify the CPU functionality

e)

Verify the performance of the operator workstation

f)

Verify the functionality of the printer

g)

Verify the overall system network

h)

Verify the interfaces with all third party systems

i)

Verify the configuration logic for the PMCS (based on the process control narrative/P&ID)

j)

Verify the graphic and I/O configuration (based on the P&ID and I/O’s list)

k)

Verify time synchronization between PMCS and associated subsystems based on the PMCS master clock.


i. ii.

Ensure that all pre-commissioning activities are complete and signed off. Refer to relevant ITRs

Note: PMCS vendor representative assistance may be required.


Figure 3.6.6-1:

Typical DCS Network Architecture





612.1


612– CONTROL AND SAFEGUARDING | PROCESS CONTROLS |SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) System Description SCADA system consists of Main Terminal Units (MTU) comprises of servers/HMI and one or more field data interface devices, usually RTU’s or PLC’s, which interface to field sensing devices and valves actuators/final control devices. The major components include Master Terminal Unit (MTU), Remote Terminal Unit (RTU). Communication/networking equipment.

612.2


Piping - None.

ii)

Mechanical - None.

iii)


iv)

Instrumentation a)


b)

Refer to relevant ITR-B.

c)

Verify the functionality of the router and switches.

d)

Verify the battery back-up (if required)

e)

Verify the CPU functionality

f)

Verify the performance of the operator workstation

g)


h)

Verify the overall system network

i)

Verify the interfaces with all third party systems

j)

Verify the configuration logic for the SCADA (based on the control narrative/P&ID)



CARIGALI STANDARD PROCEDURE k)

612.3

Verify the graphic and I/O configuration (based on the P&ID and I/O’s list)


Ensure that all pre-commissioning activities are complete and signed off.

ii) Refer to relevant ITRs Note: SCADA vendor representative assistance may be required.

PSTN ISDN WAN

Field I/O

RTU20

ModBus Remote Data Concentrator DNP 3.0

RTU20

RTU20

RTU20

ModBus

FoxScada P6008

RTU20

SCADA Master Station

MTU/SCD

PLC ModBus

RTU20 ModBus

Flow Computer

Field I/O IED

Intelligent Instrumentation

Figure 3.6.6-2:

PLC Network

ModBus

DNP 3.0

RTU20 ModBus

PLC

Typical SCADA Schematic




613.1


613– CONTROL AND SAFEGUARDING | PROCESS CONTROLS |INFORMATION MANAGEMENT SYSTEM (IMS) System Description IMS covers all the systems that acquire data from all facets of a business and subsequent transformation of that data into easily usable, high value and widely distributed information for the management. The major components include communication server, networking equipment, IMS software package (PMS-Plant Management System, Historian Data server, CBMS-Condition Base Monitoring System software, Object Linking & Embedding (OLE) Process Control (OPC) server, Sequence of Events Recorder-SER) etc.

613.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

613.3

a)


b)

Perform energization of OPC server.

Instrumentation a)


b)

Refer to relevant ITR-B (according to vendor document)

c)

Check the connectivity with the control system (e.g. PMCS, SIS)

d)

Test the overall system network

e)

Check the functionality of IMS workstation inclusive Sequence of Event Register (SER) and Condition Based Monitoring System (CBMS)

f)

Verify the software configuration for the IMS




i)


ii)

Refer to relevant ITRs

Note: IMS vendor representative assistance may be required.




ASSET MANAGEMENT CLIENT

World Wide Web

Business VALVE LEAK MONITOR / PST DIAGNOSTICS

ALARM MANAGEMENT

PST DIAGNOSTICS

WEB SERVER

Services

AMS DEVICE MANAGER

PMCS

OPC SERVER / HISTORIAN

Control Network

Sub-system

PMCS CONTROLLER

SIS

HART

FF

Figure 3.6.6-3:

Typical IMS Schematic

FGS


614.1


614– CONTROL AND SAFEGUARDING | PROCESS CONTROLS |SUBSEA CONTROL System Description The topside part of the subsea production control system provides the following functions i)

Providing electrical power and communications to the control modules subsea

ii)

Supply hydraulic power (pressure) to subsea for actuating valves.

iii)

Monitoring and controlling of the above topside SPCS equipment

iv)

In some cases control of chemical injection skid.

The topside equipment includes electrical power and communications equipment, hydraulic power equipment and, in some cases, chemical injection equipment. (Chemical injection facilities normally come under topside supplied process equipment, but in some projects the CIU may come under subsea scope of supply). In addition to the equipment items, there are also some critical interfaces to the host facility and also support systems that need to be provided by the host facility (e.g. MCC, UPS etc). The major equipment are Master Control Station (MCS), Electrical Power Unit (EPU), Hydraulic Power Unit (HPU), Topside Umbilical Termination Assembly (TUTA),Chemical Injection Unit (CIU) *CIU may be supplied by others, interconnecting cables and tubing, interface to PMCS (PMCS supplied by others), interface to SIS (SIS supplied by others), interface to UPS (UPS supplied by others), interface to MCC (MCC supplied by others). 614.2

Pre-commissioning Scope of Works Include all of the topside SPCS items of equipment, electrical and hydraulic interconnections as far as the TUTA and interconnections to the host facility. i)

Piping and Tubing a)

Flushing of interconnecting tubing and piping

b)

Pressure testing of interconnecting tubing and piping

c)

Point to point checks

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE ii)

iii)

iv)

614.3


Mechanical a)

Filling of HPU and CIU reservoirs.

b)

Pre-charging and charging of accumulators

c)

Visual and functional checks of SPCS topside equipment

Electrical a)

Continuity checks of interconnecting cables

b)

Insulation resistance checks of interconnecting cables

c)

Communication checks between topside SPCS equipment packages

d)

Communication checks between SPCS equipment and host facility (e.g. PMCS/DCS/SIS)

e)

Communication checks - subsea simulation

f)

UPS checks

g)

MCC tests

Instrumentation a)

Functional checks of SPCS equipment

b)

Shutdown simulation/test

Commissioning Scope of Works Provided the above pre-commissioning work has been successfully completed, then little further topside work should be required during commissioning phase, apart from possible displacement of test fluids (e.g. potable water, hydraulic fluid) with production fluids (Methanol, corrosion inhibitor etc.) and perform actual subsea communications and shutdown testing instead of simulation. i)

Piping and tubing Displacement of test fluids (as required)

ii)

Mechanical a)

Re-filling of HPU reservoir (as required)

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE b)

Re-filling of CIU reservoir (as required)

iii)

Electrical None

iv)

Instrumentation None



HPU

CHEMICAL INJECTION SKID

SIS

MCS

PMCS

EPU

UPS

Figure 3.6.6-4:

Electrical Diagram for Subsea Control



HPU

SIS

MCS


PMCS

Chemical Injection Unit

EPU

UPS

TUTA

Figure 3.6.6-5:


Hydraulic and Chemical Diagram for Subsea Control



3.6.6.2

620 – SAFEGUARDING SYSTEM

3.6.6.2.1

621 – CONTROL AND SAFEGUARDING | SAFEGUARDING SYSTEM |SAFETY INSTRUMENTED SYSTEM (SIS)

621.1

System Description Safety Instrumented System (SIS) provides the emergency shutdown function for the entire facility. It continuously monitors the process variables and automatically initiates shutdown and blowdown if any of the variables is outside the predetermined safe limit. However, it is not intended for process control purposes. This Sub-Subsystem component includes Logic solver (CPU), I/Os card, initiating elements and final control elements, System Cabinets (includes Power supply units, serial cards, communication card etc), Marshalling Cabinets (includes field termination, barriers, etc), Printers, SER, pushbutton, MOS (Maintenance Override Switch), IRP (Interposing Relay Panel), Networking devices. etc.

621.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)

Perform energization of panel.

c)

Verify complete power distribution upon energization of panel.

Instrumentation a)


b)


c)

Verify power supply modules, main processors, communication modules, I/O modules, chassis, and field wiring connections are functioning properly.


621.3


d)

Verify the system’s latest revision of shutdown logic software is downloaded.

e)

Perform system interface check with PMCS, Fire and Gas (FGS), Public Address and General Alarm (PAGA).

f)

Verify start-up bypass, maintenance override, alarm and shutdown acknowledge and reset features are functioning correctly.

g)

Perform loop check between system and hardware console

h)

Verify the trip set points for all initiators as per approved and latest alarm/trip settings documents

i)

Perform complete shutdown logic test as per approved and latest Cause and Effect Matrix chart.

j)

Perform complete system integrity test e.g. fault tolerance and redundancy, power failure, fault diagnostics, alarm and shutdown logs, etc.

k)

Verify functionality of Sequence of Events (SOE) (if applicable)

l)




ii)


Note:

Vendor representative assistance may be required.



CARIGALI STANDARD PROCEDURE Logic Solver

DO

AI

24 VDC 4- 20 mA

Solenoid Valve Pressure Transmitter Process Line SDV

Figure 3.6.6-6:

Typical SIS Schematic


622.1


622– CONTROL AND SAFEGUARDING | SAFEGUARDING SYSTEM |FIRE AND GAS SYSTEM (FGS) System Description The system consist of Fire and Gas panel monitoring all fire detection devices and controls the automatic release of fixed fire extinguishing mediums (CO2, FM200, chemical powder, firewater, foams, etc.) on the facilities and interface with other sub-systems for shutdown and alarms. This sub-sub-system is also interfaced to third party systems such as PMCS and SIS. The Fire and Gas System (FGS) may be conventional or addressable system. The major components include gas/smoke/thermal/flame/heat detectors, fusible plug, fire & gas panel, purge panel for CO2 discharge system, deluge, firewater monitor, associated control panels, warning lights, junction boxes, break glass stations, manual stations, fire dampers, instrumentation, audible/visible alarms.

622.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)

Perform energization in the sequence specified by the vendors operating manual.

Instrumentation a)


b)


c)

Verify field detectors are installed in locations as per approved layout drawings.

d)

Verify the detectors are pointing towards the desired area of coverage as per design documents.


622.3


e)

Perform fire and gas detection device loop check. In case of addressable system, check that the device addresses and configurations are carried out as per design drawings.

f)

Perform simulation of all system inputs.

g)


h)


i)

Perform system interface check with PMCS, SIS and Address and General Alarm (PAGA).

j)

Verify maintenance override, alarm and shutdown acknowledge and reset features are functioning correctly.

k)

Verify the trip set points for all initiators as per approved and latest alarm/trip settings documents.

l)

Perform complete shutdown logic test as per approved and latest Fire and Gas Cause and Effect Matrix chart.

m)


Public



ii)




Serial Link to Other System Hardwired to Other System

FD

GD

FGS

CP

SD Tx

Rx 100% LFL Cloud

Process line

Control Valve

Figure 3.6.6-7:

Fire and Gas System



623.1


623– CONTROL AND SAFEGUARDING | SAFEGUARDING SYSTEM |FUSIBLE PLUG LOOPS System Description Fusible plug loops is used for monitoring fire in strategic locations throughout the facility by means of pressurized system in a closed loop and the fusible plug melts when the temperature exceeds the melting point. Fusible plug loops are normally hook-up to the FGS or deluge valve panel (pneumatic system) which as an input for fire detection. Deluge valve panel senses the release of fusible plug loop pressure by means of change pressure switch low and send it as an input signal to Fire and Gas Panel which sends output to de-energize deluge valve solenoid to open the deluge valve and discharge water to the sprinkler system. Deluge valve panel in turn will send feedback signal to Fire and Gas Panel when deluge is activated. Electronic transmitter also may be provided in some installations to monitor charge pressure and connected to FGS for operation of fire water pump and deluge system. The major components include initiating elements(Fusible plugs) and final control elements, complete with associated cabling, tubing and junction boxes, Fusible loop charge panel , kill knobs and other pneumatic sensors, interface with the Shutdown System / Safety Instrumented System.

623.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical – None

iv)

Instrumentation a)


b)


c)

Perform physical check on the fusible plug loop panel and verify the tubing/fitting and others part of installation as per drawing.


623.3


d)

Verify quantity and temperature ratings of fusible plugs on each loop as per drawings and specifications.

e)

Verify installation of kill knob stations as per drawings and specifications.

f)

Pressurize the system and monitor pressure indication.

g)

Perform tubing leak test for the fusible plug loop including the panel.

h)

Perform loop check for pressure switch or pressure transmitter.

i)

Simulate all system inputs such as release of each fusible plug loop and verify that the corresponding output is in accordance with approved and latest FGS Cause and Effect Matrix.



ii)


FPL PANEL

REGULATOR

PNEUMATIC RELAY RESTRICTION ORIFICE S-1

I.A.S

Fusible Plug Loop (FPL)

CHARGE VALVE

Figure 3.6.6-8:

Typical Fusible Plug Loop Schematic


624.1


624– CONTROL AND SAFEGUARDING | SAFEGUARDING SYSTEM |HIGH INTEGRITY PRESSURE PROTECTION SYSTEM (HIPPS) System Description The HIPPS valve may be provided with Partial Stroke Test devices.HIPPS systems are applied to prevent over-pressurization of a plant/ Pipe line system by shutting-off the source of the high pressure and isolation/protection of other parts. It has a complete functional loop consisting of the sensors, logic solver and final elements. The major components include Logic solver, initiating elements and final control elements, complete with associated cabling, tubing and junction boxes.

624.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)

Perform energization in the sequence specified by the vendors operating manual.

Instrumentation a)


b)


c)


d)


e)

Perform system interface check with PMCS and SIS.

f)

Verify alarm and shutdown acknowledge and reset features are functioning correctly.


624.3


g)

Verify the trip set points for all initiators as per approved and latest alarm/trip settings documents.

h)

Perform complete shutdown logic test as per approved and latest Cause and Effect Matrix chart.

i)


j)

Perform loop check for all initiators and elements which are connected to HIPPS.

k)

Verify the Sequence of Event (SOE) function.



ii)



Note: The diagram is for typical schematic only. HIPPS may be different from project to project. Figure 3.6.6-9:

Typical HIPPS Schematic


625.1


625– CONTROL AND SAFEGUARDING | SAFEGUARDING SYSTEM |WELLHEAD CONTROL PANEL (WHCP) System Description The systemconsists of a Wellhead Control Panel to provide controls and status indication of individual wellhead Surface controlled Sub-Surface Safety Valve (SCSSV), Wing Valve (WV) and Surface Safety Valve (SSV). The major components include logic devices, initiating elements and final control elements, complete with associated instrumentation, cable, tubing, junction boxes, pumps, hydraulic reservoir and etc.

625.2

625.3


Piping - None.

ii)

Mechanical - None.

iii)


iv)

Instrumentation a)


b)


c)

Pre-charge the accumulator and check any leakage.

d)

Perform leak test of the WHCP instrument and tubing assembly

e)

Perform wellhead valves (WV/SSV/SCSSV) operation from the WHCP, verify the opening/closing sequence and record the closing time for the WV/SSV.

f)

Perform wellhead valves (WV/SSV/SCSSV) operation from the DCS (if applicable)

g)

Perform simulation test of Unit Shutdown (USD), Process Shutdown (PSD) and Emergency Shutdown (ESD)





ii) Refer to relevant ITRs Note: Wellhead Control Panel vendor representative assistance may be required.



CARIGALI STANDARD PROCEDURE HS CLOSE

HS OPEN

WHCP FUNCTION LOGIC IN SIS

HS

SCSSV

SSV

WV

WV

SSV

SCSSV

OPEN

HS CLOSE

WV USD SSV

PSD SCSSV ESD

Figure 3.6.6-10:

Typical WHCP Schematic


626.1

626– CONTROL AND SAFEGUARDING | |INSTRUMENT CONTROL PANEL

PROCEDURE NO: CSP-20 REVISION : 01 PAGE : 254 SAFEGUARDING

SYSTEM

System Description This systemprovides pneumatic or Electronic for control and safeguarding system to control and protect the production facilities from process abnormalities and provide shutdown functions and status indication, including the interface with Fire & Gas and Emergency Shutdown System. The major components include pneumatic or electronic panel containing functional logics connected to initiators and final control elements, complete with necessary instrumentation, cable, tubing, junction boxes, and etc.

626.2

626.3


Piping - None.

ii)

Mechanical - None.

iii)


iv)

Instrumentation a)


b)


c)

Perform shutdown matrix functions of the panel covering the initiators and final elements

d)

Perform interface functions of the panel and other system, e.g. WHCP, DCS, SIS, alarm indications and etc.



ii) Refer to relevant ITRs



CARIGALI STANDARD PROCEDURE Note:

Instrument Control Panel vendor representative assistance may be required.

WHCP

PSLL

HS

PSHH

ICP

PALL

PAHH

LALL

ESD

PSD

USD

LAHH

SDV

LSLL

LSHH BDV

ESD FUSIBLE PLUGS

FPP

Figure 3.6.6-11:

Typical ICP Schematic



3.6.7

700 – TELECOMMUNICATION

3.6.7.1

710 – MAIN BACKBONE LINK

3.6.7.1.1

711 – TELECOMMUNICATION | MAIN BACKBONE LINK |DIGITAL MICROWAVE RADIO (DMR) SYSTEM

711.1

System Description It provides point-to-point or point-to-multipoint telecommunication network for data and voice communication between platforms and shores. DMR link requires line-of-sight (LOS) clearance, and pathloss analysis needs to be carried out prior to designing a DMR link. This system consists of (and not limited to) antenna, feeder, radio unit, cabling, junction box, telecom tower (if necessary, based on pathloss analysis, with availability of 99.995%). Interface with other systems such as LAN, PABX, CCTV, DCS, etc. is possible. 711.2 i)

Piping - None.

ii)

Mechanical - None.

iii)

Electrical - None.

iv)

711.3

Pre-commissioning Scope of Works

a)


b)

Perform energization of the equipment.

Instrumentation a)


b)


c)

Verify interface with third party systems.



ii) Perform the test per vendor’s procedure.


712.1


712 – TELECOMMUNICATION | MAIN BACKBONE LINK |VERY SMALL APERTURE TERMINAL (VSAT) SATELITE SYSTEM System Description VSAT uses microwave frequencies and free space propagation to link ground terminals to the satellite, and it requires LOS. We prefer to operate VSAT in C-band, since rain attenuation is significant. VSAT has a limited bandwidth of 2Mbps, and usually being used at a very remote location. This system consists of (and not limited to) antenna (gyro-stabilized antenna for moving FPSO or FSO), RF unit, satellite modem, indoor unit (IDU), outdoor unit (ODU) cabling and junction box. Interface with other systems such as LAN, PABX, CCTV, DCS, etc. is possible.

712.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical a) Refer to Section 3.3.4 – Common Electrical Scope of Works. b) Perform energization of the equipment.

iv)

Instrumentation a) Refer to Section 3.3.5 – Common Instrumentation Scope of Works. b) Refer to relevant ITR-B. c) Verify interface with third party systems.

712.3




3.6.7.1.3

713 – TELECOMMUNICATION | MAIN BACKBONE LINK |FIBRE OPTIC TRANSMISSION SYSTEM



System Description Submarine fibre optic cable (SFOC) is selected to be the main backbone link if a new pipeline or a submarine power cable will be laid. SFOC provides very high bandwidth, and doesn't depend on LOS. Installation and repair cost might be high. This system consists of submarine fibre optic cable, patch panel, optical amplifier and repeater (if needed, for long distance link). Interface with other systems such as LAN, PABX, CCTV, DCS, etc. is possible.

713.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

713.3

a)

Refer to Section 3.3.4 – Common Electrical Scope of Works.

b)


Instrumentation a)

Refer to Section 3.3.5 – Common Instrumentation Scope of Works.

b)


c)

Verify interface with third party system.






714 – TELECOMMUNICATION | MAIN BACKBONE LINK |UHF RADIO LINK System Description The UHF Radio Link provides telecommunication networks between platform and shore bases (for relatively short distance). It is usually being used for low capacity data transmission. This system consists of antenna, radio unit, cablingand junction box. Interface with other systems such as PABX, LAN, DCS, etc. is possible.

714.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

714.3

a)


b)


Instrumentation a)


b)


d)






715.1


715 – TELECOMMUNICATION | MAIN BACKBONE LINK |TROPOSCATTER RADIO SYSTEM System Description Troposcatter can bridge up to 400km without a repeater by illuminating a volume of the troposphere, using high-power transmitters and large antennas. Troposcatter is economical for systems up to 8Mbps and bridging up to 250km, where it is impossible or expensive to provide repeaters and there is no requirement for communication at intermediate points. This system consists of (and not limited to) antenna, RF unit, modem, amplifier, IDU, ODU, cabling and junction box. Interface with other systems such as PABX, LAN, CCTV, DCS, etc. is possible.

715.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

715.3

a)


b)


Instrumentation a)


b)


d)






720 – RADIO COMMUNICATIONS SYSTEM

3.6.7.2.1

721 – TELECOMMUNICATION | RADIO SYSTEM|VHF/FM (Marine Communication)

721.1


COMMUNICATIONS

System Description A multi-channel VHF marine band radiotelephone shall be provided for routine communications with nearby shipping and other installations, and for emergency voice communication on the marine dustress frequency of 156.8 MHz (channel 16). The control unit should be located in the radio room and/or control room so that it's always monitored, and handheld units are dedicated for key personnel. This system consists of antenna, base station, handheld unit, cabling and junction box. Digital selective calling (DSC) is required to comply with SOLAS requirement.

721.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

721.3

a)


b)


Instrumentation a)


b)






722.1


722 – TELECOMMUNICATION | RADIO COMMUNICATIONS SYSTEM | VHF/AM (Avionics Communication) System Description VHF-AM is used to assist chopper operation, and shall be provided for routine and emergency communications. VHF AM base station should be located in the radio room and/or control room, and handheld unit is dedicated for helicopter chopper landing (HLO). This system consists of antenna, base station, handheld unit, cabling and junction box.

722.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

722.3

a)


b)


Instrumentation a)


b)






723.1


723 – TELECOMMUNICATION | RADIO COMMUNICATIONS SYSTEM | HF/SSB Radio System System Description HF/SSB provides long range communication between the platform and nearby ships/vessels or onshore base. It also serves as emergency. The system components include the base station, antenna, antenna tuning unit, associated cabling and junction boxes. This system consists of antenna, antenna tuning unit (ATU), base station, cabling and junction box.

723.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

723.3

a)


b)


Instrumentation a)


b)

Refer torelevant ITR-B





724.1


724 – TELECOMMUNICATION | RADIO COMMUNICATIONS SYSTEM | NONDIRECTIONAL BEACON (NDB) SYSTEM System Description NDB should be provided on one or more platforms in a field, where scheduled helicopter operation is present. NDB is used to assist chopper landing by sending Morse code signal to chopper. This system consists of antenna (for offshore platforms, preferably to use long wire antenna), antenna tuning unit (ATU), base station and cabling.

724.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

724.3

a)


b)


Instrumentation a)


b)






725.1


725 – TELECOMMUNICATION | RADIO COMMUNICATIONS SYSTEM | DIGITAL TRUNK RADIO System Description Digital trunk radio system (DTRS) is normally used for onshore terminal. It provides the necessary flexibility and a framework for growth. It shall have a minimum of one base station transceivers (BTS) to cover a single site. This system consists of antenna, BTS, handheld units, radio operator console and cabling. Interface with PABX and PAGA is possible.

725.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

725.3

a)


b)


Instrumentation a)


b)


c)






726.1


726 – TELECOMMUNICATION | RADIO COMMUNICATIONS SYSTEM | WIRELESS SYSTEM System Description Inclusive where applicable of RFID, Wi Max, GSM/UTMS & CDMA

726.2

Pre-Commissioning Scope of Work Refer to Section 3.3.5 – Common Instrumentation Scope of Works. Note: Vendor representative assistance may be required.

726.3






3.6.7.3

730 – VOICE AND DATA COMMUNICATION

3.6.7.3.1

731 – TELECOMMUNICATION | VOICE AND DATA COMMUNICATION | PABX AND TELEPHONE SYSTEM (ANALOG & DIGITAL)

731.1

System Description PABX system is the primary voice communication network on the platform or at onshore terminal/office. It supports indoor (IP & digital) and outdoor telephone sets. PABX features are voice paging, telephone service, data and fax communication. This system consists of indoor and/or outdoor telephone sets, distribution frame and boards, hotline, private access branch exchange. Integration with other systems such as LAN and PAGA is possible.

731.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)


Instrumentation a)


b)


d)


Note: Vendor representative assistance may be required. 731.3

Commissioning Scope of Works iii) Verify that all pre-commissioning activities are complete and signed off prior to starting any work. iv) Perform the test per vendor’s procedure.


732.1


732 – TELECOMMUNICATION | VOICE AND DATA COMMUNICATION | LOCAL AREA NETWORK (LAN)/WIDE AREA NETWORK (WAN) System Description LAN/WAN system provides data communication for connection between platform to onshore gas terminal/office and also to outside network. WAN has similar functions as LAN except WAN covers broad area (normally connect two or more LAN by means of router). This system requires integrated service router (ISR), switch, servers, UPS, PCs, CPUs and cabling. Interface with other systems for monitoring purpose is possible.

732.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)


Instrumentation a)


b)


d)







733.1


733 – TELECOMMUNICATION | VOICE AND DATA COMMUNICATION | NETWORK MANAGEMENT SYSTEM (NMS) System Description NMS and engineering service features shall be provided for local monitoring functionalities on the central site. NMS shall incorporate at a minimum capability to perform system configuration, maintenance and administration, and performance monitoring. The features shall not be limited to the following: 

system link monitoring



alarm monitoring



configuration



troubleshooting and fault finding

This system requires server, PCs, CPUs, and cabling. Interface with other systems such as LAN, PABX and main backbone link is possible.


734.1


734 – TELECOMMUNICATION | VOICE AND DATA COMMUNICATION | MOBILE BROADBAND System Description Mobile broadband is wireless internet access through a portable modem, mobile phone, USB wireless modem, or other mobile devices. Bit rates of broadband support voice and video as well as other data access. This system requires PCs or laptops, USB stick (dongles) and USB modems.

734.2

Pre-Commissioning Scope of Work i)


ii) Refer to relevant ITR-B. iii) Verify interface with third party systems. Note: Vendor representative assistance may be required. 734.3






3.6.7.4

740 – SURVEILLANCE AND SAFETY SYSTEM

3.6.7.4.1

741 – TELECOMMUNICATION | SURVEILLANCE AND SAFETY SYSTEM | PABX AND TELEPHONE SYSTEM (ANALOG & DIGITAL)

741.1

System Description Offshore platforms which have LQ shall be provided with PAGA system. It is used for paging and general announcements (including azan). It should be entirely solid state and have facilities to centrally monitor the operational status of the component parts and to generate an alarm on detection of any failure. For noisy area, beacons shall be installed to assist on any alarm announcement. This system consists of PA console, distribution panels and boards, loudspeakers, beacon, (if necessary based on noise mapping), access panel, amplifiers, cabling and junction boxes. Interface with other systems such as PABX, CCTV, DCSis possible via its master control unit.

741.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)


Instrumentation a)


b)


c)









742.1


742 – TELECOMMUNICATION | SURVEILLANCE AND SAFETY SYSTEM |CCTV AND INTRUSION SYSTEM System Description The CCTV System operates as surveillance system at platform and onshore terminal, and shall be designed for continuous duty. A pan, tilt, zoom (PTZ) camera is preferred to cover almost 360° coverage. The monitoring station should be located at the control room. This system comprise of CCTV camera, IR detector, (if necessary), monitoring station, transmission cable (FO), cabinet, video amplifier, control panel and CPU.

742.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)


Instrumentation a)


b)


c)







743.1


743 – TELECOMMUNICATION | SURVEILLANCE AND SAFETY SYSTEM | METEOROGICAL SYSTEM System Description Also known as weather monitoring system (WMS), it provides the local weather and sea conditions for navigational aid. The monitoring station should be located at the control room. This system consists of meteorological system (wind speed, wind direction, rainfall, air pressure, temperature, relative humidity sensors) and hydrological system (tidal wave monitoring, where it measures current conditions at a medium range).

743.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)


Instrumentation a)


b)








3.6.7.5

750 – COMMUNICATIONS EQUIPMENT

3.6.7.5.1

751 – TELECOMMUNICATION | COMMUNICATIONS EQUIPMENT | ENTERTAINMENT SYSTEMS

751.1

System Description Entertainment systems on manned platforms should consist of an entertainment package feeding a distribution network. The possible entertainment sources are satellite television receiver, broadcast radio receiver and DVD players. This system consists of televison, decoder, central equipment racks, DVD player, satellite TV receivers, projector and bedhead entertainment units.

751.2


Piping - None.

ii)

Mechanical - None.

iii)

Electrical

iv)

a)


b)


Instrumentation a)


b)


c)








3.6.8

800 – MISCELLANEOUS

3.6.8.1

810 – MATERIAL HANDLING

3.6.8.1.1

811 – MISCELLANEOUS | MATERIAL HANDLING | PEDESTAL CRANE

811.1

System Description Pedestal crane is available on most manned facilities as it provides the main capability for lifting and transfer of personnel. Supported on a vertical column, the crane comes in a variety of capacities and sizes depending upon the lifting requirements on the facility. The main structures are the boom, the A-frame and prime mover console. The crane rotates on the vertical column with the assistance of a slew bearing which also bears most of the load during lifting. Prime mover for a crane generally comes in the form of an electric motor or an internal combustion engine. "Power takeoff" or transmission system between prime mover and hoist mechanism and for the controls are either a mechanical drive unit such as a gear or a hydraulic drive unit complete with a hydraulic pump and motor. Other equipment includes wire ropes/cables, storage drums, sheaves, pilot valves, pressure relief valves, brake subsystem, limit switches, a fuel storage tank, anti-two-block valve and associated piping and instrumentation.

811.2



ii)

Mechanical a)


b)

Verify all motors, slew bearing, sheaves and drum bearings are lubricated sufficiently with grease.

c)

Perform no-load test of the motor-driven hydraulic pump.

d)

Perform running test of internal combustion engine for a minimum of four (4) hours without stopping.

e)

Perform no-load test of the crane i.e. only slewing and luffing.

f)

Perform static load test up to 125 percent of the rated capacity.




811.3


g)

Perform dynamic load test up to 100 percent of the rated capacity.

h)

Perform function test of the anti-two-block valve.

i)

Verify installation of wire ropes is performed correctly as per vendor recommendation.

j)

Perform vessel/tank interior inspection for internal coating damage and cleanliness.Issue the final closure certificate.

k)

Verify that brakes are operating as intended.

iii)


iv)



Piping - None

ii)

Mechanical a)

Check and record motor ampere and temperature

b)

Check and record hydraulic pump pressure

c)

Check and record Internal Combustion Engine critical parameters at different load condition

d)



812.1


812 – MISCELLANEOUS | MATERIAL HANDLING | OVERHEAD/GANTRY CRANE System Description Overhead gantry crane, at times also called "jib" crane, is operated manually or with the assistance of an air-operated or a gas-operated winch. Air or gas to power the winch is tapped from utility air or utility gas system using flexible hose or tubing. Its system consists of equipment like the supporting structure, pneumatic motor and wire rope.

812.2

812.3


Piping - None.

ii)

Mechanical a)


b)

Perform functional test of pneumatic motor.

c)


d)


iii)

Electrical - None.

iv)

Instrumentation Verify that air regulator is set at correct pressure.


Piping - None.

ii)

Mechanical

iii)

a)

Check and record gas or air inlet pressure

b)

Check and record motor ampere and current (if

c)


Electrical - None.

applicable)


Instrumentation a)

Check and record gas or air regulator pressure



813.1


813 – MISCELLANEOUS | MATERIAL HANDLING | MONORAIL/TROLLEY HOIST System Description Monorail hoist Sub-Subsystem comes in two forms: manual and automated. In manual mode of operation, monorail hoist includes the use of trolleys whereby its travel and lifting capabilities are dependent upon operator’s skill and power. In automated form, hoist travel and lifting capabilities are derived from an electrical motor that powers a winch and the operator could control movement from a remote location. It includes equipment such as trolleys, a motor-driven winch, wire ropes, limit switches, a control pendant and power cables.

813.2


Piping - None.

ii)

Mechanical

iii)

iv)

a)


b)

Verify that no physical damage to the lifting chain.

c)


d)


Electrical a)


b)

Perform stop-start test of the control pendant.

Instrumentation Verify limit switches are functioning correctly.





ii) Perform the test per vendor’s procedure. iii) Refer to relevant ITR-C.





814 – MISCELLANEOUS | MATERIAL HANDLING | ELEVATORS System Description Elevator (lift) is used to move personnel between floors. Some major components of an elevator will be equipped with car module, mast, base frame, drive unit, cable guiding system, landing assemblies with call boxes, mast attachment hardware and some applicable controls. Typical elevators diagram as Figure 3.6.8-1.

814.2

814.3


Piping - None.

ii)

Mechanical a)


b)

Perform drop test as per-manufacturer’s instruction.

c)

Perform brake test (125% load) as per manufacturer’s instruction.

iii)


iv)

Instrumentation





Figure 3.6.8-1:

Typical elevators diagram.



820 – FURNITURE/APPLIANCES

3.6.8.2.1

821 – MISCELLANEOUS ACCOMMODATION SPACES

821.1

|

FURNITURE/APPLIANCES


|

GENERAL

System Description This sub-subsystem relates to various equipment found in living quarters such as kitchen and laundry appliances.

821.2

Pre-commissioning Scope of Works Verify that the System Mechanical Completion of General Accommodation Spaces has been signed and all category A punch list have been closed.



822 – MISCELLANEOUS | FURNITURE/APPLIANCES | GALLEY/MESS HALL System Description It relates to various equipment in living quarters kitchen, laundry appliances and mess hall facilities.

822.2

Pre-commissioning Scope of Works Verify that the System Mechanical Completion of Galley/ Mess Hall has been signed and all category A punch list have been closed.





823 – MISCELLANEOUS | FURNITURE/APPLIANCES | OFFICES System Description This Sub-Subsystem relates to the various office equipment, namely personal computer, walkie-talkie, photocopy machine, fax machine, etc.

823.2

Pre-commissioning Scope of Works Verify that the System Mechanical Completion of Office has been signed and all category A punch list have been closed.



824 – MISCELLANEOUS | FURNITURE/APPLIANCES | COLD ROOM System Description The system generally covers areas such as lobby room, vegetable room, meat room and fish room at the living quarters. This cold room consists of air condenser(s) and cooler(s). Other required components for the system to be in service are refrigerant, switches, valves and also power supply.

824.2


Piping - None.

ii)


iii)


v)




825 – MISCELLANEOUS | FURNITURE/APPLIANCES | COLD ROOM System Description

The system generally covers areas such as lobby room, vegetable room, meat room and fish room at the living quarters

825.2

Pre-Commissioning Scope of Work Verify the System Mechanical Completion for Cold Room has been signed and all category A punch list have been closed.


830 – AVIATION

3.6.8.3.1

831 – MISCELLANEOUS | AVIATION | HELIDECK

831.1


System Description The helideck is a landing area or platform for helicopters. The helideck surface is non-slip, painted and clean. It has perimeter lighting, safety net and fire protection system. Safety notices are visibly in place with refueling system available.

831.2

831.3


Piping - None.

ii)


iii)


iv)







832 – MISCELLANEOUS | AVIATION | AVIATION REFUELING System Description Inclusive where applicable of portable storage tanks, fuel pumps, filter separators, monitors, dispensers and all associated flexible hoses, piping, valves, instrumentation, tubing and cabling.

832.2

Pre-commissioning Scope of Works Verify the System Mechanical Completion for Aviation Refueling has been signed and all category A punch list have been closed.

832.3






3.6.8.4

840 – MARINE AND CORROSION PROTECTION

3.6.8.4.1

841 – MISCELLANEOUS | MARINE AND CORROSION PROTECTION | SACRIFICIAL ANODE CATHODIC PROTECTION

841.1

System Description Sacrificial Anodes are highly active metals that are used to prevent a less active material surface from corroding. Sacrificial Anodes are created from a metal alloy with a more negative electrochemical potential than the other metal it will be used to protect. The sacrificial anode will be consumed in place of the metal it is protecting, which is why it is referred to as a "sacrificial" anode. When metal surfaces come into contact with electrolytes, they undergo an electrochemical reaction known as corrosion. Corrosion is the process of returning a metal to its natural state as an ore and in this process, causing the metal to disintegrate and its structure to grow weak. These metal surfaces are used all around us -- from pipelines to buildings to ships. It is important to ensure that these metals last as long as they can and thus necessitates what is known as cathode protection. Sacrificial anodes are among several forms of cathode protection. Other forms of cathode protection are plating, galvanization, and the formation of alloys. Metal in seawater is one such example with the iron metal coming into contact with electrolytes. Under normal circumstances, the iron metal would react with the electrolytes and begin to corrode, growing weaker in structure and disintegrating. The addition of zinc, a sacrificial anode, would prevent the iron metal from "corroding". According to the table of Standard Reduction Potentials, the standard reduction potential of zinc is about -0.76 volts. The standard reduction potential of iron is about -0.44 volts. This difference in reduction potential means that Zinc would oxidize much faster than iron would. In fact, zinc would oxidize completely before iron would begin to react. Note: Ensure there are no construction punchlist prior to load out.


Figure 3.6.8-2:

Sacrificial Anode Cathodic Protection



842.1


842 – MISCELLANEOUS | MARINE AND CORROSION PROTECTION | MARINE GROWTH PREVENTION System Description The Marine Growth Prevention System will be used to protect the sea water systems against biological fouling. The system comprises of Hypopac-M units which include a transformer rectifier, an electrolyser, a hypo tank, a dilution air blower and hypo dosing pump. The system is designed to create sodium hypochlorite directly from seawater once it has been distributed to the sea chests and into the seawater system to revert to salt and water.

842.2

Pre-commissioning Scope of Works Verify the System Mechanical Completion for Marine Growth Prevention has been signed and all category A punch list have been closed.

842.3





843.1


843 – MISCELLANEOUS | MARINE AND CORROSION PROTECTION | DEHUMIDIFIER SYSTEM System Description Ballast De-Humidifier system is designed to reduce moisture inside ballast tank. It normally consists of a dehumidifying and regeneration zone. High moisture process air is drawn into humidifying zone of the wheel which absorbs the moisture from the process air. The moisture laden-section of the wheel rotor is then rotating as desiccant wheel roughs through the regeneration zone where the hot spurts of regeneration air is passing through the rotor and expelled-removing moisture from the rotor.

843.2

Pre-commissioning Scope of Works Verify the System Mechanical Completion of De-Humidifier has been signed and all category A punch list have been closed.

843.3





850 – STRUCTURAL

3.6.8.5.1

851 – MISCELLANEOUS | STRUCTURAL | TOPSIDE

851.1


System Description The topside structure is designed to carry out the weight of the dead and variable equipment loads. Live loads, environmental loads, bridges reaction, earthquake loads, accidental loads from dropped object and future facilities. The topside consist of Cellar Deck, Sub Cellar Deck, Mezzanine Deck, Main Deck, Venting /Flaring boom.

851.2

Pre-commissioning Scope of Works Verify that the System Mechanical Completion of Topside has been signed and all category A punch list have been closed.



852 – MISCELLANEOUS | STRUCTURAL | JACKET System Description The jacket structure is designed to support the topside structure, a rescue boat landing, riser-tube and other appurtenance in accordance with API RP 2A-WSD. The jacket is to be assumed with 4, 6 or 8 legged pile supported structure allowing a float over installation or modular of topside. The Jacket consists of Spider Deck, Boat fenders, Risers guards, Bollards, Caged ladder from spider deck to cellar deck or level 1, Sea escape ladders and Caissons.

852.2

Pre-commissioning Scope of Works Verify the System Mechanical Completion of Jackets has been signed and all category A punch list have been closed.



853 – MISCELLANEOUS | STRUCTURAL | LIVING QUARTERS (LQ)

System

800

MISCELLANEOUS

Subsystem

850

Structural

Sub-Subsystem

853

Living Quarters (LQ)

853.1

System Description Living Quarter is an essential necessity for the safe operational and life support requirements for personnel in the offshore. It consists of recreation room, office/meeting room, kitchen and bathroom and shower facilities. It has Mess hall (kitchen & galley) where personnel take their breakfast, lunch and dinner, it has an entertainment room to watch movies and listen to the music, office/meeting room to hold relevant discussions, document filing room to keep procedure, P& ID and equipment dossiers,and bathroom& shower facilities.

853.2

Pre-Commissioning Scope of Work Verify the System Mechanical Completion of Living Quarter has been signed and all category A punch list have been closed.



854 – MISCELLANEOUS | STRUCTURAL | BRIDGES System Description The bridge is a structure which connects platform to platform by using triangular structure or rectangular structure. The bridges shall be equipped with bearing support as part of installation part, bridges access stairway and handrails.

854.2

Pre-commissioning Scope of Works Verify the System Mechanical Completion of Bridges has been signed and all category A punch list have been closed.



855 – MISCELLANEOUS | STRUCTURAL | TELECOM TOWER System Description Telecom tower is the structure that is used for different applications such as internal communication, telemetry systems, telecommunication networks and external communication to the operational centre onshore.

855.2

Pre-commissioning Scope of Works Verify the System Mechanical Completion of Telecom Towers has been signed and all category A punch list have been closed.



3.6.8.6

860 – CIVIL

3.6.8.6.1

861 – MISCELLANEOUS | CIVIL | PROCESS AREA (INSIDE BATTERY LIMIT)

861.1

System Description An area designed for processing unit, including control room, electrical substation, analyzer house, pipe rack and etc.

861.2

Pre-commissioning Scope of Works Verify the System Mechanical Completion of all Process Area has been signed and all category A punch list have been closed.


862.1


862 – MISCELLANEOUS | CIVIL | NON-PROCESS AREA (OUTSIDE BATTERY LIMIT) System Description An area designed for all non proves civil facilities which may include administration building, workshop, laundries, warehouse, material yard, storage tank compounds, cooling tower, utility pump station, flare, firefighting station, training grounds, cooling water intake, pipe rack and etc.

862.2

Pre-commissioning Scope of Works Verify the System Mechanical Completion of all Non Process Areahas been signed and all category A punch list have been closed.



863 – MISCELLANEOUS | CIVIL | RECEIVING AREA System Description An area designed for hydrocarbon receiving weather from offshore or onshore, The receiving facilities consist of civil facilities for Receiver, Control building, Fencing and etc.

863.2

Pre-commissioning Scope of Works Verify the System Mechanical Completion of all Receiving Areahas been signed and all category A punch list have been closed.





864 – MISCELLANEOUS | CIVIL | LAUNCHING/EXPORT AREA System Description An area designed for hydrocarbon export weather from offshore or onshore. The export facilities consist of civil facilities for Launcher, Control building, Fencing and etc.

864.2

Pre-commissioning Scope of Works Verify the System Mechanical Completion of all Launching/Export Areahas been signed and all category A punch list have been closed.



REFERENCES

The information in this section highlights the documents that could be made as references while performing testing, pre-commissioning and commissioning activities. In a situation whereby design, fabrication and installation information is required, reference to Exhibit IX of the fabrication package would be deemed necessary.

4.1

Codes and Standards

These are documents recognized worldwide based on long term experiences in the industry for many years. Examples are Codes and Standards produced by institutions such as the American Petroleum Institute (API), American Society of Mechanical Engineers (ASME) and so forth. Some of the relevant Codes and Standards deemed required for testing, pre-commissioning and commissioning activities are: ASME Section VIII

Unfired Pressure Vessel,

ASME PTC 22

Performance Test Code on Gas Turbine

ASME PTC 10

Performance Test Code On Compressors and Exhausters

API 660

Shell and Tube Exchangers,

API 661

Air Cooled Exchangers,

ANSI B31.3

Chemical Plant and Petroleum Refinery Piping,

API 610

Centrifugal Pumps,

API 650Tanks, API 674

Positive Displacement Pumps - Reciprocating,

API 675

Positive Displacement Pumps - Controlled Volume,

API 617

Centrifugal Compressors,

API 618

Reciprocating Compressors,

API 619

Positive Displacement Compressors,

API RP 2 C

Pedestal Cranes,

ISO-2372-1974

Mechanical Vibration of Machines,

ISO-2372-1974

Mechanical Vibration of Certain Rotating Electrical Machinery,

ASHRAE

Heating, Ventilation and Air-conditioning,

API RP 550

Instrument and Controls Manual for Refinery Service



Construction Drawings

Only construction drawings of the latest revision should be used for testing, precommissioning and commissioning activities. In an event a conflict arise from interpretation of the requirements in the above documents, CARIGALI personnel shall be consulted for clarification.

4.3

CARIGALI Standard Procedure (CSP) Below is the minimum listing of PETRONAS Carigali Standard Procedure which contents are considered directly relevant for Testing, Pre-commissioning and Commissioning activities, namely: CSP 03 Final Documentation Table of Content,

4.4

CSP 04

Project Specific Procedure Guideline,

CSP 03

Ship loose Packing Procedure,

CSP 13

Bolt Tightening Procedure,

CSP 21

Upstream Facilities Hand-over Manual,

CSP 22

Flushing &Hydrotest Procedure,

CSP 23

Coating System for Bolts & Nuts,

CSP 24

Glass Reinforced Epoxy Piping Procedure,

CSP 25

Reinstatement Leak Test Procedure.

PETRONAS Technical Specification

Below is a minimum listing of PETRONAS Technical Specifications (PTS) which contents are considered directly relevant for testing, pre-commissioning and commissioning activities. More information and details should be retrieved from specific equipment specifications (refer to Exhibit IX of Contract Document). 20.094 Accuracy Requirements for Field Measurements, 20.167

Commissioning Engineering Manual,

50.007

Inspection Manual,

50.013

Handling, Storage and Preservation of Materials and Equipment,

32.32.10.10

Flow Instruments,

32.80.10.30

PLC-based Instrumented Protective Systems,

61.10.08.11

Field Inspection Prior To Commissioning of Mechanical Equipment,



Field Inspection and Testing of Instruments and Instrument Systems,

63.10.08.11

Field Commissioning and Maintenance of Electrical Installation and Equipment,

70.79.10.10

Ex Electrical Equipment Inspection and Maintenance Guidelines (Ex IMG),

70.10.70.11

The Preservation of Old and New Equipment and Piping Standing Idle,

70.10.80.11

Cleaning of Equipment,

70.10.90.11

Spare Part for Initial and Normal Operation, and

70.10.90.81

SPIR Form.



PROCEDURES This section provides a description of the procedures involving testing, pre-commissioning and commissioning activities. The procedures are provided only to assist CONTRACTOR as to the path or steps anticipated by CARIGALI in performing the activities. CONTRACTOR is advised to utilize fully vendor manuals and procedures as the vendor data tend to provide more explicit details. CONTRACTOR shall be responsible for identifying and developing procedures that are not depicted under this section.



Mechanical and Piping Pre-commissioning Procedure 5.1.1

Turbine Driven Generators This procedure serves as a guideline for the pre-commissioning of turbine-driven generators. This section covers only the mechanical portion. For electrical requirements, refer to Section 5.2.1 of the Electrical Pre-commissioning Procedures. 5.1.1.1

Pre-Startup Checks and Verification i)

Cleanliness of lube oil tank and if provided with breather or vent pipe.

ii) Cleanliness of liquid or gas fuel, air, and lube oil filters. Replace as necessary. iii) Checks lube oil for contamination. Add or replace lube oil if necessary. iv) Check hydraulic start system oil lubricator level.Add or replace as necessary. v) Temporary turbine exhaust has been installed and vent to a safe place. vi) Fuel gas shutdown valve is vented off to a safe place. vii) Lube oil fan cooler, pulley alignment, belt tension and bearing lubrication. viii) Leaks on associated piping connection air, gas/liquid, lube oil and drain lines. ix) Functional test of fire dampers.



Startup and Testing Start-up and testing procedure depicted below is for the cranking test of the turbine only. Coupled test of the whole unit shall be evaluated on case basis by the respective engineers. i)

Ensure sufficient starting air in the system.

ii) Energise and start pre-post lube oil pump. iii) Checks lube oil system for any leak. iv) Verify lube oil pressure and temperature. v) Energise and start enclosure ventilation system. vi) Energise the hydraulic starting system. vii) Verify turbine cranking speed is achieved. viii) Document all tests and checks performed. ix) Preserve the equipment after the test if not to be used for other activities. Note: Refer to ITR-B for additional parameters to be checked





Diesel Engine and Gas Engine Driven Generators This procedure serves as a guideline in the pre-commissioning of the dieselengine-driven or gas-engine-driven generators. This section covers only the mechanical portion. For electrical requirements, refer Section 5.2.2 of the Electrical Pre-commissioning Procedures. 5.1.2.1


Visual inspection for any leakage of lube oil, fuel and cooling water.

ii) Verify radiator is full and coolant is added with corrosion inhibitor. iii) Check crankcase lube oil for any sign of water and top-up or replace as necessary. iv) Lube oil level control is installed at correct elevation. v) Radiator fan, pulley and belt alignment, belt tensioning and bearing lubrication. vi) Air starter engine is provided with lubricator, top-up if required. vii) Exhaust of air starter is discharged to a safe place. viii) Diesel or gas engine is provided with spark arresting silencer and piping is insulated. ix) Cleanliness of air, gas or liquid filter elements. Replace if necessary. x) Fuel gas shutdown valve is vented off to a safe place. xi) Diesel fuel tank cleanliness, overflow arrangement and availability of sight glass, float valve and remote shut-off valve. xii) Engine and generator bearings are lubricated and greased.



Startup and Testing i)

Once engine started, check and verify the following conditions :a) Direction of rotation, b) Sufficient starting air, c) Oil level in sump pump casing has been top-up or replaced, d) Lube oil pressure and temperature, e) Exhaust temperature, f)

Cooling water pressure and temperature,

g) Noise level (in decibel) and speed in revolutions per minutes (rpm), h) Governor operation. ii) Perform continuous run testing at the following conditions :a) One (1) hour at no load, b) One (1) hour at fifty (50%) percent load, c) One (1) hour at seventy five (75%) percent load, d) Four (4) hours at one hundred (100%) percent load (for gas engine only), e) For seventy two (72) hours at one hundred (100%) percent load (for diesel engine only). iii) Log operating data as per ITR at one-half (1/2) hour intervals. iv) Hot alignment check after initial run. v) Document all tests and checks performed. vi) Preserve the equipment after the test if not to be used for other activities.

Note: Refer to ITR-B for additional parameters to be checked





Diesel Engine Driven Firewater Pumps This procedure serves as a guideline in the pre-commissioning of diesel-enginedriven firewater pumps. 5.1.3.1

Pre-Startup Check and Verification i)

Check engine radiator, top-up coolant and ensure corrosion inhibitor is added.

ii) Check engine crankcase and gearbox lube oil for any sign of debris or water contamination. Add or replace lube oil if necessary. iii) Check diesel fuel reservoir tank for cleanliness, sight glass, float valve, remote shut-off valve, overflow are provided. iv) Check all fuel, lube oil and air filters and elements for cleanliness and replace if necessary. v) Check air starter id provided with lubricator and top-up or replace if necessary. vi) Check radiator fan, pulley alignment, belt tension, size and length. vii) Check all external bearing lubrication/greasing if necessary. viii) Check direction of gearbox dive shaft rotation, rotate freely by hand and ensure it matches engine rotation. ix) Visually check pump accessories, shafting, strainers, threaded couplings and pipe columns. 5.1.3.1


Remove engine-to-gearbox coupling and start the engine.

ii) Check for noise and vibration. iii) Verify engine speed. iv) Test for manual and auto start-up shutdown. v) Check and confirm status indication. vi) Perform four (4) hours continuous no-load run of the engine. vii) Log operating data at thirty (30) minutes intervals.

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE viii) Test engine overspeed shutdown. ix) Document all test and checks performed x) Preserve the equipment after the test





Electric Motor Driven Submersible Pumps This procedure serves as a guide for the pre-commissioning of the submersible pumps. 5.1.4.1


Check pumps column accessories like bolts, gasket, etc. are stainless steel 316 or as required.

ii) Check condition of lifting device, safe working load of slings, shackles and chain blocks. iii) Check pump shaft could rotate freely by hand. iv) Check for any threaded joint on the rotating element is tightened to the recommended torque values. 5.1.4.2

Startup and Testing As pump is installed offshore, only pump motor is tested onshore. Refer to sub-section 5.2.1.2 – Uncoupled Run Test of Electric Motors.






Diesel-Engine-Driven Start Air Compressors This procedure serves as a guideline for the pre-commissioning of diesel-enginedriven start air compressors. 5.1.5.1

Pre-Startup Checks and Verifications i)

Check for any sign of fuel, lube oil and water leakage.

ii) Check engine radiator for any leak, top-up coolant and ensure corrosion inhibitor is added. iii) Check engine and compressor lube oil for contamination; top-up or replace as necessary. iv) For belt-driven compressor, check pulley alignment, belt tension, size and length. v) Check fuel supply and top-up as necessary. vi) Check engine cleaner and replace, clean if found dirty. vii) Verify engine exhaust is provided with spark arresting silencer and exhaust pipe insulated. viii) Rotate engine and compressor shafts manually to ensure free rotation. 5.1.5.2

Start-up and Testing i)

Start engine by manual crank or hydraulic start and run at minimum speed.

ii) Check lube oil pressure and for leakage if any. iii) Test manual shutdown of engine and re-start. iv) Check for any excessive vibration or noise. v) Monitor and record time taken for starting air pressure to builtup to 150 pounds per square inch (Psi) gauge or to the required maximum pressure. vi) Carry out four (4) hours continuous running test of compressor. vii) Log operating data at thirty (30) minutes intervals. viii) Document all tests and checks performed.



ix) Preserve equipment after test if not to be used for other activities.




Electric-Motor-Driven Air Compressors This procedure serves as a guideline for the pre-commissioning of electricmotor-driven air compressors. 5.1.6.1


Check lubrication, lube oil sump, lube oil filter and top-up with right grade oil to required level.

ii) Check pulley alignment, belt tension and ensure proper belt size has been used. iii) Verify intake filters clean and correctly installed. iv) Turn compressor and motor shafts by hand to ensure free rotation. 5.1.6.2


Start-up motor and verify correct rotation.

ii) Test manual and emergency shutdown function. iii) Check status of indication light, test the lead/lag sequence and start sequence. iv) Test pressure control, automatic loading/unloading function. v) Check cooler fan and main motor interlock. vi) Carry out seventy-two (72) hours continuous running test and record operating data at two (2) hours intervals. vii) Monitor and record oil consumption. viii) Document all tests and checks performed. ix) Preserve the equipment after the test if not to be used for other activities. Note: Refer to ITR-B for additional parameters to be checked





Diesel-Engine-Driven Survival Crafts (Life Boat) This procedure serves as a guideline for the pre-commissioning of survival crafts. 5.1.7.1


Check the winch system for the following:a) Turn motor shaft to ensure free rotation of motor and gearbox. b) Gearbox lube oil for contamination, top-up or replace as necessary. c) Ensure winch wire rope lubrication has been done as per vendor recommendation. d) Wire rope provided has sufficient length to lower the boat to sea level and properly wind on drum.

ii) Check the engine for the following:a) Engine lube oil; top-up or replace if necessary. b) Engine starting system, hand crank lever or battery start. c) Diesel fuel tank is filled. 5.1.7.2


Start winch motor to confirm correct direction of rotation.

ii) Function test lowering and lifting of winch with smaller load than the actual weight of boat. iii) Function test of over winch cut off switch at least three (3) times without failure. iv) Test lifting and lowering of the craft. Monitor lifting and lowering speed. Note: This is possible if sufficient room is available between platform and ground. v) Third party to witness and certify load test of winch and brake capacity. vi) Test run boat engine.



vii) Carry out one (1) hour sea trial test of the boat at fabrication yard jetty. viii) Check for any leaks after sea trial test. ix) Function test craft cooling sprinkler subsystem. x) Document all tests and checks performed. xi) Preserve the equipment after the test.





Heating, Ventilation and Air Conditioning This procedure serves as a guideline for the pre-commissioning of heating, ventilation and air conditioning (HVAC) units. 5.1.8.1


Check intake filters and pressurization fans:a) Inlet filet condition and installation, b) Type of inlet filter and protecting guard, c) Fan impeller and motor to ensure free rotation, d) Pulley alignment, belt size, tension and bearinglubrication or greasing, e) Electrical check on motor, cabling and starter of fan has been completed, and

ii) Check all dampers for the following:a) Damper condition, blade material and correct installation, b) Electrical check and function test of actuator, limit switch and remote indicator, c) Test dampers at a minimum of four (4) times with 100 percent success. iii) Check air-cooled condensing unit for the following:a) Base compressor and motor to ensure free rotation, b) That refrigeration system has been vacuumed and changed with refrigerant, and c) Refrigeration specification.

piping

insulation

material

confirm

to



iv) Check/verify air handling unit for the following:a) Flexible duct connector are fire resistance, b) Fan pulled alignment, belt size and tension, c) Mixing box and return fresh air damper installation, d) Electrical check on motors, cabling and motor control center (MCC) has been done, and e) Verify operation of air flow switch. v) Verify HVAC control panel electrical checks have been done and all indicating lights are functioning. vi) Check general condition of ducting if construction and installation conforms to specifications. 5.1.8.2


Start-up first pressurization fan and verify that fan rotation is correct.

ii) Check fan any excessive vibration or noise and motor running amperes. iii) Check control panel indication, allow fan to run for at least thirty (30) minutes and check fan capacity. iv) Start-up the first fan, v) Start-up air cooled condensing and air handling units and verify the following:a) Motor rotation is correct, b) Any excessive vibration or noise, c) Refrigeration tubing for any leak, d) Air handling fan capacity, and e) Running ampere of all electric motor. vi) Start electric duct heater. vii) Verify control panel indicating lights. viii) Adjust all volume damper indicating lights.



ix) Adjust thermostat to verify temperature control is functioning. x) Test control and shutdown system. xi) Carry out seventy two (72) hours continuous test run of the complete system and record ambient or room wet and dry bulb temperature at three (3) hours interval. xii) Switch over and test the standby unit after thirty six (36) hours of continuous running. xiii) Document all the tests and checks performed. xiv) Preserve the unit after test if not to be used for other activities.






Pedestal Cranes This procedure serves as a guideline for the pre-commissioning of diesel engine driven pedestal cranes. 5.1.9.1


Check engine crankcase lube oil for any sign of dirt or water; top-up or replace if necessary.

ii)

Check engine radiator, top-up coolant and ensure that corrosion inhibitor is added.

iii)

Check radiator fan, pulley alignment, belt size, belt tension and bearing lubrication.

iv)

Check engine breather and vent pipe if provided.

v)

Check air starting or hydraulic starting system if provided with lubricator, top-up lube oil if necessary.

vi)

Check engine exhaust if provided with spark arresting silencer and the complete exhaust pipe is insulated.

vii)

Check diesel fuel tank for cleanliness, filling arrangement, drain and sight glass. Fill up with diesel and check for any leakage.

viii)

For electric motor power pack driver, check hold down bolts of motor and verify electrical check of motor, cabling and motor control center has been completed.

ix)

Check hydraulic system for:-

x)

a)

Hydraulic lines connections, filters and system has been flushed, and

b)

Hydraulic hoses arrangement if neatly dressed.

Check structure and boom for:a)

“A” frame for any distortion or damage,

b)

Boom chord and lacing members for any distortion or damage,

c)

Grease pivot joints of boom,

d)

Load rating of crane is permanently stenciled on the boom,


xi)

xii)

xiv)


e)

Access ladders and handrails are acceptable,

f)

Cabin doors, window and wipers, and

g)

Alarm horn.

Check boom hoist:a)

At least two (2) wraps of rope remain on the drum when the hoist is at its extreme operation position.

b)

Hoist rope are properly lubricated,

c)

Lubrication of sheaves and bearings,

d)

Rope end anchorage, and

e)

Brake band adjustment as per vendor’s instruction.

Check main hoist and block:a)

At least two (2) wraps of rope remain on the drum when the block is at level with the boom at maximum angle,

b)

Hoist rope condition and ensure proper lubrication,

c)

xiii)


Grease hook and all sheaves,

d)

Rope end anchorage, and

e)

Ensure brake band adjustment as for vendor’s instruction.

Check auxiliary hoist and block:a)

At least 2 wraps of remain on the drum when the block is at sea level with the boom at maximum angle,

b)

Hoist rope condition and ensure proper lubrication,

c)

Ensure all sheaves are lubricated and check wire rope end anchorage, and

d)

Ensure brake band adjustment as per vendor’s instruction.

Check slew gears and bolts:a)

Ensure tightening of ring bolts as per vendors instruction with correct torque value,


5.1.9.2


b)

Slew gears are free of dirt and ensure proper lubrication has been done, and

c)

Ensure turntable bearing has been lubricated.


Start-up power pack and test local and remote shutdown function.

ii)

Check that control level returns to neutral position when released,

iii)

Check and record hydraulic pressure on main hoist, auxiliary hoist, boom hoist and slewing,

iv)

Check proper functioning of load and radius indicator,

v)

Set and test at least three (3) times the functioning of limit switches of the main hoist anti-two-block, auxiliary hoist antitwo-block, over-luffing, under-luffing and slewing.

vi)

Check and record the speed of main hoist, auxiliary hoist and slewing,

vii)

Simulate and test all protective function and operation function of diesel engine,

viii)

Demonstrate override function for emergency covering of boom and slewing if necessary,

ix)

Carry out load test witness by third party and certificate of fitness to be issued,

x)

Document all tests and checks performed,

xi)

Preservation of equipment to be done if not to be used.




Vapour Compression Type Water Makers This procedure serves as a guideline for the pre-commissioning of vapourcompression-type water makers. 5.1.10.1

5.1.10.2


Check pulley and belt alignment, belt tensioning of distillation, lube oil and re-circulation pumps,

ii)

Check pulley and belt alignment, belt tensioning on compressor and driver transmission.

iii)

Check compressor transmission safety guard,

iv)

Check lube oil grade type and level in compressor sump, top-up or replace as required,

v)

Check treatment storage tank is filled with distilled water of correct quantity of chemical,

vi)

Check all strainers and filters for duplex feed water, discharge from re-circulating pump and lube oil are clean. Replace if necessary,

vii)

Check direction of rotation of lube oil pump, compressor, distillate and re-circulation pump.

Startup and Testing The following steps and tests are feasible only if clean seawater is available at the fabrication yard. i)

Start-up lube oil pump,

ii)

Monitor lube oil level and pressure to compressor. Add lube oil if necessary.

iii)

Prime distillate pump with fresh potable water to prevent mechanical seal damage during start-up.

iv)

Start-up the unit in according with the vendor’s procedure.

v)

Check and record the following data when unit is in operation:a)

Lube oil pump discharge pressure,

b)

Distillate pump discharge pressure,



c)

Re-circulation pump discharge pressure, and

d)

Chemical feed pump discharge pressure.

vi)

Prime chemical treatment proportioning pump and set stroke setting in accordance with vendor recommendations.

vii)

Functional check shall be verified during equipment operation for the following:a)

Heat exchanger inlet and outlet pressures and temperatures,

b)

Lube oil pressure and temperature,

c)

Surge control relay shutdown,

d)

Water levels in boiler, and

e)

Operation of safety reset relay.

viii)

Check distillate, blowdown and boiler temperatures are as per vendor specification.

ix)

Check panel indication lights are functioning as per specification.

x)

Check for cold flushing function,

xi)


xii)

Preservethe equipment after the test if not to be used for other activities.






Wellhead Diesel Injection Pumps This procedure serves as a guideline for the pre-commissioning of diesel engine driven wellhead diesel injection pumps. 5.1.11.1

5.1.11.2


Check/inspect lube oil sump tank for cleanliness, breather or vent pipe, dipstick arrangement and correct grade of lube oil,

ii)

Check all filter elements for cleanliness and replace if necessary,

iii)

Check engine radiator and cooling water jackets, top-up coolant and ensure corrosion inhibitor is added,

iv)

Check starting air system or battery starter are adequately installed.

v)

Check pump operability of mechanical lubricator.

vi)

Check/inspect the pump plunger packing installation:a)

Correct type and number of packing ring,

b)

Correct box gland follower is square with face of box,

c)

Gland lubrication and sealing fluid piping arrangement is correctly fitted.


Remove engine-to-pump shaft coupling,

ii)

Test run diesel engine without pump i.e. no load test,

iii)

Check engine for vibration and noise,

iv)

Test engine start and stop button several times,

v)

Check engine lube oil pressure and temperature,

vi)

Check engine cooling water temperature,

vii)

Check engine over-speed shutdown,

viii)

Monitor engine running condition for two (2) hours,

ix)


x)

Preserve equipment after the test.





Electric-Motor-Driven Centrifugal Pump This procedure serves as a guideline for the pre-commissioning of electric-motordriven centrifugal pumps. 5.1.12.1

5.1.12.2


Check pump shaft seal/packing and record make, type and model,

ii)

Check pump suction strainer or that temporary strainer is provided,

iii)

Check or verify motor, gearbox and pump shafts can be rotated freely by hand.


Start motor manually to check for correct rotation,

ii)

Test manual and remote shutdown function,

iii)

Check for any noise or vibration,

iv)

Verify gearbox lube oil pressure build up,

v)

Record discharge pressure at zero flow and motor running ampere,

vi)

Fill-up surge tank or vessel with water and test for automatic start-up.

vii)

Simulate tank/vessel level and function test level and recirculation control,

viii)

Check control panel indication lights and motor running,

ix)

Check and confirm correct Distributed Control System signal.

x)

Test lead and lag operation of pump if equipped,

xi)

Carry out four (4) hours continuous running test,

xii)

Record operating data at thirty (30) minutes intervals,

xiii)

Document all tests and checks performed. Preserve the equipment after test if not to be used for other activities.




Gas- And Diesel-Engine-Driven Centrifugal Pumps This procedure serves as a guideline for the pre-commissioning of gas-enginedriven and diesel-engine-driven centrifugal pumps. 5.1.13.1


Check engine radiator, top-up coolant and ensure that sufficient corrosion inhibitor is added,

ii)

Check engine crankcase lube oil for any sign of contamination, top-up or replace oil as required,

iii)

Check correct elevation of oil level control,

iv)

Check radiator fan, pulley alignment, belt size, tension and external bearing lubrication,

v)

Check lube oil, fuel, air, cooling water filters and its elements for cleanliness and replace as required,

vi)

Check bearing arrangement and manual crank of the engine,

vii)

Check air or hydraulic starter of engine is provided with lubricator start system and check for leaks,

viii)

Check air starter exhaust is discharged to a safe area,

ix)

Verify engine if provided with a spark arresting silencer and exhaust pipe is fully insulated,

x)

Verify turbocharger is covered with removable insulation blanket,

xi)

Check engine cooling water pump, pulley alignment, belt size, tension and water piping,

xii)

Verify coupling guard is non-sparking type and coupling rating is sufficient,

xiii)

For diesel engine check diesel tank for cleanliness and supply and return line has been flush and reinstated,

xiv)

Check gearbox and pump lube oil for contamination, top-up or replace as necessary,

xv)

Turn gearbox and pump shafts manually to ensure they rotate freely,

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE xvi)


Check pump shaft seal or packing (mechanical seal),

xvii) Check pump bearing lubrication or greasing, xviii) Check pump suction strainer element or that temporary strainer is provided, xix)

5.1.13.2

Dry test control panel and confirm start-up valve opening sequence and timing.


Ensure sufficient starting air in the system,

ii)

Ensure fuel (liquid or gas) is sufficient for the duration of test.

iii)

Uncoupled run the engine and carry out intermittent on-load run of 5, 10 and 20 minutes using bottled gas or liquid fuel,

iv)

Monitor the following parameters during the uncoupled test run:a)

Any abnormal noise or vibration,

b)

Any leakage of lube oil or water,

c)

Lube oil pressure build-up for engine and gearbox,

d)

Indication status on control panel,

e)

Engine and gearbox lube oil differential pressures,

v)

Coupled run the engine and carry out four (4) hours continuous load run using fresh water,

vi)

Long operating data at every thirty (30) minute intervals,

vii)


viii)

Preserve equipment if not to be used for other activities.




Gas-Engine-Driven Reciprocating Gas Compressors This procedure serves as a guideline for the pre-commissioning of gas-enginedriven reciprocating gas compressors. 5.1.14.1


Check engine radiator,

ii)

Check engine crankcase lube oil for any sign of dirt or water, top-up or replace and check for any leak,

iii)

Check engine breather or vent,

iv)

Check radiator fan, pulley alignment, belt tension, belt size and bearing lubrication,

v)

Check if air starter engine is provided with lubricator, top-up lube oil or charge-up hydraulic start system,

vi)

Check exhaust of air starter is discharged to a safe place,

vii)

Check engine if provided with a spark arresting silencer and exhaust pipe is insulated,

viii)

Check turbocharger is covered with removable insulation blanket,

ix)

Check coupling guard and ensure of non-sparkling type,

x)

Check fuel gas filter and replace if necessary,

xi)

Check and adjust fuel gas control valves as required.

xii)

Check fuel gas shutdown valve and ensure it is vented to a safe area,

xiii)

Check compressor and gearbox lube oil for any sign of dirt or water. Top-up or replace if necessary,

xiv)

Check and record compressor crosshead clearances on all corners.

xv)

Check and record crankshaft thrust clearance,

xvi)

Check and record piston end clearances,

xvii) Check and record compressor rod run out for each throw, xviii) Check all packing vent are vent to a safe area,




5.1.14.2


xix)

Bar compressor shaft over to ensure that it turns freely,

xx)

Check that temporary strainers are installed on the upstream of each throw,

xxi)

Carry out simulation test on the following:a)

Low jacket water trip,

b)

Low engine lube oil pressure trip,

c)

Low compressor lube oil pressure trip,

d)

Compressor cylinder lube oil on flow shutdown,

e)

Recycle valve functioning,

f)

Suction scrubber high liquid level shutdown,

g)

1st/2nd stage scrubber high liquid level shutdown.

Startup and Test Run i)

Energise and start-up pre-port lube oil pump, observe and record lube oil pressure, differential pressure across filter and leaks if any,

ii)

Crank the engine with all engine spark plugs and fifty (50) percent of compressor suction valves removed,

iii)

Perform intermittent no-load run of five (5), ten (10) and twenty (20) minutes using bottled gas and observe the following:-

iv)

a)

Abnormal noise or vibration,

b)

Leakage of oil and water,

c)

Did engine, gear box and compressor lube oil pressure build up immediately?

d)

Is force feed lubrication functioning properly?

e)

Feed rate shall be adjusted as per requirement,

f)

Engine and compressor lube oil differential pressures,

g)

Is control panel status indication correctly?

Check that Distributed Control System signals are correct,



v)

Carry out four (4) hours continuous no-load run and log operating data at every thirty (30) minute intervals,

vi)

Test and record engine over-speed shutdown,

vii)


viii)

Preserve equipment after the test.





Turbine-Driven Centrifugal Compressors This procedure serves as a guideline for the pre-commissioning of turbine-driven centrifugal compressors. 5.1.15.1


Check turbine enclosure ventilation system,

ii)

Conduct turbine water wash with approved chemical to be used,

Note: This should be performed if turbine engine test is confirmed able to be carried out. Else, wash to be done offshore.

5.1.15.2

iii)

Ensure fuel gas shutdown valve relief line is vent to a safe place.

iv)

Ensure fuel gas/liquid fuel control valve is calibrated or adjusted to required setting,

v)

Check cleanliness of liquid and gas fuel strainers,

vi)

After flushing is completed, lube oil to be tested for cleanliness or contamination, replace if necessary,

vii)

Ensure seal gas system control instruments and control valves have been functionally tested.

Startup and Testing The following tests shall be performed with compressors uncoupled. i)

Energise motor control center for turbine enclosure.

ii)

Start-up pre/post lube oil pump, check for abnormalities, flow and oil pressure,

iii)

Adjust control valves setting as required,

iv)

Start-up enclosure abnormalities,

v)

Crank turbine to check and test electro-hydraulic starting system or the electric motor starting system,

vi)

Document all tests and checks performed. Preserve equipment after the test.

ventilation

system

and

check


for



Reinstatement Leak Test Procedure Reinstatement leak test is to be done after all components are installed except certain components that are recommended not to be included ex: Compressor, Pump. This general procedure serves as a guideline for the pre-commissioning of overall system. 5.1.16.1

5.1.16.2

Reinstatement Leak Test Pressure i)

The purpose of reinstatement leak test is to confirm that all joints including isolating valves, double block and bleed valves, relief valves and block valves are leak free. Tight shut-off valves can be checked for positive shut-off during the test.

ii)

All components such as instrumentations, valves and spectacle blinds shall be installed prior to Leak Test, except for those that are recommended to be excluded by the vendor/manufacturer.

iii)

Reinstatement leak test of the system shall be performed at pressure equal to ninety five (95) percent (%) of the lowest rated relief valve set point or hundred and ten (110) percent (%) of operating pressure if PSV not available.

Reinstatement Leak Test Packages Reinstatement leak test packages shall be prepared by CONTRACTOR for CARIGALI approval. The test packages shall:i)

Identify the extent of the test, define the test media and quantify the amount of re-instatement media required,

ii)

Define valve and spectacle blind positions during the reinstatement test as per operational mode,

iii)

Identify depressurized line/point including injection and measurement points,

iv)

Identify and tag joints within the system that are not being covered in the test.

v)

Any leak shall be rectified by de-pressurizing the line first. Leaking valves shall be re-conditioned or replaced as per CARIGALI’s recommendation.




5.1.16.4

Test Instruments i)

Instruments used for reinstatement shall be calibrated and witnessed by CARIGALI representative before the start of the test and re-checked after successful completion of the test,

ii)

Calibration record shall be established and signed by the instrument technician conducting the calibration test and CARIGALI representative witnessing the test. The calibration report shall be incorporated in the reinstatement test report. a)

Test Gauges – range shall be fifty (50) percent higher than the test pressure,

b)

Pressure Recorders – range shall be fifty (50) percent higher than test pressure,

c)

Minimum dial size of four (4) inches and accuracy up to one-fourth (1/4) of 1 percent of the fall scale.

Test Medium i)

5.1.16.5


The test medium is determined on the system process requirement refer to para 6.2.1 Piping Matrix.

Procedure i)

Line check the system as per the respective test package which covers the following:a)

Valves and flanges were properly installed and tightened,

b)

Check valves were installed on the right direction,

c)

Vent and drain valve if any,

d)

Line instrument and isolation valve,

e)

Relief/safety valve and interlocking device,

f)

Color-coded bond, line numbers and directional arrows

ii)

Hook-up the source of reinstatement media and test instrument as shown on the test pack,

iii)

Install danger tags to all line valves, bleed valves, drain and vent valves,

iv)

Isolate temporarily the recorder from the system,



CARIGALI STANDARD PROCEDURE v)

Where air is used as the test medium, a preliminary check of the pressure not greater than fourteen (14) psig shall be conducted. The pressure shall then gradually be increased in increments not greater than 10 percent of the system test pressure,

vi)

When water is used as test medium, pressure shall be increased in increments equal to 15,25,50,75 and 100 percent of test pressure.

vii)

Check for leaks using mixture of soap or snoop leak detector at each pressure increment,

viii)

Open the recorder isolating valve when the test pressure at the gauge has stabilized. The test pressure shall be held for one hour,

Note: Leaks occurring during this one-hour holding period shall require the start of a new one-hour period after the leaks have rectified.

5.1.16.6

ix)

Conduct system pressurization and de-pressurization sequence as highlighted in the test package to determine and identify any leaking valves,

x)

De-pressurize the system,

xi)

Retrieve the danger tags and clean-up the area.

Test Report The test report package for each system shall contain:i)

Discrepancies and leaking instatement test pack,

valves

highlighted

on

the

ii)

Recorder chart signed by the commissioning engineer and CARIGALI representative,

iii)

Calibration record of the instruments,

iv)

Issue reinstatement test acceptance certificate.



Electro-Chlorinators This procedure serves as a guideline for the pre-commissioning of electrochlorinators. 5.1.17.1

5.1.17.2


Check that the hydrogen removal tank vent trunking is complete and flame arrestor fitted,

ii)

Clean seawater supply is available.

Manual Start-up and Testing i)

Ensure that valves are properly lined-up,

ii)

Switch to manual and normal,

iii)

Switch on power supply and phase healthy lights illuminate,

iv)

Verify control circuits are now operational,

v)

Operate lamp Test, Alarm Accept and system Rest, alarms which will remain on, are low tank level, vent failure and low flow through electrolyser,

Note: These faults are by-passed on start-up. vi)

Check that indicator lights reflect a true plant state and Plant Ready light must be illuminated,

vii)

Start fan and Vent Healthy lamp should illuminate. Press reset pushbutton to clear ‘vent failure’ alarm,

viii)

Check that seawater inlet valve has opened when fan was started.

ix)

When flow through electrolyser exist, start transformer rectifier,

x)

Increase the setting of variable resistor to a nominal setting and monitor increase in direct current (DC) voltage and current,

xi)

Check level switch high operates at 75 millimeters below the overflow pipe. Open tank outlet valve fully,

xii)

Simulate the low flow shutdown condition by gradually closing electrolyser outlet valve,

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE xiii)

5.1.17.3


Re-establish flow to design requirement, reset and restart the system.

AUTOMATIC Start-up and Testing i)

Ensure plant status is the same as for manual operation sequence,

ii)

Select auto and normal switch,

iii)

Check that transformer rectifier is available with no fault lights,

iv)

Check that indicator lights reflect a true state of plant,

v)

Adjust the setting of variable resistor to a nominal setting required,

vi)

Press Auto Start at panel broad and monitor the unit starting up,

vii)

Open hypochlorite outlet valve,

viii)

With plant running satisfactorily press Auto Stop button and monitor the unit shutting down,

ix)

Re-start the plant and start variable resistor progressively in gradual steps to give the maximum output,

x)

Check and record all cell voltages when all operating conditions are stable,

xi)

Adjust variable resistor to nominal setting required and conduct seventy two (72) hour test run,

xii)

Record and check performance every two (2) hours and indicate any adverse trends.




Nitrogen Gas Generators This procedure serves as a guideline for the pre-commissioning of nitrogen generation equipment. 5.1.18.1

5.1.18.2


Check that instrument air supply is between 5.6 to 8.3 Bar gauge and temperature less than 43°C,

ii)

Ensure plant is in unit shutdown mode and that all actuated ball valves are shut,

iii)

Ensure indication lamps has been established for functioning,


Switch on panel power supply,

ii)

Acknowledge any indication alarms if any,

iii)

Activate manual override of high oxygen content trip switch on the panel,

iv)

Unlatch stop push button on the panel and press start-up button. The generation will begin operating automatically according to the timed sequences,

v)

As receiver pressure builds, open bleed valve in the nitrogen outlet line, to provide a through flow. Keep monitoring this flow and maintain receiver pressure above the alarm point,Cancel the manual override on oxygen high content trip,

vi)

Open the block valve on nitrogen receiver outlet to the distribution header and shutoff the bleed valve on nitrogen outlet line,

vii)

Reset alarm annunciator button. Ensure that pressure control valve upstream of nitrogen receiver outlet maintain a back pressure at 6.5 Bar gauge,

viii)

Monitor the oxygen content per vendor specification

ix)

Document all test and checks performed,

x)

Preserve the equipment if not used for other activities.




Standard Alignment Procedure This procedure stipulates the requirements for checking shaft alignment for various rotating equipment. This includes areas such as prime mover i.e. turbine, engine or motor, to gearbox, prime mover to driven equipment such as compressor, pump or generator, gearbox to driven equipment and prime mover to pulley. There are several methods for achieving a good alignment. The requirements listed below are only minimum. For the proper method and for more accurate details, manufacturer alignment procedure shall be referred to. 5.1.19.1

Reverse Alignment i)

Attach the alignment brackets firmly to both shafts and position the indicator on the perimeter of the other shaft as shown in Figure 5-1.

ii)

Set the indicators to zero at the 12 o’clock position,

iii)

Then slowly rotate both the shafts and bracket arrangement to 90 degree intervals stopping at 3 o’clock, 6 o’clock and 9 o’clock positions. Record reading at each position,

Note: Counter clockwise readings shall be indicated as a negative (-) value and clockwise readings are indicated as positive (+) value. iv)

Then return to the 12 o’clock position to see if the indicator(s) return to zero,

v)

Repeat steps (ii) to (iv) to verify the first set of readings,

vi)

Measure the distance between the outboard and inboard feet of both equipment.



CARIGALI STANDARD PROCEDURE LINE UP INDICATORS AXIALLY MARK PERIPHERIES AT 90 DEGREE INTERVALS

COUPLING DISTANCE DRIVER SIDE

DRIVER SIDE

ALL CLOCK READINGS TO BE TAKEN VIEWING DRIVING UNIT

Figure 5-1:

COUPLING HUBS HELD IN THE SAME RELATIVE POSITION TO EACH OTHER WHEN SHAFTS ARE RELATED TOGETHER

Reverse Alignment Indicator Position


5.1.19.2

5.1.19.3


vii)

Measure the distance from the dial indicator to the bracket mounting position.

viii)

Plot all graph with obtain reading on appropriate graphing paper (attached) and find out the correct shims.

Peripheral and Lace Alignment i)

Attach the alignment bracket firmly to one shaft and position the indication on the face and perimeter of the other shaft,

ii)

Zero the indicator at the 12 o’clock position,

iii)

Slowly rotate both shafts and bracket arrangements through 90 degrees interval stopping at 3 o’clock, 6 o’clock and 9 o’clock position. Record each reading (plus or minus),

iv)

Return to the 12 o’clock position to see if the indicator returns to zero,

v)

Repeat steps ii) through iv) to verify the first set of readings,

vi)

Record all results in “Alignment ITRs”,

vii)

Plot all readings using graph paper inclusive of the following parameters:-

a)

The distance between the inboard and outboard feet on both machines,

b)

The distance from the top of the indicator reading to the bottom (or hub radius),

c)

The distance from the dial indicator to the bracket mounting position,

viii)

Compute the required shim plates to attain the correct alignment,

Calibrated Eyeball i)

Check the in-line straightness of the driver and driven by pointing your view from one of the (driver or driven) hub to another,

ii)

Adjust vertical alignment by putting shims at the mounting,

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE iii)

5.1.19.4


Adjust horizontal alignment by adjusting the jack bolt on the left or right,

Straight Edge Method i)

Use straight edge steel bar,

ii) Put the straight edge bar on the top or sides of driver and driven hubs, iii) The misalignment of the equipment can be seen roughly as the clearance between the hub and straight edge bar, iv) Adjust this to get a correct alignment. 5.1.19.5

Taper or Feeler Gauge Method i)

Put the feeler gauge in between the two hubs (driver and driven),

ii) Put the feeler gauge on the 0 degree, 90 degrees, 180 degrees and 270 degrees to check the clearance, iii) If there is a difference in clearance (misalignment), adjust to get the correct alignment.

Note: Refer to Vendor or third party for laser alignment method



Nitrogen Purging Procedure 5.1.20.1

Objective The objective is to purge oxygen from the hydrocarbon systems i.e. process gas, process liquid and fuel gas, prior to introduction of hydrocarbon. This is accomplished by introducing nitrogen into system to less than 4 percent oxygen.

5.1.20.2

Preparation i)

Verify mechanical completion, commissioning and other preparatory activities have been completed, and all relevant ITRs and certification formalities complied correctly up this point,

ii) The necessary barriers and warning signs are placed around the system to be purged, iii) Industrial water in sufficient quantities is available, iv) Sufficient nitrogen bottles with regulators and manifolds are available (if facilities is not equipped with a nitrogen generating equipment), v) Oxygen analyzers and portable radio for operators is available, vi) A dedicated set for P&ID’s are maintained to record valve settings and purging progress. 5.1.20.3

Procedure Package should include listing of nitrogen fitting points, venting points and oxygen analysis point. i)

Isolate the system to be purged by closing all isolation valves except nitrogen fitting point,

ii)

Fit nitrogen connection as indicated, open the block valve, adjust regulator to required setting and commence admitting nitrogen,

iii)

Allow pressures in the system to rise to around 2 Bar gauge and then shut the nitrogen supply,

iv)

Hold the pressure for 30 minutes to allow dilution of oxygen,



v)

After holding for 30 minutes, open up the vent valves. As pressures now fall, re-open nitrogen supply to maintain a reasonably steady flow,

vi)

Continue venting for around four (4) hours, ensuring a constant flow of nitrogen through all designated routes. Appropriate adjustment to nitrogen input and output to maintain appropriate pressure,

vii)

When four (4) hours have elapsed commence checking oxygen content for every 15 minutes on each of the listed points. Keep record of the time and test results,

viii)

Upon two (2) consecutive test from all sample point show less than 4 percent oxygen,close all vent valves and allow pressures to reach about 5 pounds per square inch (Psi) gauge,

ix)

Shut off the nitrogen supply

x)

Maintain a positive pressure until system gas up or hydrocarbon introduction.




Electrical Pre-commissioning Procedures 5.2.1

Insulation Resistance Test Procedure Insulation resistance testing of electrical cable shall be performed by using a 500 Volt DC Insulation Tester (for Low Voltage as per PTS 63.10.08.11), to measuring insulation resistance of the electrical cable cores to ground and cores to cores. The procedures shall be as follows:i)

Ensure proper installation of joints and terminations, proper shield/armoured grounding, cable support and termination of conductors

ii)

Inject test voltage then measure the insulation resistance (IR) of each conductor with all other conductors and shields grounded.

iii)

Discharge all conductors to ground for a minimum period of 1 minute

iv)

Torque all bolts to recommended manufacturer’s standard.

v)

Record all test result

For medium and high voltage (MV/ HV) Cables the procedure shall follows steps as per ITR E-22-B For submarine cable, the procedure shall follows steps as per ITR E-23-B. 5.2.2

Turbine-Driven Main Power Generator 5.2.2.1

Electrical Checks and Test of Generator i)

Carry out insulation resistance test on rotor bearing (applicable for insulated bearing), main rotor winding, rotating diodes, exciter rotor and exciter stator windings, and generator heaters,

ii)

Carry out a polarization index test on the main stator winding,

iii)

Check and confirm that the rotating diode connection are correctly installed,

iv)

Check correct operation of humidity detectors,

v)

Functional test all Resistance Temperature Detectors (RTD) and thermocouples fitted to winding and bearings,


5.2.2.2

5.2.2.3


vi)

Check neutral earthing resistor connections, earth impedance, insulation resistance, and cross-sectional area of earth lead and measure all earth resistance values,

vii)

Calibration and current injection test of protection relays and verify relay setting,

viii)

Measure resistance values of earth-lead conductors for Generator skid, low voltage terminal box, neutral earth resistor terminal box and casing

ix)

Functional test of Generator Metering and Control System.

Functional Tests Turbine Engine Electric Motors i)

Uncoupled and coupled run test of turbine engine on-skid electric motors in accordance with subsection 5.2.11.

ii)

Check the rotation direction of electro-hydraulic start motor with the charge pump inlet arrow showing the same direction as the pump.

Turbine Enclosure Fire and Gas Detection and Fire Suppression System i)

Check completeness of installation in accordance with assembly drawings,

ii)

Check all terminations are correct and all terminals are tight.

iii)

Verify that the rating of all the fuses are as per schematic drawings,

iv)

Ensure right card type is used for each slot of Fire and Gas input and output (I/O) card. Mark the card appropriately after checking.

v)

Connect direct current power supply voltage and verify if polarity is correct,

vi)

Turn on power supply circuit breaker and verify power distribution to all points as per schematic,

vii)

Functional check of Common Control Board switch functions such as Reset, Alarm Silence, Fault Silence and Lamp Test,


5.2.2.4


viii)

Functional check of Fire Suppression Control Board that provides all input and output functions, programmable logic, and system status indicators for suppression system activation,

ix)

Functional check of all Fire Detection System controllers,

x)

All ultra-violet (U/V) flame detectors are to be tested by activating U/V test heads using U/V test lamps,

xi)

Test all heat detectors by applying considerable heat source such as heat gun,

xii)

Apply gas concentration of 50 percent Low Explosive Limit (LEL) to gas detection sensor, using portable purge calibrator for specified gas (methane, propane, etc),

xiii)

Perform logic test and verify conformance to the established Fire and Gas Shutdown Matrix.

Engine Pre-Startup i)

Verify that charger circuit breakers are ON,

ii)

Verify that all gage isolation valves at generator panel are in open position,

iii)

Verify skid-mounted Fire System Auto/Inhibit switches positioned to Auto,

iv)

Switch On circuit breaker panel inside the console, verify that all control system circuit breakers are closed (ON position),

v)

Switch On Fire System Supervisory/Release Panel inside console, verity the only light illuminated is green i.e. circuit current (DC) power on,

vi)

Verify that Reduced Speed Test Crank and Water Wash switches on Turbine Control Panel is de-activated,

vii)

Verify Fire System Auto/Inhibit switch is in Auto position (fire system enabled),

viii)

Verify breaker control circuit is in Trip (open) position or and that Circuit Breaker Open indication light illuminates,

ix)

Verify operation of generator space heater,



CARIGALI STANDARD PROCEDURE x)


Verify that voltage and engine speed Isochronous/Droop switches are positioned as required for intended mode of operation,

Note: For mechanical Pre-Initial Start-Up checks, refer to Section 5.1.2 5.2.2.5

Alarm and Shutdown Tests Tests shall be conducted by operation of the system (if possible) by simulation of the appropriate signal condition or both. All limits and set-point shall be verified. System tests shall include:i)

ii)

iii)

iv)

v)

Turbine Engine a)

Pre-post lube oil pump shutdown,

b)

Fail-to-Crank and Fail-to-Start shutdown,

c)

Speed Sensor Probes shutdown,

d)

Gas Producer and Power Turbine over-speed shutdown,

e)

Power Turbine backup over-speed shutdown,

Lube Oil System a)

Low oil pressure and level alarm and shutdown,

b)

High lube oil temperature alarm and shutdown,

c)

High lube oil filter differential pressure alarm

Temperature Monitoring System a)

High Turbine temperature (T5) shutdown,

b)

Temperature sensor (thermocouples) failure.

Fuel System a)

High and low fuel gas pressure shutdown,

b)

Gas Fuel Valve malfunction,

c)

Liquid Fuel Low Pressure shutdown

d)

Liquid Fuel differential pressure alarm

Vibration Monitoring System


vi)

5.2.2.6

a)

High vibration alarm and shutdown,

b)

Vibration Monitor failure.


Verify engine timer settings for the following:a)

Pre-lube, crank and purge cycles,

b)

Light off (ignition), starter dropout and cool down,

c)

Rundown, post lube and liquid manifold purge (at dual fuel transfer).

Crank Test of Turbine Engine Crank test does not involve ignition of the turbine engine. During cranking test, the following items shall be observed:i)

With power supply and circuit breakers are in ON position press and release Backup System Reset switch to reset the protective systems, the backup over-speed monitor and backup control circuitry,

ii)

On control console display screen, move cursor to highlight Test Crank and press Enter.

iii)

Monitor ventilation, pre/post lube oil pump and electrohydraulic pump start to operate,

iv)

Almost simultaneously the high transmission circuit at Hydraulic Motor inlet is pressurized. Hydraulic motor should begin cranking the turbine engine,

v)

Check system for leaks at all times,

vi)

Verify turbine is able to reach the minimum crank speed of 25 percent Gas Producer speed (NGP) with no fuel or ignition,

vii)

After satisfactory operation, at control console display screen, de-select the Test Crank to de-energize crank circuit.




Diesel-Engine or Gas-Engine-Driven Generators This procedure describes general instructions for operation of generator sets incorporating both a Manual Voltage Control and Automatic Voltage Control system. 5.2.3.1

Alarm and Shutdown Test i)

ii)

5.2.3.2

Simulate and functional test shutdown signals from associated instrumentation to the Remote and Local Control Panel. Any of the following conditions could shut down the equipment with audible and visual indications:a)

Low Oil Pressure,

b)

High Oil Temperature,

c)

High Water Temperature,

d)

Over speed Trip,

e)

Emergency Shutdown,

f)

Starter Motor Clutch Fail to disengage.

Simulate and functional alarm signals from associated instrumentation to Remote and Local Control Panel. Any of the following conditions could trigger the audible alarms with visual indications:a)

Low Water Level,

b)

Engine Over crank,

c)

High Vibration,

d)

Low Day Tank Fuel Level,

e)

High Day Tank Fuel Level,

f)

High Generator Winding Temperature,

g)

High Generator Bearing Temperature,

h)

Generator Overvoltage,

i) Generator Under voltage. Local and Manual Operation



Prior to starting of the engine, the following electrical checks shall be considered. i)

Set selector switch at Local Control Panel to LOCAL position,

ii)

Open the Output Circuit Breaker to disconnect the generator from the load,

iii)

Turn voltage adjust Rheostats to full counter clockwise position,

iv)

Actuate Auto-Manual Switch to the Manual position,

v)

Make sure that the Engine Start System functional check has been completed before starting the unit,

vi)

Start and Stop Tests a)

Start the generator set in accordance with the manufacturers specifications,

b)

Stop generator set. Check rotation as unit slows to stop

c)

Start and stop generator set several times. Observe any unusual conditions such as excessive noise or vibration,

d)

When operation is satisfactory to this point, adjust speed with Engine Speed Decrease/Increase switch to obtain desired frequency,

e)

Record speed, temperature, and pressures. Check against established norms,

f)

Turn the Voltage adjust Rheostat to approximately the midpoint position. Make certain only Manual Adjust Rheostat is turned at this point in the operational test,

g)

Close Output Circuit Breaker and apply a light load,

h)

Adjust Manual Voltage Adjust Rheostat until generator produces desired output voltage,

i)

Slowly increase load to generator rated power factor full load value. Adjust Manual Adjust Rheostat as necessary to obtain desired output voltage,



j)

Perform post-start checkout and periodically observe engine and generator instruments to ensure that generator set is operating normally,

k)

Stop unit and actuate Auto-Manual Switch to AUTO position,

l)

Re-start unit and adjust engine speed to obtain desired frequency,

m)

Adjust Auto Voltage Adjust Rheostat to obtain desired output voltage,

n)

Apply the rated power factor load, and then check the generator terminal voltage. Check voltage regulation.

Note: Refer to voltage regulator manufacturer’s instruction.

5.2.3.3

o)

During operation, observe engine and generator instruments at regular intervals so that any abnormal conditions can be corrected before any serious damage occurs.

p)

Check current on each line. Use a clip on ammeter if an ammeter is not incorporated in generator set,

q)

Check line to line to neutral voltages,

r)

Shutdown unit in accordance with the operation instructions supplied by the manufacturer of the prime mover or the engine.

Automatic Operation The equipment is capable of starting automatically via an automatic transfer switch on failure of normal power supply. To start the engine automatically, the following procedures shall be taken:i)

Set selector switch at Local Control Panel to “Remote” position,

ii) Simulate “Failure of Normal Supply” by cutting normal power switchgear from emergency power switchgear, iii) When the engine starts, adjust engine speed Decrease/Increase switch to obtain desired frequency,



iv) Check generator no-load voltage. Adjust Generator Voltage Adjust Rheostat to obtain normal generator voltage, v) The generator is ready to accept load. Slowly increase the load to generator rated power factor full load value, vi) During operation, observe Engine Jacket Water, Inlet Air and Exhaust temperature gauges, Engine Oil pressure and temperature and Tachometer Caution: Stopping the engine immediately after it has been working under load, can result overheating and accelerated wear of engine components.




Shutting Down of Engine Follow the stopping procedure outline below, to allow the engine to cool down. Excessive temperature in the turbocharger center housing will cause lube oil “cooking” problem. The unit shall be shutdown in accordance with the operating instructions of the prime mover manufacturer. i)

Reduce the engine to low idle,

ii)

Shift into NEUTUAL. On generators open the main electrical circuit breaker,

iii)

Increase engine speed to more half engine speed. Idle for at least five minutes to cool off the engine,

iv)

Reduce engine speed to low idle,

v)

Check the crankcase oil level while the engine is idling Maintain the oil level between the ADD and FULL marks on the CHECK WITH THE ENGINE RUNNING side of the dipstick,

vi)

The engine may be stopped by using one of the following engine mounted controls or as provided with the engine:a)

Toggle Switch – Move toggle switch to OFF position,

b)

Manual Fuel Shutoff Lever- Pull the red handle lever out to shut off the fuel supply to the engine.



Load Test and Continuous Test Run i)

Refer to Section 5.1.2.1 – Start-up and Testing mechanical procedure for Diesel-Engine- and Gas-Engine-Driven Generator for load test and continuous test run requirements,

ii)

Record all readings and test results at regular intervals on Load Test log sheet.



High Voltage Motor Control Center and Switchgear i)

Re-check insulation resistance of High Voltage Motor Control Center and Switchgear bus-bars between phases and between phases to earth.

ii)

During the test all shunts connected to instruments and derives shall be disconnected. All electronic devices shall also be disconnected. The readings shall be taken one (1) minute after the application of the test voltage.

Caution:

All switching devices shall be in close position during the test.

iii)

Ensure that circuit breaker High Voltage pressure test has been carried out with Circuit Breakers and High Voltage Contactors “close onto busbars”.

iv)

Perform mechanical operation test. All switches, pushbuttons, door mounted actuated devices, door interlocks are safely shutters shall be checked to ensure that they operate reliably and smoothly.

v)

Ensure that operational check of all protective relays by suitable injection of measure quantity has been completed and all relay settings are as per they relay setting tables.

vi)

Check polarity of direct current power supply, current transformer and potential transformer connections to ensure all circuits will operate and function properly when energized.

vii)

Energized the control circuit.

viii)

Functional check of vacuum circuit breaker’s (VCB) interlocking facilities such as electrical, key and mechanical interlocks. Simulate trip signals or interlocks sent and received.

ix)

Verification of VCB interlocks shall include but not limited to:a)

VCB cannot be inserted if earth switch is close,

b)

VCB cannot be inserted if secondary control plug is not connected,

c)

Secondary control plug cannot be withdrawn once VCB is in service position,

d)

VCB cannot be closed other than in the service, test or withdrawn position,



x)

Check operation of circuit breaker with the breaker in ISOLATED and in SERVICE position at LOCAL and REMOTE condition including indications.

xi)

Functional check of motor starter feeder and motor contactor operation.

xii)

Energized High Voltage Switchgear and Motor Control Center in accordance with CARIGALI approved start-up procedure.

xiii)

This initial start-up procedure to Energized 6.6 kilo-volt Alternating Current (AC) Switchgear and Motor Control Center incomers and busbars adopts the following sequence:a)

Vacuum Circuit Breakers are confirmed isolated,

b)

The voltage power supply of direct current for Switchgear and Motor Control Center controls is made available. Verify if the power “ON” light is illuminated,

c)

Switchgear incomer Vacuum Circuit Breaker is closed. At this point the incomer VCB is energized and feeding the AC power to Switchgear and Motor Control Center bus-bars,

d)

Verify if the Vacuum Circuit Breaker “closed” light is illuminated and confirm position indication on the Vacuum Circuit Breaker is “CLOSE”,

e)

Record each bus-bar phase to phase voltage using the voltmeter and selector switch on Vacuum Circuit Breaker Control panel,,

f)

Individual compartment / cubicle vacuum circuit breakers for High Voltage Distribution and Motor Starter feeders are energized only when pre-commissioning on downstream systems are verified to be ready. High Voltage Switchgear / Motor Control Center is left energized for power requirements on other precommissioning activities.

xiv)

Documentation of all ITRs and tests made in relevant ITRs.



Low Voltage Motor Control Center and Switchgear i)

Re-check insulation resistance of LV MCC and Switchgear bus-bars between phases and phases to earth.

ii)

During the test all shunts connected to instruments and derives shall be disconnected. All electronic devices shall also be disconnected. The readings shall be taken one (1) minute after the application of the test voltage.

iii)

Perform mechanical operation test. All switches, pushbuttons, door actuated devices, door interlocks are safely shutters shall be checked to ensure that they operate reliably and smoothly.

iv)

Ensure that operational check of all protective relays, Air Circuit Breaker and thermal overloads by suitable injection of measure quantity has been completed and all relay setting done as per the relay setting table.

v)

Check polarity of direct current power supply, current transformer and potential transformer connections to ensure all circuits will operate and function properly when energized.

vi)

Energize the control circuit.

vii)

Functional check of circuit breaker interlocking facilities such as electrical, key and mechanical interlocks. Simulate trip signals or interlocks sent and received.

viii)

Check operation of circuit breaker with the breaker in TEST and in SERVICE position at LOCAL and REMOTE condition including indications.

ix)

Functional check of motor starter feeder and motor contactor operation.

x)

Energize Low Voltage Switchgear and Motor Control Center in accordance with Carigali approved start-up procedure. This initial startup procedure to Energise 415 VAC Switchgear and MCC incomers and Busbars adopts the following sequence:a)

All Switches and MCC Circuit Breakers are confirmed isolated,

b)

The direct current power supply for Switchgear and MCC controls is made available. Verify if the power “ON” light is illuminated,

c)

Switchgear incomer Air Circuit Breakers is closed. At this point the Air Circuit Breaker is energized and feeding 415 volt AC power to



Switchgear / MCC bus-bars. Verify if the Air Circuit Breaker “closed” light is illuminated, d)

Record each bus-bar phase to phase voltage using the voltmeter and selector switch on Air Circuit Breaker Control panel,

e)

Individual compartment and cubicles circuit breakers are progressively energized when pre-commissioning is to be done on individual loads (see corresponding procedure for precommissioning individual utilization loads).

xi)

De-energizing of Switchgear and Motor Control Center after completion of pre-commissioning activities.

xii)

Documentation of all checks and tests made.



Transformers i)

Obtain factory calibration certificates and test certificates of testing done in the factory for “routine test”, “special test” and “type test”.

ii)

Complete loop check and function test of transformer auxiliary equipment such as cooling fans, oil pump motors and associated controls including WTI and OTI.

iii)

Loop check and functional loop test of trip signals (send and receive) on transformer’s primary and secondary side circuit breakers at respective high voltage and low voltage switchgears.

iv)

Test insulation resistance for primary-to-earth secondary-to-earth, and primary-to-secondary phases.

v)

Ensure high potential (hi pot) testing of transformer High Voltage windings and High Voltage cables had been carried out. Repetition of hi pot test is not recommended for transformer windings.

vi)

For oil-immersed transformers, verify that insulation oil quality had been checked by carrying out di-electric strength (breakdown) test on the sample oil.

vii)

Energized the transformer at rated voltage Record transformer tap position and secondary open circuit voltage. Verify the voltage ratio.

viii)

Verify and confirm that there is no abnormal noise and the sound level is within acceptable limits. Take note of any abnormalities.

ix)

Load test of transformer and monitor temperature rise.

x)

Simulate shutdown and trip test on transformer’s primary and secondary side circuit breakers.

xi)

Performance test of transformer for seventy two (72) hours.

xii)

Documentation of all checks and test made.





Batteries and Battery Charger i)

Check the voltage level across all individual cells to verify the voltage balance on battery system and that no cells have reversed their polarity.

ii)

Applying a substitute load, perform discharge test on battery bank. At the end of discharge test ensure that the end voltage of each cell is within the minimum level and within the required tolerance.

Note: The battery bank must have the required capacity base from the rate of discharge to supply the load. Record the voltage and discharging current at fifteen (15) minutes interval. iii)

Energized the battery charger, functional check and verify correct operation of all auxiliary equipment. Ensure that phase connection and polarity are correct. Simulate all the trip signals and indication from Fire and Gas panel and Shutdown panel.

iv)

Recharge the batteries after completion of discharge test. Take readings of battery voltage and charging current one-half (1/2) hour interval until fully charge.

Note: Charging period must be in accordance with the specification. Any abnormalities on charger output must be troubleshooting using vendor’s recommended procedure. v)

Performance test of battery and battery charger for seventy two (72) hours.

vi)

Documentation of all checks and tests made.

vii)




Uninterruptible Power Supply i)

Recheck insulation resistance of alternating current (AC) power, control and auxiliary circuits of the Uninterruptible Power Supply (UPS) system.

ii)

Perform battery charge and discharge test. Battery discharge test shall be performed at a current corresponding to the inverter input current when the inverter is delivering its rated output i.e. KVA at 0.8 power factor. Monitor the operation of timer for circuit isolation, where applicable.

iii)

Measure and record the battery voltage after the specified battery discharge time.

iv)

Energize AC power supply of UPS from AC switchboard.

v)

Functional test of converter consisting of rectifier, inverter, static switch assembly and other related auxiliaries. Test shall include but not limited to:-

vi)

a)

Rectifier to fulfill the inverter input requirement and recharge the battery within the period of eight (8) hours from partially discharge condition to 90% full rated capacity when inverter is delivering its rated output at 0.8 power factor lagging,

b)

Functional test of rectifier battery float-charge and rapid charge operation. Rapid charge shall not be done for sealed battery.

c)

Output of the inverter shall be maintained within the voltage frequency tolerances of the load at all time,

d)

Output voltage of the inverter shall also be controlled to maintain in synchronism and in phase with the mains bypass supply voltage,

e)

Start switch shall initiate manually and automatically uninterrupted transfer of the load from inverter to the bypass circuit, and from the bypass circuit to the inverter,

f)

Verify the correct functioning of all measuring instrument, alarms and indications, protection and controls,

Energize UPS Distribution Board. Measure incoming and branch circuit voltage at distribution board with all circuits on.



vii)

Performance test of UPS system at rated capacity for seventy two (72) hours.

viii)

Documentation of all checks and test made.



Navigational Aids i)

Recheck insulation resistance of individual circuit without the lanterns being in place.

ii)

Energize alternating current (AC) power supply of Nav-aid battery charger from AC switchboard.

iii)

Test navigational aid battery system as per Battery and Battery Charger testing procedure (see Section 5.2.6).

iv)

Energize navigational aid lanterns direct current (DC) distributor board.

v)

Measure incoming and branch circuit voltage at distributor board with all circuits on. Ensure voltage value is within the allowable limits.

vi)

Verify navigational aid lanterns operation in each circuit and measure the lantern terminal voltage.

vii)

Check and functional test lamp charger operation.

viii)

Check the navigational aid lanterns synchronization.

ix)

Verify if the flashing light exhibit Morse code “U” for every fifteen (15) seconds.

x)

Measure illumination levels at each lantern area and verify if it is within the illumination level to be maintained.

xi)

Test the operation of photocells (if present).

xii)

Perform test of Navigational Aid system for 72 hours.



Small Power and Lightings i)

Energize the lighting panel and distribution board from alternating current (AC) switchboard or low voltage motor control center.

ii)

Energize individual lighting and small power circuit.

iii)

Measure the incoming branch voltage lighting panel and distribution board with all the circuits ON.

iv)

Verity the fight fittings operation in each circuit.

v)

Perform battery charge and discharge tests (for emergency) light fittings with battery pack.

vi)

Perform “Able” and “Disable” control circuit test.

vii)

Test operation of photocell (if present).

viii)

Test operation of circuit wall-mounted switches and verify that it controls the correct light fittings.

ix)

Verify power receptacles or sockets operation.

x)

Measure the voltage at each point.

xi)

Test ground continuity of grounded pole. Trip test of receptacles due to earth fault by earth leakage circuit breaker (ELCB) tester.

xii)

Measure illumination levels at specified areas when all the paintings are completed.

xiii)

Perform test of small power and lighting system for seventy two (72) hours.





Earthing and Lighting Protection i)

Inspect earth cable lugs, earth boss stud diameter and welding and earthing resistor connections.

ii)

Ensure that earthing layout and connections conform to the design.

iii)

Inspect that all contacts are cleaned, greased and bonded with Denso tape where applicable.

iv)

Check tightness of all earth connection.

v)

Check earth cable protection such as kick plates or kick pipes.

vi)


vii)

Continuity and resistance checks shall be performed for the following:a)

Bonding of cable wire armor or braid, brass cable glands and equipment frame to earth,

b)

Main earth resistance, and

c)

Earth loop resistance,

Note: Resistance values shall not exceed one (1) ohm for signal cables earthed at one point. The ohmic resistance of the lightning conductor system without earth connection should be about one-half (0.5) ohm. If it exceeds one (1) ohm, there shall be some faults either electrically or mechanically, which shall be inspected and defects rectified. viii)

Measure resistance ohmic value of the Neutral Earthing Resistor (NER).

ix)

Inspect the NER internal connections, supports and fixing details.

x)

Perform installation resistance test on the NER.

xi)

Document all tests and checks performed.

xii)




Heat Tracing 5.2.12.1

5.2.12.2

Pre-Startup Checks i)

Check fuse ratings of the control circuits and power supply circuit breaker rating as per design,

ii)

Verify the cleanliness of heat tracing panel exterior and interior,

iii)

Inspect equipment grounding system and measure the ground resistance,

iv)

Functional check of Panel switches, pushbuttons and verify that all indicating lights illuminates with fault audible alarm when Lamp Test circuit is ON,

v)

As individual heat tracing circuit is being energized with a minimum time interval of one (1) minute between each individual start-up, note to status indication in the heat tracing panel.

Distribution Board Inspection and Testing i)

Check for interior and exterior cleanliness of Distribution Board (DB).

ii)

Check operation of DB isolator and padlock facilities,

iii)

Check main feeder and distribution feeder circuit breaker ratings as per heat tracing circuit load demand,

iv)

Check close and open operation of main circuit breaker (MCB) by hand,

v)

Check if board is fitted with circuit identification labels,

vi)

Check all feeder cable terminations. Continuity and insulation test of all incoming and outgoing cables,

vii)

Check Distribution Board earthing,

viii)

When all heat tracing circuits are energized measure the main feeder voltage and individual circuit. Verify that voltage drop is within the acceptable value.



Heat Tracing Circuit Inspection and Testing The following checks and inspections shall be performed on each heat tracing circuit:-

5.2.12.4

i)

Check installation as to completeness and correctness in accordance with the approved isometric drawings and manufacturer’s drawings,

ii)

Ensure that each circuit components such as heating tape, joint seal, junction box, and end seals are properly fitted,

iii)

Check heater cable entry to insulation is correctly installed. Also check power cable entry to junction box,

iv)

Perform insulation resistance testing of heat tracing circuit in accordance with Insulation Resistance Procedure described below in Item 4,

v)

Inspect all insulation installation if in accordance with the specification.

Insulation Resistance Test Procedure Insulation Resistance of Heat Tracing Circuit shall be performed by using a 500 Volt DC Insulation Tester, by measuring insulation resistance of the heater cable cares to ground. The procedures shall be as follows:vi)

Insulation Resistance test the circuit after end seal was fitted,

vii)

Sock the end seal in the bucket of water for one (1) hour,

viii)

After soaking the end seal in water, Insulation Resistance test the circuit for at least one (1) minute,

ix)

After finishing isolation installation, Insulation Resistance r test the circuit again,

x)

Record all test result.


5.2.12.5


Testing After completion of various checks, inspections and tests performed on the system’s panels and components, the heat tracing circuit shall be tested continuously for at least two (2) hours. During test, the following information shall be monitored and recorded at regular intervals. i)

Startup current of each circuit,

ii)

Individual circuit load (amps),

iii)

Pipe maintenance temperature of each circuit,

iv)

Thermal output,

v)

Total load of each distribution panel, and

vi)

Ambient temperature.



Un-coupled and Coupled Run Test of Electric Motors 5.2.13.1

Pre-Startup Checks and Verifications The following actions shall be observed prior to starting up and electric motor:i)

Verify shaft coupling and beltings are removed,

ii)

Electrical inspection and checks on motor stator winding connections, terminal box flange and fixing bolts, motor earthing, motor heater rating and voltage, and winding temperature detector.

iii)

Insulation resistance and continuity check of all power and control cables, motor windings and space heaters,

iv)

Measure earthing of distribution boards and end devices,

v)

At the motor control center ensure that protective relays circuit breakers and thermal overload relay setting and breaker size are correct for the motor to be started.

vi)

Functional test of motor starter feeder control including the remote control unit / control station with the power supply to the motor disconnected,

vii)

Functional test of motor starter feeder control including the remote control unit / control station with the power supply to the motor disconnected,

viii)

Motor with space heaters should be turned on as soon as possible and left on while then motor is not running,

ix)

Recheck insulation resistance of windings between line-toline and line-to-ground. Also recheck insulation resistance of heater, temperature detector to earth,

x)

Ensure correct power supply and proper operation of motor starter feeder control including the remote control unit / control stations.



Startup i)

For no load run test, start and operate the motor for sufficient time to carry out the following checks:a)

Check the direction of rotation against the indicated rotation of the driven machine. Record the time to coast to stop after rotational check.

b)

For low voltage motor, run the motor for thirty (30) minutes and for high voltage motor run the motor for four hours. Measure the starting current, running current, voltage and frequency noting any abnormalities,

c)

Check speed and vibration level,

d)

Check motor bearing temperature during and at the end of run. Also check for winding/frame temperatures,

e)

Record all readings on the ITR.

ii)

At the end of uncoupled run recheck the insulation resistance of the windings. Remake the couplings and install belts. Check alignment and end-play of fixer coupling. In the case of belt coupling, the line-up of pulleys, the capacity and the number of belts and belts tension checked.

iii)

For load run of motors start and run the motor for four (4) hours – Shall be in conjunction with mechanical test run of the driven equipment and carry out the following checks:a)

Measure starting current, running current with load, voltage and frequency and note for any abnormalities,

b)

Check speed and vibration level.

c)

Check motor bearing temperature during and at the end of run. Also check for winding/frame temperatures,

d)

Record all readings on the ITR.





iv)

For special motors in intermittent duty services determine maximum running time on nameplate and technical data which will not cause any damage to the motor.

v)

Documentation of all tests and checks made.



Heater Control Panels and Heaters 5.2.14.1

5.2.14.2

Inspection of Heater Control Panels i)

Check and record fuse and circuit breaker rating,

ii)

Verify wiring and core marking correct to circuit diagram,

iii)

Inspect all earthing connections and measure earth resistance,

iv)

Test for manual operation of control switches and control buttons (selector switches, pushbuttons, etc.)

v)

Ensure availability of power supply for control system. Check and measure voltage.

vi)

Check operations of all panel indications. Verify that all system status indicators illuminates and sounds fault buzzer when the lamp test switch is on,

vii)

Function test alarm and shutdown logic as per system shutdown matrix,

viii)

Check panel tie-in to Platform Shutdown Panel, Fire & Gas Panel and Distributed Control System (DCS)

Inspection of Heaters i)

Check all electrical terminals in the control panel and the heater terminal housings,

ii)

Inspect and ensure that all grounding requirements are met and that ground connections are tight,

iii)

Power wiring should be connected at the line side of the circuit breaker (CB) in the control panel,

iv)

Verify that the main power feeder and feeder circuit breaker are sized with respect to the load demand of the Heater Assembly,

v)

Functional test the shunt trip signal to Motor Control Center Circuit Breaker from Positive Pressure Purge System controls,



vi)

Turn the heater circuit breaker OFF and remove the heater terminal housing cover and check that all heater terminal connections are tight,

vii)

Check the resistance readings leg to leg for each circuit of each heater. The resistance value for each circuit shall be as per manufacturer’s requirement,

viii)

Perform megger testing between each phase and ground. In each case, insulation resistance value greater than 0.5 MΩ should be observed,

Note: Under no circumstances should the resistance value between any phase and ground be close to zero ohms. ix)

5.2.14.3

5.2.14.4

Replace the heater terminal housing cover before proceeding.

Sheath Temperature Set-Point i)

With power upstream of the control panel is OFF, turn the Power OFF/ON switch on the front of the control panel to the OFF position,

ii)

Open the control panel door and locate the Overtemperature Controller (OTC). Adjust OTC required setpoint for sheath over-temperature limit,

iii)

Locate the Process Controller on the inside panel and select the desired operating temperature

Energization i)

With the circuit breaker upstream of the control panel OFF, open the electrical enclosure and set the temperature controls to the desired set-point,

ii)

Turn the heater circuit breaker to the “ON” position,

iii)

Turn the rotary switch on the integral motor starters clockwise to the “AUTO” position,

iv)

Close and tighten the bolt all the panels in preparation for running the heaters. Turn the circuit breaker upstream of the heater unit to ON,



v)

Turn the circuit breaker for the heater system to the ON position. Process temperature can be observed by way of digital readout visible through the viewing window,

vi)

Set the temperature set point on the TIC in the control panel to the desired process temperature,

vii)

Place the heater system “ON/OFF” switch to the “ON” position. The “Power On” light will illuminate and temperature indicator will display current process temperature,

viii)

Verify the operation of shutdown valve. Indication of valve status is provided by the indicator light.



Instrumentation Pre-commissioning Procedures 5.3.1

General Construction Verification After each instrument the components of a loop have been installed and hooked-up it is necessary to check that the work has been carried out in satisfactory manner in accordance with the hook-up drawing. The completed installation is defined as when all necessary connections (tubing and wiring) are completed for all instrument within a loop and should now be ready for loop checking and testing, After verifying against available documentation that installations are completed, loop test to check that each instrument and components of the loop function correctly as per design requirement shall be performed. Test signals shall be injected into the loop, at the sensor using calibrated test equipment e.g. ‘dead’ weight tester or ‘sand bath’, in order to verify correct responses. Loop Test shall be performed under Pre-Commissioning and Commissioning parts.

5.3.2

Loop Test of Pressure Instrument 5.3.2.1

Pressure Transmitter i)

Verify the test equipment and gauge calibration validity.

ii) Connect the test equipmentand gauge to the process impulse line. iii) Review calibration sheet for pressure transmitter and other instruments in the loop. iv) Apply pressure of 0, 50, and 100 percent of range and confirm a correct transmitter output signal of 4 to 20 millamperes is received at control panel or PMCS HMI. v) Verify for correct reading through PMCS HMI display. vi) Verify correct Recorder and Indicator reading at control panel. vii) Ensure that all relevant alarms are functioning correctly.



viii) Pre-commissioning ITR to be duly filled in and witnessed by CARIGALI and CONTRACTOR Quality Control personnel. ix) Typical test set-up for pressure transmitter is shown in Figure 5-2.

5.3.2.2

Pressure Switch (Electric) i)

Verify the test equipment and gauge calibration validity,

ii) Verify the connection to the switch with the approved termination drawing i.e. normally close or open, iii) Connect the test equipment and gauge to the process impulse line, iv) Review calibration sheet for pressure switch and other instruments in the loop, v) Hook-up test equipment and instrument to be tested as per set-up shown in Figure 5-3, vi) For Pressure Switch Low (Falling Pressure),


Figure 5-2:


Typical Test Setup for Pressure Transmitter

a) Increase applied pressure above the reset point to indicate normal condition at control panel, b) Decrease applied pressure to the desired set-point and observe change of status from normal to alarm/trip condition, c) Ensure that all relevant alarms are functioning correctly, d) Pre-commissioning ITR to be duly filled in and witnessed by CARIGALI and CONTRACTOR Quality Control personnel,

vii) For Pressure Switch High (Rising Pressure)

a) Increase applied pressure to the required set-point to observe change of status from normal to alarm/tripcondition. b) Ensure that all relevant alarms are functioning correctly,





c) Decrease applied pressure below the reset point and observe change of status from alarm to normal condition. Contact should change from normally-open position to normally-close position,

Figure 5-3:

Typical Test Setup for Pressure Switches (Electric Type)

d) Pre-commissioning ITR to be duly filled in and witnessed by CARIGALI and CONTRACTOR Quality Control personnel. 5.3.2.3

Pneumatic Pressure Switch i)

Hook-up test equipment and instrument to be tested as per set-up shown in Figure 5-4.

ii)

For Pressure Switch Low (Falling Pressure), a) Increase applied pressure above the reset point to indicate normal condition at control panel. b) Decrease applied pressure to the desired set-point and observe change of status from normal to alarm condition. c) Ensure that all relevant alarm are functioning correctly.



d) Pre-commissioning ITR to be duly filled in and witnessed by CARIGALI and CONTRACTOR Quality Control personnel. iii)

Figure 5-4:

For Pressure Switch High (Rising Pressure)

Typical Test Setup for Pneumatic Pressure Switches a) Increase applied pressure to the required set-point and observe change of status from normal to alarm condition, b) Ensure that all relevant alarm are functioning correctly, c) Decrease applied pressure below the reset point and observe change of status from alarm/trip to normal condition, d) Pre-commissioning ITR to be duly filled in and witnessed by CARIGALI and CONTRACTOR Quality Control personnel.



Loop Test of Level Instruments 5.3.3.1

Level Transmitter (Electric) – Differential Pressure Cell Type i)


ii)

Connect the test equipment and gauge to the process impulse line.

iii)

Review calibration sheet for DP cell transmitter and other instruments in the loop.

iv)

Induce signal of 0, 50 and 100 percent of the differential pressure range.

v)

Confirm correct transmitter output of 4 to 20 milleamperes is received at control panel.

vi)

Verify for correct reading through PMCS HMI display.

vii)

Ensure that all relevant alarms are functioning correctly.

viii)

A typical test set-up is shown in Figure 5-5.

ix)

Record test results in Instrument closed loop ITR (ITR-B for pre-commissioning and ITR-C for commissioning) and shall be witnessed by CARIGALI representative and CONTRACTOR Quality Control personnel.


Figure 5-5:


Test Setup for Differential Pressure Cell Type Electrical Level Transmitters

5.3.3.2

Level Transmitter (Electric) – Displacer or Float Type i)

Hook-up test equipment and instrument loop to be tested as per set-up shown in Figure 5-6.

ii)

Fill in water at 0, 50, and 100 percent of the range.

iii)

Confirm correct transmitter output signal of 4 to 20 mille amperes is received at control panel.

iv)

Verify for correct reading through PMCS HMI display.

v)


vi)

Record test results in Instrument closed loop ITR (ITR-B for pre commissioning and ITR-C for commissioning) and shall be witnessed by CARIGALI representative and CONTRACTOR Quality Control personnel. Note: For displacer, ensure necessary correction is applied to compensate the density difference between water and process fluid.


Figure 5-6:


Test Setup for Displacer or Float Type Electric Level Transmitter

5.3.3.3

Level Transmitter (Pneumatic) – Displacer or Float Type i)

Hook-up test equipment and instrument loop to be tested as per set-up shown in Figure 5-7,

ii)

Fill in water at 0, 50 and 100 percent of the range.

iii)

Confirm correct transmitter output signal of 20 to 100 kilopascal (kPa) is received at Instrument Control Panel. Note:For displacer, ensure necessary correction is applied to compensate the density difference between water and process fluid.

iv)

Verify correct controller action to the final control element.

v)

Record test results in Instrument closed loop ITR (ITR-B for pre commissioning and ITR-C for commissioning) and shall be witnessed by CARIGALI representative and CONTRACTOR Quality Control personnel,


Figure 5-7:


Test Setup for Displacer or Float Type Pneumatic Level Switches



Level Switch (Electric) – Displacer or Float Type i)

Figure 5-8:



Test Setup for Displacer or Float Type Electric Level Switches

ii) For Level Switch Low (Falling Level) a) Increase calibrating level above the reset point to indicate normal condition at control panel. Contact should change from normally-open (NO) position to normally-losed (NC) position, Note: If signal is normally energized (fail safe). b) Decrease calibrating level to the required set point and observe change of status from normal to alarm condition. Contact should change from normally-closed (NC) position to normally-open (NO) position, Note: For displacer, ensure necessary correction is applied to compensate the density difference between water and process fluid. c) Ensure that all relevant alarms are functioning correctly,



d) Record test results in Instrument closed loop ITR (ITR-B for pre commissioning and ITR-C for commissioning) and shall be witnessed by CARIGALI representative and CONTRACTOR Quality Control personnel. iii) For Level Switch High (Rising Level) a) Increase calibrating level to the required set point. Contact should change from normally-closed (NC) position to normally-open (NO) position, Note: If signal is normally energized (fail safe). b) Ensure that all relevant alarms are functioning correctly, c) Decrease calibrating level below the reset point and observe change of status from alarm to normal condition. Contact should change from normally-open (NO) position to normally-close (NC) position, Note: For displacer, ensure necessary correction is applied to compensate the density difference between water and process fluid. d) Record test results in Instrument closed loopITR (ITR-B for pre commissioning and ITR-C for commissioning) and shall be witnessed by CARIGALI representative and CONTRACTOR Quality Control personnel.



Level Switch (Pneumatic) – Displacer or Float Type i)


ii) For Level Switch Low (Falling Level) a) Increase calibrating level above the reset point to indicate normal condition at control panel. Confirm 200 kPa output from the switch. b) Decrease calibrating level to the required set point and observe change of status from normal to alarm condition. Confirm zero (0) kPa output from the switch. Note: For displacer, ensure necessary correction is applied to compensate the density difference between water and process fluid. c) Ensure that all relevant alarms are functioning correctly.

iii) For Level Switch High (Rising Level) a) Increase calibrating level to the required set point to observe change of status from normal to alarm condition. Confirm zero (0) kPa output from the switch. b) Ensure that all relevant alarms are functioning correctly. c) Decrease calibrating level below the reset point and observe change of status from alarm to normal condition. Confirm 200 kPa output from the switch, Note: For displacer, ensure necessary correction is applied to compensate the density difference between water and process fluid.


Figure 5-9:


Test Setup for Displacer or Float Type Pneumatic Level Switches



Loop Test of Temperature Instruments 5.3.4.1

Sensor Calibration (Temperature Bath) Note: To refer to vendor for specific procedure.

5.3.4.2

Figure 5-10:

Resistance-Temperature-Detector (RTD) Transmitters i)

Connect a decade resistance box to the temperature transmitter.

ii)

Induce equivalent resistances at 0, 50 and 100 percent of the temperature range and confirm the correct recorded or indicator reading at respective control panel in the control room.

iii)


iv)

Pre-commissioning ITR to be duly filled in and witnessed by PETRONAS Carigali and CONTRACTOR Quality Control personnel.

v)

A typical test set-up is shown in Figure 5-10.

Typical Test Set-Up for RTD-type Temperature Transmitters


Figure 5-11:


Temperature Switches (Electric) i)

Review calibration sheet for temperature switch and other instruments in the loop,

ii)

Hook-up test equipment and instrument to be tested as per set-up shown below in Figure 5-11.

iii)

Actuate the switch by actual or simulation of input. Note: For temperature-low switch, contact should change from normally open (NO) position to normally-close (NC) position. For temperature-high switch, contact should change from normally-close (NC) to normally-open (NO) position. Note: Only applicable normally energized signal (fail-safe).

iv)

Observe the change from normal to alarm condition ensure that all relevant alarms are functioning correctly.

v)

Pre-commissioning ITR to be duly filled in and witnessed by PETRONAS Carigali and CONTRACTOR Quality Control personnel.

Typical Test Set-Up for Temperature Switch (Electric Type)



Loop Test of Flow Instruments A – Direct Positive Displacement  Variable Area B – Inferential 1) Head Meter – Loop check only involves transmitter to the control panel/PMCS.  Orifice Plate  Venturi Tube  Flow Nozzle  Pitot Tube  Annubar  V-Cone i)


ii) Connect the test equipment and gauge to the process impulse line. iii) Review calibration sheet for DP cell transmitter and other instruments in the loop. iv) Induce signal of 0, 50 and 100 percent of the differential pressure range. v) Confirm correct transmitter output of 4 to 20 mille amperes is received at control panel. vi) Verify for correct reading through PMCS HMI display. vii) Ensure that all relevant alarms are functioning correctly. viii) Record test results in Instrument closed loop ITR (ITR-B for pre commissioning and ITR-C for commissioning) and shall be witnessed by CARIGALI representative and CONTRACTOR Quality Control personnel.

2) Velocity – Involves simulated signal.  Turbine  Vortex  Magnetic  Ultrasonic



CARIGALI STANDARD PROCEDURE i)


Verify the test equipment (current or frequency simulated) calibration validity.

ii) Connect the test equipment to the flow transmitter. iii) Review calibration sheet of the flowmeters. iv) Induce simulated signal corresponding 0, 50 and 100 percent of the meter calibrated range v) Confirm correct transmitter output of 4 to 20 mille amperes or frequencies is received at control panel is received at control panel. vi) Verify for correct reading through PMCS HMI display. vii) Ensure that all relevant alarms are functioning correctly.

3) Mass  Coriolis  Thermal i)

Verify the test equipment (current or frequency simulated) calibration validity.

ii) Connect the test equipment to the flow transmitter. iii) Review calibration sheet of the flowmeters. iv) Induce simulated signal corresponding 0, 50 and 100 percent of the meter calibrated range. v) Confirm correct transmitter output of 4 to 20 mille amperes or frequencies 0is received at control panel. vi) Verify for correct reading through PMCS HMI display. vii) Ensure that all relevant alarms are functioning correctly.




Flow-Temperature’s-Differential Pressure Cell Type i)

Figure 5-12:


Connect test equipment to flow transmitter as per test diagram shown in Figure 5-12.

Typical Test Set-Up for Differential Pressure Cell Type Flow Transmitters ii)

Induce signal of 0, 50 and 100 percent of the differential pressure range and confirm the correct transmitter output (e.g. linear or square root) of 4 to 20 mille amperes is received at control panel.

iii)

Verify for correct reading through PMCS HMI.

iv)

Apply pressure to the high side of transmitter with the low side vent to atmosphere.

v)

Record test results in Instrument Closed Loop ITR (I11-B for pre commissioning and I11-C for commissioning) and shall be witnessed by CARIGALI representative and CONTRACTOR Quality Control personnel.



Flow Switches i)

Connect test equipment to flow transmitter as per test diagram shown in Figure 5-13.

ii)

Push the trigger assembly to the left and right, then observe the change of contact from normally-open (NO) position to normally-close (NC) position and vice versa.

iii)

Ensure all relevant alarms are functioning as per drawings.

iv)

Record test results in Instrument Closed Loop ITR (I11-B for pre commissioning and I11-C for commissioning) and shall be witnessed by CARIGALI representative and CONTRACTOR Quality Control personnel.

Figure 5-13:

5.3.5.3

Test Setup for Flow Switches

Flow Totalizer i)

Verify that installation checks and inspections including calibration of instruments had been performed based on the CARIGALI ITR (I03-A and I04-A).

ii)

Simulated process input signals to pressure, temperature and flow transmitters shall be applied as shown in the tabulation below.



Element

Step 1

Step 2

Step 3

Step 4

Flow

0

100

50

25

Pressure

25

25

50

100

Temperature

100

100

25

50

Note: Units are in percentages. iii)

Manually entered parameters such as discharged coefficient super-compressibility factor, conversion factor, flow coefficient, etc. shall be verified against relevant standard and vendor data.

iv)

At each step individual pressure temperature and flow signals from transmitter shall be checked against control panel indicator and PMCS HMI.

v)

Manual calculation shall be performed and compared with rate indication at each step.

vi)

Hold simulated process signal values constant at each step for 5 minutes to verify correct accumulation on counters at control panel or PMCS HMI. Result shall be recorded in CARIGALI instrument closed loop ITR (I11-B for pre commissioning and I11-C for commissioning) for each loop.

5.3.5.4

Turbine Flowmeters i)

Disconnect signal lead wires at the flowmeter and the connector of a signal generator and frequency counter,

ii)

Note flowmeter K-factor and adjust signal generator in steps to frequency values corresponding to 0, 25, 50, 75 and 100 percent of the design flowrates.



iii)

Check flow rate indication in metering panel or PMCS HMI for each step. Results shall be recorded in CARIGALI Closed Loop ITR (I11-B for pre commissioning and I11-C for commissioning).

iv)

Hold flowrate signal steady for 5 minutes at each step and verify accumulation on metering panel totalizer and PMCS HMI.

v)

For net oil/water computing loops, connect 4 to 20 mille amperes signal operator to analog output signal leads.

vi)

Repeat flowrate step procedure and adjust signal to 50 percent at each flowrate step.

vii)

Hold signals steady for 5 minutes and verify net oil and net water flowrate indication at metering panel and PMCS HMI. Result shall be recorded in CARIGALI Instrument Calibration ITR (I03-A).

viii)

Verify gross accumulating at metering panel counter and net oil and net water accumulation at metering panel counter and at PMCS HMI display over the 5 minute period. Result shall be recorded in CARIGALI Instrument Calibration ITR (I03-A).

ix)

CARIGALI Instrument Closed Loop ITR to be filled for each loop (I11-B for pre commissioning and I11-C for commissioning).



Loop Test Final Control Instruments 5.3.6.1

Control Valves i)

Prior to testing, set the auto/manual selector to “Manual” and ensure control action is according to specification.

ii)

Simulate controller output signals at 0, 50 and 100 percent to control valve transducer and positioner. Confirm the control valve is functioning correctly. If control valve position feedback is available, verify the position indicated at control panel or PMCS HMI against the actual control valve opening.

iii)

Turn Auto/Manual selector to “Auto”. Confirm that the control valve and other instrument within the loop is functioning as per design requirements and specifications.

iv)

CV/SDV/BDV (control/shutdown valve/blow down valve) Installation & Calibration ITR-Ato be dully filled in and witnessed by CARIGALI representative and CONTRACTOR Quality Control personnel.

5.3.6.2

Actuated Choke Valves NOTE : Manual Stroke Test. - Considering that the pneumatic supply is not available, the stroking test could possibly be done manually since the transmitter is still giving feedback to the PMCS. i)

Prior to testing, ensure that the pneumatic supply is isolated.

ii)

If possible disconnect termination at both solenoid valves open/close. You can still proceed with termination intact but you will hear the clicking sounds of solenoids valve, PMCS will keep giving the signal to open/close solenoid when it sees incorrect feedback compared to set points.

iii)

Workability of transmitter – Please checks that the transmitter is giving feedback to the PMCS. To test - turn the



handwheel of the valve and expect the changes happen at the PMCS. iv)

Stroking the valve manually by using hand wheel – Pull up and engage the hand wheel to the hex nut.

Stroking Procedure i)

Turn the hand wheel to close the valve – Ensure that the hand wheel cannot be turn anymore. This is important step that we wanted to check that at fully close, local indicator pointing at “CLOSE”. Check travel indicator, if it is pointing at CLOSE position – it is good. Local indication is correct as per factory setting. If it is not pointing to “CLOSE”, record the travel that it is pointing to. Record the value of BEAN SIZE appears at the PMCS.

ii)

Turn the hand wheel to open the valve until local indicator pointing at 10 % travel. Record the value of BEAN SIZE appears at the PMCS.

iii)

Repeat step 2 for 0, 10, 20, 30, 40, 50, 60, 70, 80, 90 and 100%. (minimum 5points).

iv)

And finally stepping down from 100, 90, 80, 70, 60, 50, 40, 30, 20, 10 and 0% (minimum 5points).

v)

Data shall be recorded as shown in the tabulation below.



HCV-xxxx Step Up Percent Travel (%) Bean Size (DCS) 0 10 20 30 40 50 60 70 80 90 100

vi)

5.3.6.3

Step Down Percent Travel (%) Bean Size (DCS) 100 90 80 70 60 50 40 30 20 10 0

A typical test set-up for actuated choke valve loop test is shown in Figure 5-14.

Shutdown Valve Supply the specified instrument air to shutdown valve system (actuator).

i)

When 24 volts of direct current output signal from Control Panel is supplied to energize the solenoid valve, the shutdown valve should open.

ii) If manual reset is provided to the solenoid valve or pilot valve manually reset the solenoid valve or pilot valve before the shutdown valve opens.

Note: If manual reset is provided, manually reset the pneumatic relay before the shutdown valve opens.



iii) Confirm limit switches is functioning by observing the shutdown valve status indication which changes from close to open (in the form either at the valve or control system HMI). iv) When 24 volts of direct current output signal from Control Panel is cut off to de-energize the solenoid valve the shutdown valve should close. v) Confirm limit switches is functioning by observing the shutdown valve status indication which changes from open to close (in the form either lamp or screen color changes from red to green). vi) In case the shutdown valve action is controlled by a pneumatic relay with air pilot signal from Local Pneumatic Panel, confirm the shutdown valve opens when the air pilot signal to pneumatic relay is healthy. vii) During shutdown condition, reset handle is immediately released when air pilot signal to pneumatic relay is unhealthy. The shutdown valve should close. If limit switch is provided with shutdown valve confirm the status indication changes correctly to the valve opening and closing action. viii) Record travelling time (from open to close) 1 inch 1second. ix) A typical test set-up for a shutdown valve loop test is shown in Figure 5-15.

5.3.6.4

Blowdown Valves i)

Supply the specified instrument air to blowdown valve system (actuator). When 24 volts of direct current output signal from Control Panel is supplied to energise the solenoid valve, the blowdown valve should close.



If manual reset is provided to the solenoid valve or pilot valve manually reset the solenoid valve or pilot valve before the blowdown valve closes. Note: If manual reset is provided, manually reset the pneumatic relay before the blowdown valve closes. Confirm limit switches is functioning by observing the blowdown valve status indication which changes from open to close (in the form either at the valve or control system HMI). When 24 volts of direct current output signal from Control Panel is cut off to de-energise the solenoid valve the blowdown valve should close. Confirm limit switches is functioning by observing the blowdown valve status indication which changes from close to open (in the form either lamp or screen color changes from green to red). In case the blowdown valve action is controlled by a pneumatic relay with air pilot signal from Local Pneumatic Panel, confirm the blowdown valve opens when the air pilot signal to pneumatic relay is healthy. During blowdown condition, reset handle is immediately released when air pilot signal to pneumatic relay is unhealthy. The blowdown valve should open. If limit switch is provided with blowdown valve confirm the status indication changes correctly to the valve opening and closing action. Record travelling time (from close to open) 1 inch 1second. A typical test set-up for a blowdown valve loop test is shown in Figure 5-15



CARIGALI STANDARD PROCEDURE CCR

PROCESS AREA

DCS / SIS MARSHALLING HMI

AO

CABINET /

4 – 20 mA

JUNCTION BOX

ELCO BOARD

O% 25 % 50 % 75 % 100 %

PROCESS LINE CV / XCV

Figure 5-14:

Loop Test for Control valve and Choke valve

CCR

PROCESS AREA

DCS / SIS MARSHALLING HMI

DO

CABINET /

JUNCTION BOX

24 V

ELCO BOARD

I.A.S

S

PROCESS LINE SDV / BDV / MOV

Figure 5-15:

Loop Test for Shutdown valve, Blowdown valve and Motor-operated valve



Motor (Electric) Valve i)

Note: To refer to vendor for specific procedure. A typical test set-up for motor-operated valve loop test is shown in Figure 5-15.

5.3.6.6

Partial Stroke Test Note: Refer to OEM Partial Stroke Test Procedure and ITR.




Loop Test Rotating Equipment Monitoring System 5.3.7.1

Proximity Probe Verification This section shows how to verify the operation of a proximity transducer system by calculating the incremental scale factor (ISF) and the deviation from straight line (DSL) of the system and then comparing the calculated values with the specified values for the system. Although Bently Nevada proximity transducer systems do not normally require verification, we recommend that you verify your system if any of the following conditions occurs: •

system components are replaced

•

components remounted

•

components appear to be damaged

•

machine being monitored is over‐hauled

are

removed,

reinstalled,

moved,

or

Verification Test Setup The scale factor verification requires the following instruments and equipment: •

Digital multimeter

•

Spindle micrometer

•

Fixed resistor, 10 kΩ

•

Power supply (‐24 Vdc ± 1)

The scale factor verification uses the test setup as shown in the following figure:




Figure 5-16:


Scale Factor Verification

(1) Proximitor® Sensor (2) Multimeter (3) Power Supply (4) Probe, target, and spindle micrometer

Scale factor verification procedure The verification procedure consists of recording the output voltages of the system at a series of gap increments, using these voltage values to calculate the incremental scale factor and the deviation from straight line, and then comparing the calculated values with the specified values for that probe. a) Compensate for mechanical backlash and adjust the spindle micrometer for electrical zero by adjusting the micrometer first to setting 1 and then to setting 2.

Probe Type Nsv 3300 16mm High Temp

Micrometer Setting 1 0.4mm (18 mil) 0.45mm (18 mil)

2 0.5mm (20 mil) 0.50 mm (20 mil)



b) Adjust the gap to electrical zero by moving the probe until the multimeter reads the voltage for electrical zero as listed in the following table.

Figure 5-17:

Probe

Probe Type

Voltage for electrical zero (Vdc)

Nsv

-3.00 ± 0.1

3300 16mm High Temp

-2.00 ± 0.2

c) Compensate for mechanical backlash in the micrometer and adjust to the start of the linear range by adjusting the micrometer to setting 1 and then to setting 2.

Probe Type Nsv 3300 16mm High Temp

Micrometer Setting 1 0.2mm (8 mil) 0.4mm (18 mil)

2 0.25mm (10 mil) m (20 mil)

d) From the following table, identify the range and increment for the micrometer settings for your probe type and then




copy the settings into the appropriate column in Table 3-2. Worksheet for calculating ISF and Vdiff. Table 3.1 Ranges and increments for calculating ISF and Vdiff Range (mm)

Probe Type

Range (mil)

Start End Increment Start End Increment

Nsv

0.25

2.0

0.25

10

80

10

3300 16mm 0.5 4.5 0.5 20 180 20 High Temp

e) For each micrometer setting n, enter the measured output voltage into the column of the worksheet labeled “Output Voltages, Vdcn”.

Table 3.2 Worksheet for calculating ISF and Vdiff




f)

Calculate the values ISFn using the following equation:

Where “gap increment” is taken from Table 3-1.Ranges and increments for calculating ISF and Vdiff. g) For each increment n, calculate the difference voltage, Vdiffn, using one of the following equations. Enter the calculated value into the column of the worksheet labeled “Vdiffn”. Vdiffn = Vdcn+(mmn•SFmm) or Vdiffn = Vdcn+(miln•SFmil) Where the values for scale factor (SF) are as follows:

Table 3.3 Values for scale factor (SF) Probe Type

SF mm [Vdc/mm]

SF mil [Vdc/mil]

Nsv 3300 16mm High Temp

7.87 3.94

0.2 0.1

h) From the Vdiffn column in the worksheet, select the largest voltage difference (Vdiffmax) and the smallest voltage difference (Vdiffmin) and use these values to calculate the deviation from straight line (DSL) using one of the following equations:




Where the values for SFmm and SFmil are listed in Table 3-3. Values for scale factor (SF).

i)

Compare the calculated values for ISF and DSL in the worksheet to the values listed below.

Table 3.4 Typical Values for ISF and DSL ISF

Probe Type

mV/um 7.87 + 12.5% - 20.0%

mV/mil 200 + 12.5% - 20.0%

3.94 ± 9.65%

100 ± 9.65%

Nsv 3300 16mm High Temp

DSL um

Mil

±60

±2.3

±78

±3.1

If the incremental scale factor (ISF) or the deviation from straight line (DSL) are not within the ranges listed above, verify the following items: a) The probe, the extension cable, and the Proximitor® sensor are a matching system. b) The connectors between the probe, extension cable, and sensor are free from corrosion and dirt. c) The connectors between all system components are tightened correctly.

5.3.8

Process Monitoring Control System (PMCS) Note: Vendors procedure shall be used for pre-commissioning and commissioning with the following activities shall be included as minimum where applicable 5.3.8.1

Alternating Current Power Supply Check i)

Check incoming power supply.



ii) Check systemgrounding.

iii) Power up Distributed Control System (PMCS) AC/DC Power circuit breaker.

iv) Make sure that the AC/DC INPUT indication lamp at DCS AC/DC Distribution Panel is ON. If the system has redundant AC/DC power, both AC/DC INPUT lamps must be on.

v) Turn on all AC/DC sub circuit breakers on the PMCS as per wire diagram attached.

vi) Make sure that each AC/DC OUTPUT lamp goes ‘ON’ as each AC/DC circuit breaker is turned on (if applicable).

5.3.8.2

Direct Current Power Supply Check i)

Verify and check each AC/DC Power Supply light indicators.

ii) Follow vendor’s instruction manual for direct current (DC) power supply energization. iii) Measure voltage at all of the DC Bus assemblies. Note: Refer to OEM or PSU Manual. iv) Verify and record the voltage on bus assembly at the furnished device. Tag No.

Reading (Volts)





Battery Backup Test Note: Battery backup for controller RAM i)

Turn off AC breakers.

ii) Verify the battery backup system is in operation. Note: Verification method to follow vendor’s procedure. iii) Turn on AC breakers. iv) Verify that the system is back in operation automatically without any system rebooting required.

5.3.8.4

Operator Interface Check i)

Turn on Operator Interface Station (OIS).

ii) After the main menu is displayed, make sure that all cards have their green LED’s on.

5.3.8.5

Communications (Control Network Status) Check i)

After all Control Files and Consoles are up and running, systems communications must be verified. The following steps shall be observed. ii) Call up the Control Network Status screen. iii) Verify that the node addresses and the devices that are installed on the Control Network match. iv) Configure the Control Network Overview screen. Refer to manufacturer’s instructions for the necessary details. 5.3.8.6

Peripheral Device Check i)

Check that cabinet cooling fans are operational.

ii) Verify Printer operation.


5.3.8.7


System Input and Output Verification i)

Verify input and output (I/O) points of each Controller Processer card.



Safety Instrumented System (SIS) (LAT) Note: Vendors procedure shall be used for pre-commissioning and commissioning with the following activities shall be included as minimum where applicable 5.3.9.1



ii) Check system grounding. iii) Power up SIS Power circuit breaker. iv) Make sure that the AC/DC INPUT indication lamp at SIS AC/DC Distribution Panel is ON. If the system has redundant AC/DC power, both AC/DC INPUT lamps must be on. v) Turn on all AC/DC sub circuit breakers on the SIS. vi) Make sure that each AC/DC OUTPUT lamp goes ‘ON’ as each AC/DC circuit breaker is turned on (if applicable). 5.3.9.2

Direct Current Power Supply Check i) Verify and check each AC/DC Power Supply light indicators. ii) Follow vendor’s instruction manual for direct current (DC) power supply energization. iii) Measure voltage at all of the DC Bus assemblies. Note: Refer to OEM or PSU Manual. iv) Verify and record the voltage on bus assembly at the furnished device. Tag No.

Reading (Volts)



Battery Backup Test Note: Battery backup for controller RAM i)


ii) Verify the battery backup system is in operation. Note: Verification method to follow vendors’ procedure. iii) Turn on AC breakers. iv) Verify that the system is back in operation automatically without any system rebooting required.

5.3.9.4

System Energization i)

Perform visual check to verify completeness of field devices such as breakglass, switch, transmitter, cables, junction boxes, marshalling cabinet and panel installation etc.

ii) Verify completeness of cable insulation resistance and continuity tests. iii) Inspect all power supply distribution wiring to ensure correct polarity and secured connections. iv) Connect the power suppliers to the incoming terminals, close each circuit breaker and insert associated fuse. Confirm that only correct group of terminals are energized. v) Measure the voltage at the incoming terminals and panel/cabinet distribution. Confirm that the voltage is not significantly different from the power supply voltage. 5.3.9.5

Loop Checking i)

If the system is Programmable-Logic-Controlled (PLC) based, verify that the alarm and shutdown logic program in the SIS controller is the same with the one in Engineering Workstation (EWS).



ii) Perform system loop check from input field devices e.g. breakglass, switches, pushbuttons, transmitters etc. to the panel. iii) Perform system loop check from panel to output field devices i.e. shutdown/blowdown valves and motor control center (MCC). iv) Perform system interface check with Fire and Gas, PMCS and General Platform Alarm System. 5.3.9.6

System Integrity Test i)

Manually activate the signal path integrity test on input cards, if available. Confirm that the output cards respond correctly.

ii) Activate the automatic signal path integrity test. Confirm correct response of all output cards. iii) Simulate failure of cards with hot standby spare. Confirm communication of card failure and changeover to hot standby spare.

5.3.9.7

Operational System Test i)

Achieve “System Healthy” status by setting all inputs to “normal” state.

ii) Change the state of one of the inputs that causes the Emergency Shutdown and Blowdown (ESD) to “alarm/shutdown” condition. iii) Verify that the input change of state is annunciated in PMCS and Operator Pushbutton Station. iv) Confirm that resetting the system without changing the state of the input back to normal will not restore “System Healthy” condition.



v) Normalize the input and reset the system. vi) Repeat steps (ii) to (iv) for all other ESD inputs. vii) Repeat steps (ii) to (v) for Process Shutdown (PSD) and Unit Shutdown (USD). viii) Activate the “Start-Up By-Pass” of an input which has similar facility. ix) Confirm that the system does not trip when the input changes from normal to alarm/shutdown state. Nonetheless, the input change of state is annunciated in PMCS and Operator Pushbutton Station. x) Repeat steps (viii) and (ix) for all inputs with “Start-Up ByPass” facility. xi) Activate the “Maintenance Override” of an input which has such facility. xii) Confirm that the system does not trip when the input changes from normal to alarm/shutdown state. Nonetheless, the input change of state is annunciated in PMCS and Operator Pushbutton Station. xiii) Repeat steps (xi) and (xii) for all inputs with “Maintenance Override” facility. xiv) Test other normal operational (non-shutdown) logic e.g. pump lead lag, motor duty/standby etc. by simulating the inputs. Confirm correct operation of equipment per the operational logic.

5.3.10 Fire and Gas System (FGS) Note: Vendors procedure shall be used for pre-commissioning and commissioning with the following activities shall be included as minimum where applicable 5.3.10.1





ii) Check system grounding. iii) Power up SIS Power circuit breaker. iv) Make sure that the AC/DC INPUT indication lamp at SIS AC/DC Distribution Panel is ON. If the system has redundant AC/DC power, both AC/DC INPUT lamps must be on. v) Turn on all AC/DC sub circuit breakers on the SIS as per wire diagram attached. vi) Make sure that each AC/DC OUTPUT lamp goes ‘ON’ as each AC/DC circuit breaker is turned on (if applicable).

5.3.10.2

Direct Current Power Supply Check i)

Verify and check each AC/DC Power Supply light indicators.

ii) Follow vendor’s instruction manual for direct current (DC) power supply energization. iii) Measure voltage at all of the DC Bus assemblies. Note: Refer to OEM or PSU Manual. iv) Verify and record the voltage on bus assembly at the furnished device. Tag No.

Reading (Volts)



Battery Backup Test Note:Battery backup for controller RAM i)


ii) Verify the battery backup system is in operation. Note: Verification method to follow vendors’ procedure. iii) Turn on AC breakers. iv) Verify that the system is back in operation automatically without any system rebooting required.

5.3.10.4

System Energization i)

Perform visual check to verify completeness of field devices such as breakglass, switch, transmitter, cables, junction boxes, marshalling cabinet and panel installation etc.

ii) Verify completeness of cable insulation resistance and continuity tests. iii) Inspect all power supply distribution wiring to ensure correct polarity and secured connections. iv) Connect the power suppliers to the incoming terminals, close each circuit breaker and insert associated fuse. Confirm that only correct group of terminals are energized. v) Measure the voltage at the incoming terminals and panel/cabinet distribution. Confirm that the voltage is not significantly different from the power supply voltage. 5.3.10.5

Loop Checking i)

If the system is Programmable-Logic-Controlled (PLC) based, verify that the alarm and shutdown logic program in the SIS controller is the same with the one in Engineering Workstation (EWS).



ii) Perform system loop check from input field devices e.g. breakglass, switches, pushbuttons, transmitters etc. to the panel. iii) Perform system loop check from panel to output field devices i.e. shutdown/blowdown valves and motor control center (MCC). iv) Perform system interface check with Fire and Gas, PMCS and General Platform Alarm System. 5.3.10.6

System Integrity Test i)

Manually activate the signal path integrity test on input cards, if available. Confirm that the output cards respond correctly.

ii) Activate the automatic signal path integrity test. Confirm correct response of all output cards. iii) Simulate failure of cards with hot standby spare. Confirm communication of card failure and changeover to hot standby spare.

5.3.10.7

Operational System Test i)

Achieve “System Healthy” status by setting all inputs to “normal” state.

ii) Change the state of one of the inputs that causes the Emergency Shutdown and Blowdown (ESD) to “alarm/shutdown” condition. iii) Verify that the input change of state is annunciated in PMCS and Operator Pushbutton Station. iv) Confirm that resetting the system without changing the state of the input back to normal will not restore “System Healthy” condition.





v) Normalize the input and reset the system. vi) Repeat steps ii) to iv) for all other ESD inputs. vii) Repeat steps ii) to v) for Process Shutdown (PSD) and Unit Shutdown (USD). viii) Activate the “Start-Up By-Pass” of an input which has similar facility. ix) Confirm that the system does not trip when the input changes from normal to alarm/shutdown state. Nonetheless, the input change of state is annunciated in PMCS and Operator Pushbutton Station. x) Repeat steps viii) and ix) for all inputs with “Start-Up By-Pass” facility. xi) Activate the “Maintenance Override” of an input which has such facility. xii) Confirm that the system does not trip when the input changes from normal to alarm/shutdown state. Nonetheless, the input change of state is annunciated in PMCS and Operator Pushbutton Station. xiii) Repeat steps xi) and xii) for all inputs with “Maintenance Override” facility. xiv) Test other normal operational (non-shutdown) logic e.g. pump lead lag, motor duty/standby etc. by simulating the inputs. Confirm correct operation of equipment per the operational logic.

5.3.10.8

Pre-Functional Check i)

Check that the correct cable has been used and installed satisfactorily.

ii) Check the connection of 24 volts of direct current power supply as per vendor’s drawings and wiring diagrams.



iii) Check that each supply is between 22 volts and 33 volts direct current. iv) Check subrack(s) earthing connection. v) Verify the fitting of the module(s) to subrack(s). Ensure that all modules are mounted in their specified positions and located fully home in their connectors before securing.

5.3.10.9

Commissioning of Detectors and Callpoints i)

Heat Detectors a) Override the associated trip function of the device. b) Using a hot air blower, operate a detector in the detection circuit and ensure an Alarm condition is raised. c) Remove override. d) Repeat the above procedure for all heat detectors in each detection circuit.

ii) Smoke Detectors a) Override the associated trip function of the device. b) Operate the detector using appropriate tester. c) Check that the detector flashers for a certain number of seconds and then automatically resets for the same number of seconds. d) Remove override e) Repeat the above procedure for all smoke detectors in each detection circuit. iii) Ultra-Violet Flame Detectors





a) Override the associated trip function of the device. b) Switch on the portable ultra-violet (UV) test lamp and aim towards the quartz window of the detector in the selected detection unit. c) After a pre-set period of up to 14 seconds maximum the detector operates. Ensure that a fire condition is raised at the module. d) Switch off the portable UV test lamp and ensure that the module returns to ‘Standby’. e) Switch on the portable UV test lamp and test detector operation from various positions within protected area, ensuring that the ‘Fire condition’ is raised on each case. f)

Remove override

g) Repeat above procedure for each UV flame detector. iv) Infra-Red Flame Detectors Refer to the appropriate section of vendors publications, the detectors are tested by using portable test lamp to operate the detector from various positions within the area it is protecting. v)

Gas Detectors – Catalytic Type a) Override the associated trip function of the device. b) Place the channel in the calibration mode. c) Adjust the zero potentiometer (on the Combustible gas Controller) until the Low-Explosive-Limit (LEL) display reads zero. This must be done in a ‘clean’ atmosphere i.e. no combustible gas present. d) Turn the main valve on the lecture bottle counterclockwise until pressure is indicated on the gauge and turn the gas ‘on’.



e) Place the plastic cup over the outer sensor guard (cup should fit closely but not seal). Caution: Do not adjust the regulator, as it is factory adjusted for optimum flow. f)

Wait momentarily for the Controller and the Sensor circuits to stabilize (controller display should move upscale and approach a reading of 50% LEL).

g) Adjust the Controller ‘span’ potentiometer until the Controller LEL display reading corresponds to the LEL mixture (in percentage) indicated on the Portable Purge Calibrator. h) Release the lever operated valve, stopping the flow of gas through the plastic tube. i)

Remove the cup from the sensor.

j)

Re-check LEL display when it has re-stabilized (reading should return to zero).

k) Turn the main valve clockwise to turn the gas off and return the channel to the normal operating mode. vi) Infra-Red Gas Detectors Note: Refer to the appropriate section of vendors publications vii) Call Points a) Override the associated trip function of the device. b) Operates the call point; ensure that an ‘Alarm Condition’ is raised at the module and the callpoint LED indicator (if fitted) flashes for a certain number of seconds. c) Remove the override. d) Repeat the above procedure for each callpoint.





Alarm and Shutdown i)

Each input shall be simulated individually against the cause and effect chart. The following action shall occur:-

ii) The corresponding module and annunciation window(s) shall show an alarm. iii) The common facilities module shall sound an alarm tone and show a flashing alarm indication. viii) When the ‘SILENCE’ button is operated, the alarm indication shall change to steady, and the sounder shall be silenced. ix) When the input alarm is removed, no change shall be observed. x) When the corresponding module and annunciation window(s) are reset, all the associated indication shall clear. xi) The following faults shall be observed to operate correctly on all modules and on the common facilities module. This action shall not inhibit normal operation: a)

Card (module) removed (Fire, gas and IR).

b)

Field wiring fault (Fire, gas and IR).

c)

Power output fuse failure.

xii) Isolations or inhibits on fire, gas and IR modules shall cause the common ‘INHIBIT’ indication to light on. a) Document all checks and tests made. b) Preserve the system prior to load out.



5.3.11 Pneumatic Instrument Control Panel 5.3.11.1

Instrument Control Panel Function Test i) Turn on the instrument air supply to the Instrument Control Panel (ICP) and monitor pressure gauge reading. Adjust instrument air supply pressure regulator if necessary. Note: Instrument air supply pressure shall be maintained at 7 bar gauge (100 psig) or as defined in the approved design drawing ii) Set the two (2) panel headers to the required pressure as defined in the approved design drawing. iii) Monitor panel pressure gauge reading. Adjust pressure regulators if necessary. iv) Hold the pressure for fifteen (15) minutes. Apply SNOOP or equivalent leak tester and visually check fittings header and bulkhead connections for leaks. Record the pressure gauge reading. If the pressure gauge reading drops significantly, check for leaks. v) Functional test pressure and flow records by simulating input signal from transmitters at 0, 25, 50, 75 and 100 percent. Check the rising and falling readings of recorded scale. vi) Calibration checks of field transmitters and control valves, and corresponding controllers installed at the panel. Perform complete loop check. vii) Functional test of Flow Totalizer (FQI) by applying a specific input signal and check the actual output (counts per minute) to be multiplied by a factor. viii) Set pneumatic timers to their corresponding settings. ix) Test all pneumatic indicators (for indication only) by supplying air pressure as defined in the approved design drawing to the corresponding bulkheads.



Panel Energization i) Confirm the output signal from Instrument Control Panel will be blocked and pressurized up to the instrument. ii) Put all the bypass valves in normal “green” position. iii) Connect test gauges to ICP output bulkheads to monitor outputs during functional test are as per Shutdown Matrix. iv) Push/PullEmergency Shutdown (ESD) button. Verify the test gauges give zero reading. Reset relay until the pneumatic indicator turns to “green”. v) Steps iv) shall also cause the ESD Signal and ESD (Time Delayed) Signal output gauges to indicate ‘healthy’ signal pressure respectively. vi) Pull and pin Process Shutdown (PSD). Reset relay until the pneumatic indicator turns to “green”. vii) Pull all bypass valves of PSD inputs respectively and shall be in bypass “yellow” position. viii) Simulate shutdown of respective PSD inputs. ix) Put all PSD input to normal process condition. Push all the bypass valves back to the initial “normal” state. x) Pull and pin Unit Shutdown (USD) reset relay for the test separator until the pneumatic indicator turns to “green”. xi) Pull all bypass valves of Unit Shutdown (Test Separator) USD inputs respectively and shall be in bypass “yellow” position. xii) Simulate shutdown of respective Unit Shutdown (Test Separator) USD inputs. xiii) Put all Unit Shutdown (Test Separator) USD input to normal process condition. Push all the bypass valves back to the initial “normal” state.



xiv) Pull and pin Unit Shutdown (Gaslift) USD Reset relay until the pneumatic indicator turns to “green”. xv) Pull all bypass valves of Unit Shutdown (Gaslift) USD inputs respectively and shall be in bypass “yellow” position. xvi) Simulate shutdown of respective Unit Shutdown (Gaslift) USD inputs. xvii) Put all Unit Shutdown (Gaslift) USD inputs to normal process condition. Push all the bypass valves back to the initial “normal” state. xviii) During the panel energization, check the operation of output devices connected to respective output signals. 5.3.11.3

Emergency Shutdown Test i)

Simulate abnormal condition of individual Emergency Shutdown (ESD) input.

ii) Reset the above shutdown by putting the respective ESD input back to normal, pushing to actuate ESD Reset Relay and pulling and pinning to actuate PSD Reset Relay, USD (Test Separator) Reset Relay and USD (Gaslift) Reset Relay. iii) Confirm that Instrument Control Panel ‘trips’ the corresponding output devices and shutdown valves go to closed position in accordance with CARIGALI Alarm and Shutdown Matrix. iv) Document all checks and tests made and preserve the system prior to load out. 5.3.11.4

Process Shutdown Test i)

Simulate abnormal condition of individual Process Shutdown (PSD) input.

ii) Reset the above shutdown by putting the respective PSD input back to normal and pulling & pinning to actuate PSD Reset Relay.



iii) Confirm that Instrument Control Panel ‘trips’ the corresponding output devices and shutdown valves go to closed position in accordance with CARIGALI Alarm and Shutdown Matrix. iv) Document all checks and tests made and preserve the system prior to load out. 5.3.11.5

Unit Shutdown (Test Separator) Test i)

Simulate abnormal condition of individual Unit Shutdown (Test Separator) USD input.

ii) Reset the above shutdown by putting the respective USD (Test Separator) input back to normal and pulling & pinning to actuate USD (Test Separator) Reset Relay. iii) Confirm that Instrument Control Panel ‘trips’ the corresponding output devices and shutdown valves go to closed position in accordance with CARIGALI Alarm and Shutdown Matrix. iv) Document all checks and tests made and preserve the system prior to load out.



Unit Shutdown (Gaslift) Test i)

Simulate abnormal condition of individual Unit Shutdown (Gaslift) USD input.

ii) Reset the above shutdown by putting the respective USD (Gaslift) input back to normal and pulling & pinning to actuate USD (Test Separator) Reset Relay. iii) Confirm that Instrument Control Panel ‘trips’ the corresponding output devices and shutdown valves go to closed position in accordance with CARIGALI Alarm and Shutdown Matrix. iv) Document all checks and tests made and preserve the system prior to load out.



5.3.12 Wellhead Control Panel(WHCP) 5.3.12.1

Pre-Energization Check i)

Verify specifications of Wellhead Control Panel (WHCP) components and instruments check. ii) Verify cable terminations have been completed (Refer to termination ITR). Note: Applicable for electronic/pneumatic/hydraulic WHCP. iii) Verify that pneumatic leak test for tubing and components had been carried out. (Refer to pneumatic leak ITR). iv) Verify that hydraulic pressure test or hydraulic discharge tubing and component had been carried out. (Refer to hydraulic leak ITR). v) Verify pop test on relief valve had been completed. vi) Check panel ingress protection. 5.3.12.2

Master Pneumatic Start-up Operation i)

Set the air supply to the required pressure by adjusting the air regulators.

ii) Open air supply isolating valve. iii) Simulate emergency shutdown (ESD) pneumatic/electronic signal by supplying air pressure to ESD bulkhead or energizing the ESD relay solenoid from SIS iv) Normalize Total Sub-Surface Safety Valve shutdown (SCSSV S/D) circuit by pushing Push & Pin to Reset ESDor Push to Reset ESD button and Push to Reset & Pull to Total SCSSV S/Dor Push to Reset total SCSSV S/D button with alarm indicator turns to green. v) Fill reservoirs with correct type of hydraulic oil to approximately one-half (1/2) of the reservoir level.



vi) Check the reservoir low level alarm indicator should turn green. vii) Supply pneumatic pilot signal to Process Shutdown (PSD) pneumatic/electronic signal by supplying air pressure to ESD bulkhead or energizing the PSD relay solenoid SIS. PSD alarm indicator should turn green. viii) Normalize Total Surface Safety Valve shutdown (SSV S/D) circuit by pushing Push & Pin to Reset ESDor Push to Reset PSD button and Push to Reset & Pull to Total SSV S/D or Push to Reset total SSV S/D button with alarm indicator turns to green. ix) Check for air leak within the basic cabinet. 5.3.12.3

Master Hydraulic Start-Up Operation i)

Turn pressure regulators anti-clockwise until it stop.

ii) Operate hydraulic supply valves to the desired position as per manufacturer’s instruction. iii) Slowly turn pressure regulators clockwise to regulate the hydraulic pressure to the required setting. iv) Isolate ball valves to module and set relief valve to the required setting by pressuring up the hydraulic system using manual pumps. v) After completion of each relief valves depressurized and reset back to stated value. 5.3.12.4

Individual Module Start-Up Operation i)

Set the two pressure regulators inside the module, one set for Sub-Surface Safety Valve (SCSSV) equalization pressure and the other for SCSSV final pressure.

ii) Set the ON Delay timer for SCSSV final pressure and the OFF Delay timer for SCSSV equalization pressure to the required setting. Note: If the timer reside externally e.g. SIS, this procedure is not applicable.



iii) Open pressure indicator isolation valves for HI-LO Pilot pressure, Hydraulic Control Pressure to SCSSV and Hydraulic Control Pressure to SSV. iv) Open valves for Total Surface Safety Valve (SSV) S/D line, Module Air Supply Line, Total SCSSV S/D Line and SCSSV Pump Hydraulic Suction Line. v) Close valves for Manual SCSSV Pump Supply Line and SSV Hydraulic Supply Line. vi) Turn Manual Override Valves for SCSSV and SSV hydraulic Control Pressure clockwise until it stop. vii) Open Manual SCSSV Pump Supply Line valve to test supply check valve position and operation of Manual SSV Override valve. viii) Open SSV Hydraulic Supply Line valve to test supply check valve position and operation of Manual SSV Override valve. ix) Turn Manual Override Valves for SCSSV and SSV Hydraulic Control Pressure anti-clockwise until it stop. Hydraulic Control SCSSV and SSV pressure gauges should reflect zero. x) Connect simulated HI-LO Pilot to bulkhead. HI-LO Pilot pressure gauge should reflect the simulated pressure. For electronic/pneumatic/hydraulic WHCP, energized the flowline PZAHH/LL solenoid relay. xi) Push individual module “SCSSV Push to Reset and Pull to Shutdown” valve. xii) After the ON Delay Timer times out Hydraulic Control SCSSV pressure gauge should show the SCSSV final pressure. xiii) Push individual module “SSV Push to Reset and Pull to Shutdown” valve.



xiv) Slowly turn regulator for SCSSV Final Pressure clockwise to regulate to 130% normal setting. Check for hydraulic leak. After leak test is completed, set to stated normal value. xv) Put test probe at HI-LO Pilot pressure switch junction box. Pull “HI-LO Pilot Pull to Bypass & Push to Normal” valve. Change of pressure contact position should occur. Note: Not applicable for electronic/pneumatic/hydraulic WHCP. xvi) All modules should be tested on the same manner as per the procedure stated herein. 5.3.12.5

Individual Module Shutdown Operation 5.3.12.5.1 For pneumatic/hydraulic WHCP i)

Turn off simulated HI-LO Pilot. HI-LO Pilot pressure gauge should show zero pressure.

ii) Normalized HI-LO pilot. HI-LO pilot pressure gauge should show incoming pressure. iii) Push individual module “SSV Push to Reset and Pull to Shutdown” valve. iv) Push individual module “SCSSV Push to Reset and Pull to Shutdown” valve. “SSV Push to Reset and Pull to Shutdown” valve should pop out. v) Normalize by pushing “SCSSV Push to Reset and Pull to Shutdown” valve. After ON Delay timer times out push “SSV Push to Reset and Pull to shutdown” valve. vi) Repeat item i) to v) for the rest of the module. 5.3.12.5.2 For electronic/pneumatic/hydraulic WHCP i)

De-energized PZAHH/LL relay solenoid. SSV status indicator turns to red.



ii) Energized PZAHH/LL relay solenoid, SSV status indicator turns to green. iii) De-energized ESD relay solenoid, SSV and SCSSV status indicator turns to red. iv) Energized ESD relay solenoid, SSV and SCSSV status indicator turns to green. v) Push “PUSH TO CLOSE SSV” button on individual module. SSV status indicator turns to red. vi) Push “PUSH TO OPEN SSV” button on individual module. SSV status indicator turns to green. vii) Push “PUSH TO CLOSE SCSSV” button on individual module. SSV and SCSSV status indicator turns to red. viii) Push “PUSH TO OPEN SCSSV” button on individual module. SSV and SCSSV status indicator turns to green. ix) Repeat item i) to viii) for the rest of the module. 5.3.12.6

Master Shutdown Operation 5.3.12.6.1 For pneumatic/hydraulic WHCP i)

Shut off pneumatic pilot signal to PSD bulkhead simulating that the process shutdown occur. PSD status indicator to turn red. Total SSV S/D header pressure gauge should reflect zero indicating that no pressure passing to individual modules

ii) Normalize by simulating the pneumatic pilot signal to PSD bulkhead, pushing “Push & Pin to Reset PSD” valve and individual module “Push to Reset & Pull to S/D valves”. PSD status indicator to turn green. iii) Pull “Push to Reset & Pull to S/D Total SSV” valve. PSD status indicator to turn red. Total SSV S/D header pressure gauge should reflect zero indicating that no pressure passing to individual modules.



iv) Normalize by pushing “Push to Reset & Pull to S/D Total SSV” valve and individual module “Push to Reset & Pull to S/D SSV valves”. PSD status indicator to turn green. v) Shut off pneumatic pilot signal to ESD bulkhead simulating that the emergency shutdown occur. ESD status indicator to turn red vi) Total SCSSV S/D header and Total SSV S/D header pressure should reflect zero. vii) Normalize by pushing “Push & Pin to Reset ESD”, “Push to Reset & Pull to S/D Total SCSSV”, “Push to Reset & Pull to S/D Total SSV” valves and individual module SCSSV and SSV valves. viii) Pull “Push to Reset & Pull to S/D Total SCSSV” valve. 5.3.12.6.2 For electronic/pneumatic/hydraulic WHCP Note: ESD and PSD signal from SIS will de-energize individual solenoid relay in each Well Control Module. Hence, no ESD and PSD simulation is to be conducted for Master Shutdown Operation.

i)

Push “Close All SSV” button. Every SSV status on each WCM to turn red.

ii) Push “Reset” button. Every SSV status on each WCM to stay red. Note: A) the “Reset” button on basic cabinet is only meant for total reset. Opening of individual SSV shall be carried out through its WCM. B) If remote SSV opening is applicable, the reset button should only require to be activated upon total SCSSV close. iii) Push “Close All SCSSV” button. Every SSV and every SCSSV status on each WCM to turn red.



iv) Push “Reset” button. Every SSV and every SCSSV status on each WCM to stay red. Note: The “Reset” button on basic cabinet is only meant for total reset. Opening of individual SSV shall be carried out through its WCM.

5.3.12.7

Testing Accumulators i)

Check that SSV hydraulic supply header drain valves and bypass valves are closed.

ii) Open accumulator’s isolation valves. iii) Slowly turn pressure regulators clockwise to set SSV hydraulic supply header pressure setting and charge accumulators. iv) Increase the pressure to 130% of normal setting to test for leakage. Check performance of pressure relief valve on accumulators. v) After completion, set to the normal stated value. vi) Start-up master and individual modules SCSSV and SSV. vii) Drain off oil in Reservoir #1 and Reservoir #2 – if required viii) Document all tests and checks made. ix) Preserve Wellhead Control Panel prior to loadout to include depressurization of the whole system.





5.3.13 Fusible Plug Loop Pre-commissioning i)

Bubble leak test the whole fusible plug and kill knob circuit. Verify that there is no bubble.

ii) After completing the leak test and all tubing are completely hook-up, restore the fusible plug loop and kill knob circuit toFusible Plug Loop panel and monitor the charge pressure. iii) Perform instrument loop check on fusible plug loops, kill knob circuit and associated instruments. iv) Activate manually kill knob circuit and check its operation. v) Simulate all system inputs such as release of fusible plug loop pressure and kill knob activation. vi) Verify corresponding outputs are in accordance with Fire and Gas cause and effect matrix including checking for visual and audible alarms. Note: Fire and gas panel vendor representative assistance may be required. vii) Documentation of all checks and tests made. viii) Preservation of the system prior to load out. Commissioning i)

Verify the pre-commissioning ITR has been completed.

ii) Activate manually kill knob circuit and check its operation. iii) Simulate all system inputs such as release of fusible plug loop pressure and kill knob activation. iv) Verify corresponding outputs are in accordance with Fire and Gas cause and effect matrix including checking for visual and audible alarms. Note: Fire and gas panel vendor representative assistance may be required.





v) Documentation of all checks and tests made.

5.3.14 Test of Pressure Safety Valve (PSV) i)

During construction, pop test shallbe conducted prior to installation. Certification and documentation shall be made available.

ii) Verify the activities for PSV installation and inspection has been completed. Note: Refer to relevant ITR. iii) Note: API Recommended Practice 527 Seat Tightness of Pressure Relief Valves API 576 Inspection of Pressure Relieving Devices

5.3.15 Test of Analyzer        

Moisture/dew point analyzer Water in oil Densitometer Gas chromatograph Oil in water (ppm) pH analyzer Turbidity Salinity

Note: To refer to vendor for specific procedure. i)

Ensure that the analyzer is in good condition. The analyzer is installed as per vendor recommendation. Ensure Factory Acceptance Test for analyzer is completed.



GENERAL REQUIREMENTS

6.1

Organization 6.1.1

Organization Chart 6.1.1.1 A typical CONTRACTOR's testing, pre-commissioning and commissioning organization chart is shown in Figure 6-1 on the next page. The chart shows only key personnel involve at its nominal level. Additional manpower would be required proportional to the magnitude of the activities.

Figure 6-1: Contractor Onshore Team



Figure 6-2: Contractor Offshore Team

6.1.2

Individual Roles and Functions Below are some of the responsibilities identified by CARIGALI for the respective key position in preparation, execution, reporting and handover of the pre-commissioning activities.

6.1.2.1

Testing, Pre-commissioning & Commissioning (TP&C) Coordinator Reporting directly to the Project Manager, TP&C Coordinator should possess sound management quality and should acquire a commendable overall knowledge of process, piping, mechanical equipment, electrical systems and instrumentations involved in oil and gas facilities.



Supported by a group of discipline engineers and supervisors, TP& C Coordinator is responsible for:i)

ensuring safety program for testing, Pre-commissioning and Commissioning activities are developed and implemented strictly,

ii) ensuring procedures and work activities are in adherence to Contract, drawings, specifications, Codes and Standards and vendor recommendations, iii) coordinating with construction focal point and/or project planner and scheduler to ensure timely completion of other activities prior to commencement of testing, precommissioning and Commissioning activities, iv) organizing support facilities required to perform testing, pre-commissioning and commissioning activities on-shore such as water, diesel fuel, power supply, lifting equipment, storage tanks, access platforms, load banks, etc. with project services or support groups, v) coordinating with engineering group for timely acquisition of vendor data, factory acceptance reports, latest revision of fabrication/construction drawings, vi) coordinating with subcontractors on matters related to manpower planning, appropriate methodology of work execution, tools and equipment and updating of documentation vii) coordinating with procurement section pertaining outstanding materials, late deliveries and non-conformance of materials to specification, viii) coordinating with materials section or support services for tertiary services and materials required, ix) organizing requirement for and mobilization of vendors and third parties, x) monitoring and controlling work progress, and xi) submitting daily reports, ITRs and updated drawings for review by the relevant parties.



Discipline Engineer Engineering scope is divided mainly in three fields of engineering i.e mechanical and piping, electrical and instrumentation whereby each is managed by a discipline engineer. It is common that some activities may require multiple disciplinary involvements in which cases the roles and responsibilities would be better defined by the T/P Coordinator. Generally, discipline engineers are responsible for:i)

organizing daily testing, pre-commissioning and commissioning activities in adherence to approved plan and strategy,

ii) organizing manpower distribution consistent with daily loads, iii) identifying the necessary tools and equipment, consumables and utilities to perform the activities, iv) preparing complete compilation of procedures and ITRs, v) preparing and developing procedures that are not covered in the Testing, Pre-commissioning& Commissioning Guideline, vi) reviewing and approving test data and commissioning ITRs, vii) developing and monitoring troubleshooting activities, viii) identifying need of third party inspectors and vendors, ix) preparing progress reports, analyzes and areas of concern, x) ensuring timely compilation and preparation of As-Built drawings and final documentation, xi) clarifying inquiries on operations and maintenance of the system and/or equipment, xii) preparing the relevant documentation for release of equipment and tools from the warehouse.



xiii) monitoring the progress of shiploose materials, fabrication and the staggered issuance until completion of shiploose list including shiploose for punchlist from Engineering. xiv) the Discipline Engineers shall ensure that: a. Respective deliverables are met b. Vendors Field Site Representative (FSR) are timely mobilized and product delivery are met c. Clients are trained and in-situ training with FSR on board are given d. Operating & Maintenance (O&M) manuals are ready to be handed to Client e. Special tools (if any) are provided for handover f. The 72-hr endurance test run with performance monitoring are recorded throughout the duration of the test run- SAT to develop g. Cat D punchlist are closed prior to final handover

6.1.2.3

Supervisors Reporting to the respective discipline engineer, supervisors are responsible for:i)

reviewing all relevant pre-commissioning documents,

ii) coordinating and supervising subcontractor's resources; for example manpower, tools, equipment, etc. iii) ensuring relevant tools and materials are available in advance of the activity commencing, iv) ensuring daily plan activities are being met to prevent delay on the schedule until the target completion date. v) submitting daily progress and test reports or ITRs and highlighting areas of concern, vi) monitoring technicians performance,

or

subcontractor's

work

vii) ensuring work areas, tools and equipment are kept in good and clean condition at all times, viii) assisting vendor representatives or third party inspectors,



ix) gathering data as required in the ITRs.

6.1.2.4

Commissioning Manager (Onshore Lead) The Commissioning Manager’s responsibility shall include but not be limited to the following:  Responsible for Smooth Start-Up Programme;  Plan, manage direct, and control the Pre-Commissioning and Commissioning procedures, plans and activities including those for the Smooth Start-Up Programme;  Manage the preparation, review and approval of training resources / Materials and training sessions for commissioning & operations personnel;  Manage and plan the preparation of procedures that meet the health, safety, environment and security plan, codes of practice and other standards specified inthe contract, for all Pre-commissioning, testing and Commissioning activities;  Review and approve Pre-commissioning, Commissioning & Start-Up and training programme and procedures;  Manage the preparation, review and approval of maintenance schedule, scope and procedures;  Manage the maintenance repair work, during the commissioning phase, with subcontractors and suppliers;  Manage and control the Pre-commissioning and Commissioning activities to ensure that the results are as per design and/or Contractual Requirements; and  Promote Safety and Quality by setting a good example.  Has overall responsibility for the Facility systems from turnover of subsystems from Construction through to handover of facility to Client after successful performance acceptance  Responsible for verifying Systems Completion at the various stages of the handover. Is responsible for witnessing and verifying Performance acceptance test.

6.1.2.5

Commissioning Engineer (Discipline Lead) The Commissioning Engineer’s responsibility shall include but not be limited to the following:



 Execute the commissioning activities, review the PreCommissioning and Commissioning procedures, plans and activities including Performance test;  Review the preparation of procedures that meet the health, safety, environment and security plan, codes of practice and other standards specified in the contract, for all Precommissioning, testing and Commissioning activities;  Review and recommend for approval Pre-commissioning, Commissioning procedure and training records;  Shall coordinate the preparation, review and approval of training resources/materials and training sessions for operations personnel;  Coordinate the preparation, review and approval of maintenance schedule, scope and procedures during the commissioning phase;  Coordinate, monitor and witness the implementation of maintenance repair work with sub-contractors and suppliers during the commissioning phase;  Coordinate, monitor and witness the Pre-commissioning and Commissioning activities to ensure that the results are as per design and/or Contractual Requirements;  Direct involvement in execution of Smooth Start-Up Programme. i) Responsible for generating the discipline acceptance packs for subsystems. Also responsible for the system acceptance of the said system ii) Report directly to Commissioning CSR/ HU-CSU lead iii) Work directly with Discipline engineers and System completion engineer iv) Verify that handover certificates of all systems/subsystems (including Re-instatement leak test certificate) are signed off and that no critical punchlist are affecting the Commissioning activities v) Check E & I integrity, i.e., protective system- alarm & shutdown, F & G, etc. vi) Carry out final line check along with discipline engineers; record exceptions found vii) Check all Cat D punchlist items are closed prior to final handover viii) Check all PASR Cat 1 mitigation works have been closed prior to CSU and Cat 2 items have been done prior to final handover



ix) Work with Commissioning CSR during the 72-hr endurance test monitoring x) Carry out the completion of remaining works till Final handover

6.1.2.6

Construction Superintendent  Obtain PTW; carry out tool box talk before commencement of work  Brief commissioning team on the day to day activities  Carry out final line check together with Process Engineer  Provide manpower assistance in lining up all critical valves including Lock Out Tag Out (LOTO) as per Process/Operations requirement  Carry out PIR 04-Cat C mitigation works prior to SU and Cat D punchlist items are closed prior to final handover  Carry out PSAR Cat 1 and 2 mitigation works  Arrange with HSE focal person to deploy Fire Watchers as required prior to Start-up

6.1.2.7

Commissioning CSR or Offshore HU/CSU  Work and provide directives to Discipline lead, Construction Superintendent, Logistic Marine Coordinator, HSE, QA/QC  Verify all discipline’s deliverables are met, documented including Re-instatement leak test report /certificate  Ensure Commissioning & Operational spares are available  Verify all Cat C items of PIR 04 are closed/mitigated and ensure cat D punchlist items are closed prior to final handover  Ensure that all PSAR Cat 1 items are closed prior to SU and Cat 2 items prior to final handover  Ensure HSE requirement is in-place prior to Start-up, i.e., PTW, JSA, deployment of Fire Extinguishers with Contractor personnel (Fire watchers) deployed at strategic locations  Ensure ERP is in-place  Ensure Ready for Start-up Certificate (RFSU) is signed by PMT & approved by Operation  Ensure final line check is carried out prior to SU  Ensure assistance and monitoring is given during the 72-hr test parameters  Ensure works are completed till final handover of facilities



6.1.2.8

HUC Manager  Accountable for the entire HUC operations  Accountable to Interface with the management of Engineering, Procurement, Construction, Installation and Commissioning.  Align HUC strategic direction with overall goals & aspiration.  Be the main driver for the Commissioning & StartUpManagement;  Manage resources, set priorities, monitor progress  Oversee the implementation of the Commissioning & StartUp Management Practices, assessments and systems including Smooth Start-Up Program

6.1.2.9

Offshore Lead  Reports directly to Lead Commissioning  Responsible for the HSE, schedule, cost and quality of the Offshore HUC.  Closely coordinate and work hand in hand with Onshore Lead.  Responsible for the Offshore Testing, Pre-Commissioning and Commissioning and Operational Team of HUC Campaign  Responsible to implement and manage the offshore project scope, HUC strategy, overall schedule and cost estimation.  Proactively coordinate CSU Activities and drive to achieve IFH.

6.1.2.10

Workpack Team Leader  Responsible for the Workpack Development  Responsible for the HSE, schedule, cost and quality of the Onshore HUC.  Coordinate and responsible for integration of Disciplines Workpack Completion.  Responsible to implement the CMS system, i.e. jobcards, punchlist, ITRs compilation into the CMS system

6.1.2.11

Operation Team Leader  Responsible for the HSE, schedule, cost and quality of the Onshore HUC.  Responsible for both onshore and offshore activities for scope definition and scope verification.



 Responsible to coordinate and set up onshore support team for efficient offshore resolution.  Responsible for providing administrative and logistic support to the project.

6.1.2.12

Logistic Lead  Responsible for coordination requirement on material, marine spread, material inventory and logistic for project requirement.  Responsible to cascade the function task of :i. Material Coordinator – physical check material at site ii. Marine Coordinator – Marine bunkering, loading, inspection, mob/demob iii. Material Planner – inventory, update, tracking and request iv. Logistic Coordinator – Manpower, material , custom etc. v. Logistic/Marine Coordinator  Facilitate marine spread management for project optimization and efficiency.  Conduct OSVIS and evaluate marine technical specifications  Manage utilization of HUC marine spread  Ensure compliance to marine spread mobilization, such as approval of anchor patterns, are met.



Testing and Pre-commissioning Sequence 6.2.1

Flowchart 6.2.1.1

A typical Onshore Testing and Pre-commissioning flowchart is shown below

6.2.1.2

The main activity flowpath is highlighted with thick bold lines and other incoming activities to the main activity are shown with a single line.

6.2.1.3

Most of the times, activities under main flowpath would fall under the category of CARIGALI hold points - areas where inspection or review and approval by CARIGALI precommissioning personnel or its appointed third party would be required.

6.2.1.4

From the figures, one could determine that there exist a point where some activities that one would consider under Fabrication Team workscope is transposed into Yard Precommissioning scope. This mainly involves area of material receiving, its clearance and installation.

6.2.1.5

Such transposition is shown separately from the main flowpath . Requirements on hold points for these activities are covered under separate documentation.



CARIGALI STANDARD PROCEDURE A. Piping Metallic (CS/SS/Duplex/ Super Duplex) Non-Metallic GRE/GRP/ PVC etc.

1

Weld

Record

QC Report

QC Report

Receiving Inspection

Cutting & Edge Preparation

Fit-up

Glue QC Report

Screw P06-B

QC Report

Flanges Management

QC Report

Installation: -Pipe spool -Valves

Flanges Alignment

Utility System

P06-A

System/ Subsystem Commissioning

Completed

Nitrogen Purging

HC System

Reinstatement Leak Test/ Service Test

Note : Flanges insulation shall be done after leak test P11-A

Drying/ Blowing

P09-A / P04-B2

Shiploose

Hydrotest P05-A

Packing & Preserve

NDT

P12-A

Painting

P08-A

P05-A

Reinstallation work/ Reinstatement

PWHT

*Insulation (If any)

Chemical Cleaning

Touch –up Painting

NDT

P07-A

P04-B2 / P10-B

External Pickling (SS)

Painting

Bolt Torque/ Tensioning

Drying/ Blowing

P04-A

Flushing P03-A P04-A

Hydrotest

Conformity Linewalk P01-A

P03-A

P02-A

Flushing



CARIGALI STANDARD PROCEDURE PIPING READINESS PRIOR COMMISSIONING ACTIVITIES PRESSURE TEST

Degreasing

REINSTATEMENT LEAK TEST

NITROGEN PURGING

N2 PRESERVATION

Process Gas (Note C)

SS

1

1

Y

Y

Y

3

5

4

4

2 3 4 5 6 7 8 9 10

Process Gas (Note C) Process Gas Sour (Note C) Crude Oil Crude Oil Crude Oil Sour Process Condensate Process Condensate Process Condensate Sour Process Condensate Sour High Pressure Wellhead Production High Pressure Wellhead Production High Pressure Wellhead Production Sour Low Pressure Wellhead Production Low Pressure Wellhead Production Low Pressure Wellhead Production Sour Test Wellhead Production Test Wellhead Production Test Wellhead Production Sour Low Pressure Flare Lines Low Pressure Flare Lines Sour High Pressure Flare Lines High Pressure Flare Lines High Pressure Flare Lines, Sour High Pressure Flare Lines, Sour Vent Atmospheric Vent Sour Fuel Gas

CS CS SS CS CS SS CS SS CS

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

Y Y

Y Y

Y Y

3 3 3 3 3 3 3 3 3

5 5 5 5 5 5 5 5 5

4 4 4 4 4 4 4 4 4

4 4 4 4 4 4 4 4 4

SS

1

1

5

4

4

CS

1

1

5

4

4

CS

1

1

5

4

4

SS

1

1

5

4

4

CS

1

1

5

4

4

CS

1

1

5

4

4

SS CS CS CS CS SS CS SS CS CS CS CS

1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1

5 5 5 5 5 5 5 5 5

4 4 4 4 4 4 4 4 4

4 4 4 4 4 4 4 4 4

1

1,3 or 4

5

4

4

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 Y

Y

Y

3 3

SERVICE TEST

FLUSHING ( Note F)

1

N o.

1. Water 2. Oil 3. Dry Air 4. N2 5. N2 + HE

Pickling and Rising Passivation and Rinsing

MATERIAL

CHEMICAL CLEANING

DRYING/ BLOWING (Note B)

DESCRIPTION



Fuel Gas Sour Aviation Fuel Inert Gas Instrument Gas Glycol (Lean) Glycol (Rich) Diesel Fuel Oil Hot Oil Jet Oil Hydraulic Oil ( Note D) Lube Oil ( Note D) Lube Oil ( Note D) Seal Oil Seal Oil Breathing Air Combustion Air Instrument Air Utility Air Steam Cleaning Chem. Inj. Corrosion Inhibitor Chem. Inj. Biocide Chem. Inj. Catalyst Demusifier Demusifier, Sour Reverse Demusifier Antifoam Scale Inhibitor PH Control Chem. Inj. Corrosion Inhibitor Polyelectrolyte Chem. Inj. Methanol Chem. Inj. Methanol Sour Carbon Dioxide Chem. Inj. Sodium Hypochlorite

Y Y

Y Y

Y Y

Y

Y

Y

Y Y Y Y Y Y Y Y

Y Y Y Y Y Y Y Y

Y Y Y Y Y Y Y Y

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

5 4 4 4 4 4 4 4 4 4 4 4 4 4

4 4 4 4

N2 PRESERVATION

NITROGEN PURGING

1,3 or 4 1,3 or 4 1,3 or 4 1,3 or 4 1 1 1 or 3 1 or 3 1 or 3 1 or 3 1 or 3 1 or 3 1 or 3 1 or 3 1 or 3 1 or 3 1 or 3 1 or 3 1 or 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1


1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1


CS CS CS CS CS CS CS CS CS SS SS CS SS CS SS CS CS CS CS SS SS SS SS SS SS SS SS SS SS SS SS SS SS SS

ACTIVITIES CHEMICAL CLEANING Degreasing

PRESSURE TEST

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62


FLUSHING ( Note F)

N o.

MATERIAL

DESCRIPTION

SERVICE TEST




4 4 4 4 4 4 4 4 4 4 4 4 4 4

3 3 3 3 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4 3 or 4

4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4




74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94

Ferric Sulphate Wax Inhibitor Oxygen Scavenger General Chemical Dry Chemicals Open Drain Open Drain Sour Closed Drain Closed Drain Sour Soil System (Sewage) (Note E ) Soil System (Sewage) (Note E) Closed Circuit Glycol/Water (Note E) Engine Exhaust Fire Water (Note E) Fire Water (Note E) Hot Water (Note E) Hot Water (Note E) Injection Water (Note E) Injection Water (Note E) Produced Water (Note E) Produced Water(Note E) Produced Water Sour (Note E) Potable Water(Note E) Potable Water(Note E) Sea Water Service (Note E) Sea Water Service (Note E) Utility Water (Note E) Utility Water (Note E) Cooling Water (Note E) Cooling Water (Note E) Waste Water (Note E) Waste Water (Note E)

CS GRP CS CU SS CS GRP CS SS CS PE SS SS GRP CS GRP CS GRP CS GRP

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

3 or 4 3 or 4 3 or 4 3 or 4 3 or 4

N2 PRESERVATION

1

NITROGEN PURGING

1


CS

3 3 3 3 3 3 3 3 3 3 3

SERVICE TEST

1 1 1 1 1 Note G Note G 1 1 Note G Note G


1 1 1 1 1 1 1 1 1 1 1


GRP SS SS SS SS CS CS CS CS CS GRP

CHEMICAL CLEANING Degreasing

PRESSURE TEST

63 64 65 66 67 68 69 70 71 72 73

FLUSHING ( Note F)

No


ACTIVITIES MATERIAL

DESCRIPTION

4 4 4 4 4

1 1 5 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4 4

4 4



Note A : The purging acceptance is 0.4 % Oxygen content Note B : Blowing/Drying acceptance is -10 Deg Note C : All piping between gas suction scrubber and Gas Compressor shall be chemical cleaned Note D : To perform Lube oil Flushing Note E : To perform drying/blowing after Re-nstatement Leak Test Note F : Hydrojeting shall be concidered if flushing velocity ( 3 m/s) is not achived Note G: To perform static test ( Full of water )



CARIGALI STANDARD PROCEDURE B. Valve


CSP 20 FSP-XX-22

Valve Leak Test/ Air Seat Test

1 Pre-comm

Preserve

FSP-XX-25

CSP 13

Reinstatement Leak Test

Bolt Tightening

MC

DMC

Complete Ready For Service CSP 07

Shiploose

Fabrication

Packing & Preserve

FSP-XX-20

Cleaning/ Flushing

Install



CARIGALI STANDARD PROCEDURE C. Pump/Compressor

1

CSP 20

CSP 20

PSP-16

PSP-18

Install

Fabrication

Pre-comm

Alignment Check DMC Ready For Solo Run Comm

CSP 20 PSP-18

Complete

Endurance Test (72 hrs)

Pre-comm CSP 20

CSP 20

PSP-18

PSP-18

Un-Couple/ No-Load Test (1 hr)

Load Test (4 hrs) MC Ready For System Run



CARIGALI STANDARD PROCEDURE D. GTG/GTC  

Documents/R eport Punchlist

CSP-20 CSPT-25 CSP-24 PSP-18 CONSTRUCTION ITR-A

FAT

Constructions

DMC

PRE-COMMISSIONING ITR-B/C

Pre-com/ Commissioning (onshore)

SAIL AWAY

Commissioning/ Start-up

Offshore

>FINAL ALLIGNMENT SYSTEM >REINSTATEMENT LEAK TEST >RECHECK/VERIFY LUBE OIL QUALITY (MINERAL/SYTNTHETIC)

CSP-20/CSPT- 25 PIPING -Piping Alignment -Flushing (Lube oil Flushing/Acid cleaning) -Hydrotest CIVIL WORKS -Foundation -Grouting MECHANICAL -Coupling/gearbox/engine Installation -Leveling STRUCTURAL -Equipment supports/poles -HVAC ELECTRICAL -Cabling/Termination -Insulation test/Meggering INSTRUMENTATION -Detectors/Sensors -Callibration SAFETY

CSP-07 CSP-03

PRESERVATION

CSP-20

-Discipline Functional Check -SAT (Site Acceptance Test) -Dry Crank

CSP-20

For GTG (Dual Fuel): -Load Test@yard using Load Bank -Diesel supply via Lorry tanker

N2 PURGING CSP-20 COMMISSIONING & START-UP ITR C

DAC (DISCIPLINE ACCEPTANCE CERTIFICATE)

GTC

(DISCIPLINE

*SURGE TEST (Compliance to compressor performance curve)

CSP-21 *PERFORMANCE TEST RUN CSP-21

ENDURANCE TEST (Compliance to 72 hrs stability, uninterruptable as per intended design parameters)

INITIAL FACILITY HANDOVER (IFH) TO OPERATION CSP-21

*NOTE: Acceptance criteria has to be in agreement with ORSA and Vendor

CSP-20

GTG

LOAD TEST (test@platform load capacity) +Synchronization



E. Electric Motor CSP 20 FSP-XX-22

1

Winding Insulation Test Comm

Complete

Pre-comm

CSP 20

CSP 20

PSP-18

PSP-18

Load Test/PTR (4 hrs)

Pre-comm

CSP 07

Shiploose

Packing & Preserve

PSP-16

Un-Couple Test/ No-Load Test (LV=1/2hr & HV=4hr)

MC Ready For System Run

Fabrication

Install DMC

Ready For Solo Run

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE F. Instrument


CSP 20

FSP-XX-22

Calibration Check (Field Instrument/SDV/BDV/CV)

1

Pre-comm

Complete MC

Fabrication

CSP 20

CSP 20

PSP-18

PSP-18

Cause & Effect Matrix SD Test (simulate)

Tubing Leak Test Cable Test (Megger & Continuity) Junction Box Check

Loop Test DMC

RFSU Ready to Energize CSP 07

Shiploose

Packing & Preserve

PSP-16

Install



CARIGALI STANDARD PROCEDURE G. Instrument Panels Fabrication

CSP 20

Pre-comm CSP 20

PSP-18 PSP-18 PSP-16

1

Install

Cold Loop Check + Cable Testing + Earthing Integrity Check + Installation Inspection

Power Up

Loop Check & FGS Calibration

DMC Ready to Energize

Complete

CSP 20

CSP 20

PSP-18

PSP-18

Matrix Shutdown Test

Performance Test (7 Days) & LIVE ESD Test MC RFSU

Composite Integrated System Test (CIST)



Preparation Activities

6.2.2.1

General Overview of Critical Activities

Prior to commencement of any testing and pre-commissioning activity, CONTRACTOR Commissioning Team shall have completed the necessary preparation works in accordance to the relevant procedures and specifications. General requirements on the preparation works shall include:i)

Detailed and realistic planning and scheduling shall be prepared consisting of the following documents:a) OVERALL DETAILED TESTING, PRE-COMMISSIONING AND COMMISSIONING PROCEDURE. See attached APPENDIX VII for sample Table of Content. b) Safety Manual, c) Critical Path Network (CPN), d) Bar chart, e) Manpower Histogram, f)

Jobcards,

g) Vendor Mobilization Schedule, h) S-Curve i)

T & P JHA apart from construction JHA

j)

ITR/ Checksheet Overview

ii) Review and approve all testing, pre-commissioning and commissioning procedures, iii) Completion of all construction and installation Works including activities highlighted in corresponding ITR in Section 7 – Records. iv) Submission of Request for Testing, Pre-commissioning and Commissioning including the relevant ITR to CARIGALI for approval on any activity at least 48 hours in advance, v) Availability of all tools, test equipment, consumables and other devices necessary to perform a particular activity.


6.2.2.2


Summary Preparations i)

Interface Agreements and Developments of SIMOPS (Simultaneous Operation System)

ii) Prepare Quality Plan and HSE Plan. iii) Creating Awareness of Commissioning Objectives and requirements for early commissioning in the correct sequence have been implemented and are realistic. iv) Participate in factory acceptance tests/supplier visits where necessary. v) Verify and audit of Mechanical completion and system cleanliness. vi) Review supply contracts and purchase orders to ensure commissioning requirements are clearly stated. vii) Prepare Organizational development, planning coordination and management reporting system. viii) Preparation of controlling documentation including system boundary drawings based on P& ID's. ix) Review the preservation procedures to ensure they fulfill the requirements for optimal equipment protection against corrosion and damage. x) Mobilize commissioning personnel to fabrication/construction sites to prepare for commissioning activities, organizational/administration matters, site procedures, reporting systems, liaisons with the site teams. xi) Ensure that all operational spares for the first two years of operations have been correctly ordered, delivered, preserved and placed into stores to enable easy retrieval when required. xii) Joint"Punchlist" Records, control and clearance to the satisfaction of Pre-Commissioning/Commissioning Team.





Critical Path Network 6.2.3.1

Critical Path Network (CPN) is a work schedule that set forth detailedplanning for execution of the day-to-day activities in a logical representation of the sequence and interrelationship.

6.2.3.2

It is used essentially as a tool for monitoring and controlling the progress of the yard pre-commissioning to meet its schedule completion date and most useful to CONTRACTOR as well as to CARIGALI.

6.2.3.3

CPN is presented in the form of arrows and shall be computeranalyzed and prepared with sufficient details to demonstrate the sequence of activities to be performed. For instance, hydrotesting of a completed piping system shall commence when the respective non-destructive tests (NDT) are completed. Similarly, the latter would only commence when fitting and welding of joints are performed.

6.2.3.4

CPN shall provide the following details and information:i)

Planned duration,

ii) Early Start and Early Finish dates iii) Late Start and Late Finish dates, iv) Floats in number of days, v) Task or activity description, vi) Corresponding jobcard number (optional), vii) Disciplines i.e. electrical, instrumentation, etc. viii) Indication of critical and non-critical activities in the form of different colours or shades,



Bar chart 6.2.4.1

Bar chart provides a summary of the activity schedule in chart form. It highlights information such as:i)

planned start and finish dates,

ii) planned and actual percentage completion for each activity, iii) weightage values, iv) correspondingjobcard numbers. 6.2.4.2

Most of the information are readily available in the CPN except for the weightage values. Weightage values are assigned to each activity based on the individual resource consumption i.e. manhours pro-rated over the total resource level at the given reporting point.

6.2.4.3

It is essential that the weightage values are assigned in a rational manner as indiscriminately appointed weightage values would provide false indication of the progress.



Manpower Histogram 6.2.5.1

Manning levels for a specific work is normally presented in the chart form called Manpower Histogram. It highlights in detail the number of personnel and its breakdown so that the actual manning level could be monitored and easily compared to the planned manning level.

6.2.5.2

It is vital tool to troubleshoot progress slippage so that any remedial action could be determined ahead of time. A sample of a typical manpower histogram is shown in Figure 6-3.

MANPOWER LOADING FOR PROJECT XXX 35 30

manpower

25 20 15 10 5 0 1

2

3

4

5

6

7

8

9

10 11 12 13 14 15 16 17 18 19 20 day

Direct manpower

Indirect manpower

Project: ……………………. Work order: ……………….. Figure 6-3: Typical Manpower Histogram




n o. Description Direct manpower 1 Welder 2 Fitter

1

MANPOWER LOADING FOR PROJECT XXX Day 1 1 1 1 2 3 4 5 6 7 8 9 0 1 2 3

1 4

1 5

1 6

1 7

1 8

1 9

2 0

4 2

4 2

4 2

4 2

4 2

4 2

4 2

4 2

4 2

2 2

2 2

2 2

2 2

2 2

2 2

2 2

0 0

0 0

0 0

0 0

3 4

Rigger Technician

2 2

2 2

2 2

2 2

2 2

2 2

4 4

4 4

4 4

4 4

4 4

4 4

4 4

4 4

4 4

4 4

2 2

2 2

2 2

2 2

5 6

Electrician Firewatcher

1 2 1 3

1 2 1 3

1 2 1 3

1 2 1 3

1 2 1 3

1 2 1 3

2 4 2 0

2 4 2 0

2 4 2 0

2 4 1 8

2 4 1 8

2 4 1 8

2 4 1 8

2 4 1 8

2 4 1 8

2 4 1 8

1 2

1 2

1 2

1 2

7

7

7

7

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

3 1 1

3 1 1

3 1 2

3 1 2

3 1 2

3 1 2

3 1 3

3 1 3

3 1 3

3 1 3

3 1 3

3 1 3

3 1 3

3 1 3

3 1 3

3 1 3

3 1 2

3 1 2

3 1 2

3 1 1

7

7

8

8

8

8

9

9

9

9

9

9

9

9

9

9

8

8

8

7

TOTAL Indirect manpower 1 Supervisor 2 Planner Discipline 3 engineer 4 Foreman 5 Inspector TOTAL

Figure 6-4: Typical manpower Loading Comment/additional input – For clearer understanding, the manpower histogram shows the total mandays and the total manhours to easily determine if the histogram was prepared on the basis of normal hours or extended hours.



Jobcards 6.2.6.1

Execution of specific activity is described in details in the form of a jobcard. A jobcard should highlight as a minimum the following details:i)

Work or project title and code number,

ii) Planned duration, iii) A list of sequential activities involved, iv) Manpower required and its quantity, v) Tools, equipment and consumables required and their quantities, vi) Specific instructions. 6.2.6.2

A typical jobcard for testing and pre-commissioning activities is shown in previous page

6.2.6.3

Jobcard coding system is developed to include the work category; either pre-commissioning (P) or testing (T), the system number, the discipline and the sequential numbering. For example, the jobcard sample code number shown on the upper right hand corner in the figure, T-311-M-01 stands for the number one testing of mechanical equipment in system 311.

6.2.6.4

It is recognised the use of jobcards in testing and precommissioning is not a typical requirement. However, the use of jobcard in the field of turbomachinery has proven to be most beneficial when it pertains to resources controls and monitoring.

6.2.6.5

As a minimum, CONTRACTOR shall utilize the jobcard when testing for turbomachinery equipment.



Safety As testing, pre-commissioning and commissioning activities are generally performed towards the end of a project, there is a tendency for lower safety awareness amongst the workers. Admittedly, activities are less at the later stages but the working environment is no less hazardous. Introduction of electrical power, utilities and hydrocarbon into various systems which at times are unproven and energization of equipment would require extensive safety awareness. Further to the nominal safety gears and regulations that personnel are subjected to as described in the overall safety manual, additional precautions as described below are excellent reminders while performing testing and pre-commissioning activities. 6.3.1

Pre-cautions Below are some of the precautions and reminders pertaining to testing, precommissioning and commissioning activities that may not be highlighted in the Fabrication Safety Manual. 6.3.1.1

General i)

Testing areas are barricaded and signs erected showing the type of hazards involved such as chemicals, high voltage, hydrocarbon, etc.

ii) A permit system is established informing all parties of the upcoming tests, the hazards involved and the precautions to be taken. iii) Firefighting equipment is available at the test area at all times. A dedicated firefighting crew could be formed and be stationed at test area during tests. v) A safety officer shall be present at test area at all times during all testing. vi) ERT is in-place for any call of emergency. vii) Emergency fire and ambulance quick response drill. 6.3.1.2

Rotating Equipment Rotating equipment constitutes items such as turbines, compressors, internal combustion engines, pumps and



alternators. In order to prevent accidents and damage to the equipment, the following safety measures are recommended. i)

Protective guards on exposed rotating members should be in place. If guard is not provided then a reasonably effective protective barrier is provided by CONTRACTOR.

ii) Only skilled and authorised personnel should be permitted to operate or maintain rotating equipment. The number of personnel in the testing area should be minimised as low as the activity requires. iii) In addition to normal safety gears, ear plugs should be worn when working around operating rotating equipment. iv) Frayed or loose clothing, rings, ties, jewelry, etc, should not be worn around operating machines or other sources of entanglement. v) All isolating points shall be identified, locked out and tagged to prevent accidental energization or release of hydrocarbon and chemicals into the environment. Never bypass safety interlock devices on machinery. vi) Wait for rotating equipment has reached to a complete stop before attempting any adjustment or performing isolation. Do not slow down or stop moving machinery and parts by hand. vii) Inspect equipment daily for loose or damaged parts, lubrication, lighting, etc, before starting up. viii) Do nottest the machinery and equipment to above their pressure and temperature ratings. 6.3.1.3

Electrical Equipment Facilities include motor control centers (MCC), switchgears, transformers, breakers, batteries, chargers, etc. In addition to guidelines in the Safety Manual, the following safety measures are recommended. i)

Earthing protection is available and secured prior to energizing any equipment.





ii) Only correct tools and equipment such as test pens, meters, etc., are identified and used for the specific activities. iii) Tools and equipment shall be in good working condition especially those used for voltage and current measurements. iv) All wiring and circuit to be checked continually for loose connection and physical damage. v) When equipment is not operating, the breaker shall be secured in the "off" position and the appropriate signs to indicate its status shall be displayed at all times. Padlocks shall be installed for the appropriate breaker. vi) All conductors shall be regarded and handled as "live" until it is verified they are de-energized. vii) Fuse capacity shall not be greater than the circuit it is protecting and never pull a fuse that is carrying current. Always use fuse retrievers to remove fuses. viii) Exercise care in handling mercury-filled items. ix) For Brownfield projects all temporary portable generating sets and welding machines shall follow the PETI guideline



Pressurized Equipment Pressurized equipment generally denotes vessels that hold process medium like separators, collection vessels, accumulators, scrubbers, bottles, etc. In addition to guidelines in the Safety Manual, the following safety measures are recommended. i)

All relief valves shall be in service or isolated as required. Calibration certificate should be available prior to start of testing.

ii) Ensure all joints and connections are properly tightened e.g. valves, manholes, fittings, etc. iii) Pressurize and depressurize gradually during testing.





Punchlist During the course of the Yard Pre-commissioning, certain activities may have to be executed offshore because of the following reasons. i)

Non-execution of CONTRACTOR's Works,

ii)

Material or equipment damaged by CONTRACTOR,

iii)

Fabrication Works were out of specifications,

iv)

Defective CONTRACTOR-supplied materials and equipment,

v)

Design changes,

vi)

Late delivery of CARIGALI-supplied materials and equipment,

vii)

Defective CARIGALI-supplied materials and equipment, and

viii)

CARIGALI-supplied materials or equipment is out of specifications.

ix)

Late identification/determination on the shortfall of material.

It is CARIGALI's intention that punchlist should be limited to a minimum. CONTRACTOR Fabrication Team is responsible to ensure that a complete listing of outstanding fabrication activities to be compiled prior to commencement of testing, precommissioning and commissioning. This would allow review and assessment of the situation by CARIGALI if any of the punchlist prohibits the commencement of testing, pre-commissioning and commissioning activities. A Final Punchlist shall be compiled by CONTRACTOR for all activities including nonperformance of test and submitted to CARIGALI for review. As a minimum, a punchlist should contain the following information:i)

'CAT' classification,

ii)

System identification,

iii)

Description and location of the activity,

iv)

Equipment name should the activity is pertinent to a specific equipment,

v)

Materials required to carry out the activity, and

vi)

Status of the materials i.e. purchase order issued date, delivery date, vendors, etc.

A typical punchlist format is shown in Figure 6-5 on the next page.



Punchlist items are categorized according to the priorities set forth by the ongoing testing, pre-commissioning and commissioning activities. For example, if lube oil flushing on a turbine engine is not completed, it shall be classified as a ''CAT – B'' punchlist items which means the turbine engine shall not be tested or started up until the punchlist is cleared; in this case, the lube oil flushing; has been cleared.

Punchlist Categories Cat – A: Punchlist items shall be completed before it is safe to proceed to precommissioning Cat – B: Punchlist items shall be completed before it is safe to proceed to commissioning. Cat – C: Punchlist items shall be completed before it achieved system/subsystem handover. Cat – D: Punchlist items that shall be completed before final acceptance.

6.4.1

It is the responsibility of CONTRACTOR to ensure all punchlist materials are provided for and shipped out together with the modules or platform for implementation during Offshore Hookup and Commissioning.


Figure 6-5: Example of Punchlist Register




Final Documentation 6.5.1

It is the responsibility of CONTRACTOR to prepare and compile all documentation as stipulated in the CONTRACT. Final documentation shall follow CSP-03 requirement.

6.5.2

Final Documentation shall cover all project phases (engineering, procurement, construction and commissioning).

6.5.3

Apart from the requirements as listed in CSP-03, CONTRACTOR to ensure the following documents to be included in the Final Documentation: i)

Equipment operations and maintenance manuals,

ii)

Programmable Logic Diagrams, and

iii)

Equipment parts list.

i)

Commissioning Spare Listing,

ii)

One-Year and Two-Year Operating Spare listing, and

iii)

Vendor contact listing.

iv)

Preservation Master List



Commissioning and Operating Spares 6.6.1

CONTRACTOR shall ensure all spare parts recommended by CONTRACTORsupplied equipment vendors are provided for as stipulated in the approved Spare Parts Identification and Requisition (SPIR) forms.

6.6.2

A sample of the SPIR form could be referred to in PETRONAS Technical Specification 70.10.90.81 - SPIR Form.

Note: Refer to CSP-21 on Commissioning, First year or initial spares and 2-year Operating spares



Shiploose Materials 6.7.1

It is the responsibility of CONTRACTOR to supply and deliver all on-module and off-module shiploose materials.

6.7.2

On-module shiploose materials are items designated for module tie-ins whereas off-module shiploose materials are items identified for module-toexisting-facility tie-ins.

6.7.3

On-module materials are shipped out together with the module or platform constructed by CONTRACTOR. Thus, CONTRACTOR shall ensure the materials are packed and tied down suitably for such mode of transportation according to CSP-07 Shiploose Packing Procedure.

6.7.4

Off-module materials are normally sent separately to a designated point such as Kemaman Supply Base (KSB), Asean Supply Base (ASB) or other destination as instructed by CARIGALI.

6.7.5

CONTRACTOR is also responsible to ensure all shiploose materials are properly preserved, tagged, packaged and secured for delivery as per requirement in CSP-07 Shiploose Packing Procedure.



Preservation 6.8.1

At the end of the pre-commissioning period, all items shall be preserved for sea travel and offshore commissioning. In some cases, the length of time between pre-commissioning and offshore commissioning could take up to six months. Thus, preservation is a vital aspect.

6.8.2

CONTRACTOR shall adhere strictly to the preservation specification highlighted under PETRONAS Technical Standard PTS 70.10.70.11–The Preservation of old and new equipment and piping standing idle.

6.8.3

In the event any item is not covered in the specification, CONTRACTOR shall seek clarification from CARIGALI on the matter.





Tools and Equipment 6.9.1

Mechanical Below is a listing of minimum number of tools and equipment necessary in executing mechanical testing, pre-commissioning and commissioning activities. Further determination of the complete listing and quantity required shall be based upon vendor data and manuals. 6.9.1.1

Dial indicator (small clock) with magnetic base; readings from zero to two-hundred-fifty-thousandth of an inch (0.00 - 0.250"); preferred make: "MITUTOYO".

6.9.1.2

Inside micrometer stick; readings from two inches to sixty inches.

6.9.1.3

Outside micrometer - readings from zero to one inch.

6.9.1.4

Precision machinist level; 8 inches long; with reading intervals of half thousandth of an inch (0.0005") or one thousandth of an inch per graduation (0.001").

6.9.1.5

Feeler gauge; 4 inches long; with thicknesses from one thousandth of an inch to fifty thousandth of an inch (0.001" 0.050").

6.9.1.6

Feeler gauge; 10 inches long; with thicknesses from one thousandth of an inch up to fifty thousandth of an inch (0.001" 0.050").

6.9.1.7

Torque wrench; half inch (1/2") drive; readings from zero to two hundred fifty foot-pounds (0 - 250 ft.lbs).

6.9.1.8

Torque wrench; three quarter inch (3/4") drive; readings from one hundred up to eight hundred foot-pounds (100 ft.lbs - 800 ft.lbs).

6.9.1.9

Adjustable Wrenches; sizes 8, 10, 12, 18 and 24 inches.

6.9.1.10

Pipe Wrenches; sizes 6, 8, 10, 12, 18 and 24 inches.

6.9.1.11

Combination wrenches; close and open positions; sizes from 5/16 inch to 1 1/2 inch (with rachet) and 6 millimeters to 35 millimeters (without ratchet).

6.9.1.12

Socket wrenches; 3/4 inch drive; sizes 37, 39, 40, 43, 44, 45, 47, 48, 49, 51, 52, 53, 56, 57, 59, 61, 62, 63, 64, 65 millimeters.



6.9.1.13

Socket wrenches; 1/2" drive with ratchet; sizes from 12 mm to 30 mm and 1/2" up to 1 1/4".

6.9.1.14

Impact wrench; 1" drive with sockets.

6.9.1.15

Hydraulic torque wrench; come with sockets.

6.9.1.16

Vernier caliper; come with a MITUTOYO dial indicator; readings from zero to eight inches (0 - 8") or in metric scale from zero to three hundred millimeters (0 - 300 mm).

6.9.1.17

Straight edge; one meter long; material stainless steel.

6.9.1.18

Allen keys; sizes from two to nineteen millimeters (2 mm - 19 mm).

6.9.1.19

Allen keys; sizes from one eighth of an inch to three fourth of an inch (1/8" - 3/4").

6.9.1.20

Mechanical scissor; thin shear.

6.9.1.21

Measuring tape; 3 meters long; preferred make: "STANLEY".

6.9.1.22

Inspection mirror; round telescopic type.

6.9.1.23

Steel squares; sizes 150 mm x 300 mm and 400 mm x 800 mm.

6.9.1.24

Cold chisel; 6 inches long; heavy duty.

6.9.1.25

Plumb bob; 15 ounces weight.

6.9.1.26

Ballpeen hammer; 3 pounds weight.

6.9.1.27

Rubber mallet; 2 pounds weight.

6.9.1.28

Sledge hammer; 12 pounds weight.

6.9.1.29

Centering puncher; 4 inches long.

6.9.1.30

Numbering puncher.

6.9.1.31

Round claw bars; 24 and 36 inches long.

6.9.1.32

Screw driver; flat type; 10 inches long.

6.9.1.33

Screw driver; “Phillips" type; 10 inches long.


6.9.2


6.9.1.34

Torch light.

6.9.1.35

Mechanical plier; 13 inches long.

6.9.1.36

Grease gun; lever type.

6.9.1.37

Electric drill; portable; medium size.

6.9.1.38

Electric grinders; portable; angle type and straight type.

6.9.1.39

Drill bits; sizes from 1/13" to 5/13".

6.9.1.40

Electrical cord; 50 meters long.

6.9.1.41

Hydraulic jacks; with hand pump; sizes 5 and 50 tons.

6.9.1.42

Chain blocks; capacity 1.5 and 3 tons.

6.9.1.43

Nylon slings; 60 millimeters x 4 meters x 1.5 tons and 120 millimeters x 6 meters x 5 tons capacities.

6.9.1.44

Wire rope sling; 25 millimeters x 4 meters x 6 tons capacity.

6.9.1.45

Millwright toolbox; steel body; with padlock.

6.9.1.46

Files; round type; fine and coarse grains; 8 inches long.

6.9.1.47

Files; flat type; fine grain; 8 inches long.

6.9.1.48

Files; triangular type; coarse grain; 8 inches long.

6.9.1.49

Hand top; fine and coarse threading; range from 5/16 inch up to 7/8 inch.

6.9.1.50

Hacksaw; come with blade and 30 pieces of spare blades.

6.9.1.51

Vibration Meter and Vibration Analyzer for GTG, GTC & large pumps.

6.9.1.52

Handheld tachometer.

6.9.1.53

Walkie-talkies.

HVAC HVAC Testing Equipment: 6.9.2.1

Vacuum Pump (1 unit)




6.9.3

6.9.2.2

Refrigerant Charging Kit (1 unit)

6.9.2.3

Anemometer (1 unit)

6.9.2.4

Temperature and Humidity Recorder (1 unit)

6.9.2.5

Pressure recorder (1 unit)

6.9.2.6

Brazing tools (1 unit)

Piping Flushing, Hydro testing & Chemical Cleaning Tools & Equipment 6.9.3.1

Lube Oil Flushing pump

6.9.3.2

Lube Oil tanks c/w heater

6.9.3.3

Chemical Acid Cleaning Pump

6.9.3.4

Chemical Acid tanks

6.9.3.5

Shower station

6.9.3.6

Eyewash station

6.9.3.7

Hydro Jet water pump

6.9.3.8

Hydrotest (Haskel) Pump

6.9.3.9

Hydraulic jack (10 & 20 tons)

6.9.3.10

Hydraulic torque machine

6.9.3.11

Bolt tensioner machine

6.9.3.12

Nitrogen regulator low pressure

6.9.3.13

Nitrogen regulator high pressure

6.9.3.14

SS wire braided hose (1” dia. x 12 ft long)

6.9.3.15

SS wire braided hose ( 2” dia. x 12 ft long)

6.9.3.16


6.9.3.17








Electrical Below is a listing of minimum number of tools and equipment for executing electrical testing, pre-commissioning and commissioning activities. Further determination of the complete listing and the item quantities shall be based upon vendor data and manuals. 6.9.4.1

Megger tester; constant voltage; ratings: 5 kV, 1000 V, 500 V, 250 V.

6.9.4.2

Earth resistance tester; “Megger" type; hand-operated; maximum reading: 100 ohms; complete with earth spikes and clads.

6.9.4.3

Voltage ammeter; clamp-on type; current ranges: 0 - 10 A, 0 - 25 A, 0 - 250 A, 0 - 600 A; voltage ranges: 0 - 150 V, 0 - 600 V + 10 percent.

6.9.4.4

Phase sequence indicators; ratings: 50 - 65 Hertz, 20 - 400 Volts.

6.9.4.5

Voltmeter; portable type; ranges 0 - 150 V, 0 - 300 V, 0 - 600 V + 10 percent.

6.9.4.6

Stopwatch.

6.9.4.7

Current injection tester; 2000 A injection current.

6.9.4.8

High voltage tester; test voltage: 0 - 70 kV DC.

6.9.4.9

Low resistance ductor tester.

6.9.4.10

Phase shifter.

6.9.4.11

Frequency generator.

6.9.4.12

Automatic voltage regulator (AVR).

6.9.4.13

Tachometer.

6.9.4.14

Vibration meter; portable type.

6.9.4.15

Refrigeration leak detector.

6.9.4.16

Direct current ammeter; for batteries.

6.9.4.17

Thermometer calibration: 0 - 100 0C + 10 percent.

secondary and primary; ratings:

0-



6.9.4.18

Tool kit; containing screw driver, pliers, wrenches and special tools.

6.9.4.19

Recording ammeter; spring-wound, 5 Amperes, 110 Volts, complete with ink, pens, record rolls.

6.9.4.20

Recording wattmeter; spring-wound, 5 Amperes, 110 Volts, complete with ink, pens, record rolls.

6.9.4.21

Light Meter, portable.

6.9.4.22

Load bank; for switchgear, transformer and diesel generator testing.

6.9.4.23

Soldering gun; 110 VAC/35W complete with tips.

6.9.4.24

Solder; 60/40 mix with resin core.

6.9.4.25

Direct current (DC) supply unit; range 0 to 40 V; 25 amperes

6.9.4.26

Crimping tools; range nos. 8 to 16 American Wire Gauge (AWG).

6.9.4.27

Hammer, ball peen; 16 ounce.

6.9.4.28

Wire strippers.

6.9.4.29

Vice grip pliers; 250 mm (10 inches) nominal size.

6.9.4.30

Flashlight; two-cell; intrinsically safe.

6.9.4.31

Transformer oil dielectric tester

6.9.4.32

Contact resistances (ductor test)



Instrumentation Below is a listing of minimum number of tools and equipment for executing instrumentation testing, pre-commissioning and commissioning activities. Further determination of the complete listing and the item quantities shall be based upon vendor data and manuals. 6.9.5.1

Digital thermometer, preferred make: "FLUKE" or equal.

6.9.5.2

Pneumatic calibrator, preferred make: "WALLACE & TIERNAN" or equal; kPa type; range: 24 to 210 kPa (100 to 820 inch H2O).

6.9.5.3

Digital Multimeter, preferred make: "FLUKE" or equal; range: 0 1000 VDC, 0 - 750 VDC, 0 - 10 A, 2000 ohm - 20 Mohm.

6.9.5.4

Dead Weight Tester, preferred make: "BUDENBERG"; range: 0 100,000 kPa.

6.9.5.5

Standard test gauges; preferred make: "BUDENBERG" or equal; Ranges: 0-2000 kPa (300 psi), 0-3500 kPa (500 psi), 0-7000 kPa (1000 psi), 0-14,000 kPa (2000 psi) 0-35,000 kPa (5000 psi) 0-50,000 kPa (7000 psi) 0-75,000 kPa (11,000 psi) 0-100,000 kPa (15,000 psi)

6.9.3.6

Constant Current Source, model: EMERSON HANDHELD or equal, Range: 0 - 24mA.

6.9.3.7

Decade Resistance Box, range: 0 - 10K Ohm.

6.9.3.8

DC supply unit, range: 0 - 40 VDC (0 - 25A).

6.9.3.9

Bubble test set, for example: Snoop.

6.9.3.10

Stopwatch.


Water column or trough.

6.9.3.12

Pressure chart recorder; ranges: 0-7000kPa (1000psi), 0-21,000kPa (3000 psi), 0-42,000kPa (6000 psi), 0-70,000kPa (10,000 psi).

6.9.3.13

Temperature bath.

6.9.3.14

Oscilloscope; dual trace; range 0 to 100 MHz

6.9.3.15

Signal generator; range 5 Hz to 1 MHz.

6.9.3.16

Temperature recorder.

6.9.3.17

Instrument manufacturer's handheld EMERSONSmart Transmitter calibrators.

6.9.3.18

Fieldbus Communicator e.g. FBT

6.9.3.19

Hydraulic Pump

6.9.3.20

Portable Temperature Gun

6.9.3.21

Portable Vibration Detector

Notes: Spares are covered under equipment specification


calibrators

e.g.



6.10 Consumables 6.10.1

Preservative Lubricants 6.10.1.1

VALVOLINE "Tectyl" 502Cm, MOBIL "Vaprotect" or PETRONAS equivalent for reciprocating compressor.

6.10.1.2

SHELL "Ensis" 152 or PETRONAS equivalent for lube oil tanks.

6.10.1.3

SHELL "Ensis" SDA or PETRONAS equivalent for all carbon steel heat exchanger, reciprocating compressors and pumps, shaft couplings, exposed rods, eccentrics, plungers, cylinders and valve chambers.

6.10.1.4

SHELL "Ensis” 158 or PETRONAS equivalent for steel heat exchanger, centrifugal pumps, reciprocating pumps, mechanical drives, gearboxes.

6.10.1.5

SHELL "VPI" 260/280 for air reservoirs, pulsation dampeners.

6.10.1.6

SOZOL grease or PETRONAS equivalent for gas turbine surfaces.

6.10.1.7

PETRONAS Hydraulic EP oil for hydraulic pump and motor.




Lubricants 6.10.2.1

SHELL "Rimula" X30 or PETRONAS "Motolube" CS3-30/ CS Urania CF30 for "Caterpillar" diesel engines.

6.10.2.2

SHELL "Mysella" R30 or PETRONAS GEOS 40 for "Caterpillar" gas engines.

6.10.2.3

PETRONAS "Motolube" C53-40 or Urania CF40 / SHELL "Rimula" X40 for gas engine, survival craft engine, and plunger oil pumps.

6.10.2.4

SHELL "Tellus" T46 or PETRONAS equivalent (Hidraulik HVI 46) for pedestal crane hydraulic oil.

6.10.2.5

SHELL "Comptella" S-46 or PETRONAS equivalent (PressolSyn SP 46) for air compressors.

6.10.2.6

SHELL "Alvania” IP grease or PETRONAS equivalent (Gris EPI) for pump motors and bearings.

6.10.2.7

SHELLCardium Compound or PETRONAS equivalent (Promexa) for wire rope and open gears.

6.10.2.8

SHELL "Tellus" Oil 32 or PETRONAS equivalent (Hidraulik EP 32) for survival craft, hydraulic oil.

6.10.2.9

SHELL "Rimula" X 10W or PETRONAS equivalent (Urania CF 10W) for air starting motor.

6.10.2.10

SHELL SAE 90 Type IL or PETRONAS equivalent for crane gear boxes and survival craft gear boxes.

6.10.2.11

ESSO "Teresso" 46 or PETRONAS Jenteram HC46 for turbogensets and compressors lube oil system.

Notes: a. b.

Equivalent item is specified in case an option is required. Lubricants to be used depend manufacturers recommendation.

on

vendors

and



Miscellaneous 6.10.3.1

General purpose grease (GRIS MPI).

6.10.3.2

Penetrating oil WD-40.

6.10.3.3

Molykote anti-seize compound (PETRONAS Long Life Coolant)

6.10.3.4

Stainless steel shim of various sizes and thicknesses (PETRONAS Gris Syn AS)

6.10.3.5

O-ring sets.

6.10.3.6

Glycerin.

6.10.3.7

Flexible hoses, assorted as required.

6.10.3.8

Wire mesh (stainless steel) as required.

6.10.3.9

Plastic tubing, assorted size as required.

6.10.3.10

Sand papers, assorted.

6.10.3.11

Electrical tapes.

6.10.3.12

Rubber tapes.

6.10.3.13

Masking tapes.

6.10.3.14

Teflon tapes.

6.10.3.15

Silicon sealant.

6.10.3.16

Grounding sleeves; assorted.

6.10.3.17

Terminal lugs; assorted.

6.10.3.18

Cable insulation kit.

6.10.3.19

Waste rags

6.10.3.20

SNOOP for instrument leak test



Others 6.10.4.1

PETRONAS “Jenteram 32” or equivalent for Wellhead Control Panel Hydraulic Oil




RECORDS Records compiles all Inspection Test Record (ITR) for project stages as follow: a) ITR-A : During Construction b) ITR-B : During Pre-Commissioning c) ITR-C: During Commissioning ITR-A, B and C has specific respective accountable parties or authority to complete, verify and accept the activities performed. Typically, the signatories for respective Inspection Test Record (ITR) are as follow: ITR-A:

Designation Company Name Signature Date

COMPLETED BY Contractor Representative

VERIFIED BY PCSB Inspector PETRONAS Carigali

ACCEPTED BY Discipline Engineer PETRONAS Carigali

ITR-B:




ACCEPTED BY Commissioning Engineer PETRONAS Carigali

ITR-C:



VERIFIED BY Commissioning Engineer PETRONAS Carigali

ACCEPTED BY Operation PETRONAS Carigali

Each of the discipline (e.g. Mechanical, Instrument, Electrical etc.) would have associated ITRA, B and C to be completed. ITR Overview in Appendix IV serve as a guideline to check which ITR is applicable for systems that we have in hands. For ITR-B (Pre-Commissioning stage), the Operations may have to witness the test being carried out onshore. They may have to initial or sign anywhere in the check-sheet for Handover purposes




ITR Listing 7.1.1

A05-A

Architectural Construction Architectural Members Room Equipment Platform Sanitary External / Internal Cladding and Insulation Doors, Hatch and Window

A06-A A07-A

Sickbay Galley

ITR No A01-A A02-A A03-A A04-A

ITR No

Pre-commissioning

ITR No

Commissioning

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 7.1.2 ITR No C01-A C02-A C03-A C04-A C05-A


Civil

Construction Building / Room Foundation Concrete Work Road Fencing & Gates

ITR No

Pre-commissioning N/A N/A N/A N/A N/A

ITR No

Commissioning N/A N/A N/A N/A N/A



CARIGALI STANDARD PROCEDURE ITR No E01-A E02-A E03-A E04-A E05-A E06-A E07-A E08-A

7.1.3 Electrical Construction GTG MTG GEG DEG Reserved for Future Reserved for Future Solar Panel Electrical network Monitoring and Control System

ITR No E01-B E02-B E03-B E04-B E05-B E06-B E07-B E08-B

Pre-commissioning GTG MTG GEG DEG Reserved for Future Reserved for Future Solar Panel Electrical network Monitoring and Control System

ITR No E01-C E02-C E03-C E04-C E05-C E06-C E07-C

Commissioning GTG MTG GEG DEG Reserved for Future Reserved for Future Solar Panel

E08-C

N/A

E09-A

Transformer (Dry Type)

E09-B

Transformer (Dry Type)

E09-C

E10-A

Transformer (Oil Type)

E10-B

Transformer (Oil Type)

E10-C

E11-A

High Voltage Switchgear

E11-B

High Voltage Switchgear

E11-C

E12-A

N/A

E12-B

E12-C

E13-A

N/A

E13-B

High Voltage CB High Voltage motor starter

Transformer (Dry Type) Transformer (Oil Type) High Voltage Switchgear N/A

E13-C

N/A

E14-A

Low Voltage Switchgear

E14-B

Low Voltage Switchgear

E14-C

E15-A

N/A

E15-B

E15-C

E16-A

N/A

E16-B

E16-C

N/A

E17-A E18-A E19-A

N/A N/A N/A Integrated Motor Control System Overhead Transmission Line High Voltage Cable Submarine Cable Busduct Low Voltage Cable Capacitor Bank and Series Reactor Electrical Equipment Room/Substation UPS DC Charger EPU Battery

E17-B E18-B E19-B

Low Voltage CB Low Voltage motor starter Protection relay CT VT Integrated Motor Control System Overhead Transmission Line High Voltage Cable Submarine Cable Busduct Low Voltage Cable Capacitor Bank and Series Reactor

Low Voltage Switchgear N/A

E17-C E18-C E19-C

N/A N/A N/A

E20-C

N/A

E21-C

N/A

E22-C E23-C E24-C E25-C

N/A N/A N/A N/A Capacitor Bank and Series Reactor

E27-B

N/A

E27-C

N/A

E28-B E29-B E30-B E31-B

UPS DC Charger EPU Battery

E28-C E29-C E30-C E31-C

UPS DC Charger EPU Battery

E20-A E21-A E22-A E23-A E24-A E25-A E26-A E27-A E28-A E29-A E30-A E31-A

E20-B E21-B E22-B E23-B E24-B E25-B E26-B

E26-C



CARIGALI STANDARD PROCEDURE E32-A E33-A E34-A E35-A E36-A E37-A E38-A E39-A E40-A E41-A E42-A E43-A E44-A E45-A E46-A E47-A E48-A E49-A E50-A

Low Voltage Distribution Board Earthing& Lightning Protection NER Variable Speed Drive System Heater Control panel High Voltage Motor Low Voltage Motor Electric Heater Electrical Heat tracing Impressed Current Cathodic Protection System Motor Operated Valve Normal Lighting (circuit/ fixture) Emergency Lighting (circuit/ fixture) Socket (Welding/power/convini ent) Navigational Aid Push Button Station/Safety Switch Junction Box Cable ladder/tray Inspection and preservation of electric motors

E48-B E49-B

Low Voltage Distribution Board Earthing& Lightning Protection NER Variable Speed Drive System Heater Control panel High Voltage Motor Low Voltage Motor Electric Heater Electrical Heat tracing Impressed Current Cathodic Protection System Motor Operated Valve Normal Lighting (circuit/ fixture) Emergency Lighting (circuit/ fixture) Socket (Welding/power/convini ent) N/A Push Button Station/Safety Switch N/A N/A

E50-B

N/A

E32-B E33-B E34-B E35-B E36-B E37-B E38-B E39-B E40-B E41-B E42-B E43-B E44-B E45-B E46-B E47-B

E32-C

N/A

E33-C

N/A

E34-C

N/A Variable Speed Drive System N/A High Voltage Motor Low Voltage Motor Electric Heater Electrical Heat tracing Impressed Current Cathodic Protection System Motor Operated Valve Normal Lighting (circuit/ fixture) Emergency Lighting (circuit/ fixture)

E35-C E36-C E37-C E38-C E39-C E40-C E41-C E42-C E43-C E44-C E45-C

N/A

E46-C

N/A

E47-C

N/A

E48-C E49-C

N/A N/A

E50-C

N/A




HVAC

ITR No

Construction

ITR No

Pre-commissioning

ITR No

Commissioning

H01- A

FAN

H01- B

FAN

H01-C

NA

H02- A

DAMPERS

H02- B

NA

H02-C

NA

H03- A

H03- B

AIR HANDLING UNIT

H03-C

NA

H04- B

NA

H04-C

NA

H05- B

NA

H05-C

NA

H06- B

NA

H06-C

NA

H07- A

AIR HANDLING UNIT DUCT WORK FOR VENTS, EXHAUST & HEATERS DUCT LEAK TEST DIFFUSERS/GRILLS/LOUV ERS/HOODS FILTERS/COALESCER

H07- B

NA

H07-C

NA

H08- A

SOUND ATTENUATOR

H08- B

NA

H08-C

NA

H09- A

HVAC DUCT HEATER

H09- B

NA

H09-C

NA

H10- A

HVAC

H10- B

H10-C

NA

H11-C

NA

H12-C

NA

H13-C

NA

H14-B

HVAC STATIC PRESSURE TEST HVAC FIRE DAMPER AND PANEL HVAC DAMPER AND PANEL HVAC MIST ELIMINATOR AND FILTER HVAC DX SYSTEM

H14-C

NA

H15-B

HVAC FANS /MOTORS

H15-C

NA

H16-B

HVAC DUCT BALANCE SHEET HVAC AREA PRESSURE TEST SHEET HVAC DUCT HEATER HVAC RECIRCULATION PUMP HVAC TANK HVAC

H16-C

NA

H17-C

NA

H18-C H19-C H20-C H21-C

NA NA NA HVAC

H04- A H05- A H06- A

H11-B H12-B H13-B

H17-B H18-B H19-B H20-B H21-B




ITR No I01-A I02-A I03-A I04-A I05-A I06-A I07-A

I08-A

Instrumentation Construction ITR No Instr. Cable Installation & I01-B Testing Instr. Fibre Optic I02-B Installation & Testing Instr. Calibration I03-B Instr. Installation I04-B Instr. Tubing Installation & I05-B Pressure Testing Instr. Panel (Electronic) I06-B Installation Instr. Junction Box I07-B Installation Pneumatic Instr. Control Panel (ICP)/ESD Station Installation

Pre-commissioning

ITR No

Commissioning

N/A

I01-C

N/A

N/A

I02-C

N/A

N/A N/A

I03-C I11-C

N/A N/A

N/A

I05-C

N/A

N/A

I06-C

N/A

N/A

I07-C

N/A

I08-B

Pneumatic Instr. Control Panel (ICP)/ESD Station Testing

I08-C

Pneumatic Instr. Control Panel (ICP)/ESD Station Testing

I09-B

N/A

I09-C

N/A

I10-B

N/A Instr. Closed Loop Check N/A Miscellaneous Process Analyzers Test

I10-C

N/A Instr. Closed Loop Check N/A Miscellaneous Process Analyzers Test

I14-B

N/A

I14-C

N/A

I15-B

N/A

I15-C

N/A

I10-A

CV/SDV/BDV (control/shutdown valve/blowdown valve) Installation & Calibration PSV Inspection & Test

I11-A

N/A

I11-B

I12-A

N/A

I12-B

I13-A

Miscellaneous Process Analyzers Test

I13-B

I09-A

I14-A I15-A

Fire & Gas Device Calibration &Installation Cable Tray Installation Check

I11-C I12-C I13-C

I16-A

N/A

I16-B

Fire & Gas Device Loop Test

I16-C

Fire & Gas Device Loop Test

I17-A

Fusible Plug Loop & Panel Installation

I17-B

N/A

I17-C

N/A

I18-A

N/A

I18-B

I19-A I20-A I21-A

N/A WHCP Installation N/A

I19-B I20-B I21-B

I22-A

HSSD(VESDA) Installation

I22-B

I23-A I24-A

Metering Skid Installation Conduit Installation Check

I23-B I24-B

Cause & Effect Matrix Verification N/A WHCP Test N/A HSSD(VESDA) Loop Test Metering Skid Test N/A

I19-C I20-C I21-C

Cause & Effect Matrix Verification N/A WHCP Test N/A

I22-C

N/A

I23-C I24-C

Metering Skid Test N/A

I18-C



CARIGALI STANDARD PROCEDURE I25-A I26-A I27A I28-A

N/A Tank Gauging System Installation MPFM Installation Pipeline Leak Detection System Installation

I25-B I26-B I27-B I28-B

N/A Tank Gauging System Testing MPFM Testing Pipeline Leak Detection System Testing

I25-C I26-C I27-C I28-C

N/A Tank Gauging System Testing MPFM Testing Pipeline Leak Detection System Testing



Mechanical

ITR No

Construction

ITR No

Pre-commissioning

ITR No

Commissioning

M01- A

Pressure Vessel Heat Exchanger (Plate / S & T)

M01- B

M01-C

Pressure Vessel

M02-C

NA

M03- A

Heat Exchanger (PCHE)

M03- B

M03-C

NA

M04- A

Gearbox

M04- B

Pressure Vessel Heat Exchanger (Plate/ S & T) Heat Exchanger (PCHE) Gearbox

M04-C

NA

M05- A

Relief valve

M05- B

Relief valve

M05-C

NA

M06- A

Air Dryer Package

M06- B

Air Dryer Package

M06-C

NA

M07- A

Filter/Strainer

M07- B

Filter/Strainer

M07-C

NA

M08- A

Pedestal Crane

M08- B

Pedestal Crane

M08-C

Pedestal Crane

M09- A

Monorail/Trolley Hoist

M09- B

M10- A

Gantry/ Bridge Crane

M10- B

Monorail/Trolley Hoist Gantry/ Bridge Crane

M11- A

Flare

M11- B

M12- A

Lifeboat & Davit

M13- A

M02- A

M02- B

M10-C

Monorail/Trolley Hoist Gantry/ Bridge Crane

Flare

M11-C

Flare

M12- B

Lifeboat & Davit

M12-C

Lifeboat & Davit

Generator

M13- B

Generator

M13-C

NA

M14- A

Mixers & Agitators

M14- B

M14-C

M15- A

Electro-Chlorinator Unit

M15- B

M16- A

Sanitary Treatment Unit

M16- B

M17- A

TEG Generation Unit

M17- B

Mixers & Agitators Electro-Chlorinator Unit Sanitary Treatment Unit Gas Dehydration Unit

Mixers & Agitators Electro-Chlorinator Unit Sanitary Treatment Unit Gas Dehydration Unit

M18- A

Submersible Pump Piston Displacement Pump

M18- B

Submersible Pump Piston Displacement Pump

M18-C

M20- A

Air Compressor

M20- B

Air Compressor

M20-C

M21- A

Diesel Engine

M21- B

Diesel Engine

M21-C

M22- A

Gas Turbine

M22- B

Gas Turbine

M22-C

M23- A

Centrifugal Compressor

M23- B

M24- A

Reciprocating Compressor

M24- B

M25- A

Refer to Vendor Equipment Skid –M036-A

M25- B

M26 A

Centrifugal Pump

M26- B

M27- A

Refer to Vendor

M27- B

M19- A

M19- B

Centrifugal Compressor Gas engine driven Reciprocating Gas Compressor Electric Motor driven Reciprocating Gas Compressor Electric Motor driven Centrifugal Pump Gas Engine driven

M09-C

M15-C M16-C M17-C

M19-C

M23-C M24-C

M25-C M26-C M27-C

Submersible Pump Electric motor Piston Displacement Pump Electric Motor Air Compressor Diesel/Gas Engine Generator Gas Turbine Generator Turbine driven Compressor Gas engine driven Reciprocating Gas Compressor Electric Motor driven Reciprocating Gas Compressor Electric Motor driven Centrifugal Pump Gas Engine driven

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE ITR No

M28- A M29-A M30-A

Construction Equipment Skid –M036-A Refer to Vendor Equipment Skid –M036-A Refer to Vendor Equipment Skid –M036-A Refer to Vendor Equipment Skid –M036-A

ITR No


ITR No

M37-B

Pre-commissioning Centrifugal Pump (COTP) Diesel engine driven Fire Pump Chemical Metering Pump Chemical Injection Package Nitrogen Gas Generator Sewage Treatment Unit Water Maker Unit (Vapour Compressor) Subsea Equipment Package Miscellaneous Equipment Vendor's Package Equipment AGRU

M37-C

Commissioning Centrifugal Pump (COTP) Diesel engine driven Fire Pump Chemical Metering Pump Chemical Injection Package Nitrogen Gas Generator Sewage Treatment Unit Water Maker Unit (Vapour Compressor) Subsea Equipment Package Miscellaneous Equipment Vendor's Package Equipment AGRU

M28- B M29- B M30- B

M31-A

Nitrogen Gas Generator

M31- B

M32-A

Sewage Treatment Unit

M32-B

M33-A

Water Maker Unit

M33-B

M28-C M29-C M30-C M31-C M32-C M33-C

M37-A

Subsea Equipment Package Miscellaneous Equipment Vendors Package Equipment Skid NA

M38-A

NA

M38-B

MRU

M38-C

MRU

M39-A

Fin Fan Cooler

M39-B

Fin Fan Cooler

M39-C

NA

M40-A

M40-B

NA

NA

M41-B

NA

NA

M42-A

Base Plate Load testing of lifting lugs /monorail Elevators

M42-B

Elevators

Elevators

M43-A

Valve Installation

M43-B

NA

NA

M44-A

Pulsation Dampener

M44-B

Pulsation Dampener

NA

M45-A M46-A M47-A M48-A

Coupling Cold Alignment Pig trap Storage tank Lubricating log

M45-B M46-B M47-B M48-B

M47-C M48-C

NA Pig trap Storage tank NA

M49-A

NA

M49-B

M49-C

NA

M50-A

Turbo Expander/Booster Compressor

Coupling Alignment Pig trap Storage tank NA Final Closure Certificate Turbo Expander/Booster Compressor

M50-C

Turbo Expander/Booster Compressor

M34- A M35-A M36-A

M41-A

M34- B M35-B M36- B

M50-B

M34-C M35-C M36-C



CARIGALI STANDARD PROCEDURE ITR No P01-A

7.1.7 Piping Construction Pipe Work Completion

ITR No P01-B

Pre-commissioning N/A

ITR No P01-C

Commissioning N/A

P02-A

Pre- Test

P02-B

N/A

P02-C

N/A

P03-A

Flushing

P03-B

N/A

P03-C

N/A

P04-A

Pressure Test

P04-B1

P04-C

N/A

P05-C

N/A

P05-A

Blowing /Drying

P05-B

Re-Instatement Work Reinstatement Leak Test N/A

P06-A

Flanges Alignment

P06-B

Flanges Management

P06-C

N/A

P07-A

Bolt Tensioning/Tourqing

P07-B

N/A

P07-C

N/A

P08-A P09-A

Chemical Cleaning Re-Installation Work

P08-B P09-B

N/A N/A

P08-C P09-C

N/A N/A

P10-A

P10-B

Service Test

P10-C

N/A

P11-B

N/A

P11-C

N/A

P12-A

Service Test Pipe Painting/ Coating/Marking Pipe Insulation

P12-B

N/A

P12-C

N/A

P13-A

Critical Valve Leak Test

P13-B

N/A

P13-C

N/A

P14-A P15-A

N/A N/A

P14-B P15-B

Witness Joint Lube Oil Flushing

P14-C P15-C

N/A N/A

P16-A

N/A

P16-B

N/A

P16-C

Nitrogen Purging

P04-B2

P11-A




Safety

ITR No

Construction

ITR No

Pre-commissioning

ITR No

Commissioning

S01- A

Escape Routes and Signs

S01- B

NA

S01-C

NA

S02- A

Safety Shower/Eyewash

S02- B

Safety Shower/Eyebaths

S02-C

NA

S03- A

Survival Equipment

S03- B

Survival Equipment

S03-C

NA

S04- A

Breathing Apparatus

S04- B

NA

S04-C

NA

S05- A

S05- B

NA

S05-C

NA

S06- B

NA

S06-C

NA

S07- B

NA

S07-C

NA

S08- B

NA

S08-C

NA

S09- A

Fire Hoses and Monitors Portable and Wheeled Fire Extinguishers Fireman Outfit Cabinet Miscellaneous Safety Equipment Life Rafts

S09- B

NA

S09-C

S10- A

Firewater/Foam System

S10- B

Firewater/Foam System

S10-C

NA Firewater/Foam System

S11-B

Fire Suppression/Total Flooding System

NA

NA

NA

NA

NA

NA Deck Integrated Fire Fighting System

NA

S06- A S07- A S08- A

S11-A S12-A S13-A S14-A S15-A

Fire Suppression/Total Flooding System Escape and Evacuation Equipment LEV Sickbay Deck Integrated Fire Fighting System

NA



CARIGALI STANDARD PROCEDURE ITR No ST01-A

7.1.9 Structural Construction Structural Members

ST02-A

Structure Painting

ST03-A

Passive Fire Protection

ST04-A

Structural Jacket

ST05-A

Riser

ST06-A

I & J Tube

ST07-A

Telecom Tower

ITR No

Pre-commissioning

ITR No

Commissioning




ITR No T01-A T02-A T03-A

Telecommunication Construction ITR No Telecommunication Cable T01-B Installation & Testing Fiber Optic Cable T02-B Installation And Testing CCTV & PIR Intrusion Detection System T03-B Installation

T04-A

PAGA System Installation

T04-B

T05-A

Indoor/Outdoor Telephone Installation

T05-B

T06-A T07-A T08-A T09-A T10-A

Telecommunication Panel /Cabinet Installation Telecommunication Junction Box Installation VHF FM Installation & Testing VHF AM Installation & Testing LAN/WAN System Installation

T06-B

Pre-commissioning

ITR No

Commissioning

NA

T01-C

NA

NA

T02-C

NA

CCTV

T03-C

NA

T04-C

NA

T05-C

NA

T06-C

NA

PAGA System/ Echo Station/ Strobelight Telephone/ LAN Port Verification & Cable Test Telecommunication Panel

T07-B

NA

T07-C

NA

T08-B

NA

T08-C

NA

T09-B

NA

T09-C

NA

T10-B

NA

T10-C

NA

T11-C

NA

T12-C

NA

T13-C

NA

T11-A

NA

T11-B

T12-A

NA

T12-B

T13-A

NA

T13-B

Radio Communication Test Telecoms Fibre Optic Cables Test Entertainment System


APPENDIX I: ITR – A (CONSTRUCTION) 8.1

APPENDIX I-I: Architecture (A)

8.2

APPENDIX I-II: Civil (C)

8.3

APPENDIX I-III: Electrical (E)

8.4

APPENDIX I-IV: HVAC (H)

8.5

APPENDIX I-V: Instrumentation (I)

8.6

APPENDIX I-VI: Mechanical (M)

8.7

APPENDIX I-VII: Piping (P)

8.8

APPENDIX I-VIII: Safety (S)

8.9

APPENDIX I-IX: Structural (ST)

8.10

APPENDIX I-X: Telecommunication (T)


CSP-20 rev. 01 Appendix I-I PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ARCHITECTURAL MEMBERS

A01-A

Project No. Project Title Facilities Tag Number System Sub System Location 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

INFORMATION Lay Out Drawing Inspection Date

INSPECTION / TEST Raised access floor completed False ceiling completed Room panel partitions completed Acoustic elements installed and secured Pre-fab fire walls / blast walls completed All insulation completed All internal gratings completed Louvered walls completed Internal stairs installed Internal handrails installed Office desks and furniture satisfactory Control desk and consoles complete Workshop benches & equipment complete Room sanitary fittings complete Windows & glazing complete Internal doors complete Vapor barrier installed All infill plates installed Laboratory benches & equipment completed Check all MCT frame completed Check all cable ladder/ tray have been proper installed COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-I PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ROOM EQUIPMENTS

A02-A

Project No. Project Title Facilities Tag Number System Sub System Location 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21


INSPECTION / TEST Wall panel condition Raised access floor plate. Flooring condition Furniture. Windows / window curtain Door / door hardware Wash basins Shower and controls, sealed and satisfactory Electrical fittings Telephone Fire and gas fighting’s HVAC fittings and controls Entertainment equipment / fittings Bunks, curtains, mattress, pillows, sheets Coat hooks Desk, cabinets, filing cabinets, printer and photocopier Washer extractor Tumbler dryer Vacuum ironing Gymnasium equipment Weighing scale COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-I PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PLATFORM SANITARY

A03-A

Project No. Project Title Facilities Tag Number System Sub System Location 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20


INSPECTION / TEST Water closet Toilet doors, frames, threshold and stoppers Cleaner and towel dispenser, towel ring Water supplies, wash basin (Check plug for tightness) Urinal flushing Pipe connections. Ensure pipework has been tested and ITR completed. Air duct, check cut out for ventilation unit Drain piping / drain from wash basin ( Check for leakage ) Wall panels (color, straightness, etc.) Floor ( slope / finish ) Shower and controls, sealed and satisfactory Shower curtain and track Shelves / mirror / light fixture Toilet brush Toothbrush tumbler Soap holder Coat / towel hook Toilet paper holder Hand wash basin with taps Automatic hand dryer

OK

N/A P/L No.

COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1

CSP-20 rev. 01 Appendix I-I PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A EXTERNAL/INTERNAL CLADDING AND INSULATION A04-A Project No. Project Title Facilities INFORMATION Tag Number Lay Out Drawing System Inspection Date Sub System Location INSPECTION / TEST Installation of insulation / cladding supports and fixings correctly installed to 1 drawings and specifications. Record type and thickness of rock wool insulation : Type : 2 Thickness : 3 Installation of stainless steel wire mesh correct 4 Corrugated aluminum installed correctly 5 Check panel material is correct 6 Wall panel installation correct to drawings 7 Installation of 2 side of aluminum foil are correct 8 Installation of stainless steel wire mesh are correct 9 Ensure that stainless steel stud pin washer proper installed

OK

N/A P/L No.






Page 1 of 1

CSP-20 rev. 01 Appendix I-I PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DOORS , HATCH AND WINDOW

A05-A

Project No. Project Title Facilities Tag Number System Sub System Location 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18


INSPECTION / TEST Installed door, hatches and window as per design drawings and specification Unit locking devices operates Door pressure relief port operates Door / hatch panic bar operates Sliding door operates and fitted with a vision panel Gaskets and compression seals installed correctly All doors self closing with dampers, self latching & non key lockable Hinged door adjusted Nuts and bolts tightened to correct values Grease nipple on hinges installed and pre charged Unit frame fixed to structure complete Unit catch and stopper fitted correctly Adequate window provided Type of window, e.g (shall be non opening) Check window certification of fire rating Door entries are provided with air locks Emergency exits are hinged & fitted with panic bars and without air locks External Doors are provided with a vision panel

OK

N/A P/L No.






Page 1 of 1

CSP-20 rev. 01 Appendix I-I PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SICKBAY

A06-A

Project No. Project Title Facilities Tag Number System Sub System Location 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20


INSPECTION / TEST Verify to ensure that all construction have been completed as per drawing Signage at entrance Lighting Entrance door open sideways Bottom clearance of doors does not exceed 0.6 cm All electrical sockets tested and functioning Water supply to all faucets and shower heads Water heater / warm water supply Floor drains doesn’t show signs of clog HVAC functioning Bed screen curtain rail Fixture for oxygen tank Hospital Bed Examination couch Biological waste bin Clinical scales Height measure Stainless steel cabinets AED Refrigerator

OK

N/A P/L No.






Page 1 of 1

CSP-20 rev. 01 Appendix I-I PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A GALLEY

A07-A

Project No. Project Title Facilities Tag Number System Sub System Location 1 2 3


INSPECTION / TEST Electrical power points are provided Fire detection and protection in the hoods, exhaust ductwork and fat fryer systems are installed Canopies and hoods have been installed over all cooking equipment

OK

N/A P/L No.

4

Canopies and hoods are fitted with cleanable grease filters and suitable drainage 5 A toilet dedicated for usage of galley staff are constructed 6 Dining table and chairs are provided as per scope of work A walk-in deep freezer has been installed & tested as the following items • Operating temperature display. • Operating temperature lower than -18 oC 7 • Thermostats. • Warning lights. • Door openable from both directions • Entrances are fitted with a flexible thermal curtain A walk-in refrigerator has been installed & installed as the following items • Operating temperature display. • Operating temperature within 1-4 oC 8 • Thermostats. • Warning lights • Door openable from both directions • Entrances are fitted with a flexible thermal curtain A walk-in vegetable storage room has been installed and tested as the following items • Operating temperature display. 9 • Operating temperature of 6 oC Thermostats. • Warning lights. • Door openable from both directions. A walk-in dry good store has been installed with its door openable from both 10 directions 11

A consumables store has been installed with its door openable from both directions 12 Dish-washing equipment has been installed & tested Page 1 of 2


A07-A INSPECTION / TEST A stand-alone chill units has been installed & tested, bears a temperature display 13 and shows no sign of damage

OK

N/A P/L No.

14

All flow drains (sinks & floor) has been constructed & tested with close fitting covers 15 Grease traps are installed & tested 16

Water taps receives both hot and cold water supply has been installed & tested 17 All wash basins and sinks has been installed 18

19

20

20 21 22 23

Hot servery counter has been installed as per the approved engineering drawing Cold servery counter c/w the following items has been installed & tested : • Ice cream dispenser • Chilled milk & fruit dispenser ( Min 5 L ) • Water boiler capable of continuous boiling water • Automatic bread toaster • Cutleries, crockery and dispensers. Verify that the following equipment has been installed & tested • Solid top, heavy duty range incorporating under oven 2/3/4 plate top • Brat pan with frying pan. • Combination steam/ convection oven. • Convection oven 6 x 1/1 gastronorm. • Salamander multi-purpose with brander 785 mm wide x 330 mm deep x 325 mm high. • Deep fat fryer, 55 kg per hour, self filter. • Sink for hand wash with elbow tap • Vegetable preparation sink. • Meat/ fish double bowl sink. • Pot wash sink with sterilizer sink. • Mobile work bench to suit minimum 1200. • Gravity fed slicer x 300mm • Pot racking 1500 mm. • Refrigerated work bench with under cabinet. • Multi-purpose bench-mounted vegetable preparation machine. • Floor standing food mixer x 23 litres. • Microwave (wall mounted), 3.2 kW input, 1.65 output. • Potato peeler & Chipper A stand-alone chill units has been installed, bears a temperature display and tested functioning Waste bins with close fitting lids has been installed Probe thermometer/ laser thermometer has been provided Page 2 of 3


A07-A

Project No. Project Title Facilities Tag Number System Sub System Location







Page 3 of 3

CSP-20 rev. 01 Appendix I-II PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A BUILDING/ ROOM

C01-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2 3 4 5 6 7 8 9 10 11 12 13

INFORMATION Location Ref Drawing Inspection Date

INSPECTION / TEST Check that the construction confirms to approved drawings and specification. Ensure that the Building is in line with the layout drawing. Check and verify all civil inspection reports are available. Check throughout the Building for cleanliness. Check painting for any damage. Check for ventilation of the room. Check the door & Window are as per approved drawing. Check the door & Window hardware is as per approved drawing. Check that the construction confirms to approved drawings and spec. Ensure that the Building is in line with the layout drawing. Check and verify all civil inspection reports are available. Check throughout the Building for cleanliness. Check painting for any damage. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-II PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FOUNDATION

C02-A

Project No. Project Title Facilities Tag Number Item Description System Sub System

INFORMATION Location Ref Drawing Inspection Date INSPECTION / TEST

1 2 3 4 5 6 7

OK

N/A P/L No.

Ensure that location / orientation of foundations is as per approved layout drawing. Check and verify all civil inspection reports are available. Check foundation level and dimensions as correct as per drawing. Check anchor bolt or pocket spacing / projections are as per drawings. Check for grouting gap between foundation and underside of base plate. Check for presence of crack on the surface etc. Check for aesthetic look of foundation & for its surface finishing. COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1

CSP-20 rev. 01 Appendix I-II PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CONCRETE WORK

C03-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2 3 4 5 6 7 8 9


INSPECTION / TEST Concrete work installed in accordance with specifications and drawings. Rebar installed in accordance with specifications and drawings. Pockets and/or anchor bolts installed in accordance with specifications and drawings. Drains and grating installed in accordance with specifications and drawings. All foundations installed do not create traps for water, ample drainage available for the area. All temporary aids / formwork removed. Backfill and cleaning of surrounding area complete. Slump Test : (mm) Concrete Break Test : (MPA) COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-II PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ROAD

C04-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1

2

3 4 5 6


INSPECTION / TEST Check road sub grade as per AFC drawing. Ensure that compliance test as the following completed and accepted. • Compaction test. • California Bearing Ratio test ( CBRT). • Plate bearing test. • Static cone penetration test. • Density test. Check rigid paving as per specification. Check the flexible paving min 50 mm. Check side drainage channel. Check centre drainage channel. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-II PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FENCING & GATES

C05-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2 3 4 5 6 7


INSPECTION / TEST Check fencing / gates installed as per AFC drawing. Check chain link face fabric as per specification. Check tension wire installed as per AFC drawing. Check string of barbed as per AFC drawing. Check steel bracing at each tenth post as per drawing. Check fencing and gates material as per specification. Check fencing and gates painting as specification. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A GAS TURBINE GENERATOR

E01-A

Project No. Project Title Facilities Tag no. Frequency Manufacturer Model Serial no. 1

2 3 4 5 6

7

INFORMATION System / Sub System no. Voltage Rating Ref. Drawing nos. Location INSPECTION / TEST

N/A P/L No

Documents required: a) GTG data sheets, GA drawings and the skid drawing b) Packing list c) Interconnection drawings (site wiring) d) Relevant portion of the cable schedule Verify and ensure that all construction / installation activities have been completed. Check all nameplate data against data sheets, approved drawing and vendor documentation. Review equipment preservation records against vendor recommendations. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Verify space heaters, instruments, indication lamps, control switches, protection relays and phase identification tags/ labels are installed as per approved drawings. All associated E & I cables (vendor & project) JB's marshalling boxes identified, installed, glanded and terminated as shown on the approved vendor drawings / project specification.

8

Verify CT's, surge capacitor, lighting arrestor and all associated wiring installed as shown on the approved drawings.

9 10 11 12 13

All labeling and warning signs correct and visible. Earthing installed to project design and specification. Unit lighting / ventilation / correctly installed. All associated instrumentation correctly installed. Confirm the air intake and the exhaust are clear of all obstructions and intake/exhaust piping works comply with approved drawings.

14

OK

Check starting battery and give commissioning charge / keep under float charging as necessary

Page 1 of 2

CSP-20 rev. 01 Appendix I-III

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A GAS TURBINE GENERATOR 15

E01-A

Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No

Item

Quantity

Location

16 17

Mark-up installation As built drawings Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 18 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 19 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical completion check-sheet from Mechanical shall be used together with this to complete the construction installation checks.





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MICRO TURBINE GENERATOR Project No. Project Title Facilities Tag no. Frequency Manufacturer Model Serial no. 1

2 3 4 5 6

7

8 9 10 11 12 13 14

E02-A


OK

N/A P/L No

Documents required: a) MTG data sheets, GA drawings and the skid drawing b) Packing list c) Interconnection drawings (site wiring) d) Relevant portion of the cable schedule Verify and ensure that all construction / installation activities have been completed. Check all nameplate data against data sheets, approved drawing and vendor documentation. Review equipment preservation records against vendor recommendations. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Verify space heaters, instruments, indication lamps, control switches, protection relays and phase identification tags/ labels are installed as per approved drawings. All associated E & I cables (vendor & project) JB's marshaling boxes identified, installed, glanded and terminated as shown on the approved vendor drawings / project specification. Verify CT's, surge capacitor, lighting arrestor and all associated wiring installed as shown on the approved drawings. All labeling and warning signs correct and visible. Earthing installed to project design and specification. Unit lighting / ventilation / correctly installed. All associated instrumentation correctly installed. Confirm the air intake and the exhaust are clear of all obstructions and intake/exhaust piping works comply with approved drawings. Check starting battery and give commissioning charge / keep under float charging as necessary

Page 1 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MICRO TURBINE GENERATOR 15

E02-A


Item

Quantity

Location

16 17

Mark-up installation As built drawings Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 18 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 19 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical completion check--sheet from Mechanical shall be used together with this to complete the construction installation checks.





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A GAS ENGINE GENERATOR

E03-A


2 3 4 5 6

7

8 9 10 11 12 13 14


OK

N/A P/L No

Documents required: a) GEG data sheets, GA drawings and the skid drawing b) Packing list c) Interconnection drawings (site wiring) d) Relevant portion of the cable schedule Verify and ensure that all construction / installation activities have been completed. Check all nameplate data against data sheets, approved drawing and vendor documentation. Review equipment preservation records against vendor recommendations. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Verify space heaters, instruments, indication lamps, control switches, protection relays and phase identification tags/ labels are installed as per approved drawings. All associated E & I cables (vendor & project) JB's marshaling boxes identified, installed, glanded and terminated as shown on the approved vendor drawings / project specification. Verify CT's, surge capacitor, lighting arrestor and all associated wiring installed as shown on the approved drawings. All labeling and warning signs correct and visible. Earthing installed to project design and specification. Unit lighting / ventilation / correctly installed. All associated instrumentation correctly installed. Confirm the air intake and the exhaust are clear of all obstructions and intake/exhaust piping works comply with approved drawings. Check starting battery and give commissioning charge / keep under float charging as necessary

Page 1 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A GAS ENGINE GENERATOR 15

E03-A


Item

Quantity

Location

16 17

Mark-up installation As built drawings Record any defects/shortcomings in the system punch-list Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 18 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 19 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical completion check--sheet from Mechanical shall be used together with this to complete the construction installation checks.





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DIESEL ENGINE GENERATOR Project No. Project Title Facilities Tag no. Frequency Manufacturer Model Serial no. 1

2 3 4 5 6

7

8 9 10 11 12 13 14

E04-A


OK

N/A P/L No

Documents required: a) DEG data sheets, GA drawings and the skid drawing b) Packing list c) Interconnection drawings (site wiring) d) Relevant portion of the cable schedule Verify and ensure that all construction / installation activities have been completed. Check all nameplate data against data sheets, approved drawing and vendor documentation. Review equipment preservation records against vendor recommendations. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Verify space heaters, instruments, indication lamps, control switches, protection relays and phase identification tags/ labels are installed as per approved drawings. All associated E & I cables (vendor & project) JB's marshaling boxes identified, installed, glanded and terminated as shown on the approved vendor drawings / project specification. Verify CT's, surge capacitor, lighting arrestor and all associated wiring installed as shown on the approved drawings. All labeling and warning signs correct and visible. Earthing installed to project design and specification. Unit lighting / ventilation / correctly installed. All associated instrumentation correctly installed. Confirm the air intake and the exhaust are clear of all obstructions and intake/exhaust piping works comply with approved drawings. Check starting battery and give commissioning charge / keep under float charging as necessary.

Page 1 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DIESEL ENGINE GENERATOR 15

E04-A


Item

Quantity

Location

16 17

Mark-up installation As built drawings Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 18 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 19 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical completion check--sheet from Mechanical shall be used together with this to complete the construction installation checks.





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SOLAR PANEL

E07-A

Project No. Project Title Facilities Tag no. Output Voltage Manufacturer Ref. Drawing nos. Type 1

2 3 4 5 6

7

8 9 10 11

INFORMATION System / Sub System no. Power Rating Battery AH Serial no. Location INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Solar Panel GA drawings b) Packing list c) Interconnection drawings (site wiring) d) Relevant portion of the cable schedule Verify and ensure that all construction / installation activities have been completed. Check all nameplate data against data sheets, approved drawing and vendor documentation. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Verify the solar panel inclination/angle against the design documents. Verify space heaters, instruments, indication lamps, control switches, protection relays and identification tags/ labels are installed as per approved drawings. All associated E & I cables (vendor & project) JB's marshaling boxes identified, installed, glanded and terminated as shown on the approved vendor drawings / project specification. All labeling and warning signs correct and visible. Earthing installed to project design and specification. Check battery and give commissioning charge / keep under float charging as necessary Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No

Item

Quantity

Location

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 12 13 14 15

SOLAR PANEL E07-A Mark-up installation AS built drawings Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ELECTRICAL NETWORK MONITORING AND E08-A CONTROL (ENMC) SYSTEM Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Model / Type IP Rating Serial no. Manufacturer Location Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required: a) ENMC system architecture and Functional Description System b) ENMC panel GA drawings c) Packing list d) ENMC block diagram and interconnection drawings e) Relevant portion of the cable schedule 2 Verify and ensure that all construction / installation activities have been completed including all accessories like printers. 3 Check and confirm that ENMC nameplate/identification details are as per approved technical drawings. 4 Verify and confirm the panel is secured properly as per drawings and hold down bolts are tight & in accordance to project specification. 5 Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) 6 Inspect physical condition and arrangement of ENMC PLC and its subsequent PLC racks i.e. power supply module, processors modules and communication modules to be as per approved technical drawings. 7 Verify space heaters, instruments, indication lamps, control switches, identification tags/ labels, interposing relays, PLC are installed as per drawings. Check and confirm Fiber Optic converters (FOC)/Fiber Termination Units (FTU) are installed as per drawings. 8 Verify and confirm that all unused cable entries are sealed using proper sealing plugs. 9 Verify Operation of all doors / drawers and confirm they can open / close freely. 10 Inspect earthing/bonding installation and arrangement to be as per approved technical drawings. Special attention to cable screens. 11 Inspect ENMC internal cables connection, wiring, core marking, and tagging to be as per approved technical drawings

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ELECTRICAL NETWORK MONITORING AND E08-A CONTROL (ENMC) SYSTEM 12 Verify the cleanliness of panel internals and confirm all loose wires, packing material etc. are removed. 13 Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No

14 18 19

Item

Quantity

Location

Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TRANSFORMER (DRY TYPE)

E09-A

Project No. Project Title Facilities Tag no. Rated kVA Frequency Manufacturer Ref. Drawing nos. Vector Group Voltage Secondary 1

2

3 4

5

6

INFORMATION System / Sub System no. Area Classification Location Insulation class Type Voltage Primary Percentage Impedance INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Transformer datasheet and GA drawing b) Packing list c) Equipment layout and Bus-duct layout drawing (if applicable) d) Overall SLD e) Relevant portion of the cable schedule Verify to ensure that all construction / installation activities have been completed. Confirm loose supplied components, if any, (fans, bushings, CTs etc.) are installed as per manufacturer’s instructions and all bolts are secured. Check name plate information against data sheets and approved drawings. Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes/bus-duct flanges, bushing cracks, corrosion, painting damage etc. Verify and confirm transformer orientation and location is as per layout drawing and hold- down arrangement is as per vendor drawings. Check the transformer elevation against the layout drawings and busduct flange dimensions against vendor drawings for bus duct connected transformers. Verify and confirm that the transformer earthing (body and neutral grounding) is completed and properly secured. Confirm the transformer star point grounding is established as per project drawings.

Page 1 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 7

8 9 10

11 12

TRANSFORMER (DRY TYPE) E09-A Verify and confirm Primary / Secondary windings / instrumentation and power cables are clearly identified, glanded, terminated and torqued to vendor recommendations. Confirm the bolted connections of power cables are marked after torqueing. Check carefully for the cable lug connection to the bus bar and ensure NO washers are installed between the lug and bus bar. Verify and confirm Current transformer for earth fault /differential protection are correctly installed and wired. Verify all labels and warning signs are correct and visible. Ensure all the incoming and outgoing cables/bus-ducts are adequately supported and the transformer terminals are stress-free. Confirm that the gland plates for single core cable are non-magnetic. Verify and confirm that all unused cable entries are sealed using proper sealing plugs. Check the mechanical operation of the tap changer. Verify and confirm that bus-duct flange (where applicable) dimensions are confirming to project drawings.

13

Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No Item Quantity Location

14

Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION

18 19





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TRANSFORMER (OIL TYPE)

E10-A

Project No. Project Title Facilities Tag no. Rated kVA Frequency Manufacturer Ref. Drawing nos. Vector Group Voltage Secondary 1

2 3

4

5

6 7


OK

N/A P/L No

Documents required: a) Transformer datasheet and GA drawing b) Packing list c) Equipment layout and Bus-duct layout drawing (if applicable) d) Overall SLD e) Relevant portion of the cable schedule Verify to ensure that all construction / installation activities have been completed. Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes/bus-duct-flanges/ radiators/conservator tank, bushing cracks, corrosion, painting damage, oil leak etc. Check and confirm drain tap is ok, vent is free, silica gel Ok and oil level is correct. Confirm loose supplied components, if any, (radiators, conservator, fans, bushings, CTs etc.) are installed as per manufacturer’s instructions. Disperse transformer fluid from transformer into radiators per the Removable Radiators Field Installation Instructions from the manufacturer. Verify correct liquid level on liquid level gauge and remove / fill oil as needed. Check name plate information against data sheets and approved drawings. Disperse transformer fluid from transformer into radiators per the attached Removable Radiators Field Installation Instructions. Verify correct liquid level on liquid level gauge and remove / fill oil as needed.

Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 8

9

10

11 12 13

14 15

16 17 18

TRANSFORMER (OIL TYPE) E10-A Verify and confirm transformer orientation and location is as per layout drawing and hold- down arrangement is as per vendor drawings. Check the transformer elevation against the layout drawings and busduct flange dimensions against vendor drawings for bus duct connected transformers. Verify and confirm the transformer room is adequately ventilated and clearances as per drawings/vendor recommendations are maintained. Verify and confirm that the transformer earthing (body and neutral grounding) is completed and properly secured. Confirm the transformer star point grounding is established as per project drawings. Verify and confirm Primary / Secondary windings / instrumentation and power cables are clearly identified, glanded / terminated and torqued to vendor recommendations. Confirm the bolted connections of power cables are marked after torqueing. Check carefully for the cable lug connection to the bus bar and ensure NO washers are installed between the lug and bus bar. Check and confirm that clearances regarding lugs and cables are maintained. Verify and confirm Current transformer for earth fault /differential protection are correctly installed and wired. Verify all labels and warning signs are correct and visible. Ensure all the incoming and outgoing cables/bus-ducts are adequately supported and the transformer terminals are stress-free. Confirm that the gland plates for single core cable are non-magnetic. Verify and confirm that all unused cable entries are sealed using proper sealing plugs. Check the mechanical operation of the tap changer. Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No Item Quantity Location

Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TRANSFORMER (OIL TYPE) E10-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A HIGH VOLTAGE SWITCHBOARD Project No. Project Title Facilities Tag no. Bus Bar Rating Frequency Short Circuit Rating/time Model / Type Serial no. 1

2

3 4 5 6

7

8 9 10 11

E11-A

INFORMATION System / Sub System no. IP Rating Voltage Ref. Drawing Location Manufacturer INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Switchboard datasheet and GA drawing b) Packing list c) Manufacturer’s installation instructions d) Equipment layout and Bus-duct layout drawing (if applicable) e) Overall SLD f) Relevant portion of the cable schedule Verify and ensure that all construction / installation activities have been completed. Confirm the arc protection hoods (if applicable) are installed. Verify any differences between nameplate details against approved drawings and data sheets. Verify hold down bolts are tight & in accordance to manufacturer recommendations. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Confirm Bus-bar alignment is correct and bolted connections are torqued to vendor specifications and the bolts are marked. Separate sheet to be attached with the record of bus-bar joint torque values. Verify space heaters, instruments, indication lamps, control switches, protection relays and phase identification tags/ label interposing relay panel, PLC are installed as per drawings. Verify and confirm that all unused cable entries are sealed using proper sealing plugs. Verify Operation of all doors & drawers and confirm they can open / close freely. Confirm Earth bar is continuous throughout the length of the switchboard. Verify Earthing is properly installed and secured as per project documentation.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 12 13 14

TRANSFORMER (OIL TYPE) E10-A Check and confirm mechanical operation of the circuit breaker, mechanical interlocks / racking mechanism CB in / out are in order Verify if construction check-sheet for all incoming cables/bus ducts are completed. Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No

15 16 17

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A LOW VOLTAGE SWITCHBOARD / MCC E14-A Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Bus Bar Rating IP Rating Frequency Voltage Short Circuit Rating/time Ref. Drawing Model / Type Location Serial no. Manufacturer INSPECTION / TEST OK 1 Documents required: a) Switchboard datasheet and GA drawing b) Packing list c) Manufacturer’s installation instructions d) Equipment layout and Bus-duct layout drawing (if applicable) e) Overall SLD f) Relevant portion of the cable schedule 2 Verify and ensure that all construction / installation activities have been completed. Confirm the arc protection hoods (if applicable) are installed. 3 Verify any differences between nameplate details against approved drawings and data sheets. 4 Verify hold down bolts are tight & in accordance to manufacturer recommendations. 5 Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) 6 Confirm Bus-bar alignment is correct and bolted connections are torqued to vendor specifications and the bolts are marked. Separate sheet to be attached with the record of bus-bar joint torque values. 7 Verify space heaters, instruments, indication lamps, control switches, protection relays and phase identification tags/ label interposing relay panel, PLC are installed as per drawings. 8 Verify and confirm that all unused cable entries are sealed using proper sealing plugs. 9 Verify Operation of all doors & drawers and confirm they can open / close freely. 10 Confirm Earth bar is continuous throughout the length of the switchboard. 11 Verify Earthing is properly installed and secured as per project documentation.

N/A P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A LOW VOLTAGE SWITCHBOARD / MCC E14-A 12 Check and confirm mechanical operation of the circuit breaker, mechanical interlocks / racking mechanism CB in / out are in order. 13 Verify if construction check-sheet for all incoming cables/bus ducts are completed. 14 Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No Item Quantity Location

15 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 16 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 17 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INTEGRATED MOTOR CONTROL SYSTEM (IMCS) E20-A Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Model / Type IP Rating Serial no. Manufacturer Location Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required: a) IMCS system architecture and Functional Description System b) Packing list c) IMCS panel GA drawings d) IMCS block diagram and interconnection drawings e) Relevant portion of the cable schedule 2 Verify and ensure that all construction / installation activities have been completed including all accessories like printers. 3 Check and confirm that IMCS nameplate/identification details are as per approved technical drawings. 4 Verify and confirm the panel is secured properly as per drawings and hold down bolts are tight & in accordance to project specification. 5 Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) 6 Inspect physical condition and arrangement of IMCS PLC and its subsequent PLC racks i.e. power supply module, processors modules and communication modules to be as per approved technical drawings. 7 Verify space heaters, instruments, indication lamps, control switches, identification tags/ labels, interposing relays, PLC are installed as per drawings. Check and confirm Fiber Optic converters (FOC)/Fiber Termination Units (FTU) are installed as per drawings. 8 Verify and confirm that all unused cable entries are sealed using proper sealing plugs. 9 Verify Operation of all doors / drawers and confirm they can open / close freely. 10 Inspect earthing/bonding installation and arrangement to be as per approved technical drawings. Special attention to cable screens. 11 Inspect IMCS internal cables connection, wiring, core marking, and tagging to be as per approved technical drawings 12 Verify the cleanliness of panel internals and confirm all loose wires, packing material etc. are removed.

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INTEGRATED MOTOR CONTROL SYSTEM (IMCS) E20-A 13 Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No

14 15 16

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TRANSMISSION LINE

E21-A

Project No. Project Title Facilities Conductor size From Location Ref. Drawing nos. 1

2 3 4 5 6 7 8 9

INFORMATION System / Sub System no. To Operating Voltage

INSPECTION / TEST Documents required: a) Layout drawings b) Pole installation details Verify to ensure that all construction / installation activities have been completed. Confirm the grounding and lightning protection are completed as per specifications and drawings. Pole Check list completed (Attach form 22 from PTS 63.10.08.11) Line sag check list completed (Attach form 23 from PTS 63.10.08.11) Line Joints integrity tested. (Attach form 24 from PTS 63.10.08.11) Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A HIGH VOLTAGE CABLE

E22-A

Project No. Project Title Facilities Tag no. Cable Core/Size Cable to Voltage

INFORMATION System / Sub System no. Cable from Ref. Drawing nos. INSPECTION / TEST

1

2 3

4 5 6 7

8

9

OK

N/A P/L No

Documents required: a) Cable layout drawing b) Cable schedule and drum list Verify to ensure that all construction / installation activities have been completed. Cable Installed, identified, dressed and secured, cable rack / tray segregation and bending radius as per project specifications and design. Verify and confirm single core cables are using trefoil clamps, cable gland and gland plate made of nonmagnetic material. Glanding, phase identification and termination kits correctly installed to vendors specifications. Verify cable type and size in accordance with Cable schedule. Verify terminations are tight. Record torque if applicable. Insulation Resistance Test. Measure and record insulation resistance (IR) of each conductor with all other conductors and shields grounded. Subsequently, measure IR for phase to phase conductor with other conductor and shield grounded. Refer PTS 63.10.08.11 for suitable test voltage and acceptable insulation reading. Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE Discharge all conductors to ground for a minimum period of 1 minute. (Note: Hi-pot test to be done during pre-commissioning and commissioning only) The cable continuity to be tested using a suitable multi-meter, set to ohms. Measured resistance to be compared with the datasheet value. Measured cable Resistance ……………... Ω Gland body to earth path resistance (Max 0.1Ω)

Page 1 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 10 11 12 13 14 15

HIGH VOLTAGE CABLE E22-A Cable joints, if any are completed, identified and the location is marked in cable schedule and relevant layout drawings. Buried/underground sections of cables are properly marked using cable markers as per project specifications. Check and confirm all related red line markings are completed. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SUBMARINE CABLE

E23-A

Project No. Project Title Facilities Tag no. Cable Core/Size Cable to Voltage 1

2 3

4 5 6 7

8

9

INFORMATION System / Sub System no. Cable from Ref. Drawing nos.

INSPECTION / TEST Documents required: a) Cable layout drawing b) Cable schedule and drum list Verify to ensure that all construction / installation activities have been completed. Cable Installed, identified, dressed and secured, cable rack / tray segregation and bending radius as per project specifications and design. Verify and confirm single core cables are using trefoil clamps, cable gland and gland plate made of nonmagnetic material. Glanding, phase identification and termination kits correctly installed to vendors specifications. Verify cable type and size in accordance with Cable schedule. Verify terminations are tight. Record torque if applicable. Insulation Resistance Test. Measure and record insulation resistance (IR) of each conductor with all other conductors and shields grounded. Subsequently, measure IR for phase to phase conductor with other conductor and shield grounded. Refer PTS 63.10.08.11 for suitable test voltage and acceptable insulation reading. Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE

OK

N/A P/L No

Discharge all conductors to ground for a minimum period of 1 minute. (Note: Hi-pot test to be done during pre-commissioning and commissioning only) The cable continuity to be tested using a suitable multi-meter, set to ohms. Measured resistance to be compared with the datasheet value. Measured cable Resistance ……………... Ω Gland body to earth path resistance (Max 0.1Ω)

Page 1 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 10 11 12 13 14 15

SUBMARINE CABLE E23-A Cable joints, if any are completed, identified and the location is marked in cable schedule and relevant layout drawings. Buried/underground sections of cables are properly marked using cable markers as per project specifications. Check and confirm all related red line markings are completed. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A BUS DUCT

E24-A

Project No. Project Title Facilities Tag no. Amperes Frequency Manufacturer Type

INFORMATION System / Sub System no. Bus bar Rating Location Ref. Drawing Nos. Voltage INSPECTION / TEST OK

N/ A

P/L No

1

Documents required: a) Bus duct installation/layout drawing b) Bus duct installation details from manufacturer c) Key single line diagram Verify to ensure that all construction / installation activities have been 2 completed. Verify Earthing links/bonding are properly installed and secured in 3 every Bus duct joint connection as per installation drawings. Verify any mechanical damage to the bus duct sections, joints or end 4 terminations. Check and confirm bus-duct installations including supports are as per 5 layout drawing and manufacturer instructions. Bus-duct properly insulated, supported and identified (As per Vendor's 6 Drawing). Bus bars and connecting links are tightened to vendor’s specified 7 torque values. Mark all the bolts after tightening. 8 Verify and confirm phase identification is correct, warning labels fitted. 9 Check and confirm all related red line markings are completed. 10 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 11 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 12 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION

Page 1 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A BUS DUCT Designation Company Name Signature Date


E24-A VERIFIED BY PCSB Inspector PETRONAS Carigali


Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A LOW VOLTAGE CABLE

E25-A


2 3

4 5 6 7 8

INFORMATION System / Sub System no. Cable from Ref. Drawing Nos.

INSPECTION / TEST Documents required: a) Cable layout drawing b) Cable schedule and drum list Verify to ensure that all construction / installation activities have been completed. Cable Installed, identified, dressed and secured, cable rack / tray segregation and bending radius as per project specifications and design. Verify and confirm single core cables are using trefoil clamps, cable gland and gland plate made of nonmagnetic material Verify cable type and size in accordance with Cable schedule. Cable gland type and size in accordance with Cable schedule. Confirm that barrier glands are installed where required. Verify Gland & Lug are properly installed. Refer to manufacturer’s recommendation as required. Verify and confirm terminations are tight. Record torque if applicable.

OK

N/A P/L No

The cable insulation resistance is to be checked using a 500V Megger. Each core is to be tested against all other cores, and earth. Test point R-YBNE Y-RBNE B-RYNE 9

10 11 12

Insulation Resistance

Remarks

The cable continuity to be tested using a suitable multi-meter, set to ohms. Measured resistance to be compared with the datasheet value. Measured cable Resistance ……………... __________Ohms Gland body to earth path resistance (Max 0.1Ω) Cable joints, if any are completed, identified and the location is marked in cable schedule and relevant layout drawings. Buried/underground sections of cables are properly marked using cable markers as per project specifications.

Page 1 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 13 14 15 16

LOW VOLTAGE CABLE E25-A Check and confirm all related red line markings are completed. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CAPACITOR BANK AND SERIES REACTORS E26-A Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. kVAR Voltage Frequency No. of steps Location Manufacturer Model / Type Serial no. Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required: a) Capacitor Bank datasheet and GA drawing b) Packing list c) Equipment layout of the room (if applicable) d) Overall SLD e) Relevant portion of the cable schedule 1 Verify and ensure that all construction / installation activities have been completed. 2 Verify any differences between nameplate details against approved drawings and data sheets. 3 Verify hold down bolts are tight & in accordance to project specification. 4 Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) 5 Verify space heaters, instruments, indication lamps, control switches, protection relays, RVTs, APFC relays and phase identification tags/ label are installed as per drawings. 6 Verify and confirm that all unused cable entries are sealed using proper sealing plugs. 7 Verify Operation of all doors & drawers and confirm they can open / close freely. 8 Verify Earthing is properly installed and secured as per project documentation. 9 Check and confirm mechanical operation of the circuit breakers/MCCBs/Isolators etc. and mechanical interlocks are in order.

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CAPACITOR BANK AND SERIES REACTORS 10

Identify the spares and special tools supplied, if any including keys, and record the storage location.

Sl. No

11 12 13

E26-A

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ELECTRICAL SUBSTATION/SWITCH ROOM E27-A Project No. Project Title Facilities INFORMATION Substation No System / Sub System no. Highest voltage level Area Classification Location Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required: a) Substation equipment layout b) Substation grounding/lightning layout c) Substation F&G layout d) Key single line diagram 2 Verify to ensure that all construction / installation activities have been completed. 3 Verify and confirm equipment locations and clearances are as per layout drawing. 4 Confirm all openings on the switch room/substation are properly sealed by approved method as per drawings and specifications. 5 Confirm all entrance doors are operating smooth and are provided with necessary panic bolts as per requirements. 6 Confirm the room lighting including emergency lighting are functional and in line with layout drawings. 7 Confirm rubber mats are placed as per drawings and are of approved quality and of correct voltage rating. 8 Confirm all danger signs, first aid charts, fire-extinguishers, framed SLDs, hand lamps, telephones, walkie-talkie, tool cabinets and other furniture as per contract requirements/drawings are supplied and installed. 9 Confirm battery rooms are equipped with eye wash-check water/fire extinguishers-check validity/gloves etc. as applicable. 10 Confirm special tools including breaker trolleys, operating handles, relay keys, switchgear interlock keys, discharge rod etc. as applicable are available in the substation / switch room. 11 Verify and confirm that the grounding and lightning protection of the building are completed as per specifications and drawings. 12 Check general house-keeping and cleanliness of the substation / switch room. Look for any building leak / leak due to condensation from HVAC system etc.

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ELECTRICAL SUBSTATION/SWITCH ROOM 13


14 15 16

E27-A

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A AC UPS

E28-A

Project No. Project Title Facilities Tag no. Rating Input Voltage Manufacturer Model No. Ref. Drawing no. 1

2 3 4 5 6 7 8 9 10 11 12

INFORMATION System / Sub System no. Frequency Output Voltage Serial No. Location IP rating INSPECTION / TEST

OK

N/A P/L No

Documents required: a) UPS datasheet, GA drawing and schematics b) Packing list c) Substation Equipment layout d) Single line drawing for the source MCC e) Relevant portion of the cable schedule Verify to ensure that all construction / installation activities have been completed. Verify any differences between nameplate details against approved drawings and data sheets. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Verify hold-down bolts are tight & in accordance to project documents. Verify all associated cables, vendor wiring installed, identified, glanded, terminated and all terminations tightened. Verify Earthing is properly installed and secured as project documents. Specifically look for neutral grounding of UPS. AC/DC power and control circuits correctly identified as shown on associated project installation drawings. Instrument Panel, indication lamps and interlocks as per site installation drawing. Padlocking / isolation facilities. Check internals for cleanliness. Verify and confirm that all unused cable entries are sealed using proper sealing plugs.

Page 1 of 2



AC UPS E28-A Identify the spares and special tools supplied, if any including keys, and record the storage location.

Sl. No

14 15 16

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DC CHARGER

E29-A

Project No. Project Title Facilities Tag no. Rating Input Voltage Manufacturer Model No. Ref. Drawing no. 1

2 3 4 5 6 7 8 9 10 11 12

INFORMATION System / Sub System no. Frequency Output Voltage Serial No. Location IP rating INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Charger datasheet, GA drawing and schematics b) Packing list c) Substation Equipment layout d) Single line drawing for the source MCC e) Relevant portion of the cable schedule Verify to ensure that all construction / installation activities have been completed. Verify any differences between nameplate details against approved drawings and data sheets. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Verify hold-down bolts are tight & in accordance to project documents. Verify all associated cables, vendor wiring installed, identified, glanded, terminated and all terminations tightened. Verify Earthing is properly installed and secured as project documents. Specifically look for neutral grounding of UPS. AC/DC power and control circuits correctly identified as shown on associated project installation drawings. Instrument Panel, indication lamps and interlocks as per site installation drawing. Padlocking / isolation facilities. Check internals for cleanliness. Verify and confirm that all unused cable entries are sealed using proper sealing plugs.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DC CHARGER

13


Sl. No

14 15 16

E29-A

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ELECTRIC POWER UNIT (EPU) Project No. Project Title Facilities Tag no. Rating Input Voltage Ref. Drawing no. Location 1

2 3 4

5 6 7 8 9 10 11 12

E30-A

INFORMATION System / Sub System no. Frequency Output Voltage Manufacturer Serial no. INSPECTION / TEST

OK

N/A P/L No

Documents required: a) EPU datasheet, GA drawing and schematics b) Packing list c) Equipment layout showing EPU location d) Single line drawing for the source MCC e) Relevant portion of the cable schedule Verify to ensure that all construction / installation activities have been completed. Verify any differences between nameplate details against approved drawings and data sheets. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles, leaking battery, battery terminal damage, bulging of battery casing etc.) Verify hold-down bolts are tight & in accordance to project documents. Verify all associated cables, vendor wiring installed, identified, glanded, terminated and all terminations tightened. Verify Earthing is properly installed and secured as project documents. Specifically look for neutral grounding of UPS. AC/DC power and control circuits correctly identified as shown on associated project installation drawings. Instrument Panel, indication lamps and interlocks as per site installation drawing. Padlocking / isolation facilities. Check internals for cleanliness. Verify and confirm that all unused cable entries are sealed using proper sealing plugs.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ELECTRIC POWER UNIT (EPU)

13


Sl. No

14 15 16

E30-A

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A BATTERY

E31-A

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Ampere Hour No. of cells System Voltage Electrolyte Type of Battery Boost Voltage Float Voltage Location Manufacturer Ref. Drawing INSPECTION / TEST 1 Documents required for verification. a. Battery Datasheet and battery rack drawing b. Packing list c. UPS/Charger drawings showing battery connection d. Battery room layout drawings 2 Ensure that Battery room is secured, lockable, ventilation systems are in place and eye wash system available (as applicable). 3 Verify to ensure that all construction / installation activities have been completed as per project drawings. 4 Inspect batteries for physical damages and mechanical condition (Look for leaking battery, damaged battery terminals, bulging of battery casings etc.) 5 Verify adequacy of battery support racks or cabinets, mounting, anchorage and clearances. 6 Confirm electrolyte level is visible for all cells and the vents/openings free from obstruction. Ensure that the battery topping-up plug (if applicable) is accessible and allows easy water top-up. 7 Verify nameplate details against approved drawings and data sheets. 8 Verify correct cell-to-cell terminal connections including connection hardware and tightness. 9 Verify correct application of manufacturer's approved corrosion inhibiting grease (if used) on all contact surface areas. 10 Inspect for evidence of corrosion at terminal, connections, racks or cabinets. 11 Confirm that all links and cables tightened and provided with insulation cap (where applicable). 12 Check racks and batteries for cleanliness. 13 Cables correctly installed, identified, glanded and terminated as shown on the project drawings.

OK

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 14 15 16 17 18

19 20 21

BATTERY E31-A All labeling and warning signs correctly installed and visible. Verify Electrolyte level correct in each cell. Verify Earthing is properly installed and secured as per project specification. Verify preservation if required and refer to preservation procedures for proper implementation. Identify the spares and special tools supplied, if any, and record the storage location. Sl. No Item Quantity Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A LV DISTRIBUTION BOARD

E32-A

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Bus bar rating Frequency Voltage Location Manufacturer IP Rating Model No. Serial no. Ref. Drawing nos. INSPECTION / TEST 1 Documents required for verification. a. LV DB GA and single line drawing b. Packing list c. Location drawing /substation equipment layout 2 Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) 3 Verify and ensure that all construction / installation activities have been completed. 4 Verify any differences between nameplate details against approved drawings and data sheets. 5 Verify hold down bolts are tight & in accordance to project documentation. 6 Verify and confirm earthing is properly installed and secured as per project documents. 7 Verify tightness of all electrical connections and confirm that all unused holes are sealed with specified sealing plug. 8 Check bus-bars, connecting links and cable terminations for tightness. 9 Confirm cables are identified, glanded and terminated correctly to the project drawings, ensure an accurate circuit schedule is installed within the DB. 10 Check internals for cleanliness. 11 Confirm tag number labels for MCBs, are correct and properly fitted. 12 Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No Item

Quantity

OK

N/A

P/L No

Location

Page 1 of 2



LV DISTRIBUTION BOARD E32-A Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A EARTHING AND LIGHTNING PROTECTION E33-A Project No. Project Title Facilities INFORMATION Area System / Sub System no. Location Main Grid Conductor Size Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required for verification. a. Earthing and lightning protection layout 2 Verify to ensure that all construction / installation activities have been completed. 3 Verify all earth bosses and studs tight and fitted with shake proof washers and coated with protective grease. Check for any corrosion of exposed part of earth electrodes. 4 Verify and confirm that all earthing conductors follow the minimum size specified in approved installation drawings, and all earthing conductors are properly installed and supported. 5 Verify all Earth Bars to be marked according to Earthing Categories. 6 All lightning conductors and air terminals installed as design drawings and securely fixed and follow the most direct route to the earth and are without sharp bends.

7 8

9 10 11 12

N/A

P/L No

Confirm all lightning conductors are located away from any other earthed equipment and do not come into contact with any other equipment earths (except at the grid level). Check that the I.S. earth bar, non-I.S earth bar and the electrical earth bar are installed as per approved drawings. Confirm all non-electrical equipment/structures (vessels, process equipment, all pipe-racks etc.) are provided with earthing as detailed on the approved installation drawings and specifications. Confirm module steelwork is provided with equipotential earth bonding connected to the Hull column top. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A EARTHING AND LIGHTNING PROTECTION E33-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A NEUTRAL EARTHING RESISTOR Project No. Project Title Facilities

E34-A

INFORMATION Tag no. System / Sub System no. Voltage Frequency Resistance Rating (A/t) Location IP Rating Manufacturer Serial no. Model No. Ref. Drawing nos. INSPECTION / TEST 1 Documents required for verification. a. NER GA, datasheet and connection diagram b. Packing list c. Location drawing /substation equipment layout 2 Verify to ensure that all construction / installation activities have been completed. 3 Verify any differences between nameplate details against approved drawings and data sheets. 4 Verify equipment certification meets the area classification requirements. 5 Verify all associated cables installed, identified, glanded and terminated in accordance with the approved drawings. 6 Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) 7 Verify unit internally and externally clean and covers securely fastened with all fixing screws installed. 8 Verify Earth connection is properly installed and secured as per project specification. 9 Check resistor insulators. 10 Inspect the Neutral Earth Isolating switch. 11 Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No Item Quantity Location

12

OK

N/A

P/L No

Record any defects/shortcomings in the system punch-list.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A NEUTRAL EARTHING RESISTOR E34-A Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 13 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 14 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A VARIABLE SPEED DRIVE SYSTEM Project No. Project Title Facilities Tag no. VSD Rating Motor kW Manufacturer Location

1

2 3

4 5 6

7 8 9 10 11 12

E35-A

INFORMATION System / Sub System no. Frequency Voltage Model Serial no. Ref. Drawing nos. INSPECTION / TEST

OK

N/A

P/L No

Documents required: a) VSD datasheet and GA drawing b) Packing list c) Electrical room Equipment layout d) Single line drawing for the source MCC Verify nameplate details against approved drawings and data sheets. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Confirm all bolts and blanking plugs are fitted. Verify hold-down bolts are tight & in accordance to project documents. Verify all associated cables, vendor wiring installed, identified, glanded, terminated and all terminations tightened. Verify Earthing is properly installed and secured as project documents and vendor recommendation. Specifically check for any additional recommendation on the grounding connection between the drive and motor. Instrument Panel, indication lamps and interlocks as per site installation drawing. Padlocking / isolation facilities. Check internals for cleanliness. Verify and confirm that all unused cable entries are sealed using proper sealing plugs. Review equipment preservation records for equipment stored long time prior to installation. Labeling and warning signs correct and visible.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A VARIABLE SPEED DRIVE SYSTEM 13


Sl. No

14 15 16

E35-A

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A HEATER CONTROL PANEL

E36-A

Project No. Project Title Facilities Tag no. Voltage Frequency Manufacturer Serial No. 1

2 3 4

5 6 7 8 9 10

INFORMATION System / Sub System no. Rating Location Ref. Drawing nos. Model No. INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Heater panel datasheet and GA drawing b) Packing list c) Electrical room Equipment layout d) Single line drawing for the source MCC Verify to ensure that all construction / installation activities have been completed. Verify nameplate details against approved drawings and data sheets. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Confirm all bolts and blanking plugs are fitted. Verify hold-down bolts are tight & in accordance to project documents. Verify all associated cables, vendor wiring installed, identified, glanded, terminated and all terminations tightened. Check internal cleanliness, Ex ’d unit cover faces to be lightly greased. Check push button / control for mechanical operation after Panel installation. Equipment installed and clearly identified as shown on the project drawings, suitable Ex / IP cert. for location. Verify Earthing is properly installed and secured as per project documentation. Identify the spares and special tools supplied, if any including keys, and record the storage location.

11

12

Sl. No

Item

Quantity

Location

Record any defects/shortcomings in the system punch-list.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A HEATER CONTROL PANEL E36-A Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 13 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 14 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A HIGH VOLTAGE MOTOR

E37-A

Project No. Project Title Facilities Tag no. KW Rating FLC Frequency Voltage RPM Connection (Y/∆) Fed from (MCC)

INFORMATION System / Sub System no. EX Rating / IP Insulation Class Location Ref. Drawing nos. Serial no. Manufacturer INSPECTION / TEST

1

2 3 4 5

6

7 8 9 10

OK

N/A P/L No

Documents required: a) Motor datasheet and GA drawing b) Packing list c) Equipment layout d) Single line drawing for the source MCC e) Relevant portion of the cable schedule Verify nameplate details against approved drawings and data sheets. Confirm the motor classification (Ex / IP) suitable for the area classification as per hazardous area drawing. Check and confirm the non-drive end of the motor is not obstructed and not facing/close to vents. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Confirm all bolts and blanking plugs are fitted. Ensure cable box covers are properly closed complete with correct gaskets in place. Verify motor terminations and star/delta links are correct as per Motor connection data. Check especially for the separate neutral cable box (where applicable) to ensure the winding connection is established as per design and the connecting links are in place and tightened. Ensure auxiliary cables - space heater cables/RTD/Thermistor cables/Differential CT cables etc. are terminated as applicable. Verify and confirm that all unused cable entries are sealed using proper sealing plugs. Verify Earthing is properly installed and secured as per project specification and drawings. Check and confirm the non-drive end of the motor is not obstructed and not facing/close to vents. Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 11 12

HIGH VOLTAGE MOTOR E37-A Ensure vertical motors are provided with additional rain hood above the fan cowl or separate rain canopy is installed. Identify the spares and special tools supplied, if any, and record the storage location. Sl. No

Item

Quantity

Location

13

Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 14 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 15 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION If the motor is not expected to be pre-commissioned shortly, do proper preservation including switching on the space heater as per preservation check sheet.





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A LOW VOLTAGE MOTOR

E38-A

Project No. Project Title Facilities Tag no. KW Rating FLC Frequency Voltage RPM Connection (Y/∆) Fed from (MCC)

INFORMATION System / Sub System no. EX Rating / IP Insulation Class Location Ref. Drawing nos. Serial no. Manufacturer INSPECTION / TEST

1

2 3 4 5

6 7 8 9 10

OK

N/A P/L No

Documents required: a) Motor datasheet and GA drawing b) Packing list c) Equipment layout d) Single line drawing for the source MCC e) Relevant portion of the cable schedule Verify nameplate details against approved drawings and data sheets. Confirm the motor classification (Ex / IP) suitable for the area classification as per hazardous area drawing. Check and confirm the non-drive end of the motor is not obstructed and not facing/close to vents. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Confirm all bolts and blanking plugs are fitted. Ensure cable box covers are properly closed complete with correct gaskets in place. Verify motor terminations and star/delta links are correct as per Motor connection data. Ensure auxiliary cables - space heater cables//Thermistor cables etc. are terminated as applicable. Verify and confirm that all unused cable entries are sealed using proper sealing plugs. Verify Earthing is properly installed and secured as per project specification and drawings. Check and confirm the non-drive end of the motor is not obstructed and not facing/close to vents.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 11 12

LOW VOLTAGE MOTOR E38-A Ensure vertical motors are provided with additional rain hood above the fan cowl or separate rain canopy is installed. Identify the spares and special tools supplied, if any, and record the storage location. Sl. No

Item

Quantity

Location

13

Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 14 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 15 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION If the motor is not expected to be pre-commissioned shortly, do proper preservation including switching on the space heater as per preservation check sheet.





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ELECTRICAL HEATER

E39-A

Project No. Project Title Facilities Tag no. KW/HP Rating Amperes Manufacturer Ref. Drawing Nos. Location 1

2 3 4 5 6 7 8 9 10 11 12

INFORMATION System / Sub System no. Voltage Frequency No. of Bundles Model No. Serial no. INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Heater datasheet and GA drawing b) Packing list c) Equipment layout d) Single line drawing for the source MCC e) Relevant portion of the cable schedule Verify to ensure that all construction / installation activities have been completed. Verify any differences between nameplate details against approved drawings and data sheets. Cables installed, identified, glanded and terminated to project design drawings. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Check heater connections against vendor drawing. Review equipment preservation records. Equipment Ex / IP certification is suitable for the area. Verify Earthing is properly installed and secured as per project specification. All cable terminations correct to associated design drawings, check all cable / wiring terminations for tightness. Labeling and warning signs correct and visible. Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No Item Quantity Location

Page 1 of 2



ELECTRICAL HEATER E39-A Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ELECTRICAL HEAT TRACING

E40-A

Project No. Project Title Facilities Tag no. Voltage Heating temperature Type of Tracer Ref. Drawing nos. Manufacturer

INFORMATION System / Sub System no. Frequency Location Distr. Board No. Area Classification INSPECTION / TEST

1

2 3 4 5

6 7 8 9 10

OK

N/A P/L No

Documents required: a) Isometric drawing of the heat traced lines b) Packing list c) Vendor drawings for insulation, tracer installation details and datasheet. d) Single line drawings for the DB and the source switchgear e) Relevant portion of the cable schedule Verify and ensure that all construction / installation activities have been completed. Check nameplate details against approved drawings and data sheets. Cables installed, identified, glanded and terminated according to project design drawings. Confirm all cable terminations are correct as per associated design drawings. Check all cable / wiring terminations for tightness. Check for any mechanical damage to the tracing tapes, insulation, junction boxes or DB. Confirm equipment (tracing tape, JBs, DBs etc.) Ex / IP certification is suitable for the area. Confirm warning labels have been fitted on cladding as per manufacturer's recommendations. Verify Earthing is properly installed and secured as per project specification. Check the heating tape installation against isometric drawings and vendor drawings to confirm the installation is in line with design documents.

Page 1 of 2



ELECTRICAL HEAT TRACING E40-A Identify the spares and special tools supplied, if any including keys, and record the storage location.

Sl. No

12 13 14

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A IMPRESSED CURRENT CATHODIC PROTECTION E41-A SYSTEM Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. TR Unit Rating (A) Voltage Location Manufacturer Serial no. Type INSPECTION / TEST OK 1 Documents required: a) ICCP system block-diagram, GA drawing and data sheet for TR unit, and control panel. b) Packing list c) Layout drawing d) Single line drawing for the source switchboard e) Relevant portion of the cable schedule 2 Verify to ensure that all construction / installation activities have been completed. 3 Verify any differences between nameplate details against approved drawings and data sheets. 4 Verify equipment name plates and confirm the equipment meets the area classification and IP requirements. 5 Verify all associated cables installed, identified, glanded and terminated in accordance with the approved drawings. 6 Check equipment for mechanical damages (dents/scratches, corrosion, leakage on oil filled transformers, damaged terminal box, broken handles etc.) 7 Verify unit internally and externally for cleanliness and confirm all covers are securely fastened with all fixing screws installed. 8 Verify earth connection and confirm it is properly installed and secured as per project specification. Check for any unintended current leakage sources like copper earth rods/ bare copper earth wires, abandoned buried steel pipes/structure etc. 9 Check installation of TR unit against vendor drawings. 10 Verify cable connections to the TR unit and cathode and anode junction boxes against vendor drawings.

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A IMPRESSED CURRENT CATHODIC PROTECTION E41-A SYSTEM 11 Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No

12 13 14

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MOTOR OPERATED VALVE

E42-A

Project No. Project Title Facilities Tag no. Voltage KW/HP Rating Valve size Manufacturer Ref. Drawing nos.

INFORMATION System / Sub System no. Frequency Location Overload setting Serial no. INSPECTION / TEST

1

2 3 4 5 6

7 8 9 10 11

OK

N/A P/L No

Documents required: a) MOV datasheet and GA drawing b) Packing list c) Single line drawing for the source switchboard d) Relevant portion of the cable schedule Verify to ensure that all construction / installation activities have been completed. Verify any differences between nameplate details against approved drawings and data sheets. Cables installed, identified, glanded and terminated to project design drawings. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Check and confirm the cable slack and cable laying against the movement of the valve and the same is not restricted by the cable arrangement. Equipment Ex / IP certification is suitable for the area. Verify Earthing is properly installed and secured as per project specification. All cable terminations correct to associated design drawings, check all cable / wiring terminations for tightness. Confirm that all unused cable entries are sealed using appropriate sealing plugs. Labeling and warning signs correct and visible.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MOTOR OPERATED VALVE

12


Sl. No

13 11 12

E42-A

Item

Quantity

Location






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A NORMAL LIGHTING (CIRCUIT / FIXTURES) E43-A Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Area Classification Circuit no. Voltage Frequency Circuit MCB rating Location Connected load (W) Ref. Drawing nos. Manufacturer INSPECTION / TEST OK 1 Documents required: a) Lighting fixture drawing and installation details b) Packing list c) lighting layout and circuit block diagram d) Relevant portion of the cable schedule 2 Verify to ensure that all construction / installation activities have been completed. 3 Inspection includes all associated junction boxes, cables and light fittings. 4 Check the light fixture / fitting, Cables and that they are glanded, terminated, installed and identified as shown on the approved drawings. 5 Check the light fittings installed in hazardous areas are certified for use in the area. 6 Verify that lighting fixtures, junction boxes and cables are clearly identified by proper tags. 7 Check there is no mechanical damage to gaskets, seals of light fittings, JB's etc. 8 Verify and confirm that the lighting fixture cleats/supports are properly installed and secured. 9 Verify and confirm that all unused cable entries are sealed using proper sealing plugs. 10 Check that the earthing are properly installed and secured.

N/A P/L No

Page 1 of 2



NORMAL LIGHTING (CIRCUIT / FIXTURES) E43-A Identify the spares and special tools supplied, if any, and record the storage location. Sl. No Item Quantity Location

12

Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 13 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 14 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Corrosion





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A EMERGENCY LIGHTING (CIRCUIT / FIXTURES) E44-A Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Area Classification Circuit no. Voltage Frequency Circuit MCB rating Location Connected load (W) Ref. Drawing nos. Manufacturer INSPECTION / TEST OK 1 Documents required: a) Lighting fixture drawing and installation details b) Packing list c) lighting layout and circuit block diagram d) Relevant portion of the cable schedule 2 Verify to ensure that all construction / installation activities have been completed. 3 Inspection includes all associated junction boxes, cables and light fittings. 4 Check the light fixture / fitting, Cables and that they are glanded, terminated, installed and identified as shown on the approved drawings. 5 Check the light fittings installed in hazardous areas are certified for use in the area. 6 Verify that lighting fixtures, junction boxes and cables are clearly identified by proper tags. 7 Check there is no mechanical damage to gaskets, seals of light fittings, JB's, battery, charger etc. 8 Verify and confirm that the lighting fixture cleats/supports are properly installed and secured. 9 Verify and confirm that all unused cable entries are sealed using proper sealing plugs. 10 Check that the earthing are properly installed and secured.

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A EMERGENCY LIGHTING (CIRCUIT / FIXTURES) E44-A 11 Identify the spares and special tools supplied, if any, and record the storage location. Sl. No Item Quantity Location

12 13 14






Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SOCKETS (WELDING/POWER/CONVENIENCE) E45-A Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Circuit no. Frequency Ex / IP Rating Voltage Manufacturer Ref. Drawing nos. Serial no. Location INSPECTION / TEST OK 1 Documents required: a) Socket outlet drawing and installation details b) Packing list c) Socket outlet layout and circuit block diagram d) Relevant portion of the cable schedule 2 Verify to ensure that all construction / installation activities have been completed. 3 Verify socket outlet and associated cables / wiring installed, identified, glanded and terminated in accordance with the approved drawings. Verify completeness of ring circuits were applicable. 4 Check installation for any mechanical damage to the sockets/JBs etc. 5 Verify suitability of equipment for area classification. 6 Verify equipment earthing are properly installed and secured. 7 Verify and confirm that all unused cable entries are sealed using proper sealing plugs. 8 Check mechanical interlocks of sockets (if fitted). 9 Identify the spares and special tools supplied (plugs, extension cables etc.), if any, and record the storage location. Sl. No Item Quantity Location

10 11 12

N/A P/L No

Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SOCKETS (WELDING/POWER/CONVENIENCE) E45-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A NAVIGATION AID

E46-A

Project No. Project Title Facilities Tag no. Area Ref. Drawing nos

1

2 3 4 5 6 7 8 9 10

INFORMATION System/Subsystem no. Location

INSPECTION / TEST Documents required: a) Navigational aid datasheet and GA drawing b) Packing list c) System block diagram/single line diagram d) Relevant portion of the cable schedule e) Check-sheet for solar panel (if applicable) Verify to ensure that all construction / installation activities have been completed. Verify any differences between nameplate details against approved drawings and data sheets. Check equipment for mechanical damages (dents/scratches, corrosion, broken handles/glass covers, leaking battery, battery terminal damage, bulging of battery casing etc.) Verify equipment Identification and installation / layout correct to project drawings, correct Ex / IP rating for location. Verify and confirm all Ex’d equipment flanges are lightly greased. Verify equipment earthing is properly installed and secured as per project specification. Verify main control panel installed properly All associated cables and vendor supplied wiring are installed, identified, glanded & terminated as described on approved drawings. Verify and confirm that all unused cable entries are sealed using proper sealing plugs.

OK

N/A P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A NAVIGATION AID

E46-A

Project No. Project Title Facilities Tag no. Area Ref. Drawing nos

INFORMATION System/Subsystem no. Location INSPECTION / TEST

11

OK

N/A P/L No

Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No Item Quantity Location

12

Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean.

13

Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

COMMENT(S) AND ADDITIONAL INFORMATION If installed, solar panel and associated equipment shall be checked against check sheet for solar panel and attached with this check sheet





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PUSHBUTTON STATION/SAFETY SWITCH E47-A Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. IP Rating Ex rating Manufacturer Ammeter range Model No. Location Serial No. Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required: a) Equipment Layout drawing b) Packing list c) Vendor drawings and datasheet for the push button station. 2 Verify and confirm that all construction / installation activities have been completed. 3 Equipment installed and clearly identified as shown on the project drawings, suitable Ex / IP cert. for location. 4 Check for any mechanical damage. 5 Verify and confirm that correct glands are installed and all unused cable entries are sealed using approved sealing plugs. 6 Verify cables are installed correctly, identified, glanded and terminated as shown on the associated project drawings. 7 Confirm that the covers/doors are properly closed and are accessible for maintenance. Ex’d unit cover faces to be lightly greased. 8 Check internal cleanliness and confirm the station is free of dust/debris and loose wires. 9 Check push button / control switch for correct mechanical operation. 10 Verify and confirm that the push button station is properly supported and accessible, padlocking facility is available. 11 Verify and confirm that the ammeter scale and range is correct for the motor/starter rating and correct for the CT installed in the starter. 12 Verify and confirm that equipment earthing is properly installed and secured as per project specification. 13 Identify the spares and special tools supplied, if any including keys, and record the storage location. Sl. No Item Quantity Location

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PUSHBUTTON STATION/SAFETY SWITCH E47-A 14 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 15 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 16 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A JUNCTION BOX

E48-A

Project No. Project Title Facilities Tag no. Area/Classification IP Rating Manufacturer Serial no. 1

2 3 4 5 6 7 8 9 10 11 12 13 14 15

INFORMATION System / Sub System no. EX Class Location Ref. Drawing nos. Type INSPECTION / TEST OK

N/A

P/L No

Documents required: a) Relevant layout drawing / block diagram b) Typical installation drawing Verify to ensure that all construction / installation activities have been completed. Verify tag plate identification is correct, and 'Ex' rating clearly identified (as appropriate). Verify JB is suitable for the area classification; confirm IP rating as per appropriate spec. Verify JB is installed properly and securely as per equipment layout drawing and typical installation details. Confirm that JB is undamaged internally and externally. Confirm that there is no unauthorized wiring or equipment fitted. Confirm that sufficient access to door/lid for maintenance is available. Verify and confirm that earthing is properly installed and secured as per project specification and installation details. Verify that all glands are properly fitted and all unused cable entries are sealed using approved sealing plugs. Check and confirm that all gaskets & seals are fitted correctly. Confirm that all terminations are correct and in accordance with relevant drawings. Check and confirm that JB internals are free of dust and debris. Ensure grease applied to flanges (Ex-d enclosures only). Identify the spares and special tools supplied, if any, and record the storage location. Sl. No Item Quantity Location

Page 1 of 2



JUNCTION BOX E48-A Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CABLE LADDER / TRAY

E49-A

Project No. Project Title Facilities Tray / Ladder material From Location 1

2 3 4 5 6 7

8

9

10 11 12

INFORMATION System / Sub System no. To Ref. Drawing nos. INSPECTION / TEST

OK

N/A

P/L No

Documents required: a) Cable ladder/Tray layout of the corresponding area b) Typical installation details of cable ladder/tray Verify and ensure that all construction / installation activities have been completed. Verify spacing and clearances are as per layout drawing. Confirm all the joints are properly completed with fishplates / fabricated joints. Verify and confirm that the ladders/trays are adequately supported as per drawings. Confirm the grounding and lightning protection are completed as per specifications and drawings. Confirm spacers/separators are installed for segregation of sensitive cables running along with disturbing cables inside the same ladder/tray. Check and confirm that the auxiliary supports are properly welded and the field welding points are repainted properly (wire brush cleaning and touch-up painting). Ensure that the ladder and tray bends are as per drawings and any site modifications are properly filed/protected to avoid damage to cables. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CABLE LADDER / TRAY E49-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A Inspection and Preservation Record for Motors E50-A and Generators which are not in operation Project No. Project Title Facilities INFORMATION Tray / Ladder material System / Sub System no. From To Location Ref. Drawing nos. INSPECTION / TEST Equipment Tag

Winding IR value

Space Heater (ON/OFF)

Rotor turned (Note-2)

Date

Page 1 of 2







Page 2 of 2

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A Project No. Project Title Facilities Tag no. Equipment Type Location Ref. Drawing nos. Serial no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

FAN

H01-A

INFORMATION System/Subsystem no. KW/HP Manufacturer RPM

INSPECTION / TEST Verify to ensure that all construction / installation activities have been completed. Name plate / Tag no. plate fitted. Details correct to specification and designs as specified in the Purchase Order Installation correct to design drawings and specifications. Impeller house inspection hatch installed. Impeller rotates freely and clears of impeller housing and bird screen. Impeller house clean. Alignment checked. Correct shim packs (minimum amount) and materials installed. Alignment jack screws/ devices fitted and lubricated. Electric motor drive connected & rotating direction check. Belt tension check record details, ensure anti static belt type. Grease nipples fitted charged and greased. Inlet / outlet dust blinds fitted. Maintenance access and facilities satisfactory. Verify fan silencer correctly installed and supported as per design. Verify earthing boss connection. Equipment release note signed and punch list agreed, cleared or recorded. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A Project No. Project Title Facilities Tag no. Equipment Type Manufacturer Serial no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

DAMPERS

H02-A

INFORMATION System/ Subsystem no. Location Ref. Drawing nos.

INSPECTION / TEST Verify to ensure that all construction / installation activities have been completed. Name plate / Tag no. plate fitted. Details correct to designs and specification as specified in the Purchase Order. Record details. Installation correct for direction of flow. Check that maintenance access hatch is fitted and closes and seals correctly. Flaps open and close smoothly / properly. Flaps adjustment is correct. Check that grease nipples if installed, charged and cleared. Check if fusible link device is fitted that flaps close on release. Check rating of fusible link and record. Actuator installed, check access for maintenance & adjustment. Check that there is no mechanical damage / interference with flap movement. Check that "open/close" indicator is fitted correctly. Check that correct type of gasket(s) to ductwork are installed and fitted correctly. Inlet / outlet dust blinds fitted and secured. Check that there is adequate access for maintenance. Check cleanliness condition. Actuator protection correctly fitted. Verify earthing boss connection. Verify preservation measures carried out. Equipment release note signed and punch list agreed, cleared or recorded. COMMENT(S) AND ADDITIONAL INFORMATION

OK

N/A P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DAMPERS



H02-A



Page 2 of 2

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A AIR HANDLING UNIT / AIR CONDITIONING H03-A UNIT Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem no. Equipment Type KW/HP Location Manufacturer Ref. Drawing nos. RPM Serial no. INSPECTION / TEST Verify to ensure that all construction / installation activities have been 1 completed. Name plate / Tag no. plate fitted, details correct to drawings and specification. Certifying authority stamps in place, where necessary. 2 Verify inspection release note signed and all punch list items cleared. 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

OK N/A P/L No

Check that location is correct according to drawings. Insulation correctly installed and joints sealed. Adequate support(s) and minimum amount of shims used. Any anti vibration mountings set correctly. Heating/ Cooling battery/ coil fitted correctly. Installation of integral components complete, resilient mountings correctly fitted and set. Complete any component check sheet and attach. Check electrical and instrumentation interfaces are in accordance with interfaces drawings and specifications. Maintenance hatch (es) fitted and accessible. Check that there is no mechanical damage and satisfactory cleanliness throughout. Check that cooling / heating connecting pipe work is fitted correctly and flushed (Refer to vendor specification/requirement). Check that sound attenuation is fitted correctly. Check that volume and fire dampers are fitted correctly. Check that drain incl. Water trap is fitted. Ensure drain tray is inclined towards the drain point. Flexible connection installed correctly. Maintenance access and any SWL of mechanical handling facility is satisfactory. Verify earthing boss connection. Page 1 of 2

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A AIR HANDLING UNIT / AIR CONDITIONING H03-A UNIT INSPECTION / TEST Check all filter elements installed correctly and adequate access for 18 maintenance. 19 Verify any preservation requirements. Equipment release note signed and punch list agreed, cleared or 20 recorded. COMMENT(S) AND ADDITIONAL INFORMATION




OK N/A P/L No


Page 2 of 2

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DUCTWORK FOR VENTS / EXHAUST / HEATERS Project No. Project Title Facilities Tag no. Equipment Type Manufacturer Serial no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

H04-A

INFORMATION System/Subsystem no. Location Ref. Drawing nos.

INSPECTION / TEST Verify to ensure that all construction / installation activities have been completed. Installation correct to drawings and specification. Material grade and thickness correct for application. Supports correct to drawings and adequate. Inspection hatches in correct locations and accessible. Internal and external condition clean, free from construction debris. Supply / extract grills fitted correctly and sealed. Bird screen fitted and weather protection secured. Check that dust drains / blinds fitted correctly. Check that test holes are fitted in correct position and accessible, covers for test holes secured and sealed. Check that any turning vanes are correctly fitted and secure. Verify any preservation procedures are complete. Check duct heaters are installed correctly, and are secured as per the ductwork drawings. Equipment release note signed and punch list agreed, cleared or recorded. COMMENT(S) AND ADDITIONAL INFORMATION



VERIFIED BY PMT Inspector PCSB

OK

N/A P/L No

ACCEPTED BY Discipline Engineer PCSB

Page 1 of 1

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A Project No. Project Title Facilities

DUCT LEAK TEST

Tag no. Equipment Type Manufacturer Serial no. 1 2 3 4 5 6 7 8 9

H05-A


INSPECTION / TEST Verify to ensure that all construction / installation activities have been completed. Duct line installed and supported correctly to drawings. Maximum permitted leakage rate Liter/Sec Duct static pressure reading Pa Diameter of orifice mm Diameter of tube, duct side mm Reading of flow measuring device. Pa Check flow measuring device calibration certificate validity. Intermediate air flow leakage rate Liter/Sec Intermediate air flow leakage rate Liter/Sec COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DIFFUSERS / GRILLS / LOUVERS / HOODS H06-A Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem no. Equipment Type Location Manufacturer Ref. Drawing nos. Serial no. INSPECTION / TEST Verify to ensure that all construction / installation activities have been 1 completed. Nameplate / Tag plate fitted, details correct to drawings and 2 specifications as specified in the Purchase Order. 3 Correct installation (Check orientation). 4 Vanes / Louvers secure 5 Adequate support. 6 Bolting and fixing secure. 7 Check that there is adequate access for maintenance. 8 Check internal/ external cleanliness, construction debris removed. Check that correct gaskets and bolting are installed and fitted to 9 ductwork flange. 10 Check that there is no mechanical damage. 11 Installation is weather tight. 12 Verify any preservation is completed. Equipment release note signed and punch list agreed, cleared or 13 recorded. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FILTERS / COALESCER Project No. Project Title Facilities Tag no. Equipment Type Manufacturer Serial no. 1 2 3 4 5 6 7 8 9 10 11

H07-A


INSPECTION / TEST Verify to ensure that all construction / installation activities have been completed. Data plate complies with data sheet. Nameplate / Tag plate fitted correctly. Installations correct (Check orientation). Adequate support(s). Check that there is adequate access for maintenance. Check internal cleanliness satisfactory. Check that there is no mechanical damage. Check drain connections are clear, correct size and slope. Verify preservation is completed. Equipment release note signed and punch list agreed, cleared or recorded. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1


SOUND ATTENUATOR

Tag no. Equipment Type Manufacturer Serial no. 1 2 3 4 5 6 7 8 9 10 11 12

H08-A


INSPECTION / TEST Verify to ensure that all construction / installation activities have been completed. Data plate complies with data sheet and drawings. Nameplate / Tag plate fitted. Installation corrects (Check orientation). Check internal cleanliness is satisfactory. Check that baffles are properly fixed. Check that sound attenuator is properly supported. Check that correct gaskets and bolting to ductwork are fitted. Check that attenuator is free from mechanical damage. Check that there is adequate access for maintenance. Check preservation is completed. Equipment release note signed and punch list agreed, cleared or recorded. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1


HVAC DUCT HEATER

Tag no. Equipment Type Manufacturer Serial no. 1 2 3 4 5 6 7 8 9 10 11 12

H09-A


INSPECTION / TEST Verify to ensure that all construction / installation activities have been completed. Cables installed, identified, glanded and terminated to project design drawings. Review equipment plate details against approved drawings and data sheets. Check heater controls to equipment drawing. Review equipment preservation records. Equipment Ex / IP certification is suitable for the system / area. Verify earthing boss connection. Check for mechanical damage. Check internals for cleanliness. All cable terminations correct to associated design drawings, check all cable / wiring terminations for tightness. Labeling and warning signs correctly install and visible. As built drawings marked up, release note signed and punch list agreed, cleared or recorded any punch list items recorded. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A HEATING, VENTILATION AND AIR CONDITIONING H21-A (HVAC) Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem no.

1 1.1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 3.1 3.2 3.3 3.4 3.5 4 4.1 4.2

INSPECTION / TEST

GENERAL Check vendor’s instruction and ensure manual and part list are available in good orders INTAKE FILTER AND PRESSURISATION FANS Check air inlet filter condition and ensure it is properly installed Check inlet filter protecting guard Check that inlet filter is of the approved type Check pressurization fan nameplate and ensure that sufficient information are provided Check that fan impeller is of non-sparking type Check pulley alignment and fan belt tension Check fan bearing lubrication/greasing Verify that electrical check on motor, cabling and fan starter has been completed Check fan casing mounting, flexible joints, vibration dampener

OK

N/A P/L No

NON-RETURN ELECTRIC DAMPER NO Check damper condition, blade material and ensure correct installation Verify that electrical check has been done Test functioning of actuator, ensure no obstruction and verify that the damper can be fully opened Check that all blades are closely tightly Check that external/remote indicator is visible VOLUME DAMPER NO Check damper condition, blade material and ensure correct installation Test operation of actuator, ensure no obstruction and verify that damper can be fully opened Page 1 of 3

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A HEATING, VENTILATION AND AIR CONDITIONING (HVAC) INSPECTION / TEST 4.3 Check that external/remote indicator is visible 5 5.1 5.2 5.3 5.4 5.5 6 6.1 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 9

H21-A OK

N/A P/L No

FIRE DAMPER NO Check damper condition, blade material and ensure correct rating and correct installation Test operation of actuator, ensure no obstruction and verify that damper can be fully opened Check closing of damper Check fusible link if fitted Check external/remote indicator is visible DUCT HEATER Verify that electrical check on heater and cable has been completed AIR COOLED CONDENSING UNIT Check package holding down bolts Check that vibration dampers are provided if specified Check motor and compressor holding down bolts Check motor/compressor alignment if not close-coupled type of coupling Check that condenser tube fin material conforms to purchase specifications Check that tube fin is free from intermeshing and deformation Check that system has been pressure tested and site test certificated Check condenser fan holding down bolts Check that safety guards are properly installed Check refrigeration piping insulation, ensure that material conform to specifications Verify that electrical check has been completed AIR HANDLING UNIT Check nameplate and ensure informations are correct Check air handling fan mounting bolts condition Check flexible duct connectors are fire resistance type Check fan pulley alignment and belt tension Check mixing box, return fresh air damper installation Check expansion cooling coil for any damage or intermeshing of fins Verify that electrical check on motors, cabling and Motor Control Center are completed ELECTRICAL DUCT HEATER Page 2 of 3

CSP-20 rev. 01 Appendix I-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A HEATING, VENTILATION AND AIR CONDITIONING H21-A (HVAC) INSPECTION / TEST OK 9.1 Check for any mechanical damage 9.2 Check that duct heater is correctly installed Verify that insulation resistance and continuity test of heater and 9.3 cabling has been done 10 HVAC CONTROL PANEL 10.1 Visual inspection of control panel for any damage 10.2 Check holding down bolts of control panel 10.3 Check all indicating lights nameplate against approved drawings 10.4 Verify that electrical check has been completed 11 DUCTING 11.1 Check general condition of ducting 11.2 Check that coating/painting of ducting conforms to specifications 11.3 Check insulation materials conform to specifications 11.4 Check sealing materials conform to specifications 11.5 Check that each section of ducting is bonded 11.6 Check that flexible joints are provided as per drawing of fan, etc.

N/A P/L No

COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheet from vendor shall be attached with this (If any).





Page 3 of 3

RECORD INDEXES INSPECTION TEST RECORD - A INSTRUMENT

INDEX I01-A I03-A I04-A I05-A I06-A I07-A I08-A I09-A I10-A

I13 - A I14-A I15-A I17-A I20-A I22-A I23-A I24-A I26-A I27-A

INSPECTION TEST RECORD - A INSTRUMENT CABLE INSTALLATION & TESTING INSTRUMENT CALIBRATION CHECK INSTRUMENT INSTALLATION CHECK INSTRUMENT TUBING INSTALLATION & PRESSURE TESTING INSTRUMENT PANEL (ELECTRONIC) INSTALLATION INSTRUMENT JUNCTION BOX INSTALLATION PNEUMATIC INSTRUMENT CONTROL PANEL (ICP)/ESD STATION INSTALLATION CV/SDV/BDV INSTALLATION & CALIBRATION PSV INSPECTION & TEST MISCELLANEOUS PROCESS ANALYZER INSTALLATION& CALIBRATION FIRE AND GAS (FGS) DEVICE CALIBRATION & INSTALLATION CABLE TRAY INSTALLATION CHECK FUSIBLE PLUG LOOP & PANEL INSTALLATION WELL HEAD CONTROL PANEL (WHCP) INSTALLATION HSSD (VESDA) SYSTEM INSTALLATION METERING SKID INSTALLATION CONDUIT INSTALLATION CHECK TANK GAUGING SYSTEMS MULTIPHASE FLOW METER (MPFM) INSTALLATION

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INSTRUMENT CABLE INSTALLATION AND TESTING Project No. Project Title Facilities

I01-A

INFORMATION Tag Number Platform Cable From Cable To Cable Core/Size Voltage System Number Sub System Number ACCEPTANCE CRITERIA The cable insulation resistance is to be checked using a 250V / 500 V Megger. (ACCORDING TO THE CABLE RATING) 1 Minimum acceptable resistance is 10 Meg Ohm, each core is to be tested against all other cores, and earth. The minimum measured insulation resistance. The cable continuity is to be tested using a suitable multimeter, set to Ohms range, maximum permissible resistance 2 should not exceed 12Ohms/km as per BS 5308-2: Instrumentation Cables Part 2. INSTALLATION CHECK OK N/A P/L No. 1 Check the cables are laid properly in trays/ladder as per the cable routing diagrams. In case of Intrinsically Safe (IS) or non-IS cables ensure that they are not laid/bunched 2 together and there is enough separation between them as well as other electrical cables. Verify all cable are provided complete with cable gland/cable clampand cable tags as per 3 cable schedule Checkcable gland as per design and installed with a complete gland kit comprising earth 4 tag& PVC shroud Verify the cable to have the correct outer sheath as per cable schedule. Identification 5 markings/bands of I.S, Non I.S and FGS cable shall be as per cable schedule 6 Inspect terminal lug crimping, core markers, and core lay in termination chambers 7 Inspect cable dressing and verify placement of cable markers along length of cable 8 Verify placement of cable markers on both sides of bulkhead transits 9 Inspect cable physical protection devices, i.e. coaming, kick guards, etc 10 Instrument Cable Screen shall be terminated as per termination drawing. Field device cable screen shall cut & tape inside the device housing & not to be grounded at 11 instrument device. To ensure no contact with the field device body. 12

Unused cables shall be taped and stowed inside the marshaling cabinet or terminate as per terminationdrawing.

Check whether there is sufficient spare length of cable stowed, at both ends for future use. (e.g. at Junction Box as well as at Marshalling Cabinet end) For system interface cabling within the same room, to verify the following: a) Termination as per vendor termination drawing 14 b) Cable tag/maker as per cable schedule c) Cable routing as per cable routing drawing COMMENT(S) AND ADDITIONAL INFORMATION 13

Page 1 of 2 PETRONAS CARIGALI SDN. BHD.

INSPECTION TEST RECORD (ITR) - A INSTRUMENT CABLE INSTALLATION AND TESTING INSULATION & CONTINUITY TEST Insulation Test Core to Core to Shield to Pair / Triad Core to Screen to Armor Core Ground Screen Shield Resistance No A

Type

B

C

A

B

C

A

B

C

Manufacturer

A

B

C

A

B

I01-A Continuity Test Overall Shield to Overall Shield Individual Shield to Individual Shield to Ground Ground C

TEST EQUIPMENT Model Serial Number

Calibration Expiry Date

REFERENCE DRAWINGS 1 2 3 4 5

Cable Schedule Drawing JB Schedule Drawing Cable Routing Drawing Cable Installation Drawing Termination Drawing COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INSTRUMENT CALIBRATION CHECK Project No. Project Title Facilities

I03-A

INFORMATION Tag Number Manufacturer Type Dial/Chart Signal Rate Data Sheet System Number Sub System Number Model Serial Number ACCEPTANCE CRITERIA (ERROR %) Refer to Measurement Accuracy Table as per PTS 32.31.0032 Section 2.8, Class C (1% of adjustable span) or accuracy of 1 the reference meter whichever is lower. PRE CALIBRATION CHECK OK N/A P/L No. 1 Check availability of calibration procedure 2 Check the calibration range for the transmitter against the data sheet 3 Check availability of the manufacturer’s calibration sheet 4 Visually inspect equipment for external damage 5 Verify nameplate tagging against data sheet CALIBRATION

Transmitter Rising Points % of span

Output Current (ideal)

Input

Output Current Error (% of span) (measured)

Falling Points Output Current (measured)

Error (% of span)

0 25 50 75 100 Switch Set Point

Contact Output Close Open

Pneumatic Output Pressurized Depressurized

Rising Input Falling Input REFERENCE DRAWINGS 1 2

Instrument Datasheet

Manufacturer’s Calibration Sheet Type

Manufacturer



Page 1 of 2 CSP-20 rev. 01

Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INSTRUMENT CALIBRATION CHECK COMMENT(S) AND ADDITIONAL INFORMATION




I03-A


Page 2 of 2

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INSTRUMENT INSTALLATION CHECK Project No. Project Title Facilities Tag Number Type Service Serial Number Model Number System Number 1 2 3 4 5 6 7 8

I04-A

INFORMATION Signal Range Dial/Chart Range Data Sheet Manufacturer Sub System Number

INSTALLATION CHECK Verify that devices are tested/calibrated and confirm the duration of calibration certificate is still valid Instrument is correctly mounted, elevated and positioned as per approved drawings Ensure that instrument manifold are correctly oriented and installed properly as per vendor drawings Instrument name plate /service tag are correct as per approved drawing Instrument is free of vibration Instrument is clear from obstructions and accessible Tubing (impulse, signal & hydraulic lines) are installed and properly supported (every 1.5m) Vent line to safe location

Instrument complies with hazardous specification and IP rating. To ensure the IP 9 rating and hazardous area certification are engraved at the instrument body name plate 10 Verify orifice plate is installed as per approved PTS standard/vendor drawings and approved hook up drawings. Orientation of the “jack” nut is correctly done (for flange fitting only). 11 Check in line instrument installation is as per the Vendor Drawings. 12

Check all covers are fitted, seal are in good condition and spare entries are plugged with certified plug as per instrument hazardous and IP rating

13 Check that instrument back and front cover are applied with copper grease 14 Instrument body are earthed properly 15 Ensure cable glanding are done properly Ensure the instrument cable glands (with earth lug) are earthed to the instrument 16 body/support structure 17 Verify to ensure that all construction / installation activities have been completed Ensure wiring termination is correctly done and proper ferrules (ring type) are connected, 18 screen drain wires are properly insulated 19 Verify core marker and cable tag are correctly installed as per instrument loop drawing 20 Correct size/type of cable glands fitted, cable tags attached, spare cable entries plugged off. 21 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 22 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Instrument Location Plan 2 Instrument Installation Detail 3 Hook Up Drawings 4 Vendor Drawings 5 PTS Standard Drawings 6 Instrument Loop Drawings

OK

N/A

P/L No.

Page 1 of 2 CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INSTRUMENT INSTALLATION CHECK COMMENT(S) AND ADDITIONAL INFORMATION




I04-A


Page 2 of 2

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INSTRUMENT TUBING INSTALLATION & PRESSURE TESTING Project No. Project Title Facilities Tag Number Type Service Tubing MAWP Model Number System Number Service IMP

I05-A

INFORMATION Signal Range Dial/Chart Range Data Sheet Manufacturer Sub System Number Serial Number TEST PRESSURE & ACCEPTANCE CRITERIA Test Acceptance Criteria

Process Impulse

SPL Sample Line

HYD

Notes

Hydraulic Line Transport Line Instrument Air/Gas Supply Line

Pressure Test 1.5 times of the maximum piping rating pressure

Pressure test for pipe rating 150# below can be with pneumatic/water test (hydrotest) at 1.5 times.

Pressure drop not exceeding 68.9 mbar or one(1) psi per hour. Minimum scale division of For 150# above, the test shall be test gauge or manometer used using water (hydrotest) only shall be one (1) psi because of safety concern using high pressure pneumatic.

Leak Test SIG No visible leak Test at pressure of 2 barg INSTALLATION CHECK Impulse line, signal and test gas line installed and supported as per standard hook up 1 drawings and tubing routing layout 2 All dirt and cutting debris removed from tubing 3 Vent line to safe location 4 Instrument tube fittings and isolation valves correctly installed 5 Ensure proper instrument fittings are used as per hook up drawings 6 Tubing has no sign of damage or welding spots Pneumatic Signal Line

N/A OK

N/A

P/L No.

Record Service Test: Service Test Pressure Test Medium Test Duration Hydraulic line to be flushed with the hydraulic fluid. To meet NAS specification if water 8 based hydraulic fluid is used 9 Hydraulic line depressurized, capped and tagged after test 10 Pneumatic andimpulse lineblown clear and dry 11 Confirm line is correctly re-connected as per hook up drawings 7


Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INSTRUMENT TUBING INSTALLATION & PRESSURE I05-A TESTING 12 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 13 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. PRESSURE TEST Test Test Result Instrument Tag Service Test Duration Medium Test Pressure OK N/A

Type

Manufacturer

TEST EQUIPMENT Model

Serial Number

Date Tested


REFERENCE DRAWINGS 1 2 3 4

Instrument Location Plan Instrument Installation Detail Hook Up Drawings Panel Drawings COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A I06-A

INSTRUMENT PANEL (ELECTRONIC) INSTALLATION Project No. Project Title Facilities Tag Number System Number Sub System Number Type Service Area Classification 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5

INFORMATION EX Protection IP Rating Manufacturer Model Number Serial Number

INSTALLATION CHECK Verify the Material Installed as per Bill Of Material Verify the Factory Acceptance Test (FAT) punchlist and close out report Verify panel installation is as per Vendor Installation Drawings and procedure Verify panel location and orientation is as per Location/Layout Drawings Verify the door opening is clear Verify the panel operation & maintenance accessibility is adequate Verify the panel interfaces are connected as per Instrument and Vendor Termination Drawings Verify electrical items/instruments are glanded, cabled and terminated as per Termination Drawings Verify all cable screen/drain wire are terminated only at panel instrument/clean earth. Verify that instrument earth bar is fully isolated from the panel and base frame Verify the panel earth lugs are connected to the grounding/earth boss /network Verify that all spare cable entries are plugged with the certified plugs. Verify the laminated panel schematic and wiring drawings are available in the panel and as built. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS Instrument Location Plan Instrument Installation Detail Termination Drawings and Vendor Termination Drawings Vendor Panel General Arrangement Drawings Vendor Installation Drawings and Procedure COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A


P/L No.

Page 1 of 1


INSTRUMENT JUNCTION BOX INSTALLATION Project No. Project Title Facilities Tag Number System Number Sub System Number Location Certifying Authority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3

INFORMATION EX Protection IP Rating Manufacturer Model Number

INSTALLATION CHECK Verify to ensure that all construction / installation activities have been completed Check accessibility of junction box in order to ensure that ergonomically comfortable for any maintenance work Verify JB is installed securely and correctly as per equipment layout drawing Inspect junction box for mechanical damage tagging, and attachment to supports Verify tag plate identification correct, and 'Ex' rating clearly identified Verify JB is suitable for the area classification, confirm IP rating as per datasheet Verify all fitted equipment compliance to Ex certificate (Note: For Ex-rated junction boxes only) Check whether JB is provided with terminals as per the approved JB or terminal drawing Check that all wires are terminated as per termination drawing Verify that all screen wires are insulated and terminatedas per termination drawing Inspect flange surfaces and apply copper grease compound to flange surfaces (if applicable) Inspect glands and ensure that all glands are properly installed Inspect spare gland entries are plugged with certified plug Inspect seals on the JB door are fitted correctly. Verify JB internals are free of dust and debris Check earthing of junction box as per termination drawing Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS JB Installation Drawing Typical Installation Drawing Termination Drawing COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A

P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PNEUMATIC INSTRUMENT CONTROL PANEL (ICP)/ESD I08-A STATION INSTALLATION Project No. Project Title Facilities INFORMATION Tag Number EX Protection System Number IP Rating Sub System Number Manufacturer Model Number Dial/Chart Range Certifying Authority Type Service Serial Number Pneumatic Supply: Instr. Air Instr. Gas Panel Type: Pneumatic Pneumatic - Electronic INSTALLATION CHECK OK N/A 1 Verify the Material Receiving Report 2 Verify the Factory Acceptance Test (FAT) Report 3 Verify panel installation is as per Instrument Installation Drawings 4 Verify panel location and orientation is as per location drawing 5 Verify the door opening is clear 6 Verify the panel operation & maintenance accessibility is adequate 7 Verify the panel utilities, vent and drain are connected as per Instrument Hook Up Drawing 8 Verify the panel interfaces are connected as per Instrument Hook Up Drawing 9 Verify electrical instruments are glanded, cabled and terminated at the JB 10 Verify the panel and junction box earth lugs are connected to the grounding boss / network 11 Verify that all spare tubing entries are plugged with the appropriate plugs. 12 Verify that all spare cable entries are plugged with the certified plugs. 13 Verify the laminated panel schematic drawings are available in the panel. 14 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 15 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Instrument Location Plan 2 Instrument Installation Detail 3 Hook Up Drawings 4 Panel Drawings COMMENT(S) AND ADDITIONAL INFORMATION




P/L No.


Page 1 of 1


CV/SDV/BDV INSTALLATION & CALIBRATION Project No. Project Title Facilities Tag Number Valve Type Service Line number Temperature (Operating/Design) Size and Rating P&ID Positioner or I/P Converter (Brand and Model) Pressure PressureActuating Medium Supply

3 4 5 6 7 8 9 10 11 12 13 14 15 16

Instrument Air

Instrument Gas

Hydraulic

Pneumatic Hydraulic Electric Motor Single Acting Single Acting N/A Double Acting Double Acting INSTALLATION CHECK OK N/A P/L No. Verify the Material Installed as per Bill Of Material Verify the Factory Acceptance Test (FAT) punchlist and close out report Verify the control valve / SDV / BDV / XV / MOV valve is installed as per Vendor Drawings and Procedure – following flow direction for single directional valve. Verify the control valve / SDV / BDV / XV / MOV actuator is installed as per Vendor Drawings and Procedure Verify the control valve / SDV / BDV / XV pressure filter / regulator is installed in vertically upright position Verify the valve actuator control panel or positioner is accessible. Verify the control valve is visible from the local controller (pneumatic controller only) Verify the assembly is connected to the Instrument Gas / Air /Nitrogen Back Up Supply Header Verify the assembly vent is connected to the safe vent header (NOT Process Vent Header) (only for instrument gas application) Verify I05-A; Instrument Tubing Installation & Pressure Testing/Leak Test Verify I07-A; Instrument Junction Box Installation has been done (only for pneumatic JB) Verify Checksheet for electrical cable installation – only applicable for MOV Verify the assembly junction box is connected to the control system junction box Verify the termination is done as per Vendor Termination Drawings and Instrument Loop Drawings Verify I01-A; Instrument Cable Installation & Testing Report Verify the panel and junction box and glands earth lugs are connected to the grounding boss / network and structures. CALIBRATION CHECK % Span Input Positioner Output Positioner Control Valve Position 0 25 50 75 Page 1 of 2 CSP-20 rev. 01 Actuator Type

1 2

INFORMATION Data Sheet EX Rating IP Rating Manufacturer Model Number Serial Number System No. Sub System No. Solenoid (Brand and Model) kPag/Barg/Psig kPag/Barg/Psig

Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A I09-A CV/SDV/BDV INSTALLATION & CALIBRATION Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 17 18 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. CALIBRATION CHECK % Span Input Positioner Output Positioner Control Valve Position 100 Control Valve On/Off Valve ATC Stroking Time ________sec. To specification. Yes ATO TEST EQUIPMENT Type Manufacturer Model Serial Number Calibration Expiry Date

REFERENCE DRAWINGS 1 2 3 4 5 6 7

Hook Up Drawings Instrument Location Plan Instrument Installation Detail Termination Drawings and Vendor Termination Drawings Vendor Actuator Control Schematic Vendor Installation Drawings and Procedure Instrument Valve Datasheet COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PSV INSPECTION & TEST

I10-A

Project No. Project Title Facilities INFORMATION Test Medium Set Point (Pressure) Manufacturer Model Number Serial Number System No. Sub System No. ACCEPTANCE CRITERIA FOR SEAT LEAKAGE TEST

Tag Number Type Service Data Sheet Test Pressure Test Pressure Applied Time Valve Size Test Percentage

Acceptance Criteria

Valve remains close until 90% of Set Pressure as per API Bubble rate shall be as per API 527 527 INSPECTION TEST & SEATLEAKAGE TEST OK N/A 1 Verify to ensure that all construction / installation activities have been completed 2 Verify equipment and tag plate is correct and accordance with data sheet 3 Body material is correct as per datasheet 4 Check PSVs are not damaged. 5 Pilot or spring is operated Confirm the location is correct as shown on P&ID and layout drawing and installed correctly 6 7

Check that PSV lock wires are intact and sealed

8

Verify that PSV are tested and confirm the duration of calibration certificate is still valid

P/L No.

Ensure that Pop test is conducted as per approved Instrument Test Procedure (ITP) (if required) 10 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 11 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 PSV General Arrangement 2 PSV Datasheet COMMENT(S) AND ADDITIONAL INFORMATION 9





Page 1 of 1

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MISCELLANEOUS PROCESS ANALYZER INSTALLATION & I13-A CALIBRATION Project No. Project Title Facilities INFORMATION Tag Number Data Sheet System Number Dial/Chart Range Sub System Number Signal Range Manufacturer Service Type Model Number Area Classification Serial Number INSTALLATION CHECK 1 Verify the Material Receiving Report / Fault Report are closed 2 Visually inspect equipment for external damage 3 Check interior for damage, cleanliness and remove packing 4 Verify to ensure that all construction/installation have been completed Verify Analyzer (Sampling, Sample Pre-commissioning, Sample Commissioning) mechanical 5 installation as per drawing Verify Analyzer Electrical Installation (Power, Signal, Heat Tracing& Grounding) as per 6 reference drawing 7 Verify Analyzer Instrument Installation (Tubing) as per reference drawing 8 Verify nameplate tagging against data sheet Verify each Instrument Equipment is calibrated and confirm the duration of the calibration 9 certificate from vendor are still valid Ensure that calibration is conducted as per approved instrument Calibration Test Procedure 10 ITP and record the reading as follow. (if required) 11 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 12 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Instrument Location Layout 2 Isometric Drawing 3 Instrument Cable Routing Layout 4 Vendor Installation Drawings 5 Vendor Electrical Termination Drawings 6 Vendor Instrumentation Drawings 7 Vendor General Arrangement Drawing 8 Electrical Cable Routing Layout Drawing 9 Instrument Datasheet 10 Instrument Hookup Details & Instrument Installation Details 11 Manufacturer’s Calibration Sheet/Certificate COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A

P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A I14-A FIRE AND GAS (FGS) DEVICE CALIBRATION & INSTALLATION Project No. Project Title Facilities INFORMATION Tag Number Service System Number Signal Range Sub System Number Dial/Chart Range Data Sheet Area Classification IP rating Classifying Authority Serial Number Manufacturer Model Number Location Type EX rating Protected Zone Heat Smoke Gas(Flammable/ Toxic) Breakglass Type of Fire & Gas Flow Switch Flame Kill knob Fusible Plug Detection Device CALIBRATION & INSTALLATION CHECK OK 1 Devices free from mechanical damage, tag number plate attached and clearly visible. 2 Devices installed at correct locations and as per installation drawing. Check the detectors’ view coverage as per installation drawings and not blocked by any 3 obstruction 4 Wiring termination correct, screen wires and grounding properly insulated. Correct size/type/EX certification of cable glands fitted, cable tags attached, spare cable 5 entries plugged off with certified plug. Associated junction boxes installed properly as per checksheet I07-A. Correct EX certified 6 junction box used. 7 Check/verify calibration certificate from manufacturer 8 Check that detector enclosure cover are applied with copper grease 9 Detector body are grounded properly 10 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 11 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. FUNCTION TEST ACTIVATION

CONTROLLER INDICATION

MIMIC / DISPLAY INDICATION

Press Switch Other:________

N/A P/L No.

VISUALS & AUDIBLES

Heat Flow Switch Smoke Flame Gas(Flammable/ Toxic) Kill knob Breakglass Fusible Plug GAS DETECTORS CALIBRATION Calibration gas concentration

20% LEL

40% LEL

60% LEL

___ % LEL

OK

N/A

P/L

10 PPM

20 PPM

50 PPM

___ PPM

OK

N/A

P/L

OK

N/A

P/L

Trigger each device with the appropriate stimuli and verify local and remote indication


Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A I14-A

FIRE AND GAS (FGS) DEVICE CALIBRATION & INSTALLATION 20% LEL / 10 PPM 40% LEL / 20 PPM 60% LEL / 50 PPM % LEL / PPM SHUTDOWN FUNCTION

GPA / PAPA

ASD

DCS

FIREWATER PUMP

HVAC

OTHERS

EXTINGUISHMENT RELEASED

SINGLE ZONE 2 OR/AND MORE MANUAL REFERENCE DRAWINGS 1 2 3 4 5

FGS Detectors Location Layout FGS Installation Details Detector Calibration Certificate Flammable/Toxic Calibration Gas Certificate Detector Datasheet COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CABLE TRAY INSTALLATION CHECK Project No. Project Title Facilities Job Number Area Manufacturer System Number

I15-A

INFORMATION Tray Type Location Sub System Number

INSTALLATION CHECK Conformance to specifications and drawings. Expansion joints properly installed. All braces and supports adequate to handle weight of tray and cable. Hold downs properly installed. Tray is anchored only in location shown on drawings. No sharp edges to cut cable. No obstruction to pulling off cable. All covers, fire stoper and partitions installed. All bonding jumpers installed.

OK

N/A

P/L No.

1 2 3 4 5 6 7 8 9 Grounding installed and connected. 10 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 11 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Location Plan 2 Cable Tray Installation Detail 3 Hook Up Drawings COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1


FUSIBLE PLUG LOOP & PANEL INSTALLATION Project No. Project Title Facilities Tag Number System Number Sub System Number Service Serial Number Control Medium Type 1 2 3 4 5 6 1 2 3

INFORMATION IP rating EX rating Manufacturer Model Number

Instrument Air Instrument Gas Pneumatic Pneumatic-Electronic INSTALLATION CHECK Verify to ensure that all construction / installation activities have been completed. Verify the fusible plug installation as per fusible plug loop layout drawings. Refer to I05-A: Instrument tubings installation and pressure tubing checksheet. Refer to I01-A: Instrument cable and installation checksheet Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS Instrument Fusible Plug Loop Layout Instrument Installation Detail Hook Up Drawings COMMENT(S) AND ADDITIONAL INFORMATION




Nitrogen OK

N/A

P/L No.


Page 1 of 1


WELL HEAD CONTROL PANEL (WHCP) INSTALLATION Project No. Project Title Facilities Tag Number System Number Sub System Number Type Manufacturer Service Serial Number Pneumatic Supply: Panel: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4

INFORMATION IP rating Signal Range Dial/Chart Range Data Sheet Model Number EX rating

Instrument Air Instrument Gas Pneumatic -Hydraulic Electronic – Hydraulic Pneumatic – Electronic – Hydraulic INSTALLATION CHECK OK N/A P/L No. Verify the Material Receiving Report Verify the Factory Acceptance Test (FAT) Report Verify panel installation is as per Instrument Installation Drawings Verify panel location and orientation is as per location drawing Verify the door opening is clear Verify the panel operation & maintenance accessibility is adequate Verify the panel utilities, vent and drain are connected as per Instrument Hook Up Drawing Verify the panel interfaces are connected as per Instrument Hook Up Drawing Verify electrical instruments are glanded, cabled and terminated at the JB Verify the panel instrument adjustments are accessible Verify the panel and junction box earth lugs are connected to the grounding boss / network Verify that all spare tubing and cable entries are plugged with the appropriate plugs. Verify the laminated panel schematic drawings are available in the panel. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS Instrument Location Plan Instrument Installation Detail Hook Up Drawings WHCP Drawings COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1


HSSD (VESDA) SYSTEM INSTALLATION Project No. Project Title Facilities

INFORMATION Tag Number IP rating System Number Signal Range Sub System Number Protected Zone Data Sheet Type Service Classifying Authority Area Classification EX rating Manufacturer Model Number Serial Number Location INSTALLATION CHECK 1 Devices free from mechanical damage, tag number plate attached and clearly visible. 2 Devices installed at correct locations and as per installation drawing. Detector and the mounting bracket intact in the box & Is the detector securely locked onto 3 its mounting bracket. Verify to ensure that all sampling air pipes firmly connected to the air inlet ports.Verify to 4 ensure that all sampling air pipes firmly connected to the air inlet ports. Plug at the exhaust port been removed.Ensure that the exhaust 5 Pipe (if fitted) is NOT glued andfront cover been fitted correctly. 6 Wiring termination correct, screen wires and grounding properly insulated. Correct size/type/EX certification of cable glands fitted, cable tags attached, spare cable 7 entries plugged off with certified plug. Associated junction boxes installed properly as per check sheet I07-A. Correct EX certified 8 junction box used. 9 Detector body is grounded properly. 10 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 11 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 HSSD (VESDA) Location Layout 2 HSSD (VESDA) Installation Details COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A

P/L No.


Page 1 of 1


METERING SKID INSTALLATION Project No. Project Title Facilities Tag Number System Number Sub System Number Type Area

INFORMATION Manufacturer Model Number Serial Number Flow Range

INSTALLATION CHECK Verify that the skid is installed at correct location and orientation as per Layout Drawings Verify that all mechanical installations are as per Vendor Drawings/Procedure and Piping 2 GA/Isometric 3 Verify that all the instrument installation are as per I04-A (Non skid installations) 4 Verify that all electrical installations and termination are as per Vendor Drawings 5 Verify that all instrument interface cable termination are as per the Vendor Drawings 6 Visually inspect equipment for external damage 7 Verify nameplate tagging against P&ID and name plate schedule 8 Check I06-A: Instrument Panel (Electronic) Installation checksheet 9 Check I01-A: Instrument Cable Installation and Testing checksheet 10 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 11 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Location Layout 2 Isometric and Piping GA Drawing 3 Instrument Cable Routing and Termination Drawings 4 Vendor Installation Drawings 5 Vendor Electrical Termination Drawings 6 Vendor Instrumentation Drawings COMMENT(S) AND ADDITIONAL INFORMATION

OK

N/A

P/L No.

1





Page 1 of 1

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CONDUIT INSTALLATION CHECK

I24-A

Project No. Project Title Facilities Job Number Area Manufacturer System Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14

INFORMATION Type Location Sub System Number

INSTALLATION CHECK Supports and spacing as per specification and drawing. Supports adjacent to terminal fittings. Conduits clean, stub-ups protected, open ends plugged, damage during construction period. Field bend radius corrected per specification and codes. Bends free of deformities. Expansion joints as shown on drawings. Installation neat and evenly spaced. Spacing between instrument and power conduit as per specifications. Spacing from hot pipes and from hot surfaces maintained. Conduit permanently and effectively grounded. Proper fittings installed with threads fully engaged, proper sealing compound used, no wrench cuts, conduit ends have bushings and covers installed. Seals and drains installed per drawing. Aluminium, PVC or PVC coated conduits installed where specified on drawings. Flexible conduit installed with proper bending radius and with standard fitting. Metal junction boxes levelled and supported per drawings with proper hubs, locknuts and bushing installed. Seals poured.

OK

N/A

15 16 Grounding installed and connected. 17 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 18 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Location Plan 2 Cable Tray Installation Detail 3 Hook Up Drawings COMMENT(S) AND ADDITIONAL INFORMATION





P/L No.

Page 1 of 1

CSP-20 rev. 01 Appendix I-V PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A I26 - A

TANK GAUGING SYSTEMS Project No. Project Title Facilities Tag Number System Number Sub System Number No. of Tank Gauges Type of Level Sensor Manufacturer Type of Temperature Type of Sensor 1 2 3 4 5 6 1 2 3 4 5

INFORMATION Area Classification Tank Local Indication No of JB IP rating Type of Signal EX protection

Radar Servo Float INSTALLATION CHECK Verify the Material Receiving Report. Verify the Factory Acceptance Test (FAT) Report. Verify check sheets I01-A, I03-A, I04-A, I05-A, I06-A and I07-A are filled and signed off. Verify interconnection between TGS and host system (DCS). Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS Instrument Location Plan Instrument Installation Detail Termination Drawings Panel Drawings Vendor System Drawings COMMENT(S) AND ADDITIONAL INFORMATION




Displacer OK

Other :_________ N/A P/L No.


Page 1 of 1


MULTIPHASE FLOW METER (MPFM) INSTALLATION Project No. Project Title Facilities Tag Number System Number Sub System Number Type Area Classification 1 2

INFORMATION Flow Range Manufacturer Model Number Serial Number

INSTALLATION CHECK Verify the Material Receiving Report /Fault Report is closed. Verify that the skid is installed at correct location as per Layout Drawings.

OK

N/A

P/L No.

3 4 5 6 7

Verify that all mechanical installations are as per Vendor Drawings. Verify that all electrical installations and hook-up are as per Vendor Drawings. Verify that all instrument hook-ups are as per the Vendor Drawings. Visually inspect equipment for external damage. Verify nameplate tagging against P&ID. Verify that all electrical checks (meggering) are carried out as per check sheet I01-A and 8 check sheets are signed off. Verify that all instrumentation signal checks (continuity checks) are as per check sheet I01-A, 9 I11-B and check sheets are signed off. 10 All the tubings are leak tested as per check sheet I05-A. 11 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 12 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Location Layout 2 Isometric Drawing 3 Instrument Cable Loading Layout 4 Vendor Installation Drawings 5 Vendor Electrical Termination Drawings 6 Vendor Instrumentation Drawings COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PRESSURE VESSEL

M01-A



INSPECTION / TEST Equipment and nameplate comply with Data Sheet

OK

N/A

P/L No.

Nameplate installed correctly Installation and holding down in accordance with drawings and manufacturer’s instructions Sliding feet are free & nut / bolt clearance set to correct gap / space Vessels are level in accordance with manufacturer’s specification Spare nozzles blanked off in accordance with specification Vessel fittings, trims, platforms and access ladders are complete Main piping / vent / drain connections complete and supported correctly Instrument / electrical / tubing connections complete and secured correctly

Instruments, instrument stand pipes installed and drain points tied in as per 10 P&ID Man-way access in accordance with the drawings and man-way cover 11 installation complete with correct gaskets / bolting Vessel internals including filter, demister pads, etc. clean and installed in accordance with latest drawings and specifications. Note 1: Photographs to be taken to show ALL internal installations & vessel / 12 tank cleanliness level. Attach all photographs to this report. Note 2: Vessel internal Inspections to be witnessed by PMT team and signed for below Page 1 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PRESSURE VESSEL M01-A Internal Inspection Witness Discipline Engineer have witnessed the internals of this vessel / tank and all internals are acceptable as per drawings & specifications. Name:_______________ Sign:_______________ Date:__________ Vessel internals including filter, demister pads, etc. clean and installed in accordance with latest drawings and specifications. Note 1: Photographs to be taken to show ALL internal installations & vessel / tank cleanliness level. Attach all photographs to this report. Note 2: Vessel internal Inspections to be witnessed by PMT team and signed for below Internal Inspection Witness Discipline Engineer have witnessed the internals of this vessel / tank and all internals are acceptable as per drawings & specifications. Name:_______________ Sign:_______________ Date:__________ Internal Coating complete and undamaged.Note: Vessel internal coating Inspections to be witnessed by PMT team and signed for belowInternal Inspection Witness:Discipline Engineer have witnessed the internal coating of this vessel / tank and all is acceptable as per drawings & specifications.Name:_______________ Sign:_______________ Date:__________ 14 15 16 17 18 19 20

Provision for removal of internals is acceptable Vessel undamaged and external painting / insulation complete All Valves and Instrumentation visible and accessible Equipment Vendor Release Note signed and all punch list items cleared Earthing Boss fitted and earth strap installed Accessibility for maintenance is acceptable Confirm all vessels weir plates are installed correctly & water side interface filled with fresh water to confirm no leakage across weir plate interface. Note: Vessel weir plate interface water leakage test

Page 2 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PRESSURE VESSEL INSPECTION / TEST Inspections to be witnessed by PMT and signed for below

M01-A OK

N/A

P/L No.

Weir Plate water interface leakage rate Inspection Witness: Discipline Engineer have witnessed the weir plate water interface leakage rate of this vessel / tank and all results are acceptable. Name:_______________ Sign:_______________ Date:__________ 21 Confirm vessel hydro-test completion & test certificates available 22 Check all PSV’s installed, undamaged and seals intact 23 Verify all torque certificates on flanges and man ways COMMENT(S) AND ADDITIONAL INFORMATION Note: It may not be necessary to close the man-way door due to 'B' scope commissioning checks. Verify with Commissioning Team before closing.





Page 3 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A HEAT EXCHANGER (PLATE/S & T) Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2 3 4 5 6 7

M02-A


INSPECTION / TEST Check Equipment and Nameplate comply with Data Sheet Confirm Nameplate installed correctly Installation and Holding Down in accordance with drawings and Manufacturers Instructions. Check Exchanger is level in accordance with Manufacturers specification. Check that Sliding feet are free & plate spray covers installed. Bolting and gasket materials correct. Bolts torque to specification. For plate exchangers, check end plate parallelism and plate compression bolt torque is correct as per vendor's manual.

12

Any spare nozzles blanked off in accordance as per design specification. Heater fittings, Trims, Platforms and access ladders are complete Main piping / Vent / Drain connections complete and supported correctly. Tube sheet and tube internals / externals clean and undamaged. Shell internals / externals clean and undamaged and check that all unit compartment / enclosure are clean and free from debris.

13

Adequate space for removal of tubes and maintenance. Pulling point installed where necessary.

14 15 16 17 18 19 20

Verify that all electrical/instrument signal are completed. Record preservation measures taken in preservation log. Verify earthing boss connection. External painting / Insulation complete as per design. All valves and Instrumentation visible and accessible Check all PSVs installed, undamaged and seals intact Accessibility for Maintenance is acceptable

8 9 10 11

OK N/A P/L No.

Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 21

HEAT EXCHANGER (PLATE/S & T) M02-A Equipment release note signed and punch list agreed, cleared or record. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A HEAT EXCHANGER (PCHE)

M03-A


INFORMATION Location Ref Drawing Inspection Date INSPECTION / TEST

1

Ensure that all construction / installation activities have been completed.

2

Name plate/tag details correct & in accordance with design data sheet. Manufacturers test certificates & FAT documentation available.

3

Check base frame, drip pan, holding down bolts, shims, washers correctly installed in correct location as per design specification.

4

Ensure PCHE is installed correctly as per design.

5

Ensure bolting and gasket materials correct. Bolts torque to specification values. Platform and access ladders are complete. Ensure sliding support are free and slot direction as per design specifications. Verify PCHE externals are clean and undamaged; check that all unit compartment/enclosure are clean and free from debris

6 7 8 9

Ensure PCHE channels where accessible from inlet and outlet nozzles are clean and free from debris.

10

Check PCHE operating pressure in the datasheet. The coolant operating pressure shall higher than both: - the coolant vapour pressure at the maximum exchanger process inlet temperature, to ensure that the coolant does not boil during low flow or turndown conditions - the utility outlet pressure, to ensure that any leaks in the central utility water cooler cannot cause sea water to enter the closed loop.

11 12 13 14

Verify that all electrical/instrument signal are completed. Verify earthing boss connection. Check external painting / Insulation complete as per design. Ensure accessibility and mechanical handling for maintenance is acceptable.

OK

N/A

P/L No.

Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A

15 16 17

HEAT EXCHANGER (PCHE) M03-A SWL of handling facilities correct for equipment. Record any preservation measures taken in the preservation log Ensure PCHE lifting drawing and vendor procedure is available for proper lifting. Check equipment release note have been signed and punch list agreed, cleared or recorded.






Page 2 of 2


1 2 3

4

5 6

7

GEARBOX INSPECTION / TEST Check equipment against the purchase order - contract Check manufacturers' instructions, drawings & certificates Check and inspect - nameplate details against data sheet

M04-A OK N/A

P/L No.

Check and Inspect the following : 4.1 Holding down bolts and jacking screw/side ways and length wise alignment /bolting 4.2 Check against soft foot installation 4.3 Check shim packs (no more than 3 shims per foot) 4.4 Washers installed properly 4.5 Check holding down bolts for proper (Vendor recommended) torque Check shaft alignment - driver side Check shaft alignment - load side Check & inspect sump ie : 7.1 Cleanliness after flushing 7.2 Spray pipes in position and firmly bolted 7.3 Pumps & filters if fitted 7.4 Vent pipe and breather (if applicable) 7.5 Drain connections are clear and drain valve with blind fitted 7.6 Correct grade and level of lube-oil filled 7.7 Check that no oil leaks are existing 7.8 Check gear contact area and notice area percentage 7.9 Check gear back lash and compare with Vendor's recommendation

Page 1 of 2


8

9 10 11

GEARBOX M04-A INSPECTION / TEST OK N/A Check and inspect bearing/shaft vibration and temperature monitoring and protective system: 8.1 Check that all vibration pick-up and signal transmission instrumentation is calibrated and functional checked 8.2 Check that temperature probes and signal transmission instrumentation is calibrated and functional checked

P/L No.

Record preservation measures taken in preservation log. Verify earthing boss connection. Equipment release note signed and punch list agreed, cleared or record. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SAFETY RELIEF VALVE

M05-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2 3 4

5


INSPECTION / TEST Check for physical damage to valve body Check actual guide (adjusting) ring setting Check actual nozzle ring setting Check backpressure bellow (if present) Check condition of the following 5.1 Gag pin 5.2 Lever 5.3 Adjusting bolt 5.4 Adjusting bolt locknut 5.5 Spring washers 5.6 Spindle 5.7 Gasket disc 5.8 Guide ring

OK

N/A

P/L No.






Page 1 of 1

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A Air Dryer Package

M06-A

Project No. Project Title Facilities INFORMATION Tag Number Item Description System Sub System 1 2 3 4

Location Ref Drawing Inspection Date

INSPECTION / TEST Check equipment against the purchase order

OK

N/A

P/L No.

Check manufacturers' instructions, drawings & certificates Check and inspect - nameplate details against data sheet Check and inspect holding down arrangements

5

Check for any damage

6

Check and inspect piping attachments for proper fitting and cleanliness

7 8

Check correct pre-filter is fitted and pre-filter is clean Check dessicant for settlement

9

Check and inspect action of vessel changeover valves

10

Check relief valve settings and sight check the test certificate

11

Check the vessel changeover cycle timer is correctly set

12

Ensure dessicant is in good condition

13

Pressure test plant with air

14

Check calibration of pressure and temperature gauges

15

All flange bolting, torquing and gasket materials correct as per manufacturer’s instructions.

16

Piping /Flexi hoses/ Vent / Drain connections complete, installed and supported correctly, all valves accessible and operable.

17

All instrument /electrical / tubing installed and connected and secured/supported correctly.

Page 1 of 2


18

Air Dryer Package INSPECTION / TEST Verify earthing boss connection.

M06-A OK

19

Verify that any relevant control panels or Junction box are installed correctly. Cables and connection are furnished and completed.

20

Cooler installed and connected up correctly as per design.

21

Adequate access for operations and maintenance and mechanical handling facilities.

22 23

N/A

P/L No.

Record any preservation measures taken in log. Equipment release note signed and all punch items, cleared, agreed or recorded. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. ` INSPECTION TEST RECORD (ITR) - A FILTER/STRAINER

M07-A


5


INSPECTION / TEST Check equipment against the purchase order

7

Check that sufficient space is available to replace filter elements

8

For inline filters, check that filter spool piece can be removed easily

10

Check that filters can be de-pressurized safely and can be drained appropriately Check that reading of differential pressure over filter is possible

11

Check that filter for liquids can bled off any trapped air

12

On & Off Skid Equipment / Piping / Tubing complete and secured correctly.

14

P/L No.

Check and Inspect the Element is : 5.1 As specified 5.2 Acceptable for initial commissioning and clean 5.3 Adequatly constructed for the duty and shall not corrode 5.4 Mesh type and Size is correct Check and inspect that correct type of bolts and gaskets have been used

13

N/A

Check manufacturers' instructions and documentation Check and inspect - nameplate details and attachments Verify strainer is properly installed in accordance with drawings and flow direction

6

9

OK

Piping / Vent / Drain connections, complete, installed and supported correctly. Change-over Valve fitted and operates correctly (duplex types).

Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. ` INSPECTION TEST RECORD (ITR) - A

15

FILTER/STRAINER INSPECTION / TEST Verify earthing boss connection.

M07-A OK N/A P/L No.

16

Adequate access and mechanical handling facilities for maintenance with the correct SWL for equipment.

17

Record any preservation measures taken in log.

18

Equipment release note signed and punch list agreed, cleared or record. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2


Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2 3 4 5 6 7 8

PEDESTAL CRANE

M08-A

INFORMATION


INSPECTION / TEST Check equipment against purchase order Check manufacturers' instructions, drawings and test certificates Check and inspect - nameplate details against data sheets Installation is in accordance with drawings, specs & vendor instruction Check crane boom and third party validation of crane certification Check crane manufacturers test report for any work left to be carried out in the fabrication yard Fabrication NDT records for pedestal verified Structural : 8.1 Check and inspect 'A' frame 8.1.1 General condition 8.1.2 Fitment of pins 8.1.3 Condition of sheaves 8.1.4 Condition of boom stops

OK

N/A

P/L No.

8.2 Check and inspect boom 8.2.1 Fitment of pins 8.2.2 Bolts are tight 8.2.3 Condition of sheaves 8.2.4 Distortion of lacing 8.2.5 Distortion of main members 8.2.6 Welds 8.2.7 Boom rest 8.2.8 Boom maintenance access walkway fitted properly and all lubricating points / maintenance requiring areas are accessible

Page 1 of 6


9

PEDESTAL CRANE INSPECTION / TEST Check and inspect cab: 9.1 Access ladder 9.2 Handrails 9.3 Cab and window wipers 9.4 Cab door 9.5 Drum guards 9.6 Drive guards 9.7 Hook load and radius chart 9.8 Load and radius indicators 9.9 Alarm horn

M08-A

OK

N/A P/L No.

10 Running gear Check & Inspect: 10.1 Boom machinery pins 10.1.1 Boom machinery sheaves 10.1.2 Boom machinery bearings 10.1.3 Boom machinery drum 10.1.4 Main hoist block and hook c/w latch and rope 10.1.5 Whip hoist hook c/w latch and rope connection 10.1.6 Sheave lubrication 10.1.7 Examine test certificates 10.2 Check and inspect ropes : 10.2.1 Boom line test certificate 10.2.2 Boom line condition and lubrication 10.2.3 Boom line spooling and anchorage 10.2.4 Main block line condition and lubrication 10.2.5 Main block line test certificate 10.2.6 Mainblock line spooling and anchorage 10.2.7 Whip line test certificate 10.2.8 Whip line condition and lubrication 10.2.9 Whip line spooling and anchorage

Page 2 of 6

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PEDESTAL CRANE INSPECTION / TEST 10

M08-A OK

N/A

P/L No.

Machinery 10.1 Check and inspect boom hoist : 10.1.1 Bearing condition and lubrication 10.1.2 Gear condition and lubrication 10.1.3 Clutch condition 10.1.4 Brake condition and adjustment 10.1.5 Controls 10.1.6 Indicators 10.1.7 Alarms 10.1.8 High elevation cut-out 10.2 Check and inspect main hoist : 10.2.1 Bearing condition and lubrication 10.2.2 Gear condition and lubrication 10.2.3 Clutch condition 10.2.4 Brake condition and adjustment 10.2.5 Controls 10.2.6 Indicators 10.2.7 Alarms 10.2.8 Hook approach cut-out 10.3 Check and inspect Whip hoist: 10.3.1 Bearing condition and lubrication 10.3.2 Gear condition and lubrication

10_1 10.3.3 Clutch condition 10.3.4 Brake condition and adjustment 10.3.5 Controls 10.3.6 Indicators

Page 3 of 6

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PEDESTAL CRANE 10.3.7 Alarms 10.3.8 Hook approach cut- out

M08-A

10.4 Check and inspect slew gear : 10.4.1 Bearing condition and lubrication 10.4.2 Gear condition and lubrication 10.4.3 Clutch condition 10.4.4 Brake condition and adjustment 10.4.5 Slew gear free from grit and foreign particles 10.4.6 Slewing ring bolt torque checked. State torque 10.4.7 Controls 10.4.8 Indicators 10.5 Check and inspect hydraulic system : 10.5.1 Pumps 10.5.2 Pump alignment 10.5.3 Lines, hoses and connections 10.5.4 Tanks and fittings including tank cleanliness 10.5.5 Valves and relays 10.5.6 Filters 10.5.7 Check that hydraulic system is fitted and connected in accordance with manufactrer's P & ID's and that system has been flushed and cleaned properly

10_2 10.6 Check and inspect electrical equipment :

Page 4 of 6

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PEDESTAL CRANE 10.6.1 Motor holding down bolts are secure 10.6.2 Condition of slip rings 10.6.3 Condition of brushes 10.6.3 Cable connections 10.6.4 Clearance lights 10.6.5 Working lights 10.6.6 Cab lights 10.6.7 Horn 10.6.8 Boom lights 10.6.9 All associated E&I check sheets have been completed

M08-A

10.7 Check and inspect safety equipment : 10.7.1 Radio 10.7.2 Life jacket 10.7.3 Breathing apparatus 10.7.4 Fire extenguisher 10.7.5 Check availability of all special tools as supplied by manufacturer

11 12 13 14 15 16 17

Verify safety catches on main and whip hoist hooks secure and satisfactory. Verify all limit switches set for anti two block devices correct. Verify boom rest alignment and wooden rest protectors. Verify diesel engine re fuelling facilities satisfactory. Verify drivers escape route Verify the radio communications are correctly installed. Verify preservation procedures (if required) are completed and recorded in preservation log.

18 19 20

Verify earthing boss connection. Check that all unit compartment / enclosure are clean and free from debris. Equipment release note signed and punch list agreed, cleared or record. COMMENT(S) AND ADDITIONAL INFORMATION

Page 5 of 6

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PEDESTAL CRANE



M08-A



Page 6 of 6

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MONORAIL / TROLLEY HOIST

M09-A



INSPECTION / TEST Check for exernal damage Confirm monorail beam location is correct Ensure surrounding area is clean and free from debris MONORAIL Name plate/tag details correct & in accordance with design data sheet. Manufacturers test certificates & FAT documentation available.

6

Hoist beam safe work load marking (SWL) clear and visible. Installation and holding down secure / storage system correct in accordance with design and manufacture instructions and location correct.

7

Verify instrument / Electrical / Tubing & control system installed and secured correctly.

8

HOIST Name plate/tag details correct & in accordance with design data sheet. Manufacturers test certificates & FAT documentation available requirements.

9 10 11 12 13 14

Length of operating chain / load chain correct. Swivel hook and sheaves rotate freely and lubricated. Lubrication oils/greases completed, record lube type(s). Paint working complete and satisfactory. Transverse condition satisfactory, no obstruction. Trolley condition, secure to correct width of beam, free moving.

5

OK

N/A

P/L No.

Page 1 of 2


15 16 17 18 19 20 21 22

MONORAIL / TROLLEY HOIST M09-A INSPECTION / TEST OK Hoist condition, satisfactory, operation freely. Hook safety catch installed and operating satisfactory. Verify earthing boss connection. Maintenance access satisfactory/storage location satisfactory. Verify preservation have been carried out and record in preservation log. Equipment release note signed and punch list agreed, cleared or record. WINCH Name plate/tag details correct & in accordance with design data sheet. Manufacturers test certificates & FAT documentation available.

N/A

P/L No.

Length of operating chain / load chain/ wire rope correct. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A GANTRY / BRIDGE CRANE

M10-A

Project No. Project Title Facilities INFORMATION Tag Number Item Description System Sub System 1 2 3 4 5 6 7


INSPECTION / TEST Check manufacturer's instruction, ensure manual part list are available Check and measure gauge distance of gantry girders and ensure that it is within manufacturer's tolerance

9

Check that the number and location of supports for gantry girders are as per design drawing

12 13 14 15 16

P/L No.

Check gantry drive gear box lubrication, top-up or refill Check and lubricate open trolley gear drive of gantry Check trolley gearbox lubrication, top-up or replace Check and lubricate trolley drive open gear Check that limit switch and mechanical stopper are installed at both ends of the gantry girder

11

N/A

Visual check of any damage of gantry and trolley

8

10

OK

Check and lubricate hoisting wire rope Check and confirm rope end anchorage is correct Check that when the hook is at its lowest position, at least 2 wraps of wire rope on the hoist drum Check block and hook for any distortion Check trolley condition, secure to correct width of beam, free moving. Verify earthing boss connection. Equipment release note signed and punchlist agreed, cleared or record.

Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A GANTRY / BRIDGE CRANE M10-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FLARE

M11-A



1

INSPECTION / TEST Check name plate/tag details correct & in accordance with design data sheet. Manufacturers test certificates & FAT documentation available.

2

Base frame, drip pan, holding down bolts, shims, washers correctly installed in correct location as per design specification.

3

Confirm flare and flare tip pilot assembly has been installed and made secure to manufacturer's instructions and as per design and is free of damage with no outstanding punch list.

4

Confirm flare tip to flare pipework has been flushed, tested and correctly installed, with bolts tightened in accordance to design.

5 6 7 8

9

OK

N/A

P/L No.

Confirm the wind shield is correctly installed as per design. Confirm the flare ignition cable and unit is installed as per design. Confirm the maintenance access for flare tip removal is adequate, also platform and handrails installed as per design. Confirm provision has been made for fitting flare tip removal equipment. FLARE TOWER Confirm the flare tower structure is located and orientated correctly as per the design, with the access ladder secure and damage free, and the structure is coated to project specifications.

10

Confirm the flare tower piping is fully installed / supported and conforms to project design and specification.

11 12

Confirm the cable is installed as per design and project specification. Confirm the navigation and lighting as applicable, is installed as per design.

Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FLARE

13


M11-A INSPECTION / TEST OK Confirm the flare ignition panel/equipment installed and connected as per design. COMMENT(S) AND ADDITIONAL INFORMATION



N/A

P/L No.


Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A LIFEBOAT & DAVIT

M12-A


1 2 3 4 5 6 7 1 2 3 1 2 3 4 5


INSPECTION / TEST Installation Check for external damage Confirm painting is per project specification. Check details furnished on nameplate is correct as well the equipment Tag Number Confirm all preservation for transportation are removed Confirm that final skid levelling, location and orientation is verified by QC inspector (attach QC report)

OK N/A

P/L No.

Verify full inventory is carried out against vendor list and witnessed by client authority Ensure the surrounding area is clean and free from debris Davit Inspection The winch,motor and rope is installed and greased The panel for winch motor and battery charger socket is installed The servicing platform on davit is installed complete with guard rail Lifeboat Inspection Confirm boat orientation is installed correctly The secure rope should be attached to the life boat all the time to prevent any accidental release The firewater ring line at the boat perimeter is installed All the window is not damaged The safety items inside the lifeboat are checked against the list

Page 1 of 2


6

LIFEBOAT & DAVIT INSPECTION / TEST The compressed air tank inside the boat are installed

M12-A OK

8

The seat harness for lifeboat passenger are comply with the numbers of boat passenger When suspended, the boat should be free and not touching the platform edge

9

The propeller blade is not damage

10

The lifeboat body should be provided with reflective sticker

11

Preserve sensitive item on the boat e.g. firewater nozzle , from damage

12

Record into mechanical punchlist for any incompleteness and deviation found during inspection

7

N/A

P/L No.






Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DIESEL GENERATOR

M13-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2 3

4

5


INSPECTION / TEST Check equipment against purchase order - contract Check manufacturers' instructions, drawings and certificates

N/A

P/L No.

Check and inspect - nameplate details against data Check and Inspect the following : 4.1 Chocks if fitted 4.2 Shims 4.3 Check foundation condition, and that skid is installed level (use spirit level) and holding down bolts are installed properly with appropriate torque Check barring facilities. Bar engine over

6

Check & inspect the coupling alignment and if required check that the coupling is greased appropriately

7

Check coupling guard for giving sufficient protection (i.e moving parts cannot be reached and checked guard materials (non-sparking)

8

OK

Check & inspect sump & crankcase for : 8.1 Cleanliness 8.2 Breather or vent pipe 8.3 Dipstick arrangement 8.4 Crankshaft deflections

Page 1 of 4


9

10 11 12 13 14 15 16 17 18 19 20

DIESEL GENERATOR INSPECTION / TEST Check and inspect the fuel tank for : 9.1 Cleanliness 9.2 Overflow arrangement 9.3 Level gauges or sight glasses 9.4 Remote operated shut-off valve 9.5 Flame Arrestor 9.6 M 48-A for tank is complete

M13-A P/L No.

Fuel supply & return lines including connections to engine/tank checked Fuel priming system on engine checked Check correct lube-oil temporary filters have been fitted. Check drain lines Lub oil system filled with correct type & grade of oil Check all cooling water lines have been flushed and all connections are tight Check and inspect all connections to coolers are correct and tight Engine radiator & cooling jackets are flushed clean Recommended corrosion inhibitor is added to the cooling system Test by hand using a bar the big-end and cross head bearings for axial movement Check and inspect: 20.1 Air lines between compressor, starting air vessel and engine 20.2 Batteries & connections to starter motor Check and inspect the air inlet filters and auxiliary equipment

22

Check & inspect the exhaust system c/w insulation & fixing arrangement 21.1 If fitted, check free running of turbo charger and leak free connections of lube oil lines

24

N/A

Checkfuel oil & lube oil lines have been flushed clean

21

23

OK

Check and inspect: 23.1 Starting air valves 23.2 Exhaust valves 23.3 Fuel valves 23.4 Cylinder lubricators can be manually operated Check direction of rotation and that an indicator is available for rotation direction Page 2 of 4


25

DIESEL GENERATOR M13-A Check that all safety and engine protective devices are fitted and functionally checked

27

Check that equipment and skid earthing is installed in accordance with specification CHECK AND CONFIRM EXTERNAL EQUIPMENT ITEM(S) INSTALLATION FOR GENERATOR Check that all-internal and external hatches, doors, platforms and ladders complete, are not obstructed and correct to vendor drawings.

28

Check all painting, trace heating and insulation has been completed and is correct to specification and detailed drawings.

26

29

30

Verify that vents and drains system piping have been piped up correctly using correct bolting and gaskets and that they are lead to correct location e.g. closed drains etc. Check that both Thermal and Acoustic insulation requirements for the enclosure and all ancillary items for Diesel Generator unit is correct and has been installed as per Vendors drawings.

31

Confirm all safety guards are fitted.

32

Equipment release note signed and all punch list items cleared. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 4

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MIXERS & AGITATORS

M14-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2 3 4 5 6


INSPECTION / TEST Check equipment against purchase order - contract Check Motor and Agitator name plate/tag details correct & in accordance with design data sheet. Manufacturers test certificates & FAT documentation available. Check base frame, drip pan, holding down bolts, shims, washers correctly installed in correct location as per design specification.

9 10

If pulleys are fitted -check correctly aligned. Record belt tension, verify anti static type belt(s) used.

11

Where shaft couplings are fitted, check shaft alignment and record the coupling alignment final value.

8

13

Ensure coupling guard is correctly fitted and non spark material and secured. Confirm all associated pipe work including flexible pipe are connected correctly, aligned & are damaged free.

14

Verify that all electrical/instrument signal are completed.

12

N/A

P/L No.

Check equipment supply is correct as per layout drawing, clean and undamaged. Verify Impeller is correctly installed. Check Impeller securely fastened to shaft, shaft bearing (s) correctly aligned and impeller freely rotates. Check all holding down bolts are fitted and tight. Check shaft seal installed corrected correctly, any flushing system correctly installed. If gearbox is fitted, check preservation oil removed and filled with correct grade and amount of oil (Record type / grade / quantity).

7

OK

Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MIXERS & AGITATORS INSPECTION / TEST 15 16 17 18 19

M14-A OK

N/A

P/L No.

Check all bearings lubricated in accordance with vendor recommendations. Record lubricant used. Complete preservation requirements and record in preservation log. Check maintenance accessibility is adequate and SWL of any mechanical maintenance equipment is satisfactory. Verify earthing boss connection. Check equipment release note is available and all punch list items cleared. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ELECTRO-CHLORINATION UNIT

M15-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2


INSPECTION / TEST Check equipment against purchase order - contract Check name plate details if correct & in accordance with design data sheet. Manufacturers test certificates & FAT documentation available.

4

Check skid equipment, installation, base frame, drip pan, holding down bolts, shims, washers correctly installed in correct location as per design specification. Verify if all transportation supports and aids removed, externally & internally. Skids undamaged, clean and clear of debris.

5

Ensure that all the pipeworks connect to the equipment is correctly installed and bolted in accordance to design.

3

6 7

8

9 10

OK

N/A

P/L No.

Instrument / Electrical / Tubing connections installed and secured correctly. Unit fittings, trims, platforms and access ladders are complete. INDIVIDUAL COMPONENTS INSTALLED IN ACCORDANCE WITH VENDOR INSTRUCTIONS FOR :8.1 Sea water pre-filtering 8.2 Hypochlorite generator 8.3 Hydrogen degassing tank and also vented to safe place 8.4 Tank blower is installed 8.5 Transformer/Rectifier is installed and has no oil leak 8.6 Local control panel is not damage 8.7 Hypochlorite distribution pumps installed 8.8 All valves inside the skid are installed and operable Verify that the unit is clean and undamaged Verify earthing boss connection.

Page 1 of 2


11

ELECTRO-CHLORINATION UNIT INSPECTION / TEST Equipment Release Note signed and all punch list items cleared.

M15-A OK

N/A

P/L No.






Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SANITARY TREATMENT UNIT

M16-A



1

INSPECTION / TEST Check equipment against purchase order - contract.

2

Check name plate details are correct & in accordance with design data sheet.

3

Verify skid equipment, installation, base frame, drip pan, holding down bolts, shims, washers correctly installed in correct location as per design specification.

5

All transportation supports and aids removed, externally & internally. Skids undamaged, clean and clear of debris.

6


7

Instrument / Electrical / Tubing connections complete and secured correctly (Refer to E01-A and I01-A).

9

N/A

P/L No.

Check manufacturers test certificates & FAT documentation available

4

8

OK

Unit fittings, trims, flat forms and access ladders are complete. INDIVIDUAL COMPONNENTS INSTALLED IN ACCORDANCE WITH VENDOR INSTRUCTION FOR :9.1 Surge tank 9.2 Macerator Pumps 9.3 Electrolytic Bookcell 9.4 Effluent Tank 9.5 Electrolytic Bookcell. 9.6 Effluent Tank 9.7 Hydraulic macerator (off skid). 9.8 Positive vent ejector (off skid) 9.9 Control panel

Page 1 of 2


10 11 12 13 14

SANITARY TREATMENT UNIT INSPECTION / TEST Check the unit is clean and undamage Accessibility for maintenance in acceptable Verify earthing boss connection. Preservation procedures completed and recorded in preservation log. Equipment Release Note signed and all punch list items cleared.

M16-A OK

N/A

P/L No.






Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TEG REGENERATION

M17-A



INSPECTION / TEST Verify to ensure that all construction / installation activities have been completed. This ITR to be used after TEG unit is re-assembled at final location. Name plate details correct & in accordance with design data sheet. Manufacturers test certificates & FAT documentation available.

4

Skid equipment, installation, base frame, drip pan, holding down bolts, shims, washers correctly installed in correct location as per design specification. Verify that all frame & any sub frames re-instated, installed correctly to design and also any lifting devices removed.

5

All transportation supports and aids removed, externally & internally. Skids undamaged, clean and clear of debris.

6


7 8

Instrument / Electrical / Tubing connections complete and secured correctly. Unit Fittings, Trims, Platforms and Access ladders are complete. INDIVIDUAL COMPONENTS INSTALLED IN ACCORDANCE WITH VENDOR INSTRUCTION AND ALIGNEMENT CHECKS COMPLETED FOR :-

9 10 11

GLYCOL STILL COLUMN. GLYCOL STRIPPING COLUMN. GLYCOL REFLUX CONDENSER.

OK

N/A

P/L No.

Page 1 of 3


12 13 14 15 16 17 18 19 20 21 22 23 24 25

TEG REGENERATION INSPECTION / TEST GLYCOL - GLYCOL HEAT EXCHANGER (COLD). GLYCOL - GLYCOL HEAT EXCHANGER (HOT). GLYCOL STILL COLUMN VENT CONDENSER. GLYCOL REBOILER HEAT EXCHANGER.

M17-A OK

GLYCOL SOCK FILTERS A & B. GLYCOL CARBON FILTER. ANTIFOAM CHEMICAL STORAGE TANK.

GLYCOL FLASH VESSEL. GLYCOL REBOILER. GLYCOL SURGE VESSEL. All vessels/tanks and filters to be checked to ensure internals are correctly fitted and unit is clean inside. Joint inspection required prior to boxing up vessels/tanks & filters.

28 29

Unit clean, paint and insulation satisfactory and undamaged.

30 31 32 33 34

P/L No.

GLYCOL PUMPS - A,B,C & D. pH NEUTRALIZER INJECTION PUMPS A & B. ANTIFOAM CHEMICAL INJECTION PUMPS A& B.

Vent from separators vented to safe non hazardous area. Bolting / Gaskets correct materials. Bolts torqued to correct values. PSVs installed, undamaged and seals intact. Attach copies of all calibration certificates, showing set points and calibration dates.

26 27

N/A

Accessibility for maintenance is acceptable. SWL of lifting device satisfactory. Verify earthing boss connection. Equipment Release Note signed and all punch list items cleared. Preservation procedures carried out and recorded in preservation log. Equipment release note signed and punch list agreed, cleared or record. COMMENT(S) AND ADDITIONAL INFORMATION

Page 2 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TEG REGENERATION



M17-A



Page 3 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SUBMERSIBLE PUMP

M18-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2 3 4 5

6

7


INSPECTION / TEST Verify compliance with purchase order Check manufacturers' instructions, drawings and certificates

OK

N/A

P/L No.

Check and inspect nameplate details (against Data sheets in Dossier) Check if support structure is rigid, level and of adequate strength Check access is sufficient to both removal & reinstallation of pump unit Check overhead lifting device : 6.1 Sufficient head room to remove pump 6,2 S.W.L. of device is adequate to lift unit 6.3 Condition of block and tackle Check pump caisson for : 7.1 Adequate depth and diameter to accept pump 7.2 Caisson is straight and vertical 7.3 No obstructions to snag pump 7.4 Caisson is free from mud, sand and debris

8

Check that pump and motor is free and can be rotated by hand.

9

Check discharge elbow/nozzle installed in accordance with design. Check for misalignment of pipe / pump flanges, no imposed load on pump rising column.

10

Prior to installation of pump/motor check that electric cables are long enough and without any damage

Page 1 of 3


11

SUBMERSIBLE PUMP M18-A INSPECTION / TEST OK Check that cable termination to motor and glands are water and pressure tight and are without any damage

13

Check that electric cables to motor do not foul pipes or rub against rough or sharp edges. Cable is free from external applied loads and properly secured with clamps against pump casing as recommended by the vendor installation manual Check that motor is fully filled with either inhibited distilated water or mineral oil as appropriate and that mechanical seal is undamaged and leak free

14

Teaded joints on rotating element are tightened to the correct torque. Serious damage is possible due to reaction torque during start/stopping

15

Check condition of suction mesh screen and its fixing arrangement

16

Check and inspect chemical dosing line to pump

12

17

18

N/A

P/L No.

Check that pump & riser pipe are installed satisfactorily inside caisson with adequate pump suction to caisson clearance and all riser center liners fitted properly Check all pump and risers joints have correct gasket/jointing compund fitted and all bolts, nuts and washers are of correct material & securely tighten (torque to vendor's specification)

19

Air release valve, non return valve and PSV are fitted and functional checked

20

Motor cable is securely terminated in platform junction box with sufficient spare length to allow installation flexibility

21

Electrical supply loop incorporates an ampere meter indicating normal amps (blue) and motor deteriorating amps (red)

22

With the following information on the overall length of complete pump/ casing assembly and overall length of pump caisson, check that the pump suction submerged depth versus the lowest astronomical tide gives as a minimum the required NPSR + 2 meters

23

Equipment release note signed and punch list agreed, cleared or record. COMMENT(S) AND ADDITIONAL INFORMATION

Page 2 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SUBMERSIBLE PUMP



M18-A



Page 3 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PISTON DISPLACEMENT PUMP

M19-A


6

7

8

9 10 11


INSPECTION / TEST Check if compliance with purchase order Check manufacturer's instruction, drawings and certificates

OK

N/A

P/L No.

Check and inspect nameplate details (against data sheets in dossier) Check base frame holding down bolts/ shims/ washers installed Check support structure is rigid, level & of adequate strength Examine suction and discharge pipework: 6.1 Freedom from strain 6.2 Adequate supports and pipe anchors at suction & discharge piping 6.3 location of pulsation dampers 6.4 Expansion allowance Suction line and strainer has been flushed & flushing certificate reviewed 7.1 Safety relief valve outlet piping back to suction has been flushed Check pulsation dampers: 8.1 Pressure rating 8.2 Pre-charge pressure 8.3 Pre-charge medium Check pump lubrication Check discharge relief valve and review test certificate Check operation of mechanical lubricator and oil fill with appropriate type and level

Page 1 of 3


12

13

14

15 16 17 18 19 20

PISTON DISPLACEMENT PUMP INSPECTION / TEST Check pump crankcase breather is clear

M19-A OK

N/A

P/L No.

Check and inspect pump casing: 12.1 Correct type & number of packing rings 12.2 Correct location of lantern ring (if fitted) 12.3 Stuffing box gland follower is square with box face 12.4 Check gland lubrication /sealing fluid piping arrangement (if applicable) 12.5 Check all suction and discharge valves are moving free and holding pressure without leakage. Check that there is no corrosion evidence on valve assemblies 12.6 Valves and valve head are properly installed with correct gaskets and holding down bolts are tightened to vendor recommended torque value 12.7 Check that pump casing drain is clean and free of any obstruction 12.8 Check that Piston rod cover plate is in place and properly secured 12.9 Ensure Crankshaft end play is checked and conform to vendor's specification 12.10 Crankshaft main bearing and cross head free play is in accordance with vendor recommendation. All bearings are clean and free from corrosion signs Check the following (if applicable):14.1 Pump coupling alignment 14.2 V-belt pulley alignment and tension14.3 Coupling guard

Ensure all rotating parts are lubricated before intial start up. These are to be in accordance with manufacturer's instruction Verify correct direction of rotation during test Verify that all electrical/instrument signal are completed. Verify earthing boss connection. Record preservation measures taken in preservation log. Equipment release note signed and punch list agreed, cleared or recorded. COMMENT(S) AND ADDITIONAL INFORMATION

Page 2 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PISTON DISPLACEMENT PUMP



M19-A



Page 3 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A AIR COMPRESSOR

M20-A


INSPECTION / TEST Check equipment against the purchase order Check manufacturers' instructions, drawings & certificates

4

5

If V-belt driven, check & inspect: 5.1 Pulley alignment 5.2 V-belt tension 5.3 Pulley & Belt condition 5.4 Safety guard

6

For direct coupling, check & inspect: 6.1 Coupling alignment 6.2 Coupling bolt condition 6.3 Safety guard

8

OK

N/A

P/L No.

Check and inspect - nameplate details comply with data sheet Check and inspect: 4.1 Holding down bolts 4.2 Shims 4.3 Washers

7


Check & inspect compressor bearing 7.1 Cleanliness 7.2 Lube oil connection are clean and properly fitted 7.3 Correct lubrication 7.4 Lubrication rings are immersed in oil (if fitted) Check & inspect rotor timing gears: 8.1 Free from damage 8.2 screw mesh correctly and smoothly 8.3 Lube oil connection are clean and properly fitted

Page 1 of 4


9

10

11 12 13 14 15

16

17 18 19 20

AIR COMPRESSOR INSPECTION / TEST Check and inspect sump: 9.1 Cleanliness 9.2 Fastenenrs and locking arrangement are correct 9.3 Sump breather /vent pipe or safety valve is fitted 9.4 Drainage arrangements are adequate 9.5 Oil level

M20-A OK

N/A

P/L No.

Check and inspect air line system: 10.1 Discharge air line is adequately supported and fitted to compressor without imposing any strain to the equipment 10.2 Inlet filter is correctly located and the element is clean 10.3 The air inlet is taken from a classified safe area 10.4 Check the operation of the air filter differential pressure indicator Check safety relief valves and review the test certificate Check and inspect the compressor capacity control system. This shall be in accordance with manufacturer's instruction, i.e., suction throttling arrangement, variable speed, etc. If water cooled, complete checklist for Heat Exchanger If package includes an air dryer, complete check list for Air Dryer If fitted, check and inspect the prefilter and after filter elements for damage and cleanliness Ensure the relevant electrical & instrument check lists have been completed for all electrical and instrument within the package 16.1 Check the unoading/loading pressure are set correctly in accordance with system specification (during the test run) 16.2 Check that no abnormalities occured during test run, i.e., noise, vibration, temperature Access clearance around skid/unit adequate for personnel and operational activities. SWL marked clearly on any mechanical handling device with applicable certification available. Check that compressor and skid earthing is fitted in accordance with specification Record preservation measures taken in preservation log. Equipment release note signed and punch list agreed, cleared or record.

Page 2 of 4

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A AIR COMPRESSOR

M20-A

Note: Verify correct direction of rotation during testing COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 4

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DIESEL ENGINE

M21-A



1 2

INSPECTION / TEST Check equipment against purchase order - contract Check manufacturers' instructions, drawings and certificates

3

Check and inspect - nameplate details against data

4

Check and Inspect the following : 4.1 Chocks if fitted 4.2 Shims 4.3 Check foundation condition, and that skid is installed level (use spirit level) and holding down bolts are installed properly with appropriate torque

5 6

Check barring facilities. Bar engine over Check & inspect the coupling alignment and if required check that the coupling is greased appropriately

7

Check coupling guard for giving sufficient protection (i.e moving parts cannot be reached and checked guard materials (non-sparking)

8

Check & inspect sump & crankcase for : 8.1 Cleanliness 8.2 Breather or vent pipe 8.3 Dipstick arrangement 8.4 Crankshaft deflections

OK

N/A

P/L No.

Page 1 of 3


9

DIESEL ENGINE INSPECTION / TEST Check and inspect the fuel tank for : 9.1 Cleanliness 9.2 Overflow arrangement 9.3 Level gauges or sight glasses 9.4 Remote operated shut-off valve 9.5 Flame Arrestor 9.6 M 48-A for tank is complete

M21-A

10 11

Checkfuel oil & lube oil lines have been flushed clean Fuel supply & return lines including connections to engine/tank checked

12 13

Fuel priming system on engine checked Check correct lube-oil temporary filters have been fitted. Check drain lines

14 15 16 17

Lub oil system filled with correct type & grade of oil Check all cooling water lines have been flushed and all connections are tight Check and inspect all connections to coolers are correct and tight Engine radiator & cooling jackets are flushed clean

18 19

Recommended corrosion inhibitor is added to the cooling system Test by hand using a bar the big-end and cross head bearings for axial movement Check and inspect: 20.1 Air lines between compressor, starting air vessel and engine 20.2 Batteries & connections to starter motor

20

21 22

Check and inspect the air inlet filters and auxiliary equipment Check & inspect the exhaust system c/w insulation & fixing arrangement 21.1 If fitted, check free running of turbo charger and leak free connections of lube oil lines

23

Check and inspect: 23.1 Starting air valves 23.2 Exhaust valves 23.3 Fuel valves 23.4 Cylinder lubricators can be manually operated

24

Check direction of rotation and that an indicator is available for rotation direction

OK

N/A

P/L No.

Page 2 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 25 26

DIESEL ENGINE M21-A Check that all safety and engine protective devices are fitted and functionally checked

27

Check that equipment and skid earthing is installed in accordance with specification Confirm all safety guards are fitted.

28

Equipment release note signed and all punch list items cleared. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A GAS TURBINE

M22-A



INSPECTION / TEST Check equipment against the purchase order 1 FOUNDATION Check that turbine base mounts are in correct orientation and free to move, 2 lubricate as necessary

OK

N/A

P/L No.

Check Base Frame is undistorted. Check with piano wire along length and width COMBUSTION AIR INTAKE 4 Intake filter correctly supported and installed as per design. 5 Intake ducting correctly installed as per design. 6 Air Intake Silencer correctly supported and installed as per design. GAS TURBINE EXHAUST 7 Exhaust silencer correctly installed and supported as per design. ENCLOSURE VENTILATION AIR INTAKE 8 Intake filter correctly supported and installed as per design. 9 Intake ducting correctly installed as per design. 10 Air Intake Silencer correctly supported and installed 11 Confirm Fire damper correctly installed. ENCLOSURE VENTILATION AIR OUTLET 12 Check Outlet ducting correctly installed 13 Check Outlet Silencer correctly supported and installed 14 Check Fire damper correctly installed. 15 Ventilation Air Outlet Fans correctly installed 3

Page 1 of 4

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A GAS TURBINE M22-A INSPECTION / TEST OK N/A GAS TURBINE ENCLOSURES 16 Enclosure correctly assembled, all penetrations sealed. Perform smoke/air leakage test on enclosure under supervision of Suppliers Representative Leakage rate acceptable to Suppliers representative. 17 Record leakage rate:

P/L No.

LUBE OIL BREATHER SYSTEM 18 Lube Oil Breather Coalescer and supply pipe work correctly installed 19 Lube Oil Breather Coalescer internals clean and elements installed 20 Lube Oil Breather Coalescer drain pipe work correctly installed Lube Oil Breather pipe work downstream of Coalescer correctly installed & 21 supported LUBE OIL SYSTEM 22 Lube Oil Reservoir internally is clean 23 Lube Oil Reservoir instrumentation has been correctly installed 24 Verify suction strainer on Main Lube Oil Pump is correct and installed. 25 Verify suction strainer on Auxiliary Lube Oil Pump is correct and installed. 26 Verify suction strainer on Emergency Lube Oil Pump correct and installed 27 Verify Lube Oil Pumps / Motor alignments, complete. 28 Cooling water supply and return pipe work to Lube Oil Cooler is correctly installed Ensure Lube Oil Filter elements installed. Verify filter change over 29 mechanism operates correctly. 30 31 32 33

Ensure Emergency Lube Oil Filter element installed. Ensure Hydraulic Oil Filter element installed. Ensure Lube Oil Reservoir strainer installed. Check Lube Oil Reservoir.

Page 2 of 4

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A GAS TURBINE INSPECTION / TEST DIESEL FUEL SYSTEM (IF DUAL FUEL)

M22-A OK N/A

P/L No.

Ensure Diesel Fuel Filter elements installed. Verify filter change over mechanism operates correctly. GAS FUEL SYSTEM 35 Ensure Filter element is installed. GEARBOX: Perform checksheet for Gearbox as applicable in presence of Vendor 36 Check bearing shell half in upper casing for damage caused by debris 37 Check thrust bearing faces for damage caused by debris Under the supervision of the Vendor's Representative, align the gearbox with the gas turbine. Use only stainless shims up to a maximum thickness of 38 5mm. Use machined packing pieces as necessary. Complete appropriate alignment check sheet. Under the supervision of the Vendor Representative, align the alternator with the gearbox. Use only stainless shims up to a maximum thickness of 39 5mm. Use machined packing pieces as necessary. Complete appropriate alignment check sheet. WATER WASH SKID 40 Verify Water Wash Pumps / Motor alignments and complete for each pump. 41 Check internal cleanliness of Water Wash Water Tank 42 Check internal cleanliness of Wash Additive Tank 43 Check completeness of Wash Additive Pump MISCELLANEOUS ADDITIONAL CHECKS 44 Confirm all earthing bosses fitted and earth straps installed Confirm all enclosure doors operate correctly & any Castell Key 45 arrangements function correctly, & keys are available 34

46

Confirm correct installation of package Fire Protection system

Page 3 of 4


47

GAS TURBINE M22-A INSPECTION / TEST OK N/A Check all PSVs installed, undamaged and seals intact, complete appropriate check sheet for PSVs

P/L No.






Page 4 of 4

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CENTRIFUGAL COMPRESSOR Project No. Project Title Facilities Tag Number Item Description System Sub System 1

M23-A


INSPECTION / TEST Confirm that Compressor Package Unit has been installed in correct position according to vendor instructions, is undamaged with skid location and orientation correct.

2

Check all nameplate details correct, it is securely attached, readable and not obscured and data conforms to information listed on this form

3

Check that a P.O. release note is available with a final agreed vendor punchlist from FAT if applicable

4

Check that compressor jacking-screws have been installed to enable later alignment of Compressor to its Drive unit

5

Confirm that correct type, material grade and thickness of shims at the Compressor feet have been used.

6

Confirm that Compressor casing / body holding-down bolts are of the correct type and grade and are tensioned correctly

7

Check that provision has been made at Compressor support feet for future dowelling (or mechanical locking) of casing in position following completion of hot-running alignment

8

Check alignment of both the suction and discharge pipework connections to the Compressor casing flanges and ensure there is no misalignment on trial assembly

9

Check and ensure that all suction and discharge lines are cleaned to required piping specification. Note; Compressor suction lines may require chemical cleaning / pickling (or mechanical cleaning) to achieve required cleanliness levels.

10

Confirm that the correct type and grade flange gasket material has been used at each Compressor flange connection location

11

Check all lube-oil pipework connections to compressor bearings.

OK

N/A

P/L No.

Page 1 of 5


CENTRIFUGAL COMPRESSOR M23-A Check that Lube-oil filters are correct for system, are installed and clean Check and inspect the Compressor bearings are clean, with no sign of damage or surface markings and are correctly re-assembled.

14

Check that sight-glasses and/or flow-indicators are installed on the Compressor lubrication circuit lines as required by detail drawings

15

Check Compressor rotor end to end float and also correct setting of the Compressor Thrust bearing (if applicable). Ensure that all thrust washers and bearings are clean and installed

16

Check that Compressor mechanical sealing system is correctly installed to vendors recommendation ensuring that pristine ‘clean-conditions” exist at all times due to extremely delicate nature of the seal parts.

17

For Dry-gas type sealing arrangement where applicable, ensure correct assembly and ‘cold-setting’ adjustment has been made to ensure correct sealface lift-off occurs during start-up and running of compressor. IMPORTANT: Ensure that this seal setting is correctly ‘locked’ as per seal manufacturer’s detailed instructions.

18

Check the buffer-gas supply system and lines for the Dry-gas seals are clean and clear and correctly installed. Blow through all lines prior to connecting up to each compressor seal housing.

19

For compressors with seal-oil supply arrangement (if applicable) check that all seal-oil supply and return pipework is correctly installed and internally clean. Blow through all lines prior to connecting pipework up to each compressor seal housing.

20

Check all associated Valves and Instrumentation are visible and accessible for operation and maintenance Check all sprinkler heads, rosettes and nozzles removed and plugged.

21 22 23

Confirm that System (Test Pack) is ready to be flushed and tested Confirm that all Compressor casing earthing arrangements are installed to specifications and that earth boss and earth-strap(s) is installed

24

Check and confirm that any Compressor casing vent(s) and drain(s) are installed and piped away to correct locations in accordance with P&ID’s and assembly / installation drawings

25

Confirm that Compressor Instrument / Electrical /Tubing connections are installed as per P&ID and are complete and secured correctly

Page 2 of 5


CENTRIFUGAL COMPRESSOR M23-A Confirm that all Compressor isolation valves, in-line strainers / filters and sight glasses etc are all installed as per manufacture’s drawings

27

Ensure that coupling alignment check sheet is completed for the driver to Compressor unit, taking into account any thermal growth / offsets as per designed specification or manufacturer’s instructions / recommendations

28

During Compressor alignment checks ensure there is no imposed loading from suction or discharge pipework onto Compressor casing flanges Equipment release note signed and all punch list items cleared.

29


COMPLETED BY Designation Company Name Signature Date

Contractor Representative



Page 3 of 5

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A RECIPROCATING COMPRESSOR Project No. Project Title Facilities Tag Number Item Description System Sub System 1

M24-A


INSPECTION / TEST Confirm that Compressor Package Unit has been installed in correct position according to vendor instructions, is undamaged with skid location and orientation correct

2

Check all nameplate details correct, it is securely attached, readable and not obscured and data conforms to information listed on this form.

3


4

Check that compressor jacking-screws have been installed to enable later alignment of Compressor to its Drive unit.

5

Confirm that correct type, material grade and thickness of shims at the Compressor feet have been used as recommended by vendor

6

Confirm that Compressor casing / body holding-down bolts are of the correct type and grade and are tensioned correctly

7

Check that provision has been made at Compressor support feet for future dowelling (or mechanical locking) of casing in position following completion of hot-running alignment checks in commissioning phase

8

Check alignment of suction and discharge pipework connections to the Compressor casing flanges and ensure no misalignment on trial assembly

9

Check and ensure that all suction and discharge lines are cleaned to required piping specification. Note: Compressor suction lines may require chemical cleaning / pickling (or mechanical cleaning) to achieve required cleanliness levels Check and confirm that suction and discharge pulsation dampeners where installed have been cleaned and inspected

10

OK

N/A

P/L No.

Page 1 of 3


RECIPROCATING COMPRESSOR M24-A Check that for Nitrogen Filled Pulsation dampeners (if installed) are correctly pre-charged to the required internal pressure as specified on data sheets. Note use only correct purity of Nitrogen to charge and ensure that correct pre-charge unit is available and used for this task.

12 13 14

Check all lube-oil pipework connections to compressor bearings Check that Lube-oil filters are correct for system, are installed and clean Check Compressor crankcase and ensure that all bearings, crank end and piston end are installed correctly with correct clearances and that all connecting-rod bolts are tightened and torqued correctly

15 16

Check piston head end-clearances are correct to specification Check that all suction and discharge valves are correctly installed and confirm that valve clearances are set correctly and shimmed as required

17

Check where applicable that rod packing and associated bushing/housings are installed correctly, and have been tightened to vendor’s recommendations

18

Check where applicable that “Rider Band” wear-plates are installed correctly and associated lubrication facilities (spray pipes/nozzles) are connected.

19

Check and inspect the Compressor Crankcase assembly is clean, with no sign of damage to internal paint surfaces if applicable, and that all covers are correctly re-assembled after final inspection.

20

Check that sight-glasses and/or flow-indicators are installed on the Compressor lubrication circuit lines as required by detail drawings

21

For compressors with seal-oil supply arrangement (if applicable) check that all seal-oil supply and return pipework is correctly installed and internally clean. Blow through all lines prior to connecting pipework up to each compressor seal housing

22

Check all associated external Valves and Instrumentation items are visible and accessible for plant operation and maintenance

23

Confirm that all Compressor casing earthing arrangements are installed to specifications and that earth boss and earth-strap(s) is installed.

24

Check and confirm that any Compressor casing vent(s) and drain(s) are installed and piped away to correct locations in accordance with P&ID’s and assembly / installation drawings

25

Confirm that Compressor Instrument / Electrical /Tubing connections are installed as per P&ID and are complete and secured correctly.

Page 2 of 3


RECIPROCATING COMPRESSOR M24-A Confirm that all Compressor isolation valves, in-line strainers / filters and sight glasses etc are all installed as per manufacture’s drawings

27

Ensure that coupling alignment is completed for the driver to Compressor unit, taking into account any thermal growth / offsets as per designed specification or manufacturer’s instructions / recommendations.

28

During Compressor alignment checks ensure there is no imposed loading from suction or discharge pipework onto pump casing flanges

29

Check that coupling spacer unit from Driver unit to Compressor has been installed correctly and that covers / guards are correctly installed

30

Confirm that access is available for future maintenance activities such as crankshaft or piston removal etc. or entire Compressor casing removal

31

Check preservation measures.

32

Equipment release note signed and all punch list items cleared COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CENTRIFUGAL PUMP

M26-A



1

INSPECTION / TEST Nameplate details correct, in accordance with drawings.

2

Check Baseframe holding down bolts / shims / washers installed – Check centerline coordinates and elevation

3 4 5 6 7 8 9 10

OK

N/A

P/L No.

Check for and remove internal shipping preservatives Ensure coupling alignment complete; record initial alignment & final alignment (refer ITR-45A ) Check lubrication System. Pump case vent / drain installed in accordance with drawings. a) Suction / Discharge nozzles installed in accordance with drawings. b) No mis-alignment of pipe / pump case flanges. c) No imposed load on pump casing Mechanical seal system installed in accordance with detail drawings. Check that Instruments / Valves / Strainers are installed as per P&ID. Confirm Electrical grounding installed as drawings.

11

Confirm all coupling guards are installed and secured.

12

Confirm that oil lubricator bottle is installed & free of damage (check glass for cracks & lid for seal)

13

Confirm pump/motor is free to turn by hand, rotate weekly and document.

Page 1 of 2


14

CENTRIFUGAL PUMP M26-A INSPECTION / TEST OK Check pump base has been levelled, properly grouted and foundation bolts tightened - Check for voids.

N/A

P/L No.






Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A NITROGEN GAS GNERATOR

M31-A



INSPECTION / TEST Check equipment against purchase order Check Installation and Holding down in accordance with drawings and Manufacturers instructions

OK

N/A

P/L No.

Check the General Arrangement Drawings for required maintenance access space Check equipment and nameplate comply with Data Sheets and nameplate securely attached to unit

5

Main piping / vent / drain connections complete and supported correctly.

6

Instrument / Electrical / Tubing connections complete and secured correctly

7

Unit Fittings, Trims, Platforms and Access ladders are complete

8

Check that individual components are installed in accordance with Vendor Instruction for following: 8.1 Coalescing Air Filters 8.2 Carbon Air Filters / Carbon Charge as per Vendor requirement 8.3 Nitrogen Module Separators 8.4 Nitrogen Receiver including Manway MH / Bolts / Gaskets 8.5 Local Control panel

9 10 11

Confirm vent line from separators vented to safe non-hazardous area Confirm all Bolting / Gaskets are of correct materials Check that PRV or PSVs are installed, undamaged and that test seals are intact from recent calibration

12

Check that Unit is clean and undamaged

Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 13 14 15

NITROGEN GAS GNERATOR Confirm accessibility for maintenance in acceptable

M31-A

Confirm all Earthing bosses fitted and Earth straps installed Check Equipment Release Note signed and all punchlist items cleared COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SEWAGE TREATMENT UNIT

M32-A



1 2

INSPECTION / TEST Check equipment against purchase order Check availability of consumables

3

Check manufacturers' instructions, documentation & test certificates

4

Check equipment and nameplate comply with Data Sheets and nameplate securely attached to unit

5

Check and inspect: 5.1 Alignment & Position 5.2 Holding down bolt arrangement & condition 5.3 Supply links and piping with proper support 5.4 By-pass arrangement 5.5 Drains and vents 5.6 Discharge pipe

6

Check and inspect internally: 6.1 Air piping and support 6.2 Porous ceramic air diffuses 6.3 Internal coating

7

Check and inspect comminutor: 7.1 Fitting & Alignment 7.2 Inlet screen and block in/drainage facilities to allow inlet screen maintenance Check and inspect blowers: 8.1 Fitting & Alignment 8.2 Inlet filters and block in/drainage facilities to allow filter maintenance 8.3 Outlet connection

8

9

OK

N/A

P/L No.

Check and inspect the external paintwork Page 1 of 2


SEWAGE TREATMENT UNIT Check manhole and nozzle gaskets Unit tested for leaks

M32-A

12

Check chemical tubes for dispensing arrangements

Note: Residual chlorine content of sewage to be checked during commissioning COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A WATER MAKER UNIT

M33-A

Project No. Project Title Facilities INFORMATION Tag Number Item Description System Sub System 1 2 3 4 5 6 7 8 9


INSPECTION / TEST Check equipment against purchase order Check installation against manufacturers installation documentation Check the General Arrangement Drawings for required maintenance access space Check nameplate details and attachment Ensure that packaged unit is level and holding down bolts are adequately tightened.

OK

N/A

P/L No.

Check holding down bolts of all skid mounted equipment items are adequately tightened. Check that the electrical system is properly grounded and local panel condition Check that the instrument air is properly connected to the inlet of the filter regulator Check and inspect the following on the centrifugal pumps (Tag Nos.:___________ ): 9.1 Rated suction & Discharge pressure 9.2 Pump Capacity 9.3 Specific Gravity /Product 9.4 Absorbed power (HP/KW) 9.5 Rated Speed (RPM) 9.6 Pump type/number of stages 9.7 Closed valve design pressure (at max. pump suction) 9.8 Pump casing design pressure /temperature 9.9 Pump coupling alignment (piping uncoupled) 9.10 Pump coupling bolting 9.11 Pump coupling guard 9.12 Check pump direction of rotation and ensure free rotation 9.13 Ensure proper lubricant for bearings as specified Page 1 of 4

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A WATER MAKER UNIT M33-A 9.14 Check bearing oil for any water or dirt contamination, top-up or replace as necessary 9.15 Bearings cleanliness after flushing 9.16 Bearings connections are clean and properly fitted 9.17 Bearing lubricant rings are free and immersed in lubricant 9.18 Pump casing drain is clear, valved and piping led to drain 9.19 Pump casing is clear and valve fitted 9.20 Packing rings have been performed & properly fitted 9.21 Correct type of packing 9.22 Location of lantern ring 9.23 Mechanical seals and "O" rings are to spec. 9.24 Gasket and studbolts for casing and flanges are to spec. 10 Check and inspect seal piping as well as clamp plates are square with stuffing box 11 Check and inspect for correct type of temporary pump filters are fitted for pre-commissioning 12 Check and inspect the following on the filters:13.1 Ensure that the filter is properly installed with end cap "O" rings (inside the tube) in good condition and small amount of lubricant 13.2 Filter element is as specified13.3 The filter element is of adequate construction for the duty and will not corrode13.4 Correct type bolts and gaskets are used

13 Ensure housing is filled with filtered seawater only 14 Check and inspect the following on the piping : 14.1 Ensure raw seawater piping is not of cast iron and/or mild steel 14.2 Ensure incoming line sizes are not smaller than the connection fitting on the system 14.3 Ensure no shut off valves are installed in the product line 15 Record any preservation measures taken in preservation log. 16 Equipment release note signed and punch list agreed, cleared or record. COMMENT(S) AND ADDITIONAL INFORMATION

Page 2 of 4




M33-A



Page 3 of 4


M33-A



INSPECTION / TEST Check equipment against purchase order Check installation against manufacturers installation documentation Check the General Arrangement Drawings for required maintenance access space Check nameplate details and attachment Ensure that packaged unit is level and holding down bolts are adequately tightened.

OK

N/A

P/L No.

Check holding-down bolts of all skid mounted equipment items are adequately tightened. Check that the electrical system is properly grounded and local panel condition Check that the instrument air is properly connected to the inlet of the filter regulator Check and inspect the following on the centrifugal pumps (Tag Nos.:___________ ): 9.1 Rated suction & Discharge pressure 9.2 Pump Capacity 9.3 Specific Gravity /Product 9.4 Absorbed power (HP/KW) 9.5 Rated Speed (RPM) 9.6 Pump type/number of stages 9.7 Closed valve design pressure (at max. pump suction) 9.8 Pump casing design pressure /temperature 9.9 Pump coupling alignment (piping uncoupled) 9.10 Pump coupling bolting

Page 1 of 4

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A WATER MAKER UNIT M33-A INSPECTION / TEST OK N/A 9.11 Pump coupling guard 9.12 Check pump direction of rotation and ensure free rotation 9.13 Ensure proper lubricant for bearings as specified 9.14 Check bearing oil for any water or dirt contamination, top-up or replace as necessary 9.15 Bearings cleanliness after flushing 9.16 Bearings connections are clean and properly fitted 9.17 Bearing lubricant rings are free and immersed in lubricant 9.18 Pump casing drain is clear, valved and piping led to drain 9.19 Pump casing is clear and valve fitted 9.20 Packing rings have been performed & properly fitted 9.21 Correct type of packing 9.22 Location of lantern ring 9.23 Mechanical seals and "O" rings are to spec. 9.24 Gasket and studbolts for casing and flanges are to spec.

P/L No.

10

Check and inspect seal piping as well as clamp plates are square with stuffing box 11 Check and inspect for correct type of temporary pump filters are fitted for pre-commissioning 12 Check and inspect the following on the filters:13.1 Ensure that the filter is properly installed with end cap "O" rings (inside the tube) in good condition and small amount of lubricant 13.2 Filter element is as specified13.3 The filter element is of adequate construction for the duty and will not corrode13.4 Correct type bolts and gaskets are used

13 Ensure housing is filled with filtered seawater only 14 Check and inspect the following on the piping : 14.1 Ensure raw seawater piping is not of cast iron and/or mild steel 14.2 Ensure incoming line sizes are not smaller than the connection fitting on the system 14.3 Ensure no shut off valves are installed in the product line 15 Record any preservation measures taken in preservation log. 16 Equipment release note signed and punch list agreed, cleared or record.

Page 2 of 4

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A WATER MAKER UNIT M33-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 4

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SUB-SEA EQUIPMENT

M34-A



INSPECTION / TEST Check equipment against purchase order Check installation against manufacturers installation documentation Check FAT reports and punchlist (if any)

4

Verify equipment package manual/dossier and relevant procedures are provided by vendor

5 6

Check any preservation measures taken Examine equipment package for any sign of external damage

7

Equipment release note signed and punch list agreed and recorded COMMENT(S) AND ADDITIONAL INFORMATION




OK N/A

P/L No.


Page 1 of 1

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MISCELLANEOUS EQUIPMENT Project No. Project Title Facilities Tag Number Item Description System Sub System 1

M35-A


INSPECTION / TEST Confirm Equipment and Nameplate complies with Data Sheet and design, certifying authority stamp, where applicable.

2

Confirm that Equipment Package Unit has been installed in correct position according to vendor instructions, is undamaged with skid location and orientation correct

3


4

Installation and Holding down arrangement in accordance with design and manufacturer’s instruction and location correct.

5

Access / Clearance adequate for operation and maintenance, SWL of any associated equipment correct.

6

Attached electrical, piping and instrumentation connections correct to installation and interface design.

7 8 9

Confirm any PRV, PSV seals intact, correctly installed Cleanliness & Painting condition satisfactory. Carry out lubrication in accordance with supplier’s recommendations, record lubrication grades and quantities. Check Maneuvering by rotating all working parts.

10 11 12 13

Verify that valves are installed and valves open/close freely. Verify grounding, earthing boss connection is fitted and secured. Verify preservation is carried out and recorded in the preservation log. Confirm by boroscope inspection (where applicable) that pipework is free of dirt and liquids.

14 15

Confirm internal bowl assembly correct as required (where applicable) Check that temporary filters are in place and initial mesh grade fitted.

OK

N/A

P/L No.

Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MISCELLANEOUS EQUIPMENT M35-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A VENDOR EQUIPMENT SKID

M36-A



INSPECTION / TEST Name plate/tag details correct, in accordance with manufacturers data sheet. Test certificates & FAT documentation available.

Lifting lugs satisfactory Jacking screws and brackets fitted where necessary for alignment of on-skit equipment

6 7

Skids checked for level Shimpacks between skid base & support pads satisfactory with correct material used and no soft foot

8

Attached valves installed correctly, accessible undamaged and operational. Access clearance around skid adequate for personnel and maintenance. SWL marked clearly on any unit with mechanical handling device. Ensure correct strainers/filters element installed and record type in log. Local on skid mounted control panels / JB's installed correctly, on skid connections and cables are correct to specification & undamaged.

10 11

N/A

P/L No.

Skid equipment,location, installation, base frame, drip pan, holding down bolts, shims, washers correctly installed in correct location as per design specification. All transportation supports and aids removed, externally & internally. Skids undamaged, clean and clear of debris.

4 5

9

OK

12 13

PSV's / PCV's installed and seal still intact; records available. On skid equipment; motors, pumps, gearboxes, commpressor, piping, tubing, cabling, instrumentation installed, secured and supported correctly accordance to the design.

14

Confirm all associated pipe work including flexible pipe are connected correctly, aligned & are damaged free. Page 1 of 2


15 16 17 18 19

VENDOR EQUIPMENT SKID INSPECTION / TEST Verify that all electrical/instrument signal are completed. Verify earthing boss connection. Any on skids units with doors/manholes must be jointly inspected, prior to closing and boxing up.

M36-A OK N/A

P/L No.

Record any preservation measures in place and recorded in preservation log. Skid/Equipment release note signed and punchlist agreed, cleared or recorded. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A BASE PLATE

M40-A



INSPECTION / TEST Check equipment is installed according to the manufacturer’s instructions. Ensure sea fastenings / shipping stops are removed.

OK

N/A

P/L No.

Check base plate has been installed as per design. Loosen off all pipework to the driven equipment and carry out soft foot check. Check that the base plate is level and elevation is correct to design. Confirm that all fittings such as shims, hold down bolts, mounts have been fitted correctly, (if specified on project design). Base plate welded to deck with QC records available where required. Base plate coated to design requirements. Verify earthing boss connection. All bolts and shims preserved by painting or by use of an approved preservation method COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A LOAD TESTING OF LIFTING LUGS / MONORAILS M41-A Project No. Project Title Facilities INFORMATION Tag Number Location Item Description Ref Drawing System Inspection Date Sub System INSPECTION / TEST OK Safe Working Load (SWL) marking applied and visible. Verify correct SWL for 1 intended purpose. Vendor test certificates available. 2 3 4 5 6 7 8 9 10 11

P/L No.

Monorail end cleats/stops fitted & bolts tightened and locked. Obstruction free in all directions of intended load travel. Adequate supports provided for curved beams. Sufficient lateral bracing provided. Monorail Trolley travel smooth throughout length. Supporting structure and Monorail / Lug calculations prepared / checked. Verify earthing boss connection. Material certificates recorded. NDE completed, reports recorded. TESTING REQUIREMENTS:(witnessed by Client / Certifying authority) Test loads to be applied for a Min. (10) minutes prior to any measurements being taken or as advised by Client / Cert. Authority

13

Test Method using the load cell / pad eyes. Max. deflection mid span (mm) Allowable mm Actual mm

14

Max. cantilever deflection (mm) Allowable mm Actual

15 16

Permanent deformation of monorail / Lug after test :Permanent flange deformation after test :-

12

N/A

mm

Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A LOAD TESTING OF LIFTING LUGS / MONORAILS M41-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ELEVATORS

M42-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2 3 4 5 6


INSPECTION / TEST Name plate/tag details correct & in accordance with design data sheet. Manufacturers test certificates & FAT documentation available.

N/A

P/L No.

Verify levels, alignment, orientation & installation correct as per design. Confirm that the elevators internal coating and internal parts are clean and installed in accordance with the designs and specifications. Verify earthing boss connection. Platform and access ladders are installed as per design. Provision for removal of internals is acceptable and any mechanical handling facility is correct to design. SWL clearly marked with applicable certification available.

8

Verify external painting / insulation complete as per design specifications. Confirm all associated pipe work including flexible pipe are connected correctly, aligned & are damaged free.

9 10 11

Verify that all electrical/instrument signal are completed. Record any preservation measures in place & record in log. Equipment release note signed and punch list agreed, cleared or recorded.

7

OK






Page 1 of 1

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A VALVE INSTALLATION

M43-A

Project No. Project Title Facilities Tag Number Item Description System Sub System 1 2


INSPECTION / TEST Confirm that Valve nameplate complies with Data Sheet and nameplate securely attached

Check and confirm installation and bolting arrangement is in accordance with required specification drawing and manufacturer’s instructions

4

Check access for operation is acceptable and there is sufficient clearance for maintenance removal etc

5

Confirm that inlet and outlet piping to valve mating flanges are in parallel and angular alignment with the correct gaskets installed. Ensure that on tightening bolts no imposed stress is applied to valve.

P/L No.

Check all PSVs installed, undamaged and seals intact

7

Confirm alignment of block valves. Ensure lock / car-seals are applied to PSV root valves as shown on the P&ID.

8

Ensure that hand wheel, lever or geared actuator is fitted and that valve can be operated without undue strain across complete operating range

10

Confirm that valve actuator is installed satisfactory and that any interlock mechanisms associated are fitted correctly. Ensure interlock keys are safely stored. Check Earth bonding strap is installed if required

11

Hand operated valves are to be stroked (open/closed) to confirm that valve is not tight or seized

9

N/A

Confirm valve location & orientation is correct to detail drawings

3

6

OK

Page 1 of 2


12

VALVE INSTALLATION INSPECTION / TEST Check and confirm controller installation with vendor specifications.

M43-A OK N/A

P/L No.






Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PULSATION DAMPENER

M44-A



1

INSPECTION / TEST Check that pulsation dampener conforms to the specifications

2

Check that pulsation dampener installation conforms to the specifications, drawings and to the P&IDs

3

Check that the pulsation dampener is undamaged. Additionally, check the ancillaries and any other components

4

Check the installation of pulsation dampener supports are in accordance with the specifications and drawings

5

N/A

P/L No.

Check that there is a suitable access to pre-charge pulsation dampener.

7

Check that the pulsation dampener to pipe flange has been mounted square to each other. Also that the bolting and gaskets are correct as per system specifications Check that all the bolts and fasteners are suitable lubricated

8

Check that the painting, the insulation and the trace-heating conform to the specifications (if applicable)

9

Check for the correct tagging and / or labeling of pulsation dampener

10

Produce a set of marked-up drawings in accordance with the installation

6

OK


Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PULSATION DAMPENER



M44-A



Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A COUPLING COLD ALIGNMENT Project No. Project Title Facilities Tag Number Item Description System Sub System Sub System

M45-A


INSPECTION / TEST Notes: If using laser alignment equipment, print results and attach to this ITR. Alignment of equipment included in leak test must be completed prior to leak test. MANUFACTURER’S SPECIFICATIONS Allowable Angular (or Gap or Face) misalignment: ............................ mm Total Indicator Reading Allowable Offset (or Parallel) misalignment: ..................................... mm Total Indicator Reading Length of Coupling Spacer: ................... mm +/_: ................... mm Distance between Flange Faces (D.B.F.F): ………………………………+/-: ……………………………… SPECIAL REQUIREMENTS, e.g. Allowable backlash for gear coupling with nylon sleeve, axial alignment for vertical cantilever drives, etc.: ………………………………………………………………………………………………………………………………………………………………… ………………………………………………………………………………………………………………………………………………………………… ……………………………………………………

Page 3 of 11

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A COUPLING COLD ALIGNMENT

M45-A INSPECTION / TEST

Page 4 of 11



COUPLING COLD ALIGNMENT: COUPLED, RELATED PIPEWORK LOOSE METHOD OF ALIGNMENT USED

: …………………………………………

LOOKING IN DIRECTION OF

: …………………………………………

FREE LENGTH OF COUPLER SPACER

: …………………………………………

D.B.F.F.

: …………………………………………

Page 5 of 11



Test Equipment used Type: ……………………………….……..

Serial No.: …………….

Calibration expiry date: …………….

RADIAL CONCENTRICITY OF EACH HALF COUPLING TO IT’S OWN SHAFT (Use for face/periphery and reverse alignment.) mm

1

DRIVER GAUGE No. 1

mm

mm

mm

DRIVEN GAUGE No. 2 mm

mm

mm

mm

COUPLING GAP. FACE TO FACE. (AXIAL) (use only for face/periphery method.) mm

2

mm

mm

CLOCK GAUGES 3 & 4

mm

Page 6 of 11



RADIAL CONCENTRICITY COUPLING FLANGES TO EACH OTHER. (use only for face/periphery and reverse alignment.) DRIVER GAUG E No. 5

3

mm

mm

mm

DRIVEN GAUG E No. 6

mm

mm

mm

mm

mm

COUPLING ALIGNMENT: COUPLED, RELATED PIPEWORK TIGHT METHOD OF ALIGNMENT USED

: ………………………………………… …

LOOKING IN DIRECTION OF

: ……………………………………………

FREE LENGTH OF COUPLER SPACER

: ……………………………………………

D.B.F.F.

: ……………………………………………

Page 7 of 11



Test Equipment used Type: ……………………………….……..

Serial No.: …………….

Calibration expiry date: …………….

RADIAL CONCENTRICITY OF EACH HALF COUPLING TO IT’S OWN SHAFT (Use for face/periphery and reverse alignment.) mm

1

DRIVER GAUGE No. 1

mm

mm

mm

DRIVEN GAUGE No. 2 mm

mm

mm

mm

COUPLING GAP. FACE TO FACE. (AXIAL) (Use only for face/periphery method.) mm

2 mm

mm

CLOCK GAUGES 3 & 4

mm

Page 8 of 11



RADIAL CONCENTRICITY COUPLING FLANGES TO EACH OTHER. (Use only for face/periphery and reverse alignment.)

3

DRIVER GAUGE No. 5

mm

mm

mm

mm

mm

mm

1 2 3 4 5

DRIVEN GAUGE No. 6

mm

INSPECTION / TEST Compliance with Purchase Order Check manufacturers' instructions, drawings and certificates Coupling drawings are available at site Check coupling details (against data sheets in dossier) Inspect coupling membrance and intermediary for damage

mm

OK N/A

P/L No.

Page 9 of 11



Radial Clock A1 Clock A2 (A1-A2)/2 Axial Clock B1 Clock B2 (B1-B2)/2 Radial Clock A1 Clock A2 (A1-A2)/2 Axial Clock B1 Clock B2 (B1-B2)/2

Piping Connection Loose 0 90 180

270 Radial misalignment Horizontal = Vertical =

Piping Connection Tight 0 90 180

Axial misalignment Horizontal = Vertical = 270

Radial misalignment Horizontal = Verical = Axial misalignment Horizontal = Vertical =

Page 10 of 11


M45-A




VERIFIED BY

ACCEPTED BY

PCSB Inspector PETRONAS Carigali

Discipline Engineer PETRONAS Carigali

Page 11 of 11

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PIG TRAP

M46-A


1 2 3

4

5

6

7 8 9 10


INSPECTION / TEST Ensure Name plate/tag details are correct and in accordance with design data sheet. Manufacturers test certificates and FAT documentation are available. Installation and holding down in accordance with drawings and manufacturer’s instructions

OK

N/A

P/L No.

Check levels, alignment, orientation and installation to be as per design. Ensure the following piping nozzles are provided: - Bypass line nozzle - Kicker line nozzle - Balance line nozzle - Pressurizing line nozzle - Thermal relief line nozzle (If thermal relief valve is installed) - Drain and Vent line nozzle Check If the opening of the end closure is not in the vertical plane, i.e. on vertical or sloped pig traps, the end closure shall be equipped with a counterweight or hydraulic opening system or similar system to facilitate safe and easy opening of the door. Ensure the end closure have the following safety devices: - A safety locking device to prevent opening of the door when the pig trap is pressurised. - A pressure safety device that when partially released will alert the operator to a possible hazard unless pressure in the pig trap is relieved completely. Ensure temporary blinds are installed if the piping is not connected. Confirm that the pig trap internal coating and internal parts are clean and installed in accordance with the designs and specifications. Ensure the pig trap fittings and the trims are installed as per design. Verify earthing boss connection is in place. Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 11 12 13 14 15 16 17

18

19

20 21

PIG TRAP Ensure platform and access ladders are installed as per design. Ensure accessibility and mechanical handling for maintenance is acceptable. Ensure Pig traps are undamaged and external painting / insulation complete as per design specifications.

M46-A

Confirm all associated pipe work including flexible pipe are connected correctly, aligned and are free of damage. Verify that all electrical/instrument signal are completed. Record any preservation measures taken in the preservation log. Ensure U stamp is provided for end closure of the pig trap. Ensure Pressure Test is carried out as per specification and recorded as follow :Test Date:Test Medium:Duration of Test:Ambient Temperature:Test Pressure:Ensure the following certificates are available where applicable: • Material tests and welding inspections • Relief valve testing and Setting • Pressure and vacuum valve tests • Content Gauges (calibration) Accessibility for maintenance is acceptable Check equipment release note have been signed and punch list agreed, cleared or recorded. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A STORAGE TANK

M47-A



INSPECTION / TEST Equipment and nameplate comply with Data Sheet

P/L No.

Installation and holding down in accordance with drawings and manufacturer’s instructions Sliding feet are free & nut / bolt clearance set to correct gap / space Tanks are level in accordance with manufacturer’s specification

10 11

Man-way access in accordance with the drawings and man-way cover installation complete with correct gaskets / bolting

9

N/A

Nameplate installed correctly

Spare nozzles blanked off in accordance with specification Tank fittings, trims, platforms and access ladders are complete Main piping / vent / drain connections complete and supported correctly Instrument / electrical / tubing connections complete and secured correctly Instruments, instrument stand pipes installed and drain points tied in as per P&ID

6 7 8

OK

Page 1 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A STORAGE TANK M47-A INSPECTION / TEST OK Tank internals including filter, demister pads, etc. clean and installed in accordance with latest drawings and specifications.

N/A

P/L No.

Note 1: Photographs to be taken to show ALL internal installations & vessel / tank cleanliness level. Attach all photographs to this report. Note 2: Tank internal Inspections to be witnessed by PMT team and signed for below 12

Internal Inspection Witness Discipline Engineer have witnessed the internals of this vessel / tank and all internals are acceptable as per drawings & specifications. Name:_______________ Sign:_______________ Date:__________

Internal Coating complete and undamaged. Note: Tank internal coating Inspections to be witnessed by PMT team and signed for below 13

Internal Inspection Witness: Discipline Engineer have witnessed the internal coating of this vessel / tank and all is acceptable as per drawings & specifications. Name:_______________ Sign:_______________ Date:__________

Page 2 of 3


14 15 16 17 18 19

STORAGE TANK INSPECTION / TEST Provision for removal of internals is acceptable

M47-A OK

N/A

P/L No.

Tank undamaged and external painting / insulation complete All Valves and Instrumentation visible and accessible Equipment Vendor Release Note signed and all punch list items cleared Earthing Boss fitted and earth strap installed Accessibility for maintenance is acceptable Confirm all vessels/tank weir plates are installed correctly & water side interface filled with fresh water to confirm no leakage across weir plate interface. Note: Vessel/Tank weir plate interface water leakage test Inspections to be witnessed by PMT and signed for below

20

Weir Plate water interface leakage rate Inspection Witness: Discipline Engineer have witnessed the weir plate water interface leakage rate of this vessel / tank and all results are acceptable. Name:_______________ Sign:_______________ Date:__________

21 22 23

Confirm tank hydro-test completion & test certificates available Check all PSV’s installed, undamaged and seals intact Verify all torque certificates on flanges and man ways

COMMENT(S) AND ADDITIONAL INFORMATION Note: It may not be necessary to close the man-way door due to 'B' scope commissioning checks. Verify with Commissioning Team before closing.





Page 3 of 3

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A LUBRICATING LOG

M48-A

Project No. Project Title Facilities Tag Number/Make Item Description Type of lubricant System/Sub System


INSPECTION / TEST Equipment and nameplate comply with Data Sheet 1 Lubricate equipment with the correct viscosity lubricant. Lubricant Used : _____________________ Lubricant Viscosity : ______________________ 2 Lubricant Quantity : _______________________ Lubricant Physical Appearance (Color): _____________________ 3

OK N/A P/L No.

Lubricant storage; covered or open space

Record quantity of lubricating oil for the following activities: 3.1 Initial Charge :_______ 4 3.2 Flushing :___________ 3.3 Start-up : __________ 3.4 Operation & Maintenance : ________ 5

Proper storage/positioning of drums should be exercised to eliminate condensation (lube oil drums should be positioned horizontally) COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TURBO EXPANDER/BOOSTER COMPRESSOR Project No. Project Title Facilities INFORMATION Tag Number Location Item Description Ref Drawing System Inspection Date Sub System INSPECTION / TEST 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

M50-A

Verify to ensure that all construction/installation activities have been completed. Name plate/tag details correct & in accordance with design data sheet. Manufacturers test certificates & FAT documentation available. Alignment jack screws/ devices fitted correctly. Base frame, drip pan, holding down bolts, shims, washers correctly installed in correct location as per design specification. Skid Unit location, orientation, level and alignment correctly installed as per design and specification Ensure coupling alignment check are complete and within supplier tolerances. Sight glasses checked, visible and accessible for maintenance. Drains and vents routed correctly. Verify seal system correctly installed and connected to the compressor as per design. Crankcase and packing vent and drain clear and piped up, spark arrestors checked as per design details, where applicable. Confirm all associated pipe work including flexible pipe are connected correctly, aligned with correct bolt / gasket / torque value & damaged free as per design/specification. Grease nipples fitted, charged and clear. Record grease type use. Verify earthing boss connection. Verify that the suction / discharge silencer correctly installed. Verify that strainers/filter element install correctly. Joint verification inspection required. Check all interface connection correct as per design. Verify all safety and shut down devices installed as per design. Verify that all electrical / instrument signal are completed. Verify that fire water mist cabinet is located and tubed correctly into compressor skid as per design, with all cylinder fully charged. Verify adequate clear access for maintenance and mechanical handling facilities. SWL correct marked for equipment.

OK

N/A

P/L No.

Page 1 of 2

CSP-20 rev.01 Appendix I-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TURBO EXPANDER/BOOSTER COMPRESSOR

M50-A

INSPECTION / TEST

OK

20

Record any preservation measures taken and note in the preservation log.

21

Equipment release note signed and all punch list items cleared.

N/A

P/L No.






Page 2 of 2

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PIPING WORK COMPLETION Project No. Project Title Facilities

P01-A

INFORMATION Test Package No Test Pressure System Test Medium Sub System Test Duration Location Test Date INSPECTION / TEST Check that piping is constructed and installed according to the latest 1 AFC revision of P & ID and isometric drawing and support drawings. To ensure that any welded pipe supports (cleats) shall be welded and 2 completed before PWHT / Hydrotest of the system . Check that materials used are as per specification with reference to 2 their heat no., certificates, and reference isometrics. Check that piping routing including pipe supports does not obstruct the 3 access for emergency escape and maintenance Check piping line is sloping if shown in P&ID / Isometrics (ex: flare line) 4 5 6 7 8 9 10 11 12 13

OK

N/A P/L No

Ensure maintenance accessibility for valves, psv, sample point, corrosion probe etc. . Ensure also that there is sufficient clearance for on-line retrieval / tool usage of retrievable devices Check that flange rating is correct especially at class break and code brake (ex: API-6A to ASME B 31.3) as indicated in P&ID and isometric.. Ensure that isolation gaskets have been installed as approved in the isometric for dissimilar flange material Check that the installation of piping with rayloc hub connectors has been carried pout correctly without imposing any strain. Check that new gaskets are installed prior to system hydrotest as per specification Check that flange joint is properly aligned & within acceptable tolerance. Refer to P-06A. Check bolts and nuts are adequately tightened and of correct length. Refer to P-07A . Check that required high point vent and low point drain points are provided for system hydro.

Page 1 of 3

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A

14

15 17 18 19 20 21 22 23 24 25 26 27 28

PIPING WORK COMPLETION P01-A Inspect all valves and ensure that the type, size, rating, material and flow directions are correct. End covers of valves shall only be removed immediately before installation and it shall be checked that the valve is clean. Check filter / strainer body and inspect internal element for damages. Ensure that the opening of strainer element is accessible and sufficient space is there to remove / re-install the element Check that filter / strainer element material and mesh size are correct. . Check that pipe supports are constructed and installed according to drawings. . Check that welded joint has been completely inspected. Check that actuated valve (SDV, ESD, BDV type, but not the Control Valves) is correctly installed. Check that piping penetrations are constructed according to drawings with sufficient stiffening plates and adequate sealing wherever specified, and physically ensure that the pipe do not vibrate. Check that all piping special items are installed properly. Check that spectacle blinds spades / spacer are provided and installed at location and position as per P&ID Check that exposed portion of spectacle blinds are coated to avoid corrosion. Check that all hydrocarbon instrument drains lead (piped / tubed) to the proper drain system, as per the P&ID. Verify that check valves and globe valves are installed in their correct flow direction. Check that lines are labeled at visible locations. All chain wheels and extended spindles required for specified valves have been installed as per drawing, and are accessible for operation, and ensure they are not obstructing the pathway.

Page 2 of 3

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 29 30

31 32 33

PIPING WORK COMPLETION P01-A Ensure system PSV is installed & calibrated. Check the spring hanger condition and is in locked position if required. For locked position / unlocked position during hydro test, refer to foot notes in the respective piping isometric drawing &/or follow the manufacturer instructions. Check that the forces and movements on equipment nozzles are within acceptable limits. This is particularly important for rotating equipment and glass lined equipment. Check that the installation of any glass lined or GRE piping has been carried out correctly without imposing any strain. Check that personal protection for uninsulated hot product line as per P & ID and Isometric drawing. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PRE-TEST

P02-A

Project No. Project Title Facilities INFORMATION Test Package No Test Pressure System Test Medium Sub System Test Duration Location Test Date INSPECTION / TEST Verify to ensure that all piping construction / installation activities as 1 per approved test package limit have been completed including all pipe supports. 2 Ensure that the test package can be applied. All weld inspection and NDE are complete and traceability and history 3 records complete and cleared by QA/QC Dept. Ensure that Conformity Line Check has been performed as per the test 4 package. 5 Ensure that test package including the attachment is completed. All high point vents and low point drains are installed (add temporary 6 vents and drains for testing if any is required). 7 All Check Valves to be removed or tied back. Ball valves are to be half-opened during test and fully opened for 8 flushing. Globe, butterfly and gate valves are to be fully opened for testing and 9 flushing. All temporary equipment stops, spades, bobbin pieces and supports for 10 pressure test are installed. All instruments relief valves, bursting discs, orifice plates and specified 11 control valves have been removed for pressure test. 12 All orifice flanges to be blinded off. Essential supports to be fitted and springs and bellows to be gagged 13 during test. Check that all sprinkler heads, rosettes and nozzles have been removed 14 and connections plugged. Preliminary Piping Punch List is raised and all categories "A" items 15 cleared prior to Pressure Test. COMMENT(S) AND ADDITIONAL INFORMATION

OK

N/A

Page 1 of 2

P/L No

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PRE-TEST



P02-A



Page 2 of 2

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FLUSHING

P03-A

Project No. Project Title Facilities Test Package No System Sub System Location

1 2 3 2 3 4 5 6 7 8 9

10

INFORMATION Flushing Flow rate Flushing Medium Flush Duration Flushing Date INSPECTION / TEST

OK

N/A

Verify to ensure that all piping construction / installation activities as per approved test package limit have been completed including all pipe supports. All weld inspection and NDE are complete and traceability and history records complete and cleared by QA/QC Dept. Ensure that Conformity Line Check has been performed Check that injection point and drain out point are completed as per test pack mark-up. Ensure that water quality is as per CSP-22 water quality requirements for applicable pipe materials. Equipment is bypassed and spectacle blinded. Valve status in accordance with flushing and testing procedure in CSP 22. Ensure all low point drains and high vent points are flushed. Ensure that all piping lines in this test package have been flushed Ensure that piping system has been drained out and followed by drying. Protection / preservation required and completed - if not immediately followed by hydro testing of same piping flushed. Record data as below:Injection Point Flow rate

Drain Point

Result

Page 1 of 2

P/L No

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FLUSHING P03-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PRESSURE TEST

P04-A

Project No. Project Title Facilities INFORMATION Test Package No Test Pressure System Test Medium Sub System Test Duration Location Test Date INSPECTION / TEST Verify to ensure that all piping construction / installation activities as 1 per test package limit have been completed. 2 Ensure that water flushing ( P03A) has been completed Pre-Test preparation is complete and P02-A is attached together with 3 P&ID where test limits are clearly marked. Preliminary Piping Punch List is attached and all "A" items on line are 4 clear and have been signed off. 5 Calibration Certificates for Recorders and Gauges are attached. 6 Instruments as stated in CSP 22 are removed. 7 Test Temporaries are installed. 8 Permit to Work or HSE authorization is in place. 9 Release for Pressure Test.

OK

N/A

P/L No

Record data as below as per CSP 22:Pressure Temperature Remark 0% 10 25% 50% 75% 100% 11 Pressure test complete. COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A BLOWING/DRYING

P05-A

Project No. Project Title Facilities INFORMATION Blowing Pressure Blowing Medium Blowing Duration Blowing Date INSPECTION / TEST Verify to ensure that pressure test (P04A) has been completed Ensure that water flushing ( P03A) has been completed Ensure that the test medium has been drained upon completion of the hydrotest. Ensure that no water is trapped in the system Ensure that blowing medium/ compressed air humidity is -30 Deg Ensure that all the blowing point humidity is -10 Deg. Permit to Work or HSE authorization is in place.

Test Package No System Sub System Location 1 2 3 4 5 6 7

Record data as below:Blowing Injt Blowing Point

Humidity

OK

N/A

P/L No

Result

8






Page 1 of 1

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FLANGES ALIGNMENT Project No. Project Title Facilities INFORMATION Test Pressure Test Medium Test Duration

Test Package No System Sub System Location 1 2 3 4 5

P06-A

INSPECTION / TEST Ensure that gaskets are examined to be new, clean, damage-free and of correct type and size. Ensure that all of stud bolt are loosed and free stress during inspection Flange faces are examined to be clean and damage-free. Measure vertical /facing alignment at two position ( i.e. A: smallest gap between flanges , B: Largest gap between flanges ) Measure eccentricity/horizontal alignment as table as bellow

A

A : Smallest gap between flanges

OK

N/A

P/L No

B: Largest gap between flanges C: Eccentricity

C B Flange Nozzle Description Number

Line No.

Flange Rating

Measurement Alignment (mm) A B

Eccentricity (mm) C

Details of Gasket installed / Type

Page 1 of 2

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FLANGES ALIGNMENT P06-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-VII

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A BOLT TENSIONING/TORQUING Project No. Project Title Facilities

P07-A

INFORMATION Tool Model Pump Type Serial Number Test Date INSPECTION / TEST OK Check Stud Bolt and nut for diameter, type of threads, material, coating and condition in-line with isometric drawings. Lubricate the Stud Bolt threads and nut face Check that nuts are fitted correctly Tighten sequentially according to procedure and for the required torque. Ensure that stud bolt length is sufficient as per standards. Check lock nuts if required COMMENT (S) AND ADDITIONAL INFORMATION

Test Package No System Sub System Location 1 2 3 4 5 6




N/A

P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-VII

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CHEMICAL CLEANING Project No. Project Title Facilities

P08-A

INFORMATION Test Package No Test /Oper Press System Chemical Med Sub System Test Duration Location Test Date INSPECTION / TEST Verify to ensure that all construction / installation activities have 1 been completed. 2 Marked up drawing / P&ID is attached. 3 Equipment is by-passed and blinded. Ensure the Pickling and Passivation Procedure is approved for 4 external welds and the internal surfaces /welds of all Stainless Steel/Duplex Stainless Steel/Super Duplex Stainless Steel piping. 5 De greasing works completed as per approved procedure 6 De scaling work completed as per approved procedure 7 Passivation work completed as per approved procedure 8 Ensure that piping system proper drained and dried. 9 Laboratory analysis details are satisfactory and attached. 10 System / equipment is reinstated as per approved procedure. 11 Verification of filters as required Ensure the preservation (1 bar of N2) to be performed upon 12 chemical cleaning completion. COMMENT(S) AND ADDITIONAL INFORMATION

OK

N/A

P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CHEMICAL CLEANING P08-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B RE-INSTATEMENT WORKS Project No. Project Title Facilities Test Package No System no. Sub System Location

1 2 3 4 5 6 7 8 9 10 11 12

P09-A

INFORMATION Test Pressure Test Medium Test Duration Test Date INSPECTION / TEST

OK

N/ A

P/L No

Flushing and hydrostatic testing have been satisfactorily completed and recorded. Check that drying of lines is complete. Verify that all in line units have been reinstated as per latest P &ID Correct bolts and gaskets are installed at all mechanical joints. Bolts are torqued / tensioned to correct specification. Check all manual valves are in opened position (recommended) and smoothly turned. All temporary spades, bobbins, vents and drains have been removed, and openings closed in accordance with specification. Support Gags are removed where applicable (it may be required to leave some in place for removal offshore). All process blinds, spades, valves and inline equipment have been correctly installed as per P&ID. Check/ ensure that lines are resting firmly/ properly on its support (not floating) Extended spindles and chain wheels for specified valves have been correctly installed. All locking devices and interlocks for specified valves have been correctly installed. Piping, instruments, mechanical equipment and specialty items are reinstated in accordance with the P&ID. Verify the items against pretest list. Verify earthing strap / connection if required. Verify the Base Line Survey for Corrosion Management completed COMMENT(S) AND ADDITIONAL INFORMATION

Page 1 of 2

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A RE-INSTALLATION WORKS P09-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SERVICE TEST

P10-A

Project No. Project Title Facilities INFORMATION Test Package No Test /Op Press System Test Medium Sub System Test Duration Location Test Date INSPECTION / TEST OK Verify to ensure that all construction / installation activities have 1 been completed. 2 Confirm Test Pack Line List is attached. 3 Ensure that the ITR P01-A have been signed. 4 Ensure Punch List Category-A has been completed and signed. 5 Pre-Test Flushing has been carried out and P03-A is attached. 6 Calibration Certificates are attached. 7 Permit to Work or HSE Authorization is in place. 8 Ensure number of leaks identified: 9 Ensure Service Test complete. COMMENT(S) AND ADDITIONAL INFORMATION




N/A

P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PIPE PAINTING / COATING/MARKING Project No. Project Title Facilities INFORMATION Test Package No Painting Material System Painting Code Sub System Location INSPECTION / TEST 1 Verify to ensure that all piping activities have been completed. 2 Ensure that all piping ITRs have been completed and available. 3 Sharp edges are removed prior to application. 4 All masking are completed. 5 Piping supports are painted 6 Spot painting are performed. Dry film thickness is checked to be correct. 7 Record details:8 9 10 11 12 13 14

P11-A

OK

N/A

P/L No

Record any defective area(s) on Punch List. Attached drawing(s) with highlighted piping sections are checked. Line numbering is according to P & ID. Flow direction is according to P & ID. Color coding is according to project requirements. Tagging of manual operated valves is correct. All safety / warning signs are in correct locations. Note: This painting / coating is also applicable to SS/DSS/SDSS piping as per project paint spec. COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PIPE INSULATION

P12-A


1

INFORMATION Insulation Material Insulation Code

INSPECTION / TEST Check that insulation installation in accordance with specification and AFC drawings.

3

Check that insulation sealing is completed to prevent the ingress of water or moisture Check that access point is provided in accordance with specification for corrosion monitoring.

4

Ensure that insulation will be installed after NDT hydrotest and painting are completed. Perform paint touch-up if required.

5

Check the direction of flow/color coding is indicated on the insulation cladding.

6

Ensure that oil grease, rust, other foreign matters are removed from the piping outer surface prior to installation of insulation.

2

7

8

N/A

P/L No

Check that longitudinal joint between segments is staggered. Ensure that all the insulation system is provided with 15 mm diameter drain hole for every 3 meters length and/or follow the approved project insulation spec.

9

Check that personal protection items such as open guard, shield, wire mesh or railings do not obstruct operational access.

10

Ensure that removable insulation for flanges & valve shall be suitable for quick removal and for quick reinstallation.

11

OK

Produce a defect list for issuance of punch list. COMMENT(S) AND ADDITIONAL INFORMATION

Page 1 of 2

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PIPE INSULATION



P12-A



Page 2 of 2

CSP-20 rev. 01 Appendix I-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A CRITICAL VALVE SEAT TEST CERTIFICATE Project No. Project Title Facilities Test Package No System Sub System Location 1 2 3 4 5 6 7

P13-A

INFORMATION Valve Type Valve Rating Test Pressure

INSPECTION / TEST OK Ensure the valve FAT reports are available. Ensure that critical valve testing procedure is approved. Valve has been seat leak tested as per approved procedure. Recorded on calibrated pressure recorder for 30 (thirty) minutes duration. Valve has passed test with no (ZERO) passage of test medium. All charts & Calibration Certificates for test equipment are attached. Ensure the valves are properly preserved and packing upon completion of testing. COMMENT(S) AND ADDITIONAL INFORMATION




N/A

P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-VIII

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ESCAPE ROUTES AND SIGNS Project No. Project Title Facilities Tag no. Area Ref. Drawing nos

S01-A


INSPECTION / TEST

1

Quantity of signs are correct

2

Condition of signs are satisfactory

3

Signs installed in accordance with drawings and specification

4

Signs clearly visible from all directions

5

Correct type of signs fitted at each location

6

Escape routes clearly identified and free from obstruction. Escape routes painted in accordance with relevant specification & deck layout drawings. Emergency escape route deck plans located at all deck levels in accordance with relevant drawings. Non-skid surfaces completed in accordance with specification. Escape routes signs in accordance with specification and located in accordance with relevant drawings. Emergency exit signs in accordance with specification and located in accordance with relevant drawings. Warning signs in accordance with specification and located in accordance with relevant drawings. Alarm signs in accordance with specification and located in accordance with relevant drawings. Life boat / raft signs in accordance with specification and located in accordance with relevant drawings. Muster station signs in accordance with specification and located in accordance with relevant drawings. Fire point signs in accordance with specification and located in accordance with relevant drawings.

7 8 9 10 11 12 13 14 15 16

OK

N/A P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 17 18 19 20 21

ESCAPE ROUTES AND SIGNS S01-A Emergency lighting correctly located along escape routes. Manual call points (MAC's) in accordance with specification and located in accordance with relevant drawings. Platform status lamps and sounders in accordance with specification and located in accordance with relevant drawings. CO2 sounders and beacons sounders in accordance with specification and located in accordance with relevant drawings. General area alarms (noisy areas) in accordance with specification and located in accordance with relevant drawings. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SAFETY SHOWER / EYEWASH Project No. Project Title Facilities Tag no. Area Ref. Drawing nos 1 2 3 4 5 6 7 8 9 10 11 12

S02-A


INSPECTION / TEST Check equipment against the purchase order Check manufacturers' instructions, drawings and certificates checked Check and inspect name plate details against data sheet Verify installation is in accordance with drawings and specification Unit adequately supported Operating instructions are fitted and visible Unobstructed access to equipment Connections to potable water system completed Connections to drain system completed Equipment clean and undamaged Shower drains installed as required. Operating sign installed. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A Project No. Project Title Facilities

SURVIVAL EQUIPMENT

Tag no. Area Ref. Drawing nos 1 2 3 4 5 6 7 8 9 10 11 12

S03-A


INSPECTION / TEST Check equipment against purchase order Check nameplate details against data sheet Life Jackets/ Work Vest/ Safety Equipment Cabinets. Storage cabinet in accordance with specification and located in accordance with relevant safety layout drawing. Cabinet equipment inventory in accordance with specification and attached signs. Signs fitted in accordance with specification. Ring Life buoy. Life Buoy type and construction in accordance with specification (refer to SOLAS) requirements. Life buoys correctly installed, and located in accordance with relevant safety layout drawings. Life buoy fitted with length of buoyant safety line not less than 2 x distance of mounting position to sea level, in accordance with specification. Light marker fitted. Smoke Marker fitted (where appropriate, only required on 25% of platform stock). COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A BREATHING APPARATUS

Project No. Project Title Facilities

Tag no. Area Ref. Drawing nos 1 2 3 4 5 6 7 8 9 10

S04-A


INSPECTION / TEST Check equipment against purchase order Confirm BA set is compliant with specification, and located in accordance with relevant drawings/spec. Confirm cylinder test date is easily visible and current. Confirm satisfactory condition of regulator hoses. Confirm satisfactory condition of face piece and valve assembly. Confirm satisfactory condition of face piece head-harness assembly. Check and confirm contents gauge indicates within 'green' sector (1800 liters). Confirm audible warning device fitted and serviceable. Confirm satisfactory condition of harness. Confirm storage container is undamaged and securely mounted in wall. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FIRE HOSES AND MONITORS Project No. Project Title Facilities Tag no. Area Ref. Drawing nos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

S05-A


INSPECTION / TEST Check equipment against purchase order FIRE HOSE REELS Confirm hose reel station is compliant with specification, and is located as indicated by the safety equipment layout drawing. Confirm that hose reel, hose, S/O valve etc are undamaged. Confirm tag plate is in accordance with specification, and is correct for the location. Confirm satisfactory condition of face piece head-harness assembly. Check and confirm contents gauge indicates within 'green' sector (1800 liters). Confirm hose reel is connected correctly to firewater ring main. FIRE / FOAMWATER MONITORS Confirm monitor station is compliant with specification, and located as indicated by the safety equipment layout drawing. Confirm monitor is securely fitted, and connected to Fire/Foam water ring main as appropriate (dependant on location and service). Confirm that monitor, S/O valve, and Isolation valve lubricated and are undamaged. Confirm tag plate is in accordance with specification, and is correct for the location. Confirm that monitor is facing correct direction and that range of movement is correct for the location. Confirm that monitor is facing correct direction and that range of movement is correct for the location. For automatic (oscillating) monitors, confirm free range of movement to stated horizontal and vertical limits of movement. Confirm that spray field is not obstructed. COMMENT(S) AND ADDITIONAL INFORMATION

OK

N/A P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FIRE HOSES AND MONITORS



S05-A



Page 2 of 2

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PORTABLE AND WHEELED FIRE EXTINGUISHERS S06-A Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem no. Area Location Ref. Drawing nos INSPECTION / TEST OK 1 Check Fire Extinguisher against purchase order; confirm quantities Serial / Model No.:Extinguisher Type:Extinguisher Colour:2 Specification / Data sheet No.:Size:Weight:Confirm extinguisher is compliant with specification and is located in 3 accordance with Safety Layout Diagram. 4 Confirm extinguisher is correctly mounted (as appropriate). 5 Confirm extinguisher is fully charged. 6 Confirm extinguisher carries a valid inspection and test certificate. Confirm no obvious damage to extinguisher, and that no leaks are 7 evident. Confirm that release (telltale) indicator is fitted and indicates that 8 extinguisher is unused. Confirm fire extinguishers have a pressure gauge fitted with dial gauge 9 indicating pressure Confirm portable fire extinguisher is correctly mounted (as 10 appropriate) and should not be obstructed. Wheeled fire extinguisher to be provided with canvas-type protective 11 cover. Wheeled fire extinguisher units shall have tow wheels (non-sparking) 12 for transport and to support the extinguisher upright. COMMENT(S) AND ADDITIONAL INFORMATION

N/A P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PORTABLE AND WHEELED FIRE EXTINGUISHERS



S06-A



Page 2 of 2

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FIREMAN OUTFIT CABINET Project No. Project Title Facilities Tag no. Area Ref. Drawing nos 1 2 3 4 5 6 7 8 9 10 11

S07-A


INSPECTION / TEST Check equipment against purchase order FIREMANS OUTFIT CABINET Confirm design is in accordance with specification, and is located and installed in accordance with specification and relevant safety layout drawing. Confirm tag plate details are correct Confirm inventory of contents are undamaged, and in accordance with specification. Confirm First-Aid Box is included and complete in accordance with specification. Confirm Airpack (BA) is included and is tested and complete in accordance with specification. FIREFIGHTING SUITS Confirm suits are in accordance with specification, and that locker is located in accordance with the specification and relevant safety layout drawing. Confirm all suit items are in new condition and are undamaged. Confirm inventory for each suit 'set' is complete in accordance with specification and that size of suits is generally adequate for all people. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A MISCELLANEOUS SAFETY EQUIPMENT S08-A Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem no. Area Location Ref. Drawing nos INSPECTION / TEST OK 1 Check equipment against purchase order 2 KNOTTED ROPES Confirm design is in accordance with specification, and it is located and 3 installed at all life raft stations in accordance with specification and relevant safety layout drawing. Check knotted rope data sheet and confirm minimum length = 4 Check knotted rope and record length = 5 Confirm storage bin provided for each rope. 6 ELSA (Emergency Life Support Apparatus). Confirm all ELSA's are in accordance with specification, and are located 7 / stored in accordance with the details contained in the relevant safety equipment layout drawing. 8 Confirm that all ELSA's are in a serviceable condition. 9 SAFETY GLOVES Confirm supplied gloves are compliant with specification and located in 10 accordance with project requirement. 11 FIRE BLANKETS Confirm fire blankets are compliant with specification, and are located 12 in process areas in accordance with the relevant safety equipment layout drawing. 13 Confirm storage container is undamaged. FIRST AID KIT: - 5 Triangular bandages 130cm x 90cm x 90cm - Sterile eye pads - Non-sterile 4x4” gauze pads - Sterile 4x4” gauze pads 14 - Sterile 10x10” gauze pads - Elastic bandage - 4 Roller bandages 7.5 cm - 4 Roller bandages 3 cm. - 4 Roller bandages 2.5 cm - Cold pack compress gel

N/A P/L No

Page 1 of 3

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A

15 16 17 18 19 20 21 22 23 24 25 26 27 28

MISCELLANEOUS SAFETY EQUIPMENT S08-A - Burn sheet/dressing - Pairs of gloves (disposable/ non sterile) - Stainless steel bandage scissors - Adhesive tape - Sterile multi-trauma dressing/gauze - Alcohol prep pads - Cetavlon - Cotton buds - Barrier device for CPR (pocket mask, face shield) - Elastoplasts/sterile adhesive dressing - Safety pin for triangular bandages - Thermometer - First aid manual - Waterproof waste bag Inventory of box contents (checklist) Confirm that first aid kits are compliant with inventory/specification, and are located according to the relevant safety equipment layout drawings. Confirm storage container is undamaged. FLASHLIGHTS/EMERGENCY LIGHTS Confirm that flashlights supplied are compliant with specification and are located in accordance with the relevant safety equipment layout drawing. Confirm flashlight suitable for hazardous areas (Class 1, Group D, and Division 1). Confirm holding bracket and guard for flashlight are included and are undamaged. Confirm that emergency lights are compliant with specification and are located in accordance with relevant safety equipment layout drawing. OXYGEN RESUSCITATORS Confirm that all portable resuscitators are compliant with specification, and are located in accordance with the relevant safety equipment layout drawing. Located in accordance with the relevant safety equipment layout drawing 23 Confirm oxygen cylinder test date is visible and current. LITTER BASKET Confirm that litter basket is located according to the relevant safety equipment layout drawings. Confirm that litter basket is undamaged. STRETCHER Page 2 of 3

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 29 30 31 32 33

34 35 36 37 38

MISCELLANEOUS SAFETY EQUIPMENT S08-A Confirm that stretcher is located correctly according to the relevant safety equipment layout drawings. Confirm that stretcher is undamaged. Confirm that stretcher is easily accessible. PORTABLE COMBUSTABLE GAS INDICATORS/ CALIBRATION KITS - Confirm that gas indicators or calibration kits are located in accordance to the relevant safety equipment layout drawings. - Confirm that gas indicators or calibration kits are undamaged. Has audible, visual and vibrating alarms if STEL or TWA levels are exceeded - STEL and TWA levels are set as per approved specification - Portable gas detectors to be tested, calibrated and certified SAFETY EQUIPMENT CABINET Confirm that safety equipment cabinet is compliant with inventory /specification, and is located according to the relevant safety equipment layout drawing. Confirm safety equipment cabinet is undamaged. Confirm that safety equipment cabinet is easily accessible. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A Project No. Project Title Facilities Tag no. Area Ref. Drawing nos 1 2 3 4 5 6 7 8 9 10 11 12 13

LIFE RAFTS

S09-A


INSPECTION / TEST Confirm design is in accordance with specification, and it is located and installed at all life raft stations in accordance with specification and relevant safety layout drawing. Liferaft in satisfactory condition Confirm water-tight container is secure and undamaged. Confirm inventory of life raft is in accordance with specification and SOLAS requirements (E.P.I.R.B. & Portable VHF Radio). Confirm inflation cylinder is securely fitted, and is undamaged. Confirm inflation cylinder is fully charged, and has a valid and current test date stamp. Confirm life raft launching cradle is compliant with specification (BRASK-M-0034/1) and is undamaged. Emergency Position Indicating Radio Beacon (EPIRB). Confirm EPIRB is compliant with specification and is serviceable. Portable VHF Radio. Confirm Portable VHF radio is compliant with specification, and is undamaged. Confirm that a valid test/cal date label is attached. Confirm batteries are fitted, and undamaged. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FIREWATER/FOAM SYSTEM Project No. Project Title Facilities Tag no. Area Ref. Drawing nos 1 2 3 4 5 6 7 8

S10-A


INSPECTION / TEST Check equipment against purchase order Confirm firewater/foam system equipment is compliant with approved specification, and is located as indicated by the Escape Route, Fire Fighting, Safety and Life Saving Equipment layout drawing. FIREWATER PUMP Ref. Specification/ Datasheet No.:

16 17

Check and inspect all valves are as per approved P&ID for:

10 11 12 13 14 15

N/A P/L No

Ensure that the Mechanical ITR-A for Firewater Pump is completed. Name plate/tag details correct & in accordance with approved design data sheet. Manufacturers test certificates & FAT documentation available. Ensure firewater pump is dedicated for firefighting purposes. Check access to Firewater pump. FIREWATER RING MAIN Ref. Specification/ Datasheet No.: Check that piping is constructed according to the latest AFC (Approved for Construction) revision of P & ID and isometric drawing. Check couplings, vents and drains, hangers and supports, piping penetration is as per approved project specification. Ensure Piping ITR-A for Firewater Ring Main is completed. Check that materials used are as per approved piping specification. Check piping for signs of damage. Check and inspect NDE records and attach NDE clearance certificate from quality control. Check that lines are correctly marked with flow direction. Check that any junctions of dissimilar metals liable to cause galvanic corrosion are correctly insulated. Check and inspect that piping systems do not obstruct escape ways and emergency exits/ accesses.

9

OK

Page 1 of 4


18 19 20 21 22 23 24 25 26 27 28 29 30 31

FIREWATER/FOAM SYSTEM S10-A - Type - Rating - Certified fire-safe (where stipulated) - In line correct to the direction of flow - Position indicators are correctly orientated and, where remote signaling position is included, that the correct signals are displayed - Correct type of hand-wheel or activation lever and locking devices fitted (where required) - Operate smoothly through the designated limits and are lubricated with the correct lubricant for their particular application - Valve schedule and checklists are complete and accurate - No visible external damage - Adequate access for operation and maintenance - Purpose and operating instructions are provided Check location and operation of all pressure- reducing valves. Check that flow switch is installed in line with flow direction. Check flow switch/ pressure switch indicates open circuit for no-flow condition and closed circuit for flow condition. Check sensitivity of flow switch and damper action to suit. Check for signs of external damage of flow and pressure switch. Check that access is adequate for inspection and maintenance operations. FIRE WATER/ FOAM HOSE REELS (INDOOR AND OUTDOOR) Ref. Specification/ Datasheet No.: Confirm that hose reel, hose, shut off valve etc. are undamaged. Confirm tag plate is in accordance with approved specification, and is correct for the location. FIRE WATER/ FOAM MONITORS AND HYDRANTS Ref. Specification/ Datasheet No.: Confirm monitor/ hydrant is securely fitted, and connected to Fire water /Foam ring main as appropriate. Confirm that monitor/ hydrant, shut off valve, and Isolation valve lubricated and are undamaged. Confirm tag plate is in accordance with specification, and is correct for the location. Confirm that monitor is facing correct direction and that range of movement is correct for the location. Check rotation and elevation Page 2 of 4


32 33 34 35 36 37 38 39 40 41 41

42

43 44 45 46 47 48 49 50

FIREWATER/FOAM SYSTEM S10-A capability of monitors. For automatic (oscillating) monitors, confirm free range of movement to stated horizontal and vertical limits of movement. For remote control monitors, check remote control capability. Confirm that spray field is not obstructed. Check monitor gear box is filled to its correct level with manufacturer's specified lubricant (applicable for oscillating electrical monitor). Ensure the availability of hydrant hose (applicable for hydrants) and its location is as per layout. Check couplings of each hose and any equipment to be connected with them. FOAM TANK Ref. Specification/ Datasheet No.: Ensure foam tank provided with level indicator. Check foam (AFFF/ ARFFF) tank is filled to the correct level with manufacturer's specified foam agent SPRINKLER SYSTEM Ref. Specification/ Datasheet No.: Check sprinkler heads and ensure the frangible bulbs are of correct temperature rating for the system. Ensure that the sprinkler and/ or spray head (particularly the frangible bulb) is completely clean and free of paint or other coatings other than the original manufacturer’s finish. Open sprinkler valve and inspect the condition of its interior and ensure that the movement of the valve clapper is free and that the clapper hinge is lubricated with the approved lubricant. Re-install the sprinkler valve (Note: Ensure spare sprinkler heads are available prior to any tests being performed on the sprinkler system) DELUGE SYSTEM Ref. Specification/ Datasheet No.: Ensure that the deluge spray heads are correctly installed and no external damage. Check that deluge spray heads have correct orifice size and spray angle WATER MIST SYSTEM Ref. Specification/ Datasheet No.: Check presence of nozzle caps (if specified in the approved specifications). Check location of all nozzles. FIRE ALARM PANEL (LQ AND BUILDINGS) Ref. Specification/ Datasheet No. Ensure Fire Alarm Panel is available for LQ and Non-Process Buildings. Page 3 of 4


51

FIREWATER/FOAM SYSTEM S10-A For onshore buildings, check connection to BOMBA. Ensure the correct annunciation and resultant executive action of all remote signals at the main Fire and Gas Panel.

COMMENT(S) AND ADDITIONAL INFORMATION COMMENT(S) AND ADDITIONAL INFORMATION: (List the approved specification and datasheet reference number)





Page 4 of 4

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FIRE SUPPRESSION/TOTAL FLOODING SYSTEM S11-A Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem no. Area Location Ref. Drawing nos INSPECTION / TEST OK 1 Check equipment as per Purchase Order 2 Ensure nozzles are not blocked. Ensure warning signs posted at the entrance to, and inside of, area 3 protected by total flooding systems. Check pre-discharge alarm (visual and audio) on total flooding systems 4 is provided and allows time to safely exit the area before discharge. Check extinguishing agent storage container (pressure, piping 5 connections) Ensure fire suppression/ total flooding system is connected to the fire 6 panel (including status display). COMMENT(S) AND ADDITIONAL INFORMATION




N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ESCAPE AND EVACUATION EQUIPMENT S12-A Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem no. Area Location Ref. Drawing nos INSPECTION / TEST OK 1 Check equipment as per Purchase Order ESCAPE ROUTES AND MUSTER AREA 2 Ref Drawing No: 3 Escape routes clearly marked and free from obstruction. Escape routes painted in accordance with approved specification & deck 4 layout drawings. Emergency escape route deck plans displayed at all deck levels in 5 accordance with relevant drawings. 6 Non-skid surfaces completed as per specification. Ensure muster area is clearly marked (signage and painting) and free 7 from obstruction 8 Emergency lighting correctly located along escape routes. 9 Ensure muster area location and space provision is as per drawings Ensure Escape Route, Fire Fighting, Safety and Life Saving Equipment 10 layout is displayed at each deck Safety sign is displayed in accordance with specification and located in 11 accordance with relevant drawings. ESCAPE AND EVACUATION EQUIPMENT Ref Drawing No: 12

13

N/A P/L No

Ensure the following items compliant with approved specification, and is located as indicated by the Escape Route, Fire Fighting, Safety and Life Saving Equipment layout drawing. Life Jackets Ref. Specification/ Datasheet No: -

Cabinet equipment inventory in accordance with specification Cabinet is labeled for “LIFE JACKET” Donning instructions for life jacket is permanently attached to the inside of the doors/ lids of the life jacket cabinets Life jackets shall be labelled “LIFE JACKET” and “PLATFORM NAME” Page 1 of 3

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ESCAPE AND EVACUATION EQUIPMENT S12-A - Ensure life jacket is of USCG Type 1 Personal Floatation Device (PFD) - Life jacket to include: o Whistle and lanyard o Seawater illuminating light o Lifting straps and oral inflation system o Reflective strips Workvest Ref. Specification/ Datasheet No:

14

15

16 17

18

-

Cabinet equipment inventory in accordance with specification Storage cabinet is labeled for “WORKVEST” Donning instructions for work vest is permanently attached to the inside of the doors/ lids of the life jacket cabinets - Work vest shall be labelled “WORKVEST” and “PLATFORM NAME” - Ensure work vest is of USCG Type V Personal Floatation Device (PFD) - Work vest is provided with adjustable strap Knotted Ropes/ Rope Ladder Ref. Specification/ Datasheet No: - Check knotted rope data sheet and confirm minimum length = - Check knotted rope and record length = - Confirm storage bin provided for each rope. - Ensure ladder rung is with nonslip coating/ surface - Ladder rungs equally spaced between 300 – 380 mm apart and secured in such a manner that they will remain horizontal. - Visual inspection of rope and ladder rung conditions Quick Descent Device Ref. Specification/ Datasheet No: Fire Blanket Ref. Specification/ Datasheet No: Self-Contained Breathing Apparatus (SCBA)/ Breathing Apparatus (BA) Ref. Specification/ Datasheet No: -

Check pressure gauge of available breathing air in the cylinder. Ensure airpacks are MSHA/ NIOSH certified positive pressure type rated for 30 minutes. SCBA to include o Cylinder o Valve assembly (spring loaded exhalation valve, Page 2 of 3

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A ESCAPE AND EVACUATION EQUIPMENT S12-A breathing valve, pressure demand regulator), o High pressure hose o Audible low pressure warning device o Face piece o Harness - SCBA air compressor is supplied with air purification equipment for recharging SCBA unit. - Compressor to be included with Breathing Air Test Kit and method for securing cylinder being charged to compressor skid. - Compressor is suitable to be powered from emergency power 3 phase. Manual Call Points Ref. Specification/ Datasheet No: 19 - Ensure Manual Call Points are installed as per layout and is visible. - Ensure Manual Call Points are connected to the fire panel Visual and Audio Alarms Ref. Specification/ Datasheet No: 20 - Ensure Visual and Audio Alarms are installed as per layout and is visible. - Ensure Visual and Audio Alarms are connected to the fire panel COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A Project No. Project Title Facilities Tag no. Area Ref. Drawing nos 1 2 3 4 5 6 7 8 9 10 11

LEV

S13-A


INSPECTION / TEST Verify to ensure that all construction / installation activities for LEV and stack have been completed as per drawing Ensure hood can be completely pulled closed and opened Ensure that there is no abnormal sound present when LEV is switched on Ensure lighting has been installed Ensure LEVs are labeled as per drawing. Ensure that flexible ducts are installed in a way that it allows steady uninterrupted flow i.e. no unnecessary heavy bends and dents Confirm that there is no holes, dents or other signs of physical damage on ducting; both below and above ceiling. Check that test holes are fitted in correct position and accessible, covers for test holes secured and sealed. Ensure that baseline testing has been conducted Confirm that the baseline testing covers capture/ face velocity, hood static pressure, duct static pressure, hood velocity pressure, transport velocity, air cleaner/ filter efficiency, fan capacity and fan efficiency Confirm that the result of baseline testing is within +/- 10% of design values COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A Project No. Project Title Facilities Tag no. Area Ref. Drawing nos 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

SICKBAY

S14-A


INSPECTION / TEST Verify to ensure that all construction have been completed as per drawing Signage at entrance Lighting Entrance door open sideways Bottom clearance of doors does not exceed 0.6 cm Windows with curtains All electrical sockets tested and functioning Water supply to all faucets and shower heads Water heater / warm water supply Floor drains doesn’t show signs of clog Telephone HVAC functioning Bed screen curtain rail Mirror Fixture for oxygen tank Hospital Bed Examination couch Biological waste bin Clinical scales Height measure Stainless steel cabinets AED Refrigerator COMMENT(S) AND ADDITIONAL INFORMATION

OK

N/A P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A SICKBAY



S14-A



Page 2 of 2

CSP-20 rev. 01 Appendix I-VIII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A DECK INTEGRATED FIRE FIGHTING SYSTEM S15-A Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem no. Area Location Ref. Drawing nos INSPECTION / TEST OK Verify to ensure that all construction / installation activities have been 1 completed. Confirm DIFFS is compliant with approved specification and layout 2 Ref. Specification/ Datasheet No: 3 Ensure certification by manufacturer is available. Ensure that the pop-up nozzles are closed and installed flushed with 4 the helideck surface. Ensure the piping distribution system is connected with the pop-up 5 nozzles. 6 If foam system is used, ensure foam skid is connected and filled. 7 Ensure nozzles can pop-up. 8 Ensure the DIFFS activation button is installed at accessible area. COMMENT(S) AND ADDITIONAL INFORMATION




N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A STRUCTURAL MEMBERS

ST01-A

Project No. Project Title Facilities Area No System Sub System

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

INFORMATION Ref Drawing Inspection Date Location

INSPECTION / TEST Installation of girder & nodes frame are completed as per IFC drawing Primary structural frame complete as per IFC drawing Secondary structure frame completed as per IFC drawing Blast wall & firewall completed as per IFC drawing Deck structure completed as per IFC drawing Install deck coming as per IFC drawing All stiffeners installed as per drawing Service platforms & walkways pipe rack installed correctly Deck drains installed Deck & wall penetrations installed as per IFC drawing Grating complete and installed correctly Monorails installed as per IFC drawing Pad eyes/lifting lugs installed as per IFC drawing All of rotating equipment sub bases are completed as per IFC drawing Ladders installed to drawings Stairs installed to drawings Handrails installed and secured All hatches complete to drawings Flare boom completed install as per IFC drawing Access platform complete as per IFC drawing NDT completed COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A STRUCTURE PAINTING

ST02-A


1 2 3 4 5 6 7 8 9 10 11

12

13


INSPECTION / TEST All surfaces clean and dry prior to application Sharp edges-removed prior to application All masking completed and safety 3. measures taken Visual control performed during application, record below ambient and humidity during Spot painting performed Piping supports completed Penetrations correctly coated Bulkhead joints correctly coated Structural interfaces correctly coated Dry film thickness checked correct. Record details Record any defective area(s) on punch list Details of paint type as below: Date of application : Curing time : (Hrs) Percentage of relative humidity: (%) Start of application : (Hrs) Completion of application : (Hrs) Attach drawings, highlighted with areas checked COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PASSIVE FIRE PROTECTION

ST03-A


1 2 3 4 5 6 7


INSPECTION / TEST Installed as per design drawings and specification, record type and thickness Ensure that surface preparation as per specification Ensure that passive fire protection as per specification Check protection coverings for passive fire protection damage installed where necessary. Verify adequate access for maintenance of equipment that has been passive fire protection coated Verify passive fire protection where exposed to mechanical damage has been protected Attach drawing(s), highlighted with areas checked COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A STRUCTURAL JACKET

ST04-A



INSPECTION / TEST Primary framing fabricated as per IFC drawing Elevation truss fabricated as per IFC drawing Conductor guide fabricated as per IFC drawing. Stairways installed as per IFC drawings. Shock cell and shear fender installed as per IFC drawings. Rigging platform installed as per AFC drawings. Cap plate and leg diaphragm closure installed as per IFC drawings Flooding system test and functional as per specification Flooding system test and functional as per specification Ensure that Cathodic Protection (ANODE) are installed as IFC per drawing & 10 specification 11 Lifting pad eyes and Trunion installed as per IFC drawings COMMENT(S) AND ADDITIONAL INFORMATION

OK

N/A P/L No.

1 2 3 4 5 6 7 8 9





Page 1 of 1

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A RISER

ST05-A



INSPECTION / TEST Riser is fabricated according to the AFC drawing Flanges used are as per specification. All welded joints and NDT have been completed. Bolts and nuts at riser clamp adequately tightened, correct length and 4 coating as per specification 5 Riser coatings are as per specification 6 Riser clamp secure and installed at correct elevation as per drawings. 7 Riser dimensions are as per drawings 8 Bend radius are as per drawings. 9 Coating at riser clamps are as per specification. 10 Hydrotest and Flushing completed 11 Draying and internal cleaning completed 12 Gauging Pig have been performed COMMENT(S) AND ADDITIONAL INFORMATION

OK

N/A P/L No.

1 2 3





Page 1 of 1

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A I & J TUBE

ST06-A


1 2 3 4 5 6 7 8


INSPECTION / TEST I & J Tube is fabricated according to the IFC drawing. Flanges used are as per specification All welded joints have been completed. Bolts and nuts at I-Tube clamp adequately tightened, correct length and coating as per specification. I & J Tube coatings are as per specification

OK

N/A P/L No.

I & J Tube clamp secure and installed at correct elevation as per d IFC drawings. I & J Tube dimensions are as per IFC drawings. Coating at I & J Tube clamps are as per specification COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TELECOM TOWER

ST07-A


1 2 3 4 5 6 7 8


INSPECTION / TEST Telecom tower fabricated & installed as per IFC dwg Fall arrest/ climbing cage as per IFC dwg Safety rail as per IFC dwg Maintenance platform as per IFC dwg Lightning rod as per IFC dwg Aviation warning light installed as per specification Ensure that antenna alignment not exceed +- 1.5 Deg at 64 km/in wind speed Painting as per specification COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No.


Page 1 of 1

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A JACKET PRE-LOADOUT

ST08-A



INSPECTION / TEST GENERAL • Fabricator to ensure that the structural details of the WDDP-A jacket is in accordance with the company structural standards unless noted otherwise. o Structural details o Handrails o Grating Flooring o Stair Platforms • All surface cut areas, rough edges and protrusions along the jacket are to be ground smooth.

1

OK

N/A P/L No.

• FABRICATOR is to ensure that all internal and external handrail/prism fitting to not impede or interfere with proposed access points to equipment and control units. • Check if the identification markings are clearly painted at the top elevation of the jacket for offshore identification: o Legs B3 and B4 o Legs C3 and C4 • Check all grating welds/clips are firmly secured. • Inspect the upending padeyes-based on the information provided by the CONTRACTOR. o Location o Details (as per technical design provided by the CONTRACTOR) • Compare padeyes to the shackle sizes that are provided. • Identify the position, where the topside hinged ladder would land. • Check all shackles actual pin diameter/holes size. • Compare weight control reports provided by the FABRICATION with the design calculations provided by the CONTRACTOR. • Check for the adequate protection against damage of the paint from rigging, tie down and during installation. • Inspect the cathodic anode clash with CONTRACTOR’s rigging and installation aids. • Check additional marking/paint at EL(-)25394 at Leg A1& B1 and marking at EL(-) 64673 at leg A3 and B3 as per section 2.4.10 for jacket upending. • Check marking on pile sleeve. Page 1 of 1

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A JACKET PRE-LOADOUT INSPECTION / TEST

1

ST08-A OK

N/A P/L No.

• Pile sleeve should be checked for leaks (Positive Pressure- Bulging Diaphragm). • Check all installation aids details as per drawing. • Inspect the installation riggings and aids are clear from any structural obstruction. FLOODING AND VENTING SYSTEM • The following are checked to be in accordance with the COMPANY specifications: o High Pressure Tubing Bundles o Actuated Ball Valves (Jackets) o Manually Operated Ball Valves (Jackets)

2

3

• Inspect the position if the Vent/Deballast Manifold which is located on jacket legs and Quick Control Panel (QCP) which both are located at sea deck on jacket leg B3. • All positions of Flood Valve Actuator tubing’s and ROV Operated valve are to be checked i.e. closed properly prior loadout at the relative elevations as per COMPANY’S design: a. Flood Valve Actuator tubing’s Valve i. EL(-)TBA at Legs B3,B4 & C4 ii. EL(-)45750 for Skirt Sleeve B1-4, C1-4, B1-1a & C1-1a iii. EL(-)28600 for Buoyancy Tank TB-3 & TC-3. b. ROV Operated Valves i. EL(-)17800 at Legs B3,C3,B4&C4 ii. EL(-)44750 for skirt Sleeve B1-4, C1-4,B1-1a &C1-1a iii. EL(-)27600 for Buoyancy Tank TB-3 & TC-3. • FABRICATOR is to ensure that all supports (E.g. stubs,etc) are clear from any structural obstruction. • FABRICATOR is to secure all straps that are on the jacket in order to prevent them from sliding down the jacket legs or braces during installation. • Check if the Flooding System and the Hydraulic Actuated Flooding Valve on the Vent/ Deballast Manifold S.S tubes on B3 are directly connected to the upending QCP. GROUTING SYSTEM • FABRICATOR to inspect all piping routes, to grout stations and pipe spacing should be no greater than 2m (2000mm). • FABRICATOR to confirm the positions and number of supports between the grouting lines which is 0.15m (150mm) apart and measured from the weld toe. • Check the grout stations to see if the grouting lines are positioned properly and the color coding matches the AFC drawings no: WDDP-A W-1165-001 Rev.1. The grout connection station should be accessible by the jacket seadeck walkway. Page 2 of 6

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A

3

4

5

6

7

JACKET PRE-LOADOUT ST08-A INSPECTION / TEST a. Grout Connection Station i. Located at Leg B3-for all Skirt Sleeve (B1-4, C1-4, B1-1a & C1-1a) b. Color Coding i. Primary Line-Green ii. Secondary Line-Yellow iii. Tertiary Line-Red • Inspect the 2” quick connect hose connector that is being used at the grout station (Specified by the CONTRACTOR and installed by the FABRICATOR). • Check the tertiary line at the pile sleeve along with the 2” Male R.O.V hose connector and determine that the position is at the outer region of the York Plate on the pile sleeve. ROV holding handles installed for ROV to hold during handling the valves. • FABRICATOR to check tertiary pipe supports and is clear from any structural obstruction. GROUTING PACKER & PILE GRIPPER INFLATION SYSTEM

OK

N/A P/L No.

• Inspect the Pile Gripper inflation port that is provided with the secondary inflation line system and to determine if it is ROV accessible to the surface inflation hose. • Inspect the Grout Packer inflation port that is provided with the secondary inflation line system and to determine if it is ROV accessible to the surface inflation hose. • Ensure that low heat application at the welds in the packer area is used in accordance with the manufacturers fitting instructions. • Check the position of the ROV secondary hot-tap inflation port and ensure that it is installed facing outward of the jacket that will allow the facilitation of the ROV operations. • FABRICATOR is to fully test and commission the Grout Packer Inflation System, Pile Gripper System together with air lines, grout lines and flooding lines and flooding lines at the yard and to be witnessed by the CONTRACTOR. • The Quick Connect Panel (QCP) for the grout packer & pile gripper inflation should be accessible by the walkway on jacket sea deck to jacket leg B3. BOAT LANDING • Check boatlanding pre-installed rigging make-up, arrangement, ID and tie-down (if any) • Check any potential interference when installing boatlanding to jacket. • Boat landing trail fit shall be performed by FABRICATOR and witnessed by CONTRACTOR. BOAT LANDING-POST LOADOUT • Witness MPI padeyes and shackles after lifting (if required) • Check for damages during loadout. • Check and inspect lifting riggings after lifting. JACKET POST LOADOUT • Check all sea fastenings. Page 3 of 6

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A

7

8

9

JACKET PRE-LOADOUT ST08-A INSPECTION / TEST • Confirm load out arrangement with all parties involved. • Check for positive pressure in the pile sleeves and identify if there are any leaks (Bulging Diaphragms). If a gauge is accessible, check the gauge reading. • Review quantities of all ship loose items for the jacket. • Placement of ship loose items on the barge and is properly secured. • Go through all dimensional trial-fit, As-Built and NDT reports (paper exercise) submitted by the FABRICATOR. • Check for damages during load out process. • Check the Quick Connect Panel (QCP) position that it does not interface with rigging arrangement. • Checks launch rigging and wiring plan as per drawing. Inspect all rigging arrangements and check if there is any interface with the launch lug during the launching process. • Check all stoppers at rocker arms. To be cut off after jacket is loaded out onto the barge.

OK

N/A P/L No.

• Check the location of the Centre of Gravity (COG)to be marked on the jacket leg. • Check the ESDV Service Platform sharp edges and protruding members are fully protected from rigging arrangement. • Check all installation aids for load out operation are removed. • OIC to mark self jacket launch distance on the skid beam and jacket launch cradle after completion of sea fastening. • OIC to check all the rigging aids are properly installed and clear from any obstruction. SKIRT PILES • Check roundness of pile top, middle and end sections. • Check piles length and diameter. • Ensure that the marking on Pile Sleeve are clearly marked: o B1-4 and C1-4 o B1-1a and C1-1a • Check stoppers-dimensions, details and location. • Paint mark at internal& external wall at top and bottom of pile 500mm wide with a white high intensity reflective paint on all skirt piles P1 and P2 skirt sleeve B1-4, C1-4, B1-1a&C1-1a and numbering shall start on all skirt piles P1 skirt sleeve B1-4, C1-4, B1-1a&C1-1a as Dwg No. TBA • Grind flush longitudinal seam welds 10ft from top of skirt pile • Skirt piles white paint mark at interval: o 0-10m : 1m interval o 10m onwards: 250mm interval POST LOAD-OUT PILES • Confirm position and arrangement of all piles as per approved transportation drawing. • Ballast for tow conditions (prior/concurrent/after lashing to hold piles Page 4 of 6

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A JACKET PRE-LOADOUT INSPECTION / TEST

9

10

ST08-A OK

N/A P/L No.

in places). • Overall dimensional trial fit, as built and NDT reports (paper exercise) submitted by yard. • Review quantity of shiploose. • Shiploose placement and securing. • Identify and check location of navigation light on pile barge. • Check pile upending frame condition for any damage during loadout. OTHER SHIPLOOSE ITEMS ON JACKET & PILES BARGE • Platform a joint inspector with all parties (FABRICATION/CONTRACTOR/COMPANY) on every quantity of shiploose items such as bolts, nuts and spares. COMMENT(S) AND ADDITIONAL INFORMATION





Page 5 of 6

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A JACKET POST LOADOUT

ST09-A


1

2


INSPECTION / TEST GENERAL CHECKLIST ITEMS ON JACKET LAUNCH BARGE & PILES BARGE: POST LOADOUT • Check for barge emergency lines are installed complete with Norwegian buoy and located at accessible location. • Check navigation lights are operational. • Check condition of emergency towing line operational (if any). • Check and confirm all manholes are closed prior to sailaway. • Check barge condition for any damage prior to sailaway. • Check ballast pattern as per approved transportation study and identify draft mark at bow and stern of the barge. • Brief personnel in charge for sailaway i.e Tug boat captain and crews on passage plan and Emergency Response Plan (ERP). • Check weather forecast prior sailaway. DRILLING DECK • Check overall dimension especially deck leg spacing (as-built). • Check stabbing cone OD to be verified. • Check level/vertical height length dimension (as-built). • Check pre-installed lifting rigging make-up, layout, and I.D. and tie-down arrangement. • Check padeyes as-built-NDT reports. • Position of bottom Deck leg seam weld especially relative to top stub piles(as built). • Review ship loose arrangement layout on top of deck for potential interferences when rigging up and de-rigging lifting slings (if applicable). • Stairway hinged up and secured under deck. Vertical ladder from access deck to jacket seadeck secured on access deck. • Check all bolted connections secured. • Check grating clip secured. • Review any structure/piping/cable tray protruding 1.5 meter radius around design elevation of deck that may interfere with stabbing point or any permanent structure at the jacket. • Check dimensions of stabbing cones and painted on each deck leg for offshore identification i.e B1, B2, C1&C2.

OK

N/A P/L No.

Page 1 of 1

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A JACKET PRE-LOADOUT INSPECTION / TEST • Check installation aid ( control bollards, padeyes, guides and bumpers) orientation/location/dimension/weld details (if applicable)

ST08-A OK

N/A P/L No.

• Check adequate protection against paint damage from rigging, lifting and etc. • Trial fit shiploose handrail and components and review piece marks on handrail. • Review each installation task sheet and identify any non-compliance with IFC drawings.

2

3

• Check the padlock installed at the security door by fabricator, function test and SGR Rep to keep the key (to access prior installation at field later-if applicable) • Review any structure that may interfere with riggings, aids and derrick barge crane boom during lifting and setting deck, e.g. boom rest, exhaust stack, vent/flare boom and etc. • Check and confirm all storage tanks at Deck are empty (i.e. without water, diesel or any chemical liquids inside). • Overall as built trail fit (paper exercise). • Check & confirm the counter-weight as recommended by engineering analysis, placed at right location, secured & pre-slug with valid certification (if applicable) • Paint marks all lifting padeyes with ID (B1, B2, C1, C2) secure crane boom with wires at permanent boom rest. • Ladder installed & secured properly at temporary access location. • Review final as built weight & COG location against calculation. • The remaining length of pre-installed boat landing swing rope to secured to cellar deck. (if applicable) DRILLING DESK POST LOADOUT • MPI padeyes and shackles after lifting (if applicable). • Sea fastening inspection. • Review all shiploose items, placement and securing (if applicable). • Confirm loadout arrangement/orientation • Check for damages during loadout. • Protection of equipment or weak structure/piping, e.g. exhaust duct and etc. (if applicable). • Ballast for tow conditions (prior to start of welding tie-down). Page 2 of 6

CSP-20 rev. 01 Appendix I-IX PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A JACKET PRE-LOADOUT ST08-A COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TELECOMMUNICATION PANEL /CABINET INSTALLATION Project No. Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating

1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 11

T06-A

Sys Description INSTRUMENT DATA System Number Manufacturer Location Model Number Area Serial Number Unit Temp. Class Gas Group ACCEPTANCE CRITERIA (ERROR %)

SUPPORT INSTALLATION Fabrication as per detailed drawing Fixing points correct size and orientation Location/Elevation as per layout Fixing on concrete secured Fixing on structural steel secured EQUIPMENT INSTALLATION Confirm panel installed correctly as per layout drawing, and undamaged Confirm I.S Earth Bar and Safety Earth is installed Confirm sufficient access to panel door entries for maintenance accessibility Confirm that all panel earthing is in accordance with earthing philosophy Confirm all glanding correct and appropriate to cables fitted Confirm spare gland entries are plugged correctly Confirm sufficient segregation for different voltage levels Confirm gaskets & seals fitted correctly, and undamaged Confirm swing frame (where fitted) hinge pins are securely fastened Confirm that all cables to doors and swing frames are of sufficient length to avoid tension Confirm all terminal secure

OK

N/A P/L

OK

N/A P/L

Page 1 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A

12 13 14 15 16

TELECOMMUNICATION PANEL T06-A /CABINET INSTALLATION Check the segregation of IS and non-IS wiring in the panel. Verify that all screens and unused cores are made off and earth according to the wiring diagram Confirm trunking (where fitted) secure and lids fitted Confirms panel internals are free of dust or debris Recommended grease applied to flanges (Ex-d enclosures only) Confirm barrier units are correctly mounted, labeled and segregated from none IS sources

Confirm that the cables connecting the earth bars are connect size and undamaged Verify to ensure that all construction / installation activities have been 18 completed 19 Paintwork correct REFERENCE DRAWINGS 17

TEST EQUIPMENT Type

Manufacturer

Model

Serial Number


OBSERVATION / REMARKS

Designation Company




Name Signature Date Page 2 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TELECOMMUNICATION JUNCTION BOX INSTALLATION Project No.

T07-A

Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating


SUPPORT INSTALLATION 1 Fabrication as per detailed drawing 2 Fixing points correct size and orientation 3 Location/Elevation as per layout EQUIPMENT INSTALLATION

OK N/A P/L

OK N/A P/L

Verify to ensure that all construction / installation activities have been completed Inspect junction box for mechanical damage, individual tagging, and 2 attachment to supports 1

3 Verify tag plate identification correct, and 'Ex' rating clearly identified 4

Verify JB is suitable for the area classification, confirm IP rating as per datasheet

5 Verify all fitted equipment compliance to Ex certificate (Note: For Ex-rated boxes box only)and verify that wires are terminated as per termination Open junction 6 junction 7 8 9

diagram Verify that all screen wires are insulated and terminated Inspect flange surfaces and apply copper grease compound to flange surfaces Inspect glands and ensure that all glands are properly installed Page 1 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TELECOMMUNICATION JUNCTION BOX INSTALLATION 10 Inspect sufficient access to door/lid for maintenance 11 Inspect spare gland entries are plugged correctly 12 Inspect gaskets & seals fitted correctly, and undamaged

T07-A

13 Verify JB internals are free of dust and debris 14 Verify that all spare cable entries are plugged with the appropriate plugs 15 Check earthing of junction box as per earthing philosophy 16 Verify JB is installed securely and correctly as per equipment layout drawing REFERENCE DRAWINGS

Type

TEST EQUIPMENT Manufacturer Model Serial Number Calibration Expiry Date


Designation Company Name




Signature Date Page 2 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A VHF FM INSTALLATION & TESTING Project No. Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating

1 2 3 1 2 3 4 5 6

T08-A

Sys Description INSTRUMENT DATA System Number Manufacturer Model Location Number Area Serial Number Unit Temp. Class Gas Group ACCEPTANCE CRITERIA (ERROR %)

GENERAL CHECKS Check name plate details against to data sheet Verify enclosure classification and ensure suitable for the area Identification label fixed EQUIPMENT INSPECTION Location as per the layout drawing All accessories installed and correct Antenna installed at correct elevation and direction No physical damage to installed items Earthing installed as per drawings and all connections are tightened properly Tag number correct REFERENCE DRAWINGS

OK

N/A P/L

OK

N/A P/L

TEST EQUIPMENT Type

Manufacturer

Model

Serial Number


Page 1 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A VHF FM INSTALLATION & TESTING

T08-A


Designation Company




Name Signature Date

Page 2 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. TELECOMMUNICATION VHF AM INSTALLATION & TESTING Project No. Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating

T09-A


GENERAL CHECKS 1 Check name plate details against to data sheet 2 Verify enclosure classification and ensure suitable for the area 3 Identification label fixed EQUIPMENT INSPECTION 1 Location as per the layout drawing 2 All accessories installed and correct 3 Antenna installed at correct elevation and direction 4 No physical damage to installed items 5 Earthing installed as per drawings and all connections are tightened properly 6 Tag number correct REFERENCE DRAWINGS

OK N/A P/L

OK N/A P/L

TEST EQUIPMENT Type

Manufacturer

Model

Serial Number


CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. TELECOMMUNICATION VHF AM INSTALLATION & TESTING

T09-A




VERIFIED BY PCSB Inspector

ACCEPTED BY Discipline Engineer

PETRONAS Carigali

PETRONAS Carigali

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. TELECOMMUNICATION LAN/WAN SYSTEM INSTALLATION Project No. Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating

T10-A


GENERAL CHECKS 1 Check name plate details against to data sheet 2 Verify enclosure classification and ensure suitable for the area 3 Identification label fixed EQUIPMENT INSPECTION 1 FOPP, SWR, Socket Outlet location & mounting correct 2 Check each RJ45 plug according to ANSI / TIA EIA 568A or B Color coding and 3 Switching termination hubs have correct number of ports 4 Outlet continuity tested 5 No physical damage to installed items 6 Earthing installed as per the drawing and all connections properly tightened 7 Identification tag correct REFERENCE DRAWINGS

OK N/A P/L

OK N/A P/L

TEST EQUIPMENT Type

Manufacturer

Model

Serial Number


CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. TELECOMMUNICATION LAN/WAN SYSTEM INSTALLATION

T10-A






PETRONAS Carigali

PETRONAS Carigali

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TELECOMMUNICATION CABLE INSTALLATION & TESTING Project No. Project Title Platform/ Plant name Sys Number Tag Number Cable Schedule From: No:

1 2 3 4 5 6

T01-A

Sys Description CABLE DATA System No: Cable Type: No. of Cores: To: ACCEPTANCE CRITERIA (ERROR %)

GENERAL CHECKS OK Verify to ensure that all construction / installation activities have been completed Check cable code & size correct Check cable identity and tag number correct Check glanding correct Verify cabinet and/or joint box cover seals undamaged and unused cable entries plugged correctly Make sure cable is tested as per the vendors instructions (attach any test results if applicable) INSTALLATION CHECK

1

OK

N/A P/L

N/A P/L

Verify to ensure that all construction / installation activities have been completed

2 Check interior for damage, cleanliness and remove packing 3 Visually inspect equipment for external damage 4 Verify nameplate tagging against data sheet 5

Verify each Instrument Equipment is calibrated and confirm the duration of the calibration certificate from vendor are still valid

6

Ensure that calibration is conducted as per approved instrument Calibration Test Procedure ITP and record the reading as follow (if required) Page 1 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A TELECOMMUNICATION CABLE INSTALLATION & TESTING TEST EQUIPMENT Type

Manufacturer

T01-A Model

Serial Number Calibration






PETRONAS Carigali

PETRONAS Carigali

Page 2 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FIBER OPTIC CABLE INSTALLATION AND TESTING Project No. Project Title Platform/ Plant name Sys Number Tag Number Cable Schedule From: No:

T02-A

Sys Description CABLE DATA System No: Cable Type: No. of To: Cores: ACCEPTANCE CRITERIA (ERROR %)

GENERAL CHECKS 1 Verify to ensure that all construction / installation activities have been 2 completed Check cable code & size correct 3 Cable identity and tag number correct 4 Glanding correct Cabinet and/or joint box cover seals undamaged and unused cable entries 5 plugged correctly Cable to be tested as per the vendors instructions (attach any test results if 6 applicable) OTDR & CONTINUITY TESTS 1 OTDR checked before laying of cable 2 Fiber OTDR (for UG Cables) & continuity checked after laying the cable 3 OTDR and point to point continuity check after termination 4 Final OTDR test results attached TERMINATION CHECKS: FIELD DEVICE TO PATCH PANEL 1 Fibers terminated correctly at device 2 Fibers terminated correctly at patch Panel 3 Gland earth tab connected to patch panel 4 Fiber identification correct PATCH PANEL TO PATCH PANEL /CONTROL PANEL 5 Fiber terminated correctly at patch panel

OK

N/A P/L

OK

N/A P/L

OK

N/A P/L

OK

N/A P/L

Page 1 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A FIBER OPTIC CABLE INSTALLATION AND TESTING

T02-A

6 Fiber cores terminated correctly at patch Panel/control panel 7 Gland earth tab connected to earth panel 8 Fiber identification in patch panel/control panel correct REFERENCE DRAWINGS 1 2 3 4 TEST EQUIPMENT Type

Manufacturer

Model

Serial Number







Page 2 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. TELECOMMUNICATION CCTV & PIR INTRUSION DETECTION SYSTEM INSTALLATION

T03-A

Project No. Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating

1 2 3 1 2 3 4 5 6 7 8


GENERAL CHECKS Check name plate details against to data sheet Verify enclosure classification and ensure suitable for the area Identification label fixed EQUIPMENT INSPECTION Camera location & mounting correct Control unit & monitor installed Terminal box is fixed properly Camera is fixed & aligned as per corresponding drawing Control & power connection to pan /Tilt/Zoom camera are done properly No physical damage to installed items Earthing installed as per the drawing and all connections are properly tightened Identification tag correct

9 Unused cable entries are blanked off with correct type of plugs 10 No unauthorised modifications on electrical enclosures 11 General condition of enclosure is satisfactory Enclosure glass parts and glass to metal sealing gasket and/or compounds are 12 satisfactory

OK N/A

P/L

OK N/A

P/L

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. TELECOMMUNICATION CCTV & PIR INTRUSION DETECTION T03-A SYSTEM INSTALLATION Enclosure flange faces are clean and undamaged and gaskets, if any, any are 13 satisfactory 14 Flange gap dimensions are within maximal values permitted Obstructions adjacent to flame proof flanged joints are within minimum 15 distance stipulated for specific gas group (IIA=10mm, IIB=30mm, IIC=40mm) 16 Breathing and draining devices are satisfactory Equipment is adequately protected against corrosion, weather, vibration and other adverse factors 18 No undue accumulation of dust and dirt 17

19 Where applicable, sealing is satisfactory 20

Enclosure lids are satisfactory with suitable gasket (where applicable) and fixing screws / bolts tightened and IP rating is maintained

21 Installation complies with hazardous area classification requirements REFERENCE DRAWINGS

TEST EQUIPMENT Type

Manufacturer

Model

Serial Number







CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A PAGA SYSTEM INSTALLATION Project No.

T04-A

Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating

1 2 3


GENERAL CHECKS Check name plate details against to data sheet Verify enclosure classification and ensure suitable for the area Identification label fixed EQUIPMENT INSPECTION Location as per the layout drawing Presence & connection of the corresponding key board correct No physical damage to installed items Loud speaker location & mounting correct Talk-back location & mounting correct Beacon light location & mounting correct Earthing done as per the drawing and all connections are properly tightened Verify Tag numbers of each component are correct as per the drawing Elevation and orientation correct as per the drawing Verify all components installed are suitable for the area in which it is located Verify installation of each circuit components against layout drawing All components are properly secured

OK N/A P/L

OK N/A P/L

1 2 3 4 5 6 7 8 9 10 11 12 13 Lamp rating, type, color and position are correct 14 Printed circuit boards are clean and undamaged (if visible only) 15 Unused cable entries are blanked off with correct type of plugs

Page 1 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A 16 17 18 19

T04-A PAGA SYSTEM INSTALLATION No unauthorised modifications on electrical enclosures General condition of enclosure is satisfactory Enclosure glass parts and glass to metal sealing gasket and/or compounds are satisfactory Enclosure flange faces are clean and undamaged and gaskets, if any, any are satisfactory

20 Flange gap dimensions are within maximal values permitted Obstructions adjacent to flame proof flanged joints are within minimum distance 21 stipulated for specific gas group (IIA=10mm, IIB=30mm, IIC=40mm) 22 Breathing and draining devices are satisfactory Equipment is adequately protected against corrosion, weather, vibration and 23 other adverse factors 24 No undue accumulation of dust and dirt 25 Where applicable, sealing is satisfactory Enclosure lids are satisfactory with suitable gasket (where applicable) and fixing 26 screws / bolts tightened and IP rating is maintained 27 Installation complies with hazardous area classification requirements REFERENCE DRAWINGS

Type

Manufacturer





Completed by Contractor Representative

Verified by PCSB Inspector PETRONAS Carigali

Accepted by Discipline Engineer PETRONAS Carigali

Signature Date

Page 2 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INDOOR/OUTDOOR TELEPHONE INSTALLATION Project No. Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating

1 2 3 1 2 3 4 5 6 7 8 9 10 11 12 13

T05-A


GENERAL CHECKS Check name plate details against to data sheet Verify enclosure classification and ensure suitable for the area Identification label fixed EQUIPMENT INSPECTION Telephone location & mounting correct Telephone socket location and mounting correct No physical damage to installed items Equipment as installed is clear of obstruction and accessible The equipment is free of vibration The equipment is properly supported and secure Verify installation of sound proof enclosure, where applicable Earthing installed as per the drawing and all connections are properly tightened Verify identification tag is correct Unused cable entries are blanked off with correct type of plugs No unauthorised modifications on electrical enclosures General condition of enclosure is satisfactory

OK

N/A P/L

OK

N/A P/L

Enclosure glass parts and glass to metal sealing gasket and/or compounds are satisfactory Page 1 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A INDOOR/OUTDOOR TELEPHONE T05-A INSTALLATION Enclosure flange faces are clean and undamaged and gaskets, if any, any are 14 satisfactory 15 Breathing and draining devices are satisfactory Equipment is adequately protected against corrosion, weather, vibration and 16 other adverse factors 17 No undue accumulation of dust and dirt 18 Where applicable, sealing is satisfactory Enclosure lids are satisfactory with suitable gasket (where applicable) and 19 fixing screws / bolts tightened and IP rating is maintained 20 Installation complies with hazardous area classification requirements REFERENCE DRAWINGS

TEST EQUIPMENT Type

Manufacturer

Model

Serial Number







Signature Date

Page 2 of 2


APPENDIX II: ITR – B (PRE-COMMISSIONING) 9.1

APPENDIX II-I: Architecture (A)- NA

9.2

APPENDIX II-II: Civil (C)- NA

9.3

APPENDIX II-III: Electrical (E)

9.4

APPENDIX II-IV: HVAC (H)

9.5

APPENDIX II-V: Instrumentation (I)

9.6

APPENDIX II-VI: Mechanical (M)

9.7

APPENDIX II-VII: Piping (P)

9.8

APPENDIX II-VIII: Safety (S)

9.9

APPENDIX II-IX: Structural (ST)- NA

9.10

APPENDIX II-X: Telecommunication (T)


CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GAS TURBINE GENERATOR

E01-B

Project No. Project Title Facilities Tag no. Frequency Manufacturer Model No. Serial No. 1

2

3 4 5

6 7

INFORMATION System/Sub System no. Voltage Rating Ref. Drawing nos. Location INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Completed and signed –off construction check-sheet and punch list status b) Precom check-sheet for generator feeder c) Precom check-sheet for CTs installed (if any) d) Precom check-sheets for all associated power & control cables and bus-ducts e) Precom check-sheet for substation grounding and NER f) Turbine pre-commissioning check sheets from mechanical g) Generator GA drawing, datasheet and FAT report h) Key single line diagram Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes/bus-duct flanges, bushing cracks, oil leaks, corrosion, painting damage etc. Check generator main cable supports and terminations. Check and confirm air intake and exhaust are free of obstructions. Check all CT secondary connections are secure and correct to the latest drawings. Check all temporary links have been removed and all shorting links (especially CT links) are in the correct position. Confirm that the generator star point and skid grounding are intact. Carry out IR test on the following circuits. (Test voltage shall be 500V DC for LV (up to 1kV) system and 5kV DC for HV (3.3kV and above) system. Attach report. Description IR (MΩ) Alternator Stator Winding Exciter Stator Winding Diode Bridge Assembly (Short out diodes) Space heater circuits Insulated Bearings Minimum insulation value shall be 10*(kV+1) MΩ.

Page 1 of 2

CSP-20 rev. 01 Appendix II-III

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B 8

9 10 11 12 13 14

GAS TURBINE GENERATOR E01-B Perform polarization index test on main windings. Calculate PI by dividing resistance measurement at the 10th minute by the 1st minute. Time IR (MΩ) Start 15 sec 30sec 1 min 2 min 4 min 6 min 8 min 10 min PI (R10/R1) Minimum acceptable value for PI is 2. However, PI values and IR shall be compared with the corresponding values from FAT report and any major deviations between the values need to be investigated prior to energisation. Confirm all vendor static tests have been completed satisfactorily. Attach results. Function- test the generator UCP to the vendor's pre-commissioning procedure. Perform additional pre-commissioning test as per vendor recommendation, if any, and attach results to this check sheet. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MICRO TURBINE GENERATOR

E02-B


2

3 4 5 6 7

8 9 10 11


OK

N/A P/L No

Documents required: a) Completed and signed –off construction check-sheet and punch list status b) Precom check-sheet for MTG feeder c) Precom check-sheet for CTs installed (if any) d) Precom check-sheets for all associated power & control cables and bus-ducts e) MTG GA drawing, datasheet and FAT report f) Key single line diagram Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes, signs of moisture ingress, oil leaks, corrosion, painting damage etc. Confirm that the generator star point and skid grounding are intact. Check generator main cable supports and terminations. Check and confirm air intake and exhaust are free of obstructions. Check the condition of starting battery and run a battery capacity check. Carry out IR test on the windings and power circuits. (Test voltage shall be 500V DC). Attach report. Minimum insulation value shall be 10*(kV+1) MΩ. Perform pre-commissioning checks as per vendor recommendations and attach reports. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION

Page 1 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MICRO TURBINE GENERATOR



E02-B



Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GAS ENGINE GENERATOR

E03-B


2

3 4 5

6 7


OK

N/A P/L No

Documents required: a) Completed and signed –off construction check-sheet and punch list status b) Precom check-sheet for generator feeder c) Precom check-sheet for CTs installed (if any) d) Precom check-sheets for all associated power & control cables and bus-ducts e) Precom check-sheet for substation grounding and NER f) Engine pre-commissioning check sheets from mechanical g) Generator GA drawing, datasheet and FAT report h) Key single line diagram Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes/bus-duct flanges, bushing cracks, oil leaks, corrosion, painting damage etc. Check generator main cable supports and terminations. Check and confirm air intake and exhaust are free of obstructions. Check all CT secondary connections are secure and correct to the latest drawings. Check all temporary links have been removed and all shorting links (especially CT links) are in the correct position. Confirm that the generator star point and skid grounding are intact. Carry out IR test on the following circuits. Test voltage shall be 500V DC. Attach report. Description IR (MΩ) Alternator Stator Winding Exciter Stator Winding Diode ridge Assebly (Short out diodes) Space heater circuits Insulated Bearings Minimum insulation value shall be 10*(kV+1) MΩ.

Page 1 of 2



GAS ENGINE GENERATOR E03-B Perform polarization index test on main windings. Calculate PI by dividing resistance measurement at the 10th minute by the 1st minute.

Time Start 15 sec 30sec 1 min 2 min 4 min 6 min 8 min 10 min PI (R10/R1)

9 10 11 12 13 14

IR (MΩ)

Minimum acceptable value for PI is 2. However, PI values and IR shall be compared with the corresponding values from FAT report and any major deviations between the values need to be investigated prior to energisation. Confirm all vendor static tests have been completed satisfactorily. Attach results. Function- test the generator UCP to the vendor's pre-commissioning procedure. Perform additional pre-commissioning test as per vendor recommendation, if any, and attach results to this check sheet. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B DIESEL ENGINE GENERATOR Project No. Project Title Facilities Tag no. Frequency Manufacturer Model Serial no. 1

2

3 4 5

6 7

E04-B


OK

N/A P/L No

Documents required: a) Completed and signed –off construction check-sheet and punch list status b) Precom check-sheet for generator feeder c) Precom check-sheet for CTs installed (if any) d) Precom check-sheets for all associated power & control cables and bus-ducts e) Precom check-sheet for substation grounding and NER f) Engine pre-commissioning check sheets from mechanical g) Generator GA drawing, datasheet and FAT report h) Key single line diagram Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes/bus-duct flanges, bushing cracks, oil leaks, corrosion, painting damage etc. Check generator main cable supports and terminations. Check and confirm air intake and exhaust are free of obstructions. Check all CT secondary connections are secure and correct to the latest drawings. Check all temporary links have been removed and all shorting links (especially CT links) are in the correct position. Confirm that the generator star point and skid grounding are intact. Carry out IR test on the following circuits. Test voltage shall be 500V DC. Attach report. Description IR (MΩ) Alternator Stator Winding Exciter Stator Winding Diode Bridge Assembly (Short outdiodes) Spae heater circuits Insulated Bearings Minimum insulation value shall be 10*(kV+1) MΩ.

Page 1 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B DIESEL ENGINE GENERATOR 8

Perform polarization index test on main windings. Calculate PI by dividing resistance measurement at the 10th minute by the 1st minute. Time Start 15 sec 30sec 1 min 2 min 4 min 6m 8min 10min PI (R10/R1)

9 10 11 12 13 14

E04-B

IR (MΩ)

Minimum acceptable value for PI is 2. However, PI values and IR shall be compared with the corresponding values from FAT report and any major deviations between the values need to be investigated prior to energisation. Confirm all vendor static tests have been completed satisfactorily. Attach results. Function- test the generator UCP to the vendor's pre-commissioning procedure. Perform additional pre-commissioning test as per vendor recommendation, if any, and attach results to this check sheet. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SOLAR PANEL

E07-B

Project No. Project Title Facilities Tag no. Output Voltage Manufacturer Ref. Drawing nos. Type 1

2 3 4 5 6

7 8

9 10 11

INFORMATION System/Sub System no. Power Rating Battery AH Serial no. Location INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Solar power system block diagram, schematic diagram and datasheet b) Approved FAT report c) Completed and signed-off construction check-sheets for the solar panel, battery and the control panel with punch list status d) Precom check-sheets for all associated power and control cables e) Precom check-sheets for associated battery Check equipment for mechanical damages (dents/scratches, corrosion, broken handles etc.) Verify mechanical operation of all switches Confirm incoming power feed for proper termination of conductors Ensure equipment grounding is intact Perform insulation resistance test on power, control and auxiliary circuits. (Ensure that all electronic components and circuits are disconnected and excluded from the IR test) Verify the functionality of all meters and indicating lamps Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SOLAR PANEL E07-B COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRICAL NETWORK MONITORING AND E08-B CONTROL (ENMC) SYSTEM Project No. Project Title Facilities INFORMATION Tag no. System/Sub System no. Model / Type IP Rating Serial no. Manufacturer Location Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required: a) ENMC system architecture and Functional Description System b) ENMC panel GA drawings and schematic drawings c) ENMC block diagram and interconnection drawings d) Approved FAT report e) Completed and signed-off construction check-sheet with punch list status 2 Verify the cleanliness of panel internals and confirm all loose wires, packing material etc. are removed. 3 Verify all power supply sources readings for correct input ratings. Power supply for each module shall be accordance to the ENMC system approved specification. 4 Conduct system status check for all ENMC modules i.e. processors, communication modules, power supply module, processors modules, communication modules and I/O modules. LEDs status indication at all modules shall be observed for any abnormalities. 5 Communication test with Generator/switchgears/switchboards/MCC a) Verify designated programming/user map downloaded to each Intelligent Electronic Devices (IED) b) Verify status readings on each Human Man Interface (HMI) i.e. GA, SLD and ENMC Network pages against actual status/reading on device c) Verify command function from HMI and monitor correct response at receiving end (IED) 6 Communication test with third party equipment a) DCS/PMCS b) CSS/SIS c) UPS

N/A P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRICAL NETWORK MONITORING AND E08-B CONTROL (ENMC) SYSTEM 7 Data Log and Alarm Notification Test a) Simulate basic communication break down and trip alarm from each I/O device and verify correct notification displayed on ENMC screen and engineering work station (EWS) b) Verify alarm summary triggered/simulated at HMI 8 Multiple Network HMI communication test i.e. testing with EWS/DCS/PMCS. a) Browse thru ENMC from EWS. ENMC HMI display at EWS should run without errors (Level-2) b) Browse thru ENMC from PMCS/DCS (Level-3). ENMC HMI display at PMCS/DCS should run without errors 9 ENMC redundancy test (simulate failure of modules and verify redundancy function of back-up module) a) Power supply redundancy test b) ENMC processor module redundancy test c) ENMC communication modules redundancy test d) ENMC DI/AI module redundancy test 10 Simulation test of ENMC functions- Refer to manufacturers’ SAT procedure. Attach the test report to this check-sheet. 11 Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. 12 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 13 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 14 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TRANSFORMER (DRY)

E09-B

Project No. Project Title Facilities Tag no. Rated kVA Voltage Primary Voltage Secondary Insulation class Manufacturer Model/Sl No 1

2

3 4

INFORMATION System/Sub System no. Frequency Vector Group Percentage Impedance Area Classification Location Ref. Drawing nos. INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Completed and signed –off construction check-sheet and punch list status b) Precom check-sheet for the outgoing transformer feeder c) Precom check-sheet for incoming feeder from transformer d) Precom check-sheet for CTs installed (if any) e) Precom check-sheets for all associated power and control cables and bus-ducts f) Precom check-sheet for substation grounding and NER g) Transformer GA drawing, datasheet and FAT report h) Key single line diagram Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes/bus-duct flanges, bushing cracks, corrosion, painting damage etc. Confirm that the transformer tank and core are properly grounded. Perform polarization index test. Take insulation resistance measurements from high voltage side to low voltage side and ground, from low voltage side to high voltage side and ground, and from high voltage side & low voltage side to ground. Calculate PI by dividing resistance measurement at the 10th minute by the 1st minute. Test voltage shall be 500V DC for LV (up to 1kV) system, 2.5kV DC for HV up to 4.2kV system voltage and 5kV DC for HV above 4.2kV of system voltage. Time Start 15 sec 30sec 1 min 2 min

H-LE

L-HE

H-L

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TRANSFORMER (DRY)

E09-B

4 min 6 min 8 min 10 min PI (R10/R1)

5

6

7 8 9 10 11 12

Minimum acceptable value for PI is 2 and minimum insulation value shall be 100 MΩ on HV side and 10 MΩ on LV side. However, PI values and IR shall be compared with the corresponding values from FAT report and any major deviations between the values need to be investigated prior to energisation. Remove jumpers from P.I. Test and reconnect all high-voltage, lowvoltage and neutral connections, low-voltage control systems, fan systems and meters connected to the transformer winding and core. Conduct winding resistance tests for the transformer and compare with the values from FAT report. Any abnormalities to be investigated. Further the values between phases shall not vary by more than 20%. Confirm tap setting is correct to manufacturer's specification/load flow recommendations. Ensure all transformer covers and guards are fitted. Confirm all related red-line drawings are completed. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TRANSFORMER (OIL FILLED) Project No. Project Title Facilities Tag no. Rated kVA Voltage Primary Voltage Secondary Insulation class Manufacturer Model/Sl No 1

2

3 4 5 6 7 8

E10-B

INFORMATION System/Sub System no. Frequency Vector Group Percentage Impedance Area Classification Location Ref. Drawing nos. INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Completed and signed –off construction check-sheet and punch list status b) Precom check-sheet for the outgoing transformer feeder c) Precom check-sheet for incoming feeder from transformer d) Precom check-sheet for CTs installed (if any) e) Precom check-sheets for all associated power and control cables and bus-ducts f) Precom check-sheet for substation grounding and NER g) Transformer GA drawing, datasheet and FAT report h) Key single line diagram Verify and confirm that there's no mechanical damage. (damage to terminal boxes/bus-duct-flanges/ radiators/conservator tank, bushing cracks, corrosion, painting damage, oil leak etc.) Check and confirm drain tap is ok, vent is free, silica gel Ok and oil level is correct. Confirm that the transformer case and core are properly grounded. Check the position of conservator valve (applicable to conservator type transformers only). Confirm that radiators upper and lower valves are secured in the correct position (applicable for tanks with detachable radiators). Check the silica gel breather color and confirm the breather is still ok (only applicable to transformers equipped with breather). Check the thermometer and reset the maximum temperature indicator. Using a portable oil dielectric tester perform a Dielectric Breakdown Voltage Test on the transformer insulating fluid. (Applicable for conservator type transformers only). Test shall be performed with equipment with a gap of 2.5mm between electrodes and the sample shall be tested for 6 times to breakdown voltage. The dielectric breakdown voltage shall be

Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TRANSFORMER (OIL FILLED)

E10-B

arithmetic mean of the 6 breakdown voltages and shall not be below 30kV. Reference shall be made to PTS 63.10.08.11 for further details of the test.

Test No Value

9

1

11

3

4

5

6

Average

Should the dielectric test fail, necessary corrective action (e.g. oil Filtering) shall be undertaken until acceptable test results are obtained Perform polarization index test. Take insulation resistance measurements from high voltage side to low voltage side and ground, from low voltage side to high voltage side and ground, and from high voltage side & low voltage side to ground. Calculate PI by dividing resistance measurement at the 10th minute by the 1st minute. Test voltage shall be 500V DC for LV (up to 1kV) system, 2.5kV DC for HV up to 4.2kV system voltage and 5kV DC for HV above 4.2kV of system voltage. Time Start 15 sec 30sec 1 min 2 min 4 min 6 min 8 min 10 min PI (R10/R1)

10

2

H-LE

L-HE

E-HL

Minimum acceptable value for PI is 2 and minimum insulation value shall be 75 MΩ. However, PI values and IR shall be compared with the corresponding values from FAT report and any major deviations between the values need to be investigated prior to energisation. Remove jumpers from P.I. Test and reconnect all high-voltage, lowvoltage and neutral connections, low-voltage control systems, fan systems and meters connected to the transformer winding and core. Conduct winding resistance tests for the transformer and compare with the values from FAT report. Any abnormalities to be investigated.

Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B 12 13 14 15 16 17 18

TRANSFORMER (OIL FILLED) E10-B Confirm tap setting is correct to manufacturer's specification/load flow recommendations. Ensure all transformer covers and guards are fitted. Keep the transformer energized at no-load for a minimum of 24 hours (Soak test) at the end of the pre-commissioning. Confirm all related red-line drawings are completed. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE SWITCHBOARD Project No. Project Title Facilities Tag no. Bus Bar Rating Frequency Short Circuit Rating/time Model / Type Serial no. 1

2 3

4 5 6

E11-B

INFORMATION System/Sub System no. IP Rating Voltage Ref. Drawing Location Manufacturer INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Completed and signed –off construction check-sheet and punch list status b) Precom check-sheet for CTs installed c) Precom check-sheet for VTs installed d) Precom check-sheet for circuit breakers and contactors e) Precom check-sheets for all associated power and control cables and bus-ducts f) FAT report g) Key single line diagram Verify that no voltage source is connected to the bus. Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes/bus-duct flanges, bushing cracks, corrosion, sign of water ingress / moisture condensation, painting damage etc. Inspect all doors, panels and sections for corrosion, dents, scratches, correct fit and missing hardware. Switchboard earthing intact Perform following physical tests Circuit labeling correct Operation of safety shutters Interlocking facilities, mechanical/electrical Mechanical position indicators, indicating lights Insulating bushings and barriers in place Cable box and terminations in good condition Alignment of main and auxiliary contacts are ok Verify that fuse and circuit break types / sizes correspond to project drawings. Check and confirm cleanliness of switchgear prior to electrical testing. Verify correct circuit breaker and PT cubicle shutter installation and operation. Page 1 of 3



8

9

HIGH VOLTAGE SWITCHBOARD E11-B Perform contact resistance test (Ductor test) for all bolted connections and attach the test record to this check sheet. Check the torque markings on the bolted connections. Adjust, if required, prior to ductor test. Resistances should be in micro-ohms. For identical connections, the measured values shall not differ by more than 20% from each other for different phases in same circuit. Further the test results to be compared against factory test values and any variation more than 20% from factory test results shall be investigated. Perform IR test on the switchboard incomer and bus-bar. Test voltage shall be 2.5kV DC for HV up to 4.2kV system voltage and 5kV DC for HV above 4.2kV of system voltage. Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE Minimum acceptable insulation value shall be 200 MΩ. Perform Hi-Pot test on the bus-bar with all the circuit breakers (except bus-tie) OPEN and record the leakage current. Test Duration 1 minute Test Voltage (select from table below) Test voltage applied shall be only 75% of the value in the table below if Hi-pot test had already been conducted earlier during FAT.

Max Systm Voltage Test Voltage

3.6

.2

12

17.5

24

36

0

20

28

38

50

70

Leakage current R-YBE Y-RBE

B-RYE

Remarks

Difference in leakage currents shall not differ by more than 20% for different phases in same circuit. Further, the test results to be compared against factory test values and any variation of more than 20% from the factory test results shall be investigated.

Page 2 of 3



11 12

13 14 15 16

17 18 19 20

HIGH VOLTAGE SWITCHBOARD E11-B Repeat the IR test after hi-pot test and record values. Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE Minimum acceptable insulation value shall be 200 MΩ. Reconnect all electronic equipment after insulation resistance and hipot testing. Re-install PT drawers, fuses and all relays. Perform the following functional tests on all circuits (separate sheets to be attached for individual circuit for physical and functional tests) Mechanical closing and tripping Electrical closing local/remote Electrical tripping local/remote Alarm indications local/remote Anti-condensation heater working. Temperature set at 25oC Test all DCS interface I/Os. Test F&G/SDS/Load Shedding permissive / trip (where applicable). Check all associated metering has been tested and attach records. Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Confirm all related red-line drawings are completed. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE CIRCUIT BREAKER / CONTACTOR Project No. Project Title Facilities INFORMATION Tag no. Switchboard No. Rating (A) Voltage Frequency

E12-B

System/Sub System no. Location Manufacturer Model No Serial No INSPECTION / TEST

1

2

3

4

OK

N/A P/L No

Documents required: a) FAT report b) Switchboard single line diagram Remove circuit breaker and inspect physical and mechanical condition. No loose or missing parts. No dust or foreign matters. No excessive deformation or wear. Inspect the primary disconnect finger shutters for signs of wear and erosion. Insulation Resistance test (Before Vacuum Integrity Test) – Breaker OPEN Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE Minimum acceptable insulation value shall be 200 MΩ. Vacuum Integrity test: Test duration 1 Minute. Test voltage – (select from table below) Max. System 3.6 7.2 12 Voltage Test 10 20 28 Voltage Leakage current R-YBE Y-RBE

B-RYE

17.5

24

36

38

50

70

Remarks

Difference in leakage currents shall not differ by more than 20% for different phases in same circuit. Further, the test results to be compared against factory test values and any variation of more than 20% from the factory test results shall be investigated. Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE CIRCUIT BREAKER / CONTACTOR E12-B 5 Insulation Resistance Test (After Vacuum Integrity Test) –Breaker OPEN Test point R-YBE Y-RBE B-RYE 6

10 11 12 13


Remarks

Contact resistance test (Ductor Test) for breaker / contactor contacts. Test point R Y B

8 9

Remarks

Insulation Resistance Test (After Vacuum Integrity Test) Breaker CLOSED Test point R-YBE Y-RBE B-RYE

7


Contact Resistance

Remarks

Difference in contact resistance shall not differ by more than 20% for different phases of the same breaker/contactor. Prove all Electrical, Mechanical and Earthing Interlocks. Check operation of padlocking facilities, mechanical interlocks, including safety shutters. Where applicable, confirm protection settings are correct to schedule. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE CIRCUIT BREAKER / CONTACTOR E12-B COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE CONTACTOR / MOTOR STARTER Project No. Project Title Facilities INFORMATION Tag no. Switchboard No. Rating (A) Voltage Frequency

E13-B

System/Sub System no. Location Manufacturer Model No Serial No INSPECTION / TEST

1

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

OK

N/A P/L No

Documents required: a) Precom check-sheet for CTs installed b) Precom check-sheet for VTs installed c) Precom check-sheet for related circuit breakers and contactors d) FAT report e) Switchboard single line diagram Check mechanical operation of all circuit breaker mechanisms. Check ratings of all control fuses, MCB's, power fuses and contactors are correct. Check operation of electrical and mechanical interlocks. Check operation of all padlocking facilities. Check all cable terminations including main power cable. Confirm all associated CT's and VT's have been tested. Confirm, where applicable, CB overload protection settings are correct. Check and confirm the protection relay is set correct to schedule attach Records. Check all metering has been tested where applicable - attach Vendor records. Function test control circuit to schematic diagram including remote start / stops. Test all external interface I/O's. Test F&G / IDS / Load Shedding permissive / trip (if applicable). Ensure all temporary links / jumpers have been removed and all links (special attention to CT links) restored to original condition. Confirm all related red-line drawings are completed. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Page 1 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE CONTACTOR / MOTOR STARTER



E13-B



Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE SWITCHBOARD / MCC E14-B Project No. Project Title Facilities INFORMATION Tag no. System/Sub System no. Bus Bar Rating IP Rating Frequency Voltage Short Circuit Rating/time Ref. Drawing Model / Type Location Serial no. Manufacturer INSPECTION / TEST OK 1 Documents required: a) Completed and signed –off construction check-sheet and punch list status b) Precom check-sheet for CTs installed c) Precom check-sheet for VTs installed d) Precom check-sheet for circuit breakers and contactors e) Precom check-sheets for all associated power and control cables and bus-ducts f) FAT report g) Key single line diagram 2 Verify that no voltage source is connected to the bus. 3 Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes/bus-duct flanges, corrosion, sign of water ingress / moisture condensation, painting damage etc. 4 Inspect all doors, panels and sections for corrosion, dents, scratches, correct fit and missing hardware. 5 Switchboard earthing intact 6 Perform following physical tests Circuit labeling correct Operation of safety shutters Interlocking facilities, mechanical/electrical Mechanical position indicators, indicating lights Insulating bushings and barriers in place Cable box and terminations in good condition Alignment of main and auxiliary contacts are ok Verify that fuse and circuit break types / sizes correspond to project drawings. Check and confirm cleanliness of switchgear prior to electrical testing. Verify correct circuit breaker and PT cubicle (if applicable) shutter installation and operation.

N/A

Page 1 of 3

P/L No



8

9 10

11 12 13 14

15 16

LOW VOLTAGE SWITCHBOARD / MCC E14-B Perform contact resistance test (Ductor test) for all bolted connections and attach the test record to this check sheet. Check the torque markings on the bolted connections. Adjust, if required, prior to ductor test. Resistances should be in micro-ohms. For identical connections, the measured values shall not differ by more than 20% from each other for different phases in same circuit. Further the test results to be compared against factory test values and any variation more than 20% from factory test results shall be investigated. Perform IR test on the switchboard incomer and bus-bar. Test voltage shall be 500 V DC. Test point Insulation Resistance Remarks R-YBNE Y-RBNE B-RYNE N-RYB Minimum acceptable insulation value shall be 20 MΩ. Compare the IR test values against those of FAT. Any deviation of more than 20% from FAT report need to be investigated. Reconnect all electronic equipment after insulation resistance and. Reinstall fuses and all relays. Perform the following functional tests on all circuits (separate sheets to be attached for individual circuit for physical and functional tests) Mechanical closing and tripping Electrical closing local/remote Electrical tripping local/remote Alarm indications local/remote Anti-condensation heater working. Temperature set at 25oC Test all DCS interface I/Os. Test F&G/SDS/Load Shedding permissive / trip (where applicable). Check all associated metering has been tested and attach records. Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Confirm all related red-line drawings are completed. Record defects/shortcomings, if any, in the system punch-list.

Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE SWITCHBOARD / MCC 17 18

E14-B

Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE CIRCUIT BREAKER/CONTACTOR E15-B Project No. Project Title Facilities INFORMATION Tag no. System/Sub System no. Switchboard No. Location Rating (A) Manufacturer Voltage Model No Frequency Serial No INSPECTION / TEST OK 1 Documents required: a) FAT report b) Switchboard single line diagram 2 Check operation of padlocking facilities, mechanical interlocks, including safety shutters. 3 Where applicable, confirm protection settings are correct to schedule. 4 Remove circuit breaker and inspect physical and mechanical condition. No loose or missing parts. No dust or foreign matters. No excessive deformation or wear. Inspect the primary disconnect finger shutters for signs of wear and erosion. 5 Record circuit breaker as-found operations counter reading 6 Confirm breaker rating plug matches current sensors. Confirm rating plug and current sensors conform to project drawings. 7 Insulation Resistance test (Breaker OPEN) Test point Insulation Resistance Remarks R-YBNE Y-RBNE B-RYNE N-RYB Minimum acceptable insulation value shall be 20 MΩ. Compare the IR test values against those of FAT. Any deviation of more than 20% from FAT report need to be investigated. 8 Insulation Resistance test (Breaker CLOSED) Test point R-YBNE Y-RBNE B-RYNE N-RY


N/A P/L No

Remarks

Page 1 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE CIRCUIT BREAKER/CONTACTOR E15-B 9 Contact resistance test (Ductor Test) for breaker / contactor contacts

10 11 12 13

Test point Contact Resistance Remarks R Y B N Difference in contact resistance shall not be more than 20% for different phases of the same breaker/contactor. Prove all Electrical, Mechanical and Earthing Interlocks. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE CONTACTOR / MOTOR STARTER E16-B Project No. Project Title Facilities INFORMATION Tag no. System/Sub System no. Switchboard No. Location Rating (A) Manufacturer Voltage Model No Frequency Serial No INSPECTION / TEST OK 1 Documents required: a) Precom check-sheet for CTs installed b) Precom check-sheet for VTs installed c) Precom check-sheet for related circuit breakers and contactors d) FAT report e) Switchboard single line diagram 2 Check mechanical operation of all circuit breaker mechanisms. 3 Check ratings of all control fuses, MCB's, power fuses and contactors are correct. 4 Check operation of electrical and mechanical interlocks. 5 Check operation of all padlocking facilities. 6 Check all cable terminations including main power cable. 7 Confirm all associated CT's and VT's have been tested. 8 Confirm, where applicable, CB overload protection settings are correct. 9 Check and confirm the protection relay is set correct to schedule attach Records. 10 Check all metering has been tested where applicable - attach Vendor records. 11 Function test control circuit to schematic diagram including remote start / stops. Perform earth loop impedance for motor feeders without CBCT. The 12 earth loop impedance shall not be more than 1Ω. 13 Test all external interface I/O's. 14 Test F&G / IDS / Load Shedding permissive / trip (if applicable). 15 Ensure all temporary links / jumpers have been removed and all links (special attention to CT links) restored to original condition. 16 Confirm all related red-line drawings are completed. 17 Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 18 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 19 externally clean.

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE CONTACTOR / MOTOR STARTER E16-B COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B PROTECTION RELAY

E17-B

Project No. Project Title Facilities Tag no. Switchboard No. Rating (A) Voltage Frequency 1

2 3 4 5 6

7 8

9 10 11 12 13 14

INFORMATION System/Sub System no. Location Manufacturer Model No Serial No INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Switchboard single line diagram b) Schematic diagram c) FAT report Visually inspect the relay for any damage. Confirm relevant vendor factory tests are complete and documentation available. Confirm all connections are correct, secured and there are no open circuits. Confirm relay identification is correct to design schedule. Carry out appropriate primary/secondary injection tests and confirm satisfactory operation of protection and lock-out relays and attach results. Adjust the relay settings according to the latest revision of relay setting chart. On completion of tests, confirm that all wiring has been re-instated, all 'frigs' and short circuits removed and relay settings re-set to design schedule. Confirm all relay front covers have been re-instated and seals attached. Confirm relevant calibration stickers with test date are placed on the relays. Confirm all related red-line drawings are completed. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B PROTECTION RELAY E17-B COMMENT(S) AND ADDITIONAL INFORMATION Relay calibration and testing shall be performed by COMPANY approved, competent third party. Relay calibration report and test results approved by the competent person to be attached to this check sheet.





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B CURRENT TRANSFORMER

E18-B


2 3 4 5 6 7 8 9 10 11 12 13 14


OK

N/A P/L No

Documents required: a) Switchboard single line diagram b) Schematic diagram c) FAT report Visually inspect the CT for any damage. Confirm relevant vendor factory tests are complete and documentation available. Confirm all connections are correct, secure and CT mounted correctly. Confirm CT class and ratio is correct to design data and as per schematic drawings. Confirm CT primary polarity is correct (P1 / P2). Confirm CT secondary connections are correct (S1 / S2). Prove CT polarity (Flick Test) if applicable and carry out ratio checks to confirm CT tolerance. Confirm all CT links are in correct position Confirm all secondary wiring is connected and there are no open circuits. Confirm all related red-line drawings are completed. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B VOLTAGE TRANSFORMER

E19-B


2 3 4 5 6 7 8


Pri (Sec.-E) _________ Ohms 9

14 15

N/A P/L No

Sec (Pri.-E) _________ Ohms

Confirm winding continuity:Primary:

10 11 12 13

OK

Documents required: a) Switchboard single line diagram b) Schematic diagram c) FAT report Visually inspect the VT for any damage. Confirm relevant vendor factory tests are complete and documentation available. Confirm all connections are correct, secure and VT mounted correctly. Confirm the VT ratio correct as per the latest schematic drawings. Confirm primary and secondary fuses/MCBs are correctly rated and installed. Check earthing and confirm continuity of scraping earth. Carry out 1 kV IR test on VT windings. Minimum acceptable value 10MΩ

________ Ohms

Secondary: _________ Ohms

Confirm all VT links are in correct position Prove VT ratio / phasing are correct Confirm all related red-line drawings are completed. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B VOLTAGE TRANSFORMER E19-B COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Integrated Motor Control System (IMCS) E20-B Project No. Project Title Facilities INFORMATION Tag no. System/Sub System no. Model / Type IP Rating Serial no. Manufacturer Location Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required: a) IMCS system architecture and Functional Description System b) IMCS panel GA drawings and schematic drawings c) IMCS block diagram and interconnection drawings d) Approved FAT report e) Completed and signed-off construction check-sheet with punch list status 2 Verify the cleanliness of panel internals and confirm all loose wires, packing material etc. are removed. 3 Verify all power supply sources readings for correct input ratings. Power supply for each module shall be accordance to the IMCS system approved specification. 4 Conduct system status check for all IMCS modules i.e. processors, communication modules, power supply module, processors modules, communication modules and I/O modules. LEDs status indication at all modules shall be observed for any abnormalities 5 Communication test with switchgears/switchboards/MCC a) Verify designated programming/user map downloaded to each Intelligent Electronic Devices (IED) b) Verify status readings on each Human Man Interface (HMI) i.e. GA, SLD and IMCS Network pages against actual status/reading on device c) Verify command function from HMI and monitor correct response at receiving end (IED) 6 Communication test with third party equipment a) DCS/PMCS b) CSS/SIS c) Generator d) UPS e) Navigation Aid system f) Compressors g) HVAC

N/A P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Integrated Motor Control System (IMCS) E20-B 7 Data Log and Alarm Notification Test a) Simulate basic communication break down and trip alarm from each IED and verify correct notification displayed on IMCS screen and engineering work station (EWS) b) Verify basic data logging and trending (loads current/voltage) observed at IMCS HMI c) Verify alarm summary triggered/simulated at HMI 8 Multiple Network HMI communication test i.e. testing with EWS/OWS/Laptop a) Browse thru IMCS from EWS. IMCS HMI display at EWS should run without errors b) Browse thru IMCS from OWS. IMCS HMI display at OWS should run without errors c) Browse thru IMCS from Laptop. IMCS HMI display at laptop should run without errors IMCS redundancy test (simulate failure of modules and verify redundancy function of back-up module) a) Power supply redundancy test b) IMCS processor module redundancy test c) IMCS communication modules redundancy test d) IMCS DI/AI module redundancy test 10 11

12 13 14

Simulation test of IMCS functions- Refer to manufacturers’ SAT procedure. Attach the test report to this check-sheet. Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TRANSMISSION LINE

E21-B

Project No. Project Title Facilities INFORMATION System/Sub System no. To Operating Voltage Capacity INSPECTION / TEST

Conductor size From Location Ref. Drawing nos. 1

2 3

OK N/A P/L No

Documents required: a) Transmission line datasheet b) Approved FAT report c) Completed and signed-off construction check-sheet with punch list status Confirm the grounding and lightning protection are completed as per specifications and drawings. Perform IR test Test voltage – _____________ R-Y

4

R-B

Y-B

R-E

R-YBE

Remarks

Y-RBE

Test Duration - ___________

B-RYE

RYB-E

Remarks

Line resistance test R-Y

6

B-E

Perform Hi-Pot test Test Voltage - _____________

5

Y-E

R-B

Y-B

Remarks

Check Earthing system i. Earth pits tested ii. Earth connections checked iii. Earth connections checked iv. Static earth wire checked v. Structure/Guy wire earthing checked

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B 7 8 9 10

TRANSMISSION LINE E21-B Refer to manufacturer specific tests and complete the precommissioning of the lines as per vendor recommendations. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE CABLE

E22-B


2 3 4

5 6

7

INFORMATION System no. Sub System no. Cable from Ref. Drawing nos. INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Cable datasheet b) Approved FAT report c) Completed and signed-off construction check-sheet with punch list status Confirm proper installation of joints and terminations (stress cones). Confirm proper shield/armor grounding, cable support and termination of conductors. Disconnect cable conductors at both ends. Hi-pot testing to be performed at the MCC / SWGR end of the cable. Make sure that the field end conductors are adequately separated to prevent corona discharge. If corona still exists, conductors may be taped, covered with clear plastic bags, or a corona ring or shield be used. Perform shield conductor resistance test using ohm meter. Shield shall be continuous. Insulation Resistance Test. Measure and record insulation resistance (IR) of each conductor with all other conductors and shields grounded. Subsequently, measure IR for phase to phase conductor while other conductor and shield are grounded. Refer PTS 63.10.08.11 for suitable test voltage and acceptable insulation reading. Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE Discharge all conductors to ground for a minimum period of 1 minute. Perform a DC high potential (Hi-pot) test. Individually test each conductor with all other conductors grounded as well as all shields are grounded. Hold the test at final test voltage for 3 minutes. Record leakage current for every minute once test voltage achieved. Note: Tester will taking sometime to ramp-up to final test voltage. Values should be in micro amps. Hi-pot test shall include the termination kits and joints. Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE CABLE

E22-B

Test Voltage (select from table below). Test voltage applied shall be only 75% of the value in the table below if Hi-pot test had already been conducted earlier during FAT. Max. System Voltage Test Voltage

3.6

7.2

12

17.5

24

36

10

20

28

38

50

70

Test record Volts

Time (Minutes) 1 2 3

Leakage current (µA) R-YBE Y-RBE B-RYE

Remarks

Difference in leakage currents shall not differ by more than 20% for different phases in same circuit. Further, the test results to be compared against factory test values and any variation of more than 20% from the factory test results shall be investigated.

8

Discharge all conductors to ground for a minimum of 15 minutes after each test. Repeat IR test after Hi-pot test is completed. Test point R-YBE Y-RBE B-RYE

9


Remarks

Discharge all conductors to ground for a minimum period of 1 minute. Confirm the both ends of the each phase "R" conductor are correctly marked by ringing out. Do the same for phase "Y" and phase "B".

Page 2 of 3



11 12

13 14

HIGH VOLTAGE CABLE E22-B Reconnect all conductors such that both ends of the phase "R" conductor connect to the phase "R" termination points. Do the same for phase "Y" and phase "B". Torque all bolts to recommended manufacturer's standards. Record torque setting and mark the bolts. End 'A' _________ Nm End 'B' _________ Nm Ensure all termination box covers and guards are correctly re-fitted and identified as HV. Record any defects/shortcomings in the system punch-list.

Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SUBMARINE CABLE

E23-B


2 3 4

5 6

OK

N/A P/L No

Documents required: a) Cable datasheet b) Approved FAT report c) Completed and signed-off construction check-sheet with punch list status Confirm proper installation of joints and terminations (stress cones). Confirm proper shield/armor grounding, cable support and termination of conductors. Disconnect cable conductors at both ends. Hi-pot testing to be performed at the MCC / SWGR end of the cable. Make sure that the field end conductors are adequately separated to prevent corona discharge. If corona still exists, conductors may be taped, covered with clear plastic bags, or a corona ring or shield be used. Perform shield conductor resistance test using ohm meter. Shield shall be continuous. Insulation Resistance Test. Measure and record insulation resistance (IR) of each conductor with all other conductors and shields grounded. Subsequently, measure IR for phase to phase conductor while other conductor and shield are grounded. Refer PTS 63.10.08.11 for suitable test voltage and acceptable insulation reading. Test point R-YBE Y-RBE B-RYE

7

INFORMATION System no. Sub System no. Cable from Ref. Drawing nos. INSPECTION / TEST


Remarks

Discharge all conductors to ground for a minimum period of 1 minute. Perform a DC high potential (Hi-pot) test. Individually test each conductor with all other conductors grounded as well as all shields are grounded. Hold the test at final test voltage for 3 minutes. Record leakage current for every minute once test voltage achieved. Note: Tester will taking sometime to ramp-up to final test voltage. Values should be in micro amps. Hi-pot test shall include the termination kits Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B

8

9 10

11 12 13 14

SUBMARINE CABLE E23-B and joints. Leakage current (µA) Time Volts Remarks (Minutes) R-YBE Y-RBE B-RYE 1 2 3 Discharge all conductors to ground for a minimum of 15 minutes after each test. Repeat IR test after Hi-pot test is completed. Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE Discharge all conductors to ground for a minimum period of 1 minute. Confirm the both ends of the each phase "R" conductor are correctly marked by ringing out. Do the same for phase "Y" and phase "B". Reconnect all conductors such that both ends of the phase "R" conductor connect to the phase "R" termination points. Do the same for phase "Y" and phase "B". Torque all bolts to recommended manufacturer's standards. Record torque setting and mark the bolts. End 'A' _________ Nm End 'B' _________ Nm Ensure all termination box covers and guards are correctly refitted and identified. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B BUS DUCT

E24-B

Project No. Project Title Facilities Tag no. Amperes Frequency Manufacturer Type 1

2 3

4

5

6

INFORMATION System/ Sub System no. Bus bar Rating Location Ref. Drawing Nos. Voltage INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Bus duct datasheet b) Approved FAT report c) Completed and signed-off construction check-sheet with punch list status Confirm proper installation of joints and end terminations including wall pass through and phase cross overs as per drawing. Disconnect bus bar conductors at both ends. Hi-pot testing to be performed at the MCC / SWGR end of the cable. The bus bar ends may be taped, covered with clear plastic bags, or a corona ring or shield be used to prevent corona discharge. Perform earth continuity of the earthing conductor (metallic enclosure for metal enclosed bus ducts or the separate ground conductor in case of cast resin type bus ducts) using ohm meter. Earth conductor shall be continuous. Insulation Resistance Test. Measure and record insulation resistance (IR) of each bus bar with all other bus bars and ground conductor grounded. Subsequently, measure IR for phase to phase. Refer PTS 63.10.08.11 for suitable test voltage and acceptable insulation reading (Data for cables may be used). Test point Insulation Resistance Remarks R-YBNE Y-RBNE B-RYNE Discharge all conductors to ground for a minimum period of 1 minute. Perform a DC high potential (Hi-pot) test – NOT applicable for LV bus duct. Individually test each conductor with all other conductors grounded as well as all shields are grounded. Hold the test at final test voltage for 3 minutes. Record leakage current for every minute once test voltage achieved. Note: Tester will taking sometime to ramp-up to Page 1 of 2



7

8 9

10 11 12 13

BUS DUCT E24-B final test voltage. Values should be in micro amps. Hi-pot test shall include the termination kits and joints. Leakage current (µA) Time Volts Remarks (Minutes) R-YBE Y-RBE B-RYE 1 2 3 Discharge all conductors to ground for a minimum of 15 minutes after each test. Repeat IR test after Hi-pot test is completed. NOT applicable for LV bus duct. Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE Discharge all conductors to ground for a minimum period of 1 minute. Confirm the both ends of the each phase "R" conductor are correctly marked by ringing out. Do the same for phase "Y" and phase "B". Reconnect all conductors such that both ends of the phase "R" conductor connect to the phase "R" termination points. Do the same for phase "Y" and phase "B". Torque all bolts to recommended manufacturer's standards. Record torque setting and mark the bolts. End 'A' _________ Nm End 'B' _________ Nm Ensure all termination box covers and guards are correctly refitted and identified. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE CABLE

E25-B

Project No. Project Title Facilities Tag no. Cable size 1

2 3 4

6

7 8 9 10

OK

N/A P/L No

Documents required: a) Cable datasheet b) Approved FAT report c) Completed and signed-off construction check-sheet with punch list status Confirm proper installation of joints and terminations. Confirm proper shield/armor grounding, cable support and termination of conductors. Insulation Resistance Test. Measure and record insulation resistance (IR) of each conductor with all other conductors and shields grounded. Refer PTS 63.10.08.11 for suitable test voltage and acceptable insulation reading. Test point R-YBNE Y-RBNE B-RYNE

5

INFORMATION System/ Sub System no. Voltage level INSPECTION / TEST


Remarks

Discharge all conductors to ground for a minimum period of 1 minute. Confirm the both ends of the each phase "R" conductor are correctly marked by ringing out. Do the same for phase "Y" and phase "B". Reconnect all conductors such that both ends of the phase "R" conductor connect to the phase "R" termination points. Do the same for phase "Y" and phase "B". Torque all bolts to recommended manufacturer's standards. Record torque setting and mark the bolts. End 'A' _________ Nm End 'B' _________ Nm Ensure all termination box covers and guards are correctly refitted. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE CABLE E25-B COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B CAPACITOR BANK AND SERIES REACTOR E26-B Project No. Project Title Facilities INFORMATION Tag no. System no. kVAR Sub System no. Frequency Voltage Location No. of steps Model / Type Manufacturer Ref. Drawing nos. Serial no. INSPECTION / TEST OK 1 Documents required: a) Capacitor Bank and reactor datasheet and GA drawing b) Single line diagram of associated switchgear c) Completed and signed-off construction check-sheet with punch list status. d) FAT report 2 Verify the cleanliness of panel internals and confirm the panel is free from dust, dirt, all loose wires, packing material etc. 3 Confirm earthing of the panel is intact. 4 Conduct insulation resistance test between phases and phase to ground using a 500V megger. Test point R-YBE Y-RBE B-RYE

5 6

7 8 9 10


N/A P/L No

Remarks

Minimum acceptable IR is 10 MΩ. Energize the control circuit and confirm the capacitor bank controller settings are correct. Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Confirm all red line drawings are completed. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B CAPACITOR BANK AND SERIES REACTOR E26-B COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B AC UPS

E28-B

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Rating Frequency Input Voltage Output Voltage Manufacturer Serial No. Model No. Location Ref. Drawing no. IP rating INSPECTION / TEST 1 Documents required for verification. a. UPS Datasheet, GA drawing and schematic diagram b. Single line diagram of associated MCC c. Completed and signed-off check-sheets as follows: d. Construction check-sheet for the subject UPS and punch list status e. Precom check-sheets for all associated power and control cables f. Precom check sheet for the relevant feeder at MCC g. FAT report 2 Inspect UPS for any physical damage (dents, broken handles/switches/indication lamp lenses etc.) 3 Verify mechanical operation of all switches 4 Confirm incoming power feed for proper termination of conductors 5 Perform resistance measurements through all UPS bolted electrical connections using a low resistance ohmmeter (Ducter test) 6 Ensure equipment grounding is intact 7 Perform insulation resistance test on power, control and auxiliary circuits. (Ensure that all electronic components and circuits are disconnected and excluded from the IR test) 8 Simulate all alarm/trip/indication functions from/to external sources as applicable. a. CSS system b. PMCS/DCS c. Fire & Gas System d. HVAC system e. Battery Safety switch to trip battery MCCB f. IMCS/ENMC 9 Verify the functionality of all meters and indicating lamps

OK

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B AC UPS E28-B 10 Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. 11 Record any defects/shortcomings in the system punch-list Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 12 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 13 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Testing shall in general be performed as per vendor start-up procedures. Above tests are minimum requirements and any additional tests done as per vendor start-up procedure may be appended to the above test records.





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B DC CHARGER

E29-B

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Rating Frequency Input Voltage Output Voltage Manufacturer Serial No. Model No. Location Ref. Drawing no. IP rating INSPECTION / TEST 1 Documents required for verification. a. Charger Datasheet, GA drawing and schematic diagram b. Single line diagram of associated MCC c. Completed and signed-off check-sheets as follows: d. Construction check-sheet for the subject charger and punch list status e. Precom check-sheets for all associated power and control cables f. Precom check sheet for the relevant feeder at MCC g. FAT report 2 Inspect charger for any physical damage (dents, broken handles/switches/indication lamp lenses etc.) 3 Verify mechanical operation of all switches 4 Confirm incoming power feed for proper termination of conductors 5 Perform resistance measurements through all bolted electrical connections using a low resistance ohmmeter (Ducter test) 6 Ensure equipment grounding is intact 7 Perform insulation resistance test on power, control and auxiliary circuits. (Ensure that all electronic components and circuits are disconnected and excluded from the IR test) 8 Simulate all alarm/trip/indication functions from/to external sources as applicable. a. CSS system b. PMCS/DCS c. Fire & Gas System d. HVAC system e. Battery Safety switch to trip battery MCCB f. IMCS/ENMC 9 Conduct earth fault detection and indication (for floating system) test by earthing various outgoing circuits. 10 Verify the functionality of all meters and indicating lamps

OK

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B DC CHARGER E29-B Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. 12 Record any defects/shortcomings in the system punch-list Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 13 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 14 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Testing shall in general be performed as per vendor start-up procedures. Above tests are minimum requirements and any additional tests done as per vendor start-up procedure may be appended to the above test records. 11





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRICAL POWER UNIT (EPU) Project No. Project Title Facilities

E30-B

INFORMATION Tag no. System / Sub System no. Rating Frequency Input Voltage Output Voltage Manufacturer Serial No. Model No. Location Ref. Drawing no. IP rating INSPECTION / TEST 1 Documents required for verification. a. EPU Datasheet, GA drawing and schematic diagram b. Single line diagram of associated MCC which feeds the EPU c. Completed and signed-off check-sheets as follows: d. Construction check-sheet for the subject EPU and punch list status e. Precom check-sheets for all associated power and control cables f. Precom check sheet for the relevant feeder at MCC g. FAT report 2 Inspect EPU for any physical damage (dents, broken handles/switches/indication lamp lenses etc.) 3 Verify mechanical operation of all switches 4 Confirm incoming power feed for proper termination of conductors 5 Perform resistance measurements through all bolted electrical connections using a low resistance ohmmeter (Ducter test) 6 Ensure equipment grounding is intact 7 Perform insulation resistance test on power, control and auxiliary circuits. (Ensure that all electronic components and circuits are disconnected and excluded from the IR test). Attach report. 8 Simulate all alarm/trip/indication functions from/to external sources as applicable. a. CSS system b. PMCS/DCS c. Fire & Gas System d. HVAC system e. Battery Safety switch to trip battery MCCB f. IMCS/ENMC 9 Conduct earth fault detection and indication (for floating system) test by earthing various outgoing circuits. 10 Verify the functionality of all meters and indicating lamps

OK

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRICAL POWER UNIT (EPU) E30-B Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. 12 Record any defects/shortcomings in the system punch-list Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 13 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 14 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Testing shall in general be performed as per vendor procedures. Above tests are minimum requirements and any additional tests done as per vendor start-up procedure may be appended to the above test records. 11





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B BATTERY

E31-B

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Ampere Hour No. of cells System Voltage Electrolyte Type of Battery Boost Voltage Float Voltage Location Manufacturer Ref. Drawing INSPECTION / TEST 1 Documents required for verification. a. Battery Datasheet and battery rack drawing b. UPS/Charger drawings showing battery connection c. Completed and signed-off construction check-sheet for the subject battery and punch list status d. Precom check-sheets for all associated power and control cables e. FAT report of battery (if applicable) or charge / discharge test report of prototype. 2 Inspect batteries for physical and mechanical condition. 3 Verify and confirm battery room / enclosure ventilation is working correctly. 4 Inspect for evidence of corrosion at terminal, connections, racks or cabinets. 5 Verify correct electrolyte levels of each cell (not applicable for sealed battery). 6 Check Specific Gravity of each battery cell (not applicable for sealed battery). 7 Measure inter-cell connection resistance and voltage. Resistance levels should be within manufacturer's specifications and should not vary by more than 10% from the overall average of the bank. Cell #

Voltage

Resistance

Cell #

Voltage

OK

N/A P/L No

Resistance

Inter-cell resistance value from manufacturer _____________ Ohm Nominal cell voltage _____________Volt Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B BATTERY 8

9 10 11

E31-B

Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Record any defects/shortcomings in the system punch-list Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE DISTRIBUTION BOARD E32-B Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Bus bar rating Frequency Voltage Location Manufacturer IP Rating Model No. Serial no. Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required for verification. a. LV Distribution board datasheet and single line diagram b. Completed and signed-off construction check-sheet for the subject distribution board and punch list status c. Precom check-sheets for all CTs and protection relays installed in the distribution board d. Precom check-sheets for all associated power and control cables e. FAT report 2 Confirm padlocking facilities available on panel. Verify and confirm the door interlock with the incomer is functioning. 3 Check incoming power feed for proper termination of conductors per project specifications. Verify tightness of bolts using a torque wrench if applicable and record the torque values and mark the bolts. 4 Ensure equipment grounding is complete. 5 Perform IR test on the distribution board incomer and bus-bar at 500V. Minimum acceptable value of IR is 10MΩ. All outgoing circuits OPEN. Test point R-YBNE Y-RBE B-RYN 6

Perform Hi-Pot test Test Voltage - 2kV R-YBE Y-RBE


Test Duration – 1 minute B-RYE

Repeat IR test after Hi-pot test. Test point Insulation Resistance R-YBNE Y-RBNE B-RYNE

N/A P/L No

Remarks

Remarks

Remarks

Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE DISTRIBUTION BOARD 7 8 9 10 10 11 12

E32-B

Check rating of each MCB / RCD against circuit power requirements and distribution panel schedule. Check OPEN and CLOSE operation of each MCB / RCD and incoming isolator/MCCB. Confirm phasing of internal wiring is correct. Adjust the MCCB (with adjustable settings) thermal settings to design values. Confirm circuit protection is as per distribution schedule and circuit diagram is available within the board. Confirm outgoing circuits are isolated. Perform insulation resistance of the circuit (including first JB with rest of the circuit and all fittings disconnected) test at 500V and record the IR values. Minimum resistance shall be 10MΩ. Ckt. No

R-E

Y-E

B-E

R-Y

R-B

Y-B

R-N

Y-N

B-N

Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE DISTRIBUTION BOARD 13

Perform trip test on RCDs. Verify the tripping current of the RCD using an RCD tester and record the values. For DBs without any RCD installed either at incomer or outgoing, measure and record earth loop impedance values. Earth loop impedance shall not be more than 1Ω for MCBs rated 16A and below and not more than 0.5Ω for MCBs rated above 16A. Circuit Number

14 15

16 17 18 19

E32-B

MCB Rating (A)

RCD Rating (mA)

Tripping value (mA)

Earth loop impedance (Ω)

Replace all covers / guards and bolts. Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Confirm that the red Line mark-up drawings are completed. Record any defects/shortcomings in the system punch-list Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B EARTHING & LIGHTNING PROTECTION E33-B Project No. Project Title Facilities INFORMATION Area System no. Location Sub System no. Ref. Drawing nos. Main Grid Conductor Size INSPECTION / TEST OK 1 Documents required for verification. a. Completed and signed-off construction check-sheets. b. Earthing layout 2

N/A P/L No

Confirm Earth continuity and earth resistance. (100 % for generator/transformer star point earthing, all generator/transformer/switchboard body earthing, 10% for all process plant electrical equipment body (motors, heaters etc.) and 5% for all process plant non-electrical equipment body (vessels, steel structures, columns etc.) SL.No.

Equipment Tag

Earth continuity

Earth loop resistance

Remarks

For offshore the measurement shall be done between the equipment body and the platform steel structure. For onshore, the measurement shall be between the equipment body and the earth grid. 3

Measure individual earth electrode resistance. (Only applicable for on-shore projects) Electrode No

Resistance

Electrode No

Resistance

Electrode No

Resistance

Page 1 of 2



EARTHING & LIGHTNING PROTECTION E33-B Measure earth grid resistance (Only applicable for on-shore projects) Description Overall plant grid* Electrical grid* Lightning grid

Resistance

Remarks Max-1Ω Max-1Ω Max-10Ω

* No separate instrument grid Measurement of electrical grid resistance shall be done with the lightning grid isolated and one of the electrical electrodes also isolated. Measurement of lightning grid resistance shall be done with the electrical grid isolated and one of the lightning electrodes also isolated. 5 Record any defects/shortcomings in the system punch-list Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 6 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 7 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Reference shall be made to PTS 63.10.08.11 for the testing methods.





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B NEUTRAL EARTHING RESISTOR Project No. Project Title Facilities

E34-B

INFORMATION System/ Sub System no. Frequency Rating (A/t) IP Rating Serial no. Ref. Drawing nos. INSPECTION / TEST Documents required for verification. a. Completed and signed-off construction check-sheets of the NER. b. Completed and signed-off pre-commissioning check-sheet for the connecting cables. c. Completed and signed-off pre-commissioning check-sheet for the CT installed in the NER (if any). d. Datasheet and GA drawing of NER e. FAT report of the NER Remove earth connection and perform insulation resistance tests of NER and Isolator/MCCB (if installed). Test voltage shall be 500V DC for LV (up to 1kV) system, 2.5kV DC for HV up to 4.2kV system voltage and 5kV DC for HV above 4.2kV of system voltage. Minimum resistance shall be 10(kV+1) MΩ-kV is the system voltage.

Tag no. Voltage Resistance Location Manufacturer Model No. 1

2

Equipment NER Isolator/MCCB

Test Voltage

OK

N/A P/L No

Insulation resistance

The test results shall be compared against FAT report and any deviation of more than 20% shall be investigated for any damage during transportation or moisture ingress. 3

Test OHMIC value of resistor and verify against the nameplate. Name Plate value(Ω)

4 5 6 7

Tested value(Ω)

Remarks

If fitted, test continuity of isolator/MCCB Confirm all cables are reconnected after the tests. Confirm as-built/red line drawings are complete and enclosed within the commissioning handover dossier. Record any defects/shortcomings in the system punch-list Page 1 of 2



8 9

NEUTRAL EARTHING RESISTOR E34-B Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B VARIABLE SPEED DRIVE

E35-B

Project No. Project Title Facilities INFORMATION Tag no. System no. VSD Rating Frequency Motor kW Voltage Manufacturer Model Location Serial no. Sub System no. Ref. Drawing Nos. INSPECTION / TEST 1 Documents required for verification. a. VSD datasheet and schematic diagram b. Completed and signed-off construction check-sheet for the subject VSD and punch list status c. Precom check-sheets for all CTs, VTs and protection relays installed inside the VSD d. Precom check-sheets for all associated power and control cables e. FAT report 2 Check incoming power feed for proper termination of conductors per project specifications. Verify tightness of bolts using a torque wrench if applicable and record the torque values and mark the bolts. 3 Ensure equipment grounding is complete and is intact. 4 Ensure the type of cable used including the earthing arrangements is as per vendor recommendations. Confirm toroid filters (if applicable) are fitted as per recommendations. 5 Confirm control I/O wiring and / or Device-net / Control-net wiring is correct per project drawings. 6 Perform IR test on the power circuits. Test voltage shall be 500V DC for LV (up to 1kV) system, 2.5kV DC for HV up to 4.2kV system voltage and 5kV DC for HV above 4.2kV of system voltage. Minimum resistance shall be 10(kV+1) MΩ-kV is the system voltage. Test point R-YBNE Y-RBNE B-RYNE 7 8 9

Insulation Rsitance

OK

N/A

Remarks

Ensure motor cable is disconnected from VFD output terminals. Check that moisture has not condensed inside of drive enclosure. Confirm that all Start / Stop switches connected to I/O terminals and / or Start / Stop Device-net commands are in the Stop state. Page 1 of 2

P/L No



11

12

13 14 15 16 17 18 19

VARIABLE SPEED DRIVE E35-B Energize the VFD incoming power feed and verify correct AC input voltage. ____________ Volts Confirm the VFD configuration parameters have been entered. Backup final version of drive program file if a laptop is used. Record configuration parameters in a separate sheet. Confirm VFD configured minimum and maximum speed (frequency) is within limits of coupled load i.e. minimum and maximum pump/motor speed. Confirm Device-net / Control-net communications are successful. Confirm Master Control ESD Relay is energized. Startup VFD and test without motor as per VSD vendor’s recommendations. Confirm as-built/red line drawings are complete and enclosed within the commissioning handover dossier. Record any defects/shortcomings in the system punch-list Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HEATER CONTROL PANEL

E36-B

Project No. Project Title Facilities INFORMATION Tag no. System/ Sub System no. Voltage Rating Frequency Location Manufacturer Ref. Drawing nos. Serial No. Model No. INSPECTION / TEST 1 Documents required for verification. a. Heater Control Panel datasheet and schematic diagram b. Completed and signed-off construction check-sheet and punch list status c. Precom check-sheets for all CTs, VTs and protection relays installed d. Precom check-sheets for all associated power and control cables e. FAT report 2 Check incoming power feed for proper termination of conductors per project specifications. Verify tightness of bolts using a torque wrench if applicable and record the torque values and mark the bolts. 3 Ensure equipment grounding is complete and is intact. 4 Ensure the type of cable used including the earthing arrangements is as per vendor recommendations. 5 Confirm control I/O wiring is correct per project drawings. 6 Perform IR test on the power circuits at 500V DC. Minimum acceptable

OK

N/A P/L No

value of IR is 10MΩ. All outgoing circuits OPEN. Test point R-YBNE Y-RBNE B-RYNE 7 8 9 10


Remarks

Ensure heater cable is disconnected from the control panel output terminals. Check that moisture has not condensed inside of the heater panel enclosure. Confirm that all Start / Stop switches connected to I/O terminals and / or Start / Stop commands are in the Stop state. Energize the heater panel incoming power feed and verify correct AC input voltage. ____________ Volts Page 1 of 2



12 13 14 15 16 17

HEATER CONTROL PANEL E36-B Confirm the heater control panel configuration parameters have been entered as per vendor recommendations. Backup final version of drive program file if a laptop is used. Record configuration parameters in a separate sheet. Confirm operation of Master Control ESD Relay by simulation of ESD signal. Perform additional pre-commissioning checks required, if any, as per manufacturer instructions. Confirm as-built/red line drawings are complete and enclosed within the commissioning handover dossier. Record any defects/shortcomings in the system punch-list Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE MOTOR

E37-B

Project No. Project Title Facilities INFORMATION Tag no. System/ Sub System no. KW Rating EX Rating / IP FLC Insulation Class Frequency Location Voltage Ref. Drawing nos. RPM Serial no. Connection (Y/∆) Manufacturer Fed from (MCC) Time te (For Ex’e’ motors) INSPECTION / TEST 1 Documents required for verification. a. Motor Datasheet b. Single line diagram of associated MCC c. Completed and signed-off check-sheets as follows: d. Completed and signed-off construction check-sheet for the subject motor and punch list status e. Precom check-sheets for all associated power and control cables f. Precom check sheet for the relevant starter g. Precom check-sheet for the relevant RCU/Safety switch h. FAT report / Routine test report i. Hazardous area certificate (if applicable) 2 Confirm motor, space heater and associated equipment has been deenergized and locked out / tagged out in accordance with permit to work procedures. 3 Confirm correct application of manufacturer’s lubricant, if required. 4 Ensure all motor terminal box covers and guards are fitted and all gaskets are in place. 5 Uncouple the motor and rotate the shaft manually and confirm the shaft is freely rotating (no damage to bearings) and the fan blades are not rubbing against the body/fan cowl. 6 Test and record ground resistance between motor and local ground system. Max 1.0 Ω. Ground resistance between motor and ground system _____ Ω

OK

N/A P/L No

Page 1 of 4



HIGH VOLTAGE MOTOR E37-B Perform insulation resistance test of windings including the cables from MCC side. Test voltage shall be 2.5kV DC for voltages up to 4.2kV system and 5kV DC for above 4.2kV system.

Test point R-YBE Y-RBE B-RYE


Remarks

Perform polarization index test. Take insulation resistance measurements of the windings after disconnecting the cables. Calculate PI by dividing resistance value at the 10th minute by the 1st minute. Time Start 1 min 10 min PI (R10/R1)

RYB-G

Minimum acceptable value for PI is 2 and minimum insulation value 10(kV+1) MΩ. However, PI values and IR should be compared with the corresponding values from FAT report and any major deviations (more than 20%) need to be investigated prior to energisation. 8 Test and record insulation resistance of space heater, where applicable. Test voltage shall be 500V DC. Insulation resistance __________ MΩ Minimum acceptable value is 10MΩ. 9 Confirm the respective starter has been tested and relays set. Associated power and control cables have been tested and precommissioning check sheets completed. Confirm the RCU and safety switch for the motor has been tested and pre-commissioned. Check-sheet completed and available. 10 Select test position and function check starter control circuits.

Page 2 of 4


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE MOTOR E37-B 11 Select service position and conduct bump test on the motor uncoupled from the driven machine to confirm the correct direction of rotation and if required adjust the phase connection. 12 Carry out no-load run for a minimum period of 4 hours or until temperature readings stabilizes. Time (min)

Ambient

Temperature (o C) Frame/ Bearing winding DE NDE

Remarks

0 5 10 20 30 40 50 60 75 90 120 150 180 210 240

Starting current No Load current Starting Time Normal running speed Coasting /Stopping time 13

Record setting for Winding and bearing temperature protection. Settings Winding Bearing

Alarm

Trip

Remarks

Page 3 of 4


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HIGH VOLTAGE MOTOR 14

E37-B

Repeat the insulation resistance test and record the IR values. Test point R-YBE Y-RBE B-RYE


Remarks

15 Confirm red-line drawing is completed. 16 Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 17 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 18 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION Vibration measurements shall also be taken and results attached to this check-sheet.





Page 4 of 4

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LOW VOLTAGE MOTOR

E38-B

Project No. Project Title Facilities INFORMATION Tag no. System/ Sub System no. KW Rating EX Rating / IP FLC Insulation Class Frequency Location Voltage Ref. Drawing nos. RPM Serial no. Connection (Y/∆) Manufacturer Fed from (MCC) Time te (For Ex’e’ motors) INSPECTION / TEST 1 Documents required for verification. a. Motor Datasheet b. Single line diagram of associated MCC c. Completed and signed-off check-sheets as follows: d. Completed and signed-off construction check-sheet for the subject motor and punch list status e. Precom check-sheets for all associated power and control cables f. Precom check sheet for the relevant starter g. Precom check-sheet for the relevant RCU/Safety switch h. FAT report / Routine test report i. Hazardous area certificate (if applicable) 2 Confirm motor, space heater and associated equipment has been deenergized and locked out / tagged out in accordance with project specification and permit to work procedures. 3 Confirm correct application of manufacturer’s lubricant, if required. 4 Ensure all motor terminal box covers and guards are fitted and all gaskets are in place. 5 Uncouple the motor and rotate the shaft manually and confirm the shaft is freely rotating (no serious damage to bearings) and the fan blades are not rubbing against the body/fan cowl. 6 Test and record ground resistance between motor and local ground system. Max 1.0 Ω Tested resistance value _______ Ω

OK

N/A P/L No

Page 1 of 3



LOW VOLTAGE MOTOR E38-B Perform insulation resistance test of windings including the cables from MCC side. Test voltage shall be 500V DC. Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE Note:For motors were only three terminals are available (star/delta connection is made internally and only one end of the winding is brought out), the IR test shall be conducted from individual phase to ground.

Perform polarization index test. Perform insulation resistance measurements of the windings after disconnecting the cables. Calculate PI by dividing resistance measurement at the 10th minute by the 1st minute. Time RYB-E Start 1 min 10 min PI (R10/R1)

8

9 10

Minimum acceptable value for PI is 2 and minimum insulation value 20 MΩ. However, PI values and IR shall be compared with the corresponding values from FAT report and any major deviations (more than 20%) need to be investigated prior to energisation. Test and record insulation resistance of space heater, where applicable. Test voltage shall be 500V DC. Insulation resistance __________ MΩ Minimum acceptable value is 10MΩ. Select test position and function check starter control circuits. Select service position and conduct bump test on the motor uncoupled from the driven machine to confirm the correct direction of rotation and if required adjust the phase connection.

Page 2 of 3



12

13 14 15 16

LOW VOLTAGE MOTOR E38-B Carry out no-load run for a minimum period of 30 min or until temperature readings stabilizes. Time Temperature No-Load (min) current Ambient Frame Bearing DE NDE 0 5 10 15 20 25 30 Starting current No Load current Starting Time Normal running speed Coasting /Stopping time Repeat the insulation resistance test and record the IR values. Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE Confirm red-line drawing is completed. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRIC HEATER

E39-B

Project No. Project Title Facilities INFORMATION Tag no. System/ Sub System no. KW/HP Rating Voltage Amperes Frequency Manufacturer No. of Bundles Ref. Drawing Nos. Model No. Location Serial no. INSPECTION / TEST 1 Documents required for verification. a. Heater Datasheet b. Single line diagram of associated MCC c. Completed and signed-off construction check-sheet for the subject heater and punch list status d. Precom check-sheets for all associated power and control cables e. Precom check sheet for the relevant starter/feeder/heater control panel f. Precom check-sheet for the relevant RCU/Safety switch (if installed) g. FAT report / Routine test report h. Hazardous area certificate (if applicable) 2 Confirm heater has been properly grounded. Test and record ground resistance between heater and local ground system. Max 1.0 Ohm. ________ Ohm 3 Measure and record heating element resistances. Element Resistance (Ω) Remarks

4

5 6

OK

N/A P/L No

Perform insulation resistance test at 500 V and record the IR values. Minimum resistance shall be 10MΩ Bundle R-YBE Y-RBE B-RYE Remarks 1 2 3 4 Ensure all heater terminal box covers and guards are fitted. Confirm all red-line drawings are completed. Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B 7 8 9

ELECTRIC HEATER E39-B Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRICAL HEAT TRACING

E40-B

Project No. Project Title Facilities Tag no. Voltage Oper. Temperature Type of Tracer Ref. Drawing nos. Manufacturer 1

2 3 4

INFORMATION System/ Sub System no. Frequency Location Overload setting Distr. Board No. Area Classification INSPECTION / TEST

OK

N/A P/L No

Documents required: a) Completed and signed-off construction check–sheet for the tracing system and punch list status b) Precom check-sheet for the associated DBs c) Precom check-sheet for associated power/control cables d) Vendor datasheet and installation drawing for the tracing system Confirm warning labels have been fitted on cladding as per manufacturer's recommendations. Confirm continuity of trace heating tape is satisfactory. Carry out IR test on heat tracing circuit including the tracing tape. Install the end seal and take the IR value. Later soak the end seal in water for 1 hour and measure the IR again for one minute and record the value at the end of 1 minute.

In case of SLSR type tracer tapes, DO NOT megger between phases. Test voltage shall be 500V DC and min. acceptable IR value 10MΩ. IR value before soaking end seal in water ________MΩ IR value after soaking end seal in water 5 6 7 8

9 10

________ MΩ

Confirm rating of each MCB / RCD against design drawings. Check all cover and guards are present and no bolts missing. Make safe tape and isolate as appropriate. Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Confirm all red line drawings are completed. Record defects/shortcomings, if any, in the system punch-list. Page 1 of 2



11 12

ELECTRICAL HEAT TRACING E40-B Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B IMPRESSED CURRENT CATHODIC PROTECTION E41-B SYSTEM Project No. Project Title Facilities INFORMATION Tag no. System/ Sub System no. TR Unit Rating (A) Voltage Location Manufacturer Serial no. Model No. INSPECTION / TEST OK 1 Documents required: a) Completed and signed-off construction check–sheet for the ICCP system and punch list status b) Precom check-sheet for associated power/control cables c) Vendor datasheet and wiring diagram for the ICCP system d) List of protected equipment / structures 2 Perform insulation resistance test of the TR unit at 500 V and record the IR values. Minimum resistance shall be 10MΩ. All cables to anode and cathode junction boxes shall be removed / isolated during the test. ________MΩ 3 4

Perform ratio test on the transformer and record the results. Perform continuity test between protected structures (pipe line, tank etc.) and unprotected structures (electrical conduits, unprotected pipes, etc.) by fixed cell-moving ground method or by point to point method. The purpose is to confirm that all protected structures are electrically continuous while nearby unprotected structures are electrically isolated from the protected structures. Name Eqpt-1

5

6

N/A P/L No

Eqpt-2

Voltage - mV (fixed cell method) Eqpt-1 Eqpt-2

Continuity (Yes/No/ Inconclusive)

Voltage - mV (Point - Point method)

Continuity (Yes/No/)

If the difference in voltmeter reading between two structures is less than 2mV, they are considered to be electrically continuous. If the difference in reading is more than 10mV they are electrically isolated and if the reading is between 2mV and 10mV, the testing is inconclusive and a point to point test to be conducted for such structures. Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Confirm red-line drawings are completed. Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B IMPRESSED CURRENT CATHODIC PROTECTION E41-B SYSTEM 7 Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 8 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 9 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MOTOR OPERATED VALVE (ACTUATOR) E42-B Project No. Project Title Facilities INFORMATION Tag no. System/ Sub System no. Voltage Frequency KW/HP Rating Location Valve size Overload setting Manufacturer Serial no. Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required for verification. a. MOV Datasheet b. Single line diagram of associated switchboard c. Completed and signed-off construction check-sheet for the subject MOV and punch list status d. Precom check-sheets for all associated power and control cables e. Precom check sheet for the relevant feeder f. Precom check-sheet for the relevant RCU/Safety switch g. FAT report / Routine test report h. Hazardous area certificate (if applicable) 2 Perform insulation resistance test at 500V and record the IR values. Minimum resistance shall be 10MΩ. Test point R-YBE Y-RBE B-RYE 3

4

5 6 7 8

Insulation Resistanc

N/A P/L No

Remarks

Perform winding resistance measurement. Compare the value with FAT/routine test results and any deviation of more than 20% shall be investigated. Perform function test of the MOV from local and from remote (if remote control is provided). Remote control from DCS shall also be tested either by forcing the DCS output signal or by manual control from DCS. Verify the operation of limit switch. Verify the operation of torque switch. Ensure red-line drawings are completed. Record defects/shortcomings, if any, in the system punch-list. Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MOTOR OPERATED VALVE (ACTUATOR) E42-B Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 9 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 10 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B NORMAL LIGHTING (CIRCUIT/FIXTURES) E43-B Project No. Project Title Facilities INFORMATION Tag no. System no. Area Classification Sub System no. Voltage Circuit no. Circuit MCB rating Frequency Connected load (W) Location Manufacturer Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required for verification. a. Single line diagram of associated DB b. Completed and signed-off construction check-sheet for the subject circuit and fixtures. c. Precom check-sheets for all associated power cables d. Precom check sheet for the relevant feeder in DB e. Hazardous area certificate of the fixture/JB (if applicable) 2 Visually inspect the fixtures for any damage (broken glass, denting of fixture etc.) 3 Perform earth continuity checks. 4 Ensure MCB is correctly rated and connected within the distribution board. Check circuit continuity. 5 Energize the circuit and confirm all luminaires function correctly. 6 Check the operation of photo-cell (where installed) by simulating the day/night conditions. Check the operation of the timer (where installed. Confirm the operation and functionality of the photo-cell bypass switch. 7 Confirm red-line drawings are completed. 8 Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 9 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 10 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION




N/A P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B EMERGENCY LIGHTING (CIRCUIT/FIXTURES) E44-B Project No. Project Title Facilities INFORMATION Tag no. System no. Area Classification Sub System no. Voltage Circuit no. Circuit MCB rating Frequency Connected load (W) Location Manufacturer Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required for verification. a. Single line diagram of associated DB b. Completed and signed-off construction check-sheet for the subject circuit and fixtures. c. Precom check-sheets for all associated power cables d. Precom check sheet for the relevant feeder in DB e. Hazardous area certificate of the fixture/JB (if applicable) 2 Visually inspect the fixtures for any damage (broken glass, denting of fixture etc.) 3 Perform earth continuity checks 4 Ensure MCB is correctly rated and connected within the distribution board. Check circuit continuity. 5 Energize the circuit and confirm all luminaires function correctly. 6 Check the operation of photo-cell (where installed) by simulating the day/night conditions. Check the operation of the timer (where installed. Confirm the operation and functionality of the photo-cell by pass switch. 7 Switch-off the circuit MCB/switch and confirm that the battery is NOT powering the fixture. Simulate main power failure (switch-off the feeder to the DB at MCC) with the circuit MCB’s and switches ON and confirm battery is backing up the fixtures. 8 Confirm red-line drawings are completed. 9 Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 10 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 11 externally clean.

N/A P/L No

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B EMERGENCY LIGHTING (CIRCUIT/FIXTURES) E44-B COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SOCKET OUTLET E45-B (WELDING/POWER/CONVENIENT) Project No. Project Title Facilities INFORMATION Tag no. System/ Sub System no. Area Classification Circuit no. Voltage Frequency Circuit MCB rating Location Manufacturer Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required for verification. a. Single line diagram of associated DB b. Completed and signed-off construction check-sheet for the subject circuit and socket. c. Precom check-sheets for all associated power cables d. Precom check sheet for the relevant feeder in DB e. Hazardous area certificate of the socket/JB (if applicable) 2 Visually inspect the sockets for any damage (broken pins/ covers etc.) 3 Perform earth continuity checks 4 Ensure MCB is correctly rated and connected within the distribution board. Check circuit continuity. 5 Perform insulation resistance test at 500V and record the IR values. Minimum resistance shall be 10MΩ.

6 7 8 9 10

N/A P/L No

Test point Insulation Resistance Remarks R-YBNE YRBNE B-RYNE Energize the circuit ad check voltage / polarity at each socket. Confirm red-line drawings are completed. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SOCKET OUTLET (WELDING/POWER/CONVENIENT)

E45-B






Page 2 of 2

CSP-20 rev. 01 Appendix II-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B PUSH BUTTON STATION / SAFETY SWITCH E47-B Project No. Project Title Facilities INFORMATION Tag no. System/ Sub System no. IP Rating Ex rating Manufacturer Ammeter range Model No. Location Serial No. Ref. Drawing nos. INSPECTION / TEST OK N/A P/L No 1 Documents required for verification. a. Completed and signed-off construction check-sheet for the subject push button station/ safety switch and punch list status. b. Completed and signed-off pre-commissioning check-sheet for the corresponding motor starter c. Control schematic for the associated starter d. Precom check-sheets for all associated control cables e. FAT report. 2 Check point to point panel wiring per project drawings. 3 Check and confirm grounding connections are in place. 4 Perform insulation resistance test on the control wiring using a 500 V megger. IR test result ________ MΩ Minimum acceptable value is 10 MΩ. 5 Prove mechanical operation of switches, isolators, pushbutton, etc. 6 Perform function check of the push button station through the motor starter with starter in test position. 7 Confirm red-line drawings are completed. 8 Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 9 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 10 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 1 of 1


Page 2 of 1

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Contract No. Project Title Facilities Tag no.

FAN

H01-B

INFORMATION System/Subsystem no.

INSPECTION / TEST 1 Check name plate and ensure correct information is provided. 2 Turn fan impeller and motor to ensure free rotation. 3 Check fan bearing lubrication/greasing. 4 Check fan casing mounting, flexible joints and vibration dampener. 5 Check pulley alignment and fan belt tension. Verify that electrical check on motor, cabling and fan starter has been 6 completed. Measurement Fan Performance Unit Design Actual Details Volume Rate m³/s Fan Speed rpm Static Pressure 7 Inlet Pa Outlet Pa Total Pa Motor Speed rpm Running Current Amps COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheets from the vendor shall be attached with this (if any).




OK

N/A P/L No


Page 1 of 1

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B AIR HANDLING UNIT / AIR CONDITIONING UNIT H03-B Contract No. Project Title Facilities INFORMATION Tag no. System/Subsystem no.

INSPECTION / TEST Check that unit is airtight with no air leaks through joints and access 1 doors. 2 Confirm operation of local start stop control station. Complete tests of internal items of equipment as appropriate. Air Filters Fan shut off Dampers 3 Fan Electric Heaters Fire damper Volume damper 4 Check Filter / Coalescer Unit. 5 Check Cooling Coil (water). 6 Check Heating coil (electricity). 7 Check name plate and ensure information is correct. Check flexible duct connectors are installed correctly and as per 8 specification. 9 Check mixing box and return fresh air damper installation. Verify that electrical check on motors, cabling and motor control 10 center are completed. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check sheets from the vendor shall be attached with this (if any).




OK

N/A P/L No


Page 1 of 1

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HVAC STATIC PRESSURE TEST Contract No. Project Title Facilities Tag no.

H10-B


INSPECTION / TEST Ensure that the Ductwork installation is in accordance with the current 1 GA Drawing(s) and CCN's are closed out. Confirm Mechanical Completion Records are all complete and no 2 subsequent damage has occurred. 3 Ensure all blanks have been removed. Ensure all dampers are in the open position i.e. control, shut off, 4 manual and fire dampers. 5 Check that all access hatches are closed. Test holes (with sealing covers) in ducting for air flow measurements 6 provided. 7 Preservation removed. 8 Execute H20-B. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheets from vendor shall be attached with this (if any).




OK

N/A P/L No


Page 1 of 1

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HVAC Fire Damper and Panel Contract No. Project Title Facilities Tag no.

H11-B


INSPECTION / TEST 1 Confirm electrical power supply to Fire Damper Panel. With IPS/F&G signal to damper Does damper fully OPEN - Verify OPEN LIMIT SWITCH (GSO). 2 Does Damper fully CLOSE in 2 seconds on loss of signal - Verify CLOSE LIMIT SWITCH (GSC). From Fire Damper Panel Does Damper fully CLOSE on opening of HCV (Hand Control Valve) to remove air supply. 3 Does Damper fully OPEN on provision of bottled air supply to Panel and operation of Black Start override HOV (Hand Operated Valves)(remove padlocks to open) Simulate fracture of Azeotopic Frangible Tube/Bulb (unscrew valve or 4 switch) Does Damper fully CLOSE. 5 Damper reset to normal operating mode after test. 6 Check fusible link is fitted. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheet from the vendor shall be attached with this (if any).




OK

N/A P/L No


Page 1 of 1

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HVAC DAMPER AND PANEL Contract No. Project Title Facilities

H12-B

INFORMATION Tag no. System/Subsystem no. INSPECTION / TEST Dampers Panel (Tag No.) 1 Confirm electrical power supply to each Damper panel. Check Dampers fully OPEN - Verify OPEN LIMIT SWITCH (GSO). Fan and System Shut Off Dampers (Tag No.) Simulate Fan Operating and check damper OPENS from HVAC Control Panel. 2 On Fan/System shutdown, check Damper CLOSES from signal inhibit – Verify CLOSED LIMIT SWITCH (GSC). With fan running and Dampers closed, check for effective shut off (minimal air loss). Gas Tight Dampers (Tag No.) Simulate F&G Signal to Damper and check damper fully OPENS - verify 3 OPEN LIMIT SWITCH (GSO). With loss of signal, check that damper fully CLOSES with 2 seconds Verify CLOSED LIMIT SWITCH (GSC) Modulating Control (Tag No.) Operating Dampers from HVAC Control Panel with 4-20mA check air 4 volume through Dampers conform to design requirements - Verify OPEN/CLOSED LIMIT SWITCHS. Pressure Control Dampers (Tag No.) 5 Damper correctly Marked after adjustment (Bolt adjust painted) Volume Control Dampers (Tag No.) 6 Check operating handle not obstructed through full travel, locking device secure and correctly marked. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheet from the vendor shall be attached with this (if any).




OK

N/A P/L No


Page 1 of 1

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HVAC MIST ELIMINATOR AND AIR FILTER H13-B Contract No. Project Title Facilities INFORMATION Tag no. System/Subsystem no.

INSPECTION / TEST Check the following for Mist Eliminator: Drain clear from debris 1 Pipe free flowing Drain trap primed. 2 Check filter elements are clean and preservation has been removed. 3 For filters, check DP gauge fitted. Min/Max readings indicated. Check DP gauge and switches are correctly connected to indicate 4 pressure drop across the whole unit and simulate alarm condition (check at HVAC Panel) 5 Check inlet filter protecting guard. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheet from the vendor shall be attached with this (if any).




OK

N/A P/L No


Page 1 of 1

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Contract No. Project Title Facilities Tag no.

1

2

3

HVAC DX SYSTEM

H14-B


INSPECTION / TEST Air Cooled Condensing Units: Initial Checks Check that air inlet/outlet are clean and free from obstructions. Ensure the cooling coils are not damaged and as per specification. Check that all electrical circuits are complete. Check that refrigerant circuit is complete and has been leak tested and charged for start-up. Check refrigerant piping insulation as per specification. Check oil levels on refrigerant compressors. Ensure preservation has been removed. Air Cooled Chiller: Initial Checks Check chilled water piping installed as per drawings. Check piping flushed clean and leak tested. Check chiller motor rotation correct. Check chemical water treatment complete. Check chiller water tank and water pump install correctly complete with correct connection /tie-in. Check that direct drive fan assembly rotates freely and fan impeller blades are not damaged and pitch and angles are correct. Ensure the cooling coils are not damaged and installed as per specification. Check that all electrical circuits are complete. Check that refrigerant circuit is completed and has been leak tested and charged for start-up. Check refrigerant piping insulation as per specification. Check oil levels on refrigerant compressors. Ensure preservation has been removed. Start-Up and Operation Procedures. Provide 415V supply to the HVAC Control Panel. Ensure Compressor crankcase heaters have been energised, for at least 24 hours prior to starting the compressor. Confirm operation of local start stop control station. Select AHU controller for a low value setpoint temperature compared

OK

N/A P/L No

Page 1 of 2

CSP-20 rev.01 Appendix II-IV to return air temperature and check that the 24V AV signal is present. Check that HP/LP pressure switch is set to the following: a) Low Pressure Cut Out b) Oil Pressure c) High Pressure Cut Out Simulate conditions on the unit to provide trips to AHU unit controller as follows: a) Dirty filter (pressure switch) b) Air Flow sensor c) Compressor high and low level trips. d) Check control logic activities inhibits and controller readout displays trip action. e) Run unit at design set point and check for automatic operation within design limits. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheet from the vendor shall be attached with this ( if any).





Page 2 of 2

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HVAC FANS / MOTORS

Contract No. Project Title Facilities

INFORMATION System /Subsystem no.

Tag no.

Test point ref. no

Duct size mm

H15-B

Duct area m²

Design air velocity m/s

INSPECTION / TEST Traverse Velocity (m/s)

Actual velocity m/s

% of req. velocity

Static pressure in duct Pa

Remarks

Page 1 of 2

CSP-20 rev.01 Appendix II-IV

COMMENT(S) AND ADDITIONAL INFORMATION Mechanical Check-sheet from the vendor shall be attached with this (if any).





Page 2 of 2

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Contract No. Project Title Facilities

HVAC DUCT BALANCE SHEET

INFORMATION

Tag no.

Ref. no.

H16-B

Test Point Location Duct size mm

Duct area m²

INSPECTION / TEST Design Velocity m/s Flowrate m³/s

System/Sub-system no.

Actual Velocity Flowrate m/s m³/s

% or Static req. pressure volume at TP Pa

Remarks

Page 1 of 2







Page 2 of 2

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HVAC AREA PRESSURE TEST SHEET Contract No. Project Title Facilities Tag no.

H17-B

INFORMATION

System no. Sub-system no.

Supply Air System Area Module

Class

Fan no.

Design air m³/s

Actual air m³/s

Extract Air System % of design

Fan no.

Design air m³/s

Actual air m³/s

% of design

Module/Area Air change rate volume Gross Nett Design Actual m³ m³

Module press. Wrt Atmos Req. Actual Pa Pa

Page 1 of 2







Page 2 of 2

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HVAC DUCT HEATER Contract No. Project Title Facilities Tag no.

H18-B


INSPECTION / TEST

Heater: Confirm ITR A sheet is completed. 2 Confirm control equipment correctly installed. 3 Confirm correct function of high temperature alarms and trips. 4 Simulate low air flow and confirm low air flow trip functions correctly. 5 Confirm external trips function correctly (ie; PSD/PCS etc.) Energise circuit and record the following:6 Cold : __________________________Amps Hot : ___________________________ Amps Confirm heater response is satisfactory over temperature control 7 range. 8 Make safe heater and lock off supply at source. Dehumidifiers:9 Carry out visual check on the installation and duct works for correct connection and for any general signs of damage for dehumidifier. Check and ensure the incoming supply cable and control cables have 10 been correctly installed and terminated. Ensure all components in the dehumidifier are properly secured and in 11 good order. Ensure all fuses are of correct rating and all thermal overload relays are 12 of correct setting. Ensure all fans and motors are free from obstruction and able to rotate 13 freely. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheet from the vendor shall be attached with this (if any).

OK

N/A P/L No

1

Page 1 of 2






Page 2 of 2

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HVAC RECIRCULATION PUMP Contract No. Project Title Facilities Tag no.

H19-B


INSPECTION / TEST 1 Check that the skid is clean and all components are free from damage. 2 Confirm that all preservation has been removed. Lube oil system flushing complete and that all temporaries have been 3 removed. Lube oil system filled with correct grade of lubricant and to correct 4 level. Seal oil system filled with correct grade of lubricant and to correct 5 level. 6 Check Lube and Seal Oil systems for leaks. 7 Confirm Motor start/stop station operates locally. 8 Confirm all guards are reinstated and secure. Confirm that the correct lubrication has been applied to the bearings, 9 seal glands and gearbox. Confirm forced lubrication system complete, flushed and ready for 10 service. 11 Confirm that equipment PSV's are installed. 12 Confirm the suction strainers are installed and clean. 13 Check pump discharge is protected against over pressurization. 14 Confirm that the Earth Bonding strap is intact. 15 Suction Primary System complete and ready for service. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheet from the vendor shall be attached with this (if any).




OK

N/A P/L No


Page 1 of 1

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HVAC TANK Contract No. Project Title Facilities Tag no.

H20-B


INSPECTION / TEST

OK

N/A P/L No

1

Pre Start-Up Checks. Confirm that all associated Construction checksheets are signed off 2 prior to starting any work. Confirm that the content of the accepted punchlists are complete and no subsequent damage has occurred. Check that the equipment is clean and all external components are 3 installed. 4 Confirm that all preservation has been removed. 5 Check that the sliding support is free to move. 6 Confirm all connections are complete and to vendors drawings. Confirm Pressure Relief facilities are installed and interlocks are 7 installed. Confirm that all valves are greased and free to operate and all spare 8 valves have flange connections blinded off. Confirm Tank/vessel Internals have been installed in accordance with 9 Vendor drawings. 10 Confirm all manway covers bolted up correctly with correct gaskets. 11 Earth Bonding straps complete. COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheet from the vendor shall be attached with this (if any).





Page 1 of 1

CSP-20 rev.01 Appendix II-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HEATING, VENTILATION AND AIR CONDITIONING H21-B (HVAC) Contract No. Project Title Facilities INFORMATION Tag no. System /Subsystem no.

INSPECTION / TEST Confirm that all associated Construction checksheets (ITR-A) are 1 signed off prior to starting any work. Confirm that the content of the accepted punch-lists will not impede 2 commissioning 3 Hand rotate fan impeller and motor to ensure free rotation Check that all instrument functional test had been done, i.e., limit 4 switch 5 Check closing of damper 6 Test dampers at least four (4) times with 100 percent success rate Check that all electrical checks had been carried out successfully 7 including baring the motor and compressor to ensure free rotation 8 Turn condenser fan and ensure free rotation Check that refrigeration system is vacuumed and charged with 9 refrigerant COMMENT(S) AND ADDITIONAL INFORMATION Mechanical check-sheet from vendor shall be attached with this.




OK

N/A P/L No


Page 1 of 1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B I08-B

PNEUMATIC INSTRUMENT CONTROL PANEL (ICP)/ESD STATION TEST Project No. Project Title Facilities INFORMATION Platform/ Plant name Sys Number

Sys Description

INSTRUMENT CONTROL PANEL (ICP) DATA Tag Number Signal Range Manufacturer Dial/Chart Type Model Number Range Service Data Sheet Serial Number IP rating EX rating Pneumatic Supply:  Instr. Air  Instr. Gas Panel Type: P P–E P: Pneumatic, E: Electronic 1 2 3 4

PRE-COMMISSIONING CHECK OK N/A Verify I08-A: Pneumatic Instrument Control Panel (ICP)/ESD Station Installation Check sheet Verify the availability of ICP Vendor Pre-commissioning / SAT Procedure Verify all tubing connected to the panel have been pressure tested as per check sheet I05-A Verify all cables connected to the panel have been meggered / insulation tested as per I01-A

5

Verify the instrument air is connected to the panel air / gas supply line

6

Verify the required electric power supply is connected to the panel Verify the required pressure is adjusted on the pneumatic supply and control lines Verify the pneumatic time delays are set to the specified duration Verify the individual function of the pneumatic / electronic switch input to the control outputs Verify the pressure outputs due to the actuation of process shutdown pushbutton at panel

7 8 9 10

P/L No

1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B I08-B PNEUMATIC INSTRUMENT CONTROL PANEL (ICP)/ESD STATION TEST Verify the pressure outputs due to the actuation of emergency shutdown 11 pushbutton at panel Verify the output pressure switch contacts every time shutdown function is 12 triggered 13 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 14 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Cause & Effect Matrix 2 Panel Schematic Drawings OBSERVATION / REMARKS

Designation



ACCEPTED BY Commissioning Engineer 2

Company Name Signature Date

PETRONAS Carigali

PETRONAS Carigali

3

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B INSTRUMENT CLOSE LOOP CHECK NON FIELDBUS FIELDBUS(Note1)

I11-B

Project No. Project Title Facilities INFORMATION Platform/ Plant name Sys Number Controller Tag Number Initiator Tag Number Service Loop Number Controller Action

Sys Description INSTRUMENT DATA Signal Range

Manufacturer

Dial/Chart Range Data Sheet Line of Equip No Valve Action

Model Number Serial Number Loop Diag No Final Element Tag number

PRE COMMISSIONINGCHECK Verify the device calibration check sheet I03-A & Installation check sheet I04-A 1 has been completed. 2

OK N/A P/L

Verify the cable has been installed terminated and tested as per Cable Installation & Testing check sheet I-01A completed.

Verify loop details are correct against Project / Vendor information 3 i.e. P & ID's, I/O schedule, Data sheet / Instrument index / Alarm & Trip schedule (including Rack / Slot / Channel location for all I/O devices). 3 Verify the calibration certificate of the test equipment 4 Visually inspect equipment for external damage 5 Verify nameplate tagging against data sheet 6

Verify each Instrument is calibrated, accepted and confirm the duration of the calibration certificate is still valid.

8

Test and ensure that loop is configured and functioning as per Control Narrative (Controller Action Auto Manual changeover, split range etc.) 1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B INSTRUMENT CLOSE LOOP CHECK I11-B NON FIELDBUS FIELDBUS(Note1) 9 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 10 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. Type

Manufacturer



LOOP TEST INSTRUMENTS INCLUDED IN THIS LOOP CHECK Tag No Tag No Tag No Tag No Tag No Tag No Tag No Tag No Tag No Tag No Tag No Tag No ANALOG TRANSMITTER(Note2) MODEL NO: SERIAL NO: TRANSMITTER TAG NO: LOCAL INSTR.TAG PANEL DCS Tag No: (RANGE: ) NO : INSTR.TAG NO: Input (HART / FF) Output Reading Reading Reading 0% Reading 50% 100% DIGITAL SWITCH(Note2) MODEL NO: SERIAL NO: PANEL DCS Tag LOCAL SWITCH/TRIP ALARM TAG VALVE ACTION TAG LEVEL OF SHUTDOWN No: AMPLIFIER TAG NO: NO : NO: SET POINT

READING

ACTION

ALARM

HH H 2

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B INSTRUMENT CLOSE LOOP CHECK NON FIELDBUS FIELDBUS(Note1)

I11-B

L LL MODEL NO: Controller Tag No: Output

ANALOG CONTROLLER(Note3) SERIAL NO: I/P Valve Valve LIMIT SWITCH Transducer Positioner Position

DCS

0% 50% 100% FIELDBUS CHECKLIST(Note 1) The FOUNDATION Fieldbus shall be tested using a proven Fieldbus Wiring Monitor that can test the voltage, signal levels and wiring noise. The test shall comply with FOUNDATION™ Fieldbus System Engineering Guidelines (AG-181) SEGMENT MEASUREMENT Voltage Lowest Device Signal Lowest Device Signal Address Lowest Device Signal Date/Time Avg Fieldbus Frequency Noise (940kHz) Peak Fieldbus Frequency Noise (940kHz) Peak Fieldbus Frequency Noise Date/Time Avg Low Frequency Noise (50Hz4kHz)Low Frequency Noise (50HzPeak 4kHz)Low Frequency Noise Peak Date/Time Avg High Frequency Noise (50Hz4kHz)High Frequency Noise (50HzPeak 4kHz)High Frequency Noise Peak Date/Time Shield Short LAS Address Most Recent Add/Drop Address Device Add or Drop

DATA

ACCEPTANCE VALUES 9.0V Minimum 150-1200mV N/A N/A 75mV Maximum 75mV Maximum N/A 150mV Maximum 150mV Maximum N/A 150mV Maximum 150mV Maximum N/A No Shorts N/A N/A None Added/Dropped

A

3

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B INSTRUMENT CLOSE LOOP CHECK NON FIELDBUS FIELDBUS(Note1) Date/Time of Device Add/Drop Number of Active Devices

I11-B N/A N/A N/A N/A N/A 150-1200mV Not Added/Dropped 0

DEVICE MEASUREMENTS Device Address Signal Level Added/Dropped Retransmits REFERENCE DRAWINGS 1 Control Narrative (if applicable) 2 Shutdown Narrative (if applicable) 3 Hook Up Drawings 4 Logic Diagram 5 Cause & Effect Matrix Diagram 6 Alarm List 7 Panel Drawings 8 LoopDrawings 9 Instrument Datasheet 10 Test Equipment Certificate 11 Calibration Certificate






4

Signature Date

5

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MISCELLANEOUS PROCESS ANALYZER TEST Project No. Project Title Facilities GENERAL Platform/ Plant name Sys Description Sys Number ANALYZER DATA Tag Number SignalRange Dial/Chart Type RangeSheet Service Data

I13-B

Manufacturer Model Number Serial Number

Area Classification ACCEPTANCE CRITERIA Check the performance requirement from the datasheet of respective analyzers PRE COMMISSIONING CHECK OK N/A P/L 1 Verify the analyzer has been installed as per check sheet I13-A and completed Functional check of the instrument, flow computer, HMI and interface of the 2 host system based on vendor’s SAT procedure 3 Visually inspect equipment for any external damage 4 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 5 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. TEST EQUIPMENT/CALIBRATION GAS DATA Type Manufacturer Model Serial Number Calibration Expiry Date


Analyzer Datasheet Vendor SAT procedure Manufacturer Calibration Cert (including Calibration gas) Vendor Drawings OBSERVATION / REMARKS

1


MISCELLANEOUS PROCESS ANALYZER TEST





2


FIRE & GAS DEVICE LOOP TEST Project No. Project Title Facilities GENERAL Platform/ Plant name

Sys Description FIRE & GAS DEVICE DATA Type of Detector  Heat  Smoke  Flame  Gas  Break glass  Other (To specify):_______________ Tag Number Signal Range Manufacturer Method of Classifying Authority Model Number detection Area Protected EX Protection Serial Number Loop Drawing IP rating Data Sheet PRE COMMISSIONING CHECK OK N/A P/L 1 Verify completeness of factory acceptance report of Fire & Gas systems 2 Verify the device calibration & installation check sheet I14-A has been completed Verify the cable has been installed terminated and tested as per check sheet I3 01A and completed Verify the Junction Boxes has been installed as per check sheet I-07A and 4 completed Verify the device has been calibrated and installed as per check sheet I14-A and 5 completed 6 Verify the correct electric power supply is connected to the Fire and Gas panel 7 Verify all tools/equipment/test kits for the loop test are available Verify local indication/display (if applicable), are correctly activated upon testing 8 of the loop Verify all the indication/display in FGS Panel are correctly activated upon testing 9 of the loop Verify the indication/display in DCS (if applicable) are correctly activated upon 10 testing of the loop Verify the indication/display and actions in Shutdown Systems (if applicable) are 11 correctly activated upon testing of the loop as per cause and effect matrix 12 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Sys Number

1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B I16-B FIRE & GAS DEVICE LOOP TEST 13 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Loop Drawings 2 Instrument Location Drawings 3 FGS Cause & Effect Matrix (if applicable) 4 Vendor Drawings OBSERVATION / REMARKS





2

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B CAUSE AND EFFECT MATRIX (CEM) TESTING AND VERIFICATION

I18-B

Project No. Project Title Facilities GENERAL Platform/ Plant name System Number

System Description ACCEPTANCE CRITERIA

Functionality as per approved CEM PRE COMMISSIONING CHECK 1 Verify completion of installation, pre commissioning and commissioning of SIS FGS loops Verify CEM is the final approved revision 2 and

OK

N/A P/L

3 Perform CEM testing and verification as per final approved revision of CEM 4 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 5 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Instrument Location Plan 2 Instrument Installation Detail 3 Hook Up Drawings 4 Panel Drawings 5 CEM – Process & FGS OBSERVATION / REMARKS





1


WELL HEAD CONTROL PANEL (WHCP) TEST Project No. Project Title Facilities GENERAL Platform/ Plant name Sys Number Tag Number Type Service IP rating

Sys Description Well Head Control Panel (WHCP) DATA Signal Range Manufacturer Dial/Chart Model Number Range Data Sheet Serial Number EX rating

Pneumatic Supply:  Instr. Air  Instr. Gas Panel Type:

 P-H

E–H

P–E–H

P: Pneumatic, E: Electronic, H:Hydraulic 1 2 3 4 5 6 7

PRE COMMISSIONING CHECK OK N/A P/L Verify I20-A: Well Head Control Panel (WHCP) Check sheet Verify the availability of WHCP Vendor Pre-commissioning Procedure Inspect WHCP hydraulic reservoir and verify it is filled up with the right hydraulic. Verify all cables connected to the panel have been meggered / insulation tested as per I01-A Verify the instrument air is connected to the panel air / gas supply line Verify the required electric power supply is connected to the panel Verify the accumulators are pre-charged to the specified pressure

8 Verify the required pressure is adjusted on the pneumatic supply and control lines 9 Verify the required pressure is adjusted on the hydraulic pump discharge lines 10 Verify the hydraulic reservoir pneumatic low level functions to stop the pump 11 Verify the pneumatic time delays are set to the specified duration 12 Verify the opening and closing sequence and timing of the WV, SSV and SCSSV Verify the flow line pneumatic Hi-Lo pilots are functioning to close WV / SSV and 13 providing indications Verify the individual opening & closing of WV, SSV and SCSSV from the local 14 pushbutton

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B I20-B WELL HEAD CONTROL PANEL (WHCP) TEST 15 Verify the individual opening & closing of WV, SSV and SCSSV from the solenoid valve 16 Verify the closing all of WV and SSV from the total surface local pushbutton Verify the closing all of WV, SSV and SCSSV from the total sub-surface local 17 pushbutton 18 Verify the closing all of WV and SSV from the total surface solenoid valve Verify the closing all of WV, SSV and SCSSV from the total sub-surface solenoid 19 valve 20 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean 21 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean REFERENCE DRAWINGS 1 2 3 4

Instrument Location Plan Instrument Installation Detail Hook Up Drawings WHCP Drawings OBSERVATION / REMARKS






HSSD (VESDA) LOOP TEST Project No. Project Title Facilities GENERAL Platform/ Plant name Sys Number Tag Number System Number Sub System Type NNNNNNONONu mber Service Area Classification Manufacturer Serial Number

HSSD (VESDA) DEVICE DATA Location Signal Range Protected Zone Data Sheet Classifying Authority EX rating Model Number PRE COMMISSIONING CHECK

OK N/A P/L

1 Verify installation check sheet I22-A has been completed Verify the cable has been installed terminated and tested as per check sheet 2 I-01A and completed Verify the Junction Boxes has been installed as per check sheet I-07A and 3 completed Confirm all Cabling / Terminations / Earthing /Pipework conforms to project 4 specifications and is correctly installed as per Loop drawings and Hook up diagrams. 5 Verify the correct electric power supply is connected 6 Verify all tools/equipment/test kits for the loop test are available 7 Verify local indication/display are correctly activated upon testing of the loop Verify all the indication/display in FGS Panel are correctly activated upon testing 8 of the loop Verify the indication/display in DCS (if applicable) are correctly activated upon 9 testing of the loop Verify the indication/display and actions in Shutdown Systems (if applicable) are 10 correctly activated upon testing of the loop as per cause and effect matrix 1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B I22-B HSSD (VESDA) LOOP TEST 11 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean 12 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean REFERENCE DRAWINGS 1 HSSD (VESDA) Installation Details HSSD (VESDA) Vendor Calibration Certificate 2 HSSD (VESDA) Loop Drawings 3 FGS Cause & Effect Matrix (if applicable) 4 Vendor Drawings OBSERVATION / REMARKS





2


METERING SKID TEST Project No. Project Title Facilities GENERAL Platform/ Plant name Sys Number Tag Number Type

Sys Description METERING SKID DATA Flow Range Pressure Rating

Area Protected


PRE COMMISSIONING CHECK 1 Verify the skid has been installed as per check sheet I23-A and completed 2

OK N/A P/L

Functional check of the instrument, flow computer, HMI and interface of the host system based on vendor’s SAT procedure

3 Visually inspect equipment for any external damage 4 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 5 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Vendor SAT Procedure 2 Vendor Drawings OBSERVATION / REMARKS





1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TANK GAUGING SYSTEMS

I26 - B

Project No. Project Title Facilities T Type of Sensor

 Radar  Servo

INFORMATION  Float  Displacer  Other (To specify):_________________

No. of Tank Gauges

No of JB

Manufacturer

Type of Level Sensor

IP rating

Ex protection

Area Classification Tank Local Indication

Type of Signal Interconnect ion (Field to PRETGS) COMMISSIONING CHECK

Type of Temperature Sensor

Verify the complete tank gauging system has been installed as per ITR I26-A and completed. 2 Functional check of the instrument, TGS, HMI and interface of the host system. 3 Visually inspect equipment for any external damage. Check and ensure Tank Strapping Table is configured in the tank gauge for the 4 respective tanks. 1

5 Ensure all parameterization are carried out as per Vendor requirements. 6 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 7 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Loop Drawings 2 Panel Schematic Drawings 3 Tank Strapping Table 4 P&ID 5 Vendor Drawings OBSERVATION / REMARKS

OK N/A P/L No

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TANK GAUGING SYSTEMS



I26 - B



PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MULTIPHASE FLOW METER (MPFM) TESTING

I27 - B

Project No. Project Title Facilities INFORMATION Tag Number

Flow Range

Manufacturer

Type

Model Number

Area Classification

Serial Number

PRE COMMISSIONING CHECK 1 Verify the skid has been installed as per ITR I27-A and completed Verify that re-instatement are carried out as Piping installation ITR for re2 instatement and ITR are signed off 3

OK N/A P/L No

Functional check of the instrument, flow computer, HMI and interface of the host system

4 Visually inspect equipment for any external damage 5 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean 6 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean REFERENCE DRAWINGS 1 Location Layout 2 Isometric Drawing 3 Instrument Cable Loading Layout 4 Termination Drawing OBSERVATION / REMARKS





CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Project No. Project Title Facilities Tag no.

PRESSURE VESSEL

M01-B

INFORMATION System/Subsystem No.

INSPECTION / TEST

3

Confirm that all associated construction work packs are signed off prior to starting any work. Confirm that the content of the accepted punchlists are complete and no subsequent damage has occurred. Check that the equipment is clean and all external components are installed. Confirm that all preservation has been removed.

4

Check that the sliding support is free to move.

5

Check that all spades & spec. blinds are in the correct orientation.

6

Confirm all connections are complete and to vendors drawings. Confirm Pressure Relief facilities are installed and interlocks are installed. Confirm that all valves are greased and free to operate and all spare valves have flange connections blinded off. Confirm vessel Internals have been installed in accordance with Vendor drawings and specifications. Confirm all manway covers bolted up correctly with correct gaskets.

1 2

7 8 9 10 11 12 13

OK

N/A P/L No

Earth Bonding straps complete. Confirm Vessels internal have been inspected by Commissioning and Final Closure certificate has been attached Review the manufacturers’ recommendation for preparation to start and confirm that no conflicts arise between that document and the commissioning procedure.

COMMENT(S) AND ADDITIONAL INFORMATION:



VERIFIED BY PMTInspector PETRONAS Carigali


Page 1 of 1

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B HEAT EXCHANGER (PLATE / S&T) Project No. Project Title Facilities Tag no.

M02-B


INSPECTION / TEST

OK

1

Verify ITR 02 -A is complete.

2

Check equipment for damage.

3

Pressure relief valves installed as per project drawing. Pressure relief valves have valid certification and are set to the correct values. Verify sliding supports are free to move.

4 5 6 7 8 9 10

N/A P/L No

Check all valves associated with the heat exchanger for operability. Check all spec blinds and spades are fitted and are in the correct orientation. Verify earthing strap is fitted. If required, check hydrotest is done successfully Review the manufacturers’ recommendation for preparation to start and confirm that no conflicts arise between that document and the commissioning procedure




VERIFIED BY PMT Inspector PETRONAS Carigali


Page 1 of 1


HEAT EXCHANGER (PCHE)

M03-B


INSPECTION / TEST 1 2 3 4 5 6 7 8 9 10 11

OK

N/A P/L No

Verify ITR03 -A is complete. Prior to installation of PCHE, verify that the piping system has been flush to NACE 6 or project cleanliness specification. Check that Cooling water quality is per PCHE manufacturer’s requirement Check PCHE to be free from any visual damage. Ensure that pressure relief valves installed as per project drawing. Check pressure relief valves have valid certification and are set to the correct values. Verify sliding supports are free to move. Check all valves associated with the heat exchanger for operability. Check all spectacle blinds and spades are fitted and are in the correct orientation. Verify earthing strap is fitted. If there is dissimilar flange connection between PCHE nozzle and piping nozzle, the joint shall be equipped with insulation kit Attach vendor’s FAT report if any






Page 1 of 1

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Project No. Project Title Facilities

GEARBOX

M04-B


Tag no.

INSPECTION / TEST

1 2 3 4 5 6 7 8 9 10

11

Confirm that all associated construction work packs are signed off prior to starting any work. Confirm that the content of the accepted punch-lists will not impede commissioning. Confirm all certifying authority exception items complete or transferred to punch-list. Confirm preservation has been removed. Check and confirm gearbox has been properly flushed. If not, carry out items 4, 5 and 6. Install filter screens at oil inlets to gearbox and flush pipework (If applicable). On completion of pipework flushing flush through gearbox, inspect and clean filter screens at regular intervals until satisfied with cleanliness (If applicable). On completion of flushing the lube oil system remove temporary screens and fill gearbox to correct level (If applicable). Check driver rotation is correct.

OK

N/A P/L No

Confirm coupling and guard fitted. Carry out Gear Tooth contact test. Carry out any manufacturers recommended pre-start checks i.e. oil level in sump. Run on-load and record readings at regular intervals of : a) Oil pressure at each bearing. b) Oil inlet temperature. c) Oil outlet / sump temperature. d) Vibration levels Record results. Confirm results are in accordance with manufacturer's specifications.






Page 1 of 1


RELIEF VALVE

M05-B


Tag no.

INSPECTION / TEST 1

Location (state line no. or equipment).

2

Record nameplate details.

3 4

OK

N/A P/L No

Check manufacturer's documentation (installation instructions and drawings). Check: a) Valves installed in accordance with construction drawings. b) Valve oriented correctly for direction of flow.

5

Check valve test certificate. Attach copy.

6

Check that provision exists for the easy removal of the valve from the system.






Page 1 of 1


AIR DRYER

M06-B


Tag no.

INSPECTION / TEST

OK

1

Vendors instruction, manual and part list are available.

2

Check equipment for any damage.

3

Check that the on-skid piping and supports are adequate.

4

Verify the drier towers are filled to the correct level with the recommended medium.

5

Check all valves have been exercised and are operable.

6

Check that the system exhaust is correctly installed as per approved drawings.

7

Check that the correct moisture analyzer is installed.

8 9

N/A P/L No

Check that the pre-filters and after filters are clean and correctly installed. Check and ensure that the interconnections for utility air and drains are complete.






Page 1 of 1


FILTER / STRAINER

M07-B


INSPECTION / TEST

1

Confirm that all construction packs are signed off prior to starting any work. Confirm that the content of the accepted punch-lists will not impede commissioning. Check that the filter/coalescer is externally clean and all components are free from damage.

2

Confirm that all preservation has been removed.

3

Check that the Insulation is undamaged.

4 5

Confirm that system/equipment PSV's are installed.

7

Confirm fittings and connections are complete as per vendor drawing.

8

Confirm vendor pre-start up checks complete.

9

Confirm commissioning spares available for filter change.

11 12 13

N/A P/L No

Confirm that all valves are greased and free to operate, with no handle clashes. Confirm that internals are clean and undamaged and correct to specification.

6

10

OK

Confirm that the Earth Bonding strap is intact. Confirm that correct number of elements has been fitted for start up and that piping has been properly torqued up. Ensure leak test has been completed after fitting of elements and purge skid with nitrogen (where applicable) Check filter media is filled, distributed and at correct level.






Page 1 of 1


PEDESTAL CRANE

M08-B


INSPECTION / TEST

1 2 3 4 5 6 7 8 9

10

11 12 13

Confirm that all associated construction packs are signed off prior to starting any work. Confirm that the content of the accepted punchlists will not impede commissioning. Check that the crane is clean and all components are free from damage.

OK

N/A P/L No

Confirm that all preservation has been removed. Confirm that all instrument, electrical pre-start up checks are complete. Confirm that the correct lubrication has been applied in accordance with the vendor's specifications. Check that all fuel / oil / air filters are fitted. Confirm that adequate lighting and means of communication are available. Confirm that all portable firefighting equipment is installed in nominated locations. Carry out Vendor pre-start up preparations are complete. Function test all crane movements, controls, protection in accordance with Vendor Commissioning Instructions Enter following information:Vendor Document No. Section No. Confirm required Load Test Rules with Certifying Authority is available. Load test the crane in accordance with vendor instructions and required rules. Attach copies of certificates and vendor commissioning checks to this function test certificate.

Page 1 of 2

CSP-20 rev. 01 Appendix II-VII

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B PEDESTAL CRANE M08-B COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MONORAIL/TROLLEY HOIST Project No. Project Title Facilities Tag no.

M09-B


INSPECTION / TEST 1 2 3 4 5

OK

N/A P/L No

Confirm that all associated "A" ITR's are signed off prior to starting any work. Check load test certificate validation prior to commencement of Commissioning activities. Check that S.W.L. is clearly marked on equipment. Ensure that no obstacles, i.e. piping, scaffolding or any other local operations which will impede Hoist/monorail test operations Check end stops are securely fitted to runway beams & that they will locate against rubber buffer on end carriages.

6

Check that equipment is adequately lubricated.

7

Ensure that all manufacturers’ static checks have been completed prior to commencing Commissioning activities.

8

Complete load test with CA.






Page 1 of 1


GANTRY/BRIDGE CRANE

M10-B


INSPECTION / TEST 1 2

OK

Confirm that all associated "A" ITR's are signed off prior to starting any work. Check load test certificate validation prior to commencement of Commissioning activities.

3

Check that S.W.L. is clearly marked on equipment.

4

Check that any testing requirement is successfully carried out

5

6

7 8

N/A P/L No

Ensure that no obstacles, i.e. piping, scaffolding or any other local operations which will impede Gantry/Bridge crane operations Perform functional test such as:  Lower block and lift block without load and test at least three times the overhoist cut off switch function  Move trolley to and fro the entire gantry and test at least three times the limit switches at hook end  Move gantry to and fro the entire girder and test at least three times the limit switches at hook end  Lift rated load and test brake capacity, check lifting speed  Move the load around Test party witnessed load test  Perform test at 125 percent load (load at mid-span of gantry) and issue certificate of witness Document all test and checks performed






Page 1 of 1


FLARE/FLARE TIPS

M11-B


Tag no.


Preservation removed and all facilities clean All instruments, safety devices and alarms tested and ready for service. Check flare tip is installed to relevant PIDs/vendor specification. Check flare tip to flare pipe valve bolted up to spec. w/correct size of bolt & torque value)

7

Check wind shield is correctly oriented to drawings and spec.

8

Check flare pilot assembly is complete supply system.

10 11

N/A P/L No

Confirm that all associated "A" ITR's are signed off prior to starting any work. Unit installed according to vendor instructions, with location and orientation correct, holding down arrangement complete and secure.

6

9

OK

Check pilot gas and ignition pipework flushed and dried. Check access for flare tip removal is adequate. Check flare tip for damage.

12

Carry out Vendor recommended pre-start up checks in accordance with Vendor Start Up and Operating Manual.

13

Confirm equipment is ready for dynamic commissioning as specified on relevant dynamic commissioning procedure

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B FLARE/FLARE TIPS M11-B COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 2


LIFEBOAT AND DAVIT

M12-B


Tag no.

INSPECTION / TEST

1

Life Boat Conduct thorough visual inspection of boat, davit, winch, and falls, checking for damage, deterioration and deficiencies since onshore certification.

2

Check the diesel and water level inside tanks are correct.

3

Check the motor and start system.

4 5 6 7 8 9

Ensure that power is available to the electric motor. Check correct operation of brake release mechanism, counterweights and rewind handle.

11

Check the reliability of all limit switches to guarantee repeatability.

13

Ensure all pendant cables used for maintenance are properly connected. Check that with the brake released, the falls payout from the winch with a pull of less than 75 kg applied to the falls at the drum.

14

Confirm operation of the over hoist cut-out switches.

15

Confirm correct direction of rotation of winch motor.

16

Confirm correct operation of winch start and stop buttons.

17

N/A P/L No

Confirm that all loose equipment and safety gear supplied with the lifeboat is stowed in accordance with the equipment stowage drawing as detailed in the O & M Manual This System requires final inspection and acceptance by Certifying Authority and Operations. Winch Ensure the gearbox is clean and filled with correct lubrication and to correct level. Ensure the wire cables are properly installed and free of any damage and correct length. Check reeving of fall ropes and release wire. ( Falls must be reeved under tension and adjusted to support boat in a level attitude so that the short pendants are connectable).

10

12

OK

While in position, check Lifeboat for water tightness.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LIFEBOAT AND DAVIT 18

M12-B

Check the operation of the bilge pump.






Page 2 of 2


GENERATOR

M13-B


Tag no.

INSPECTION / TEST

1

Construction check sheets ITR M13-A are complete & no subsequent damage to the equipment occurred.

2

Confirm preservation has been removed.

3 4

Check manufacturer’s instruction, manual and part list

6

Check skid weld down or hold down bolts

7

Check holding down bolts of turbine or engine, gearbox, and generator

8

Check vibration dampers installed (if applicable)

9

Remove any temporary stopper or shipping braces

10

Verify that ITR –B for Gas Turbine as generator driver is complete and signed off -for turbine generator driven

11

Check gearbox hold down bolts

12

Check gearbox lube oil for water or dirt contamination

13

Check relief valve is set correctly

14

Check alignment of gearbox and generator in accordance with vendor’s instruction

15

Check lubrication/ greasing of generator bearing

17 18

N/A P/L No

Check that Valve interlocks are installed (if applicable) and the system operates as designed. Ensure keys are safely located. Confirm for ventilation and cooling fans. Attached electrical fan test run record

5

16

OK

Confirm that all electrical checks on generator, switch and cabling has been completed Ensure generator skid is level against its’ location to facilitate good alignment of driver and generator skid Review the manufacturers’ recommendation for preparation to start and confirm that no conflicts arise between that document and the commissioning procedure

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GENERATOR M13-B COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 2


MIXERS AND AGITATORS

M14-B


INSPECTION / TEST

1 2

Confirm that all associated construction packs are signed off prior to starting any work. Confirm that the content of the accepted punchlists will not impede commissioning. Confirm all certifying authority exception items complete or transferred to punch-list. Check that the skid is clean and all components are free from damage.

3


4

Confirm that all valves are greased and free to operate.

5

Confirm that agitator mounting is secure.

6 7

OK

N/A P/L No

Confirm that power is isolated and that all shafts are free to turn by hand. Confirm Motor start/stop station operates locally after uncoupled motor run.

8

Confirm all guards are installed and secure.

9

Confirm that the correct lubrication has been applied to the bearings and gearbox.

10

Confirm that the shaft-tank seal is intact and undamaged.

11

Confirm that the Earth Bonding strap is intact.

12

Review the manufacturers’ recommendation for preparation to start and confirm that no conflicts arise between that document and the commissioning procedure

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MIXERS AND AGITATORS COMMENT(S) AND ADDITIONAL INFORMATION:



M14-B



Page 2 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRO-CHLORINATION UNIT Project No. Project Title Facilities Tag no.

M15-B


INSPECTION / TEST

1

Check that the filter/coalescer is externally clean and all components are free from damage.

2


3

Check that the Insulation is undamaged.

4 5

Confirm man-way is secured.

7

Confirm that system/equipment PSV's are installed.

8

Confirm fittings and connections are complete as per vendor drawing and specification.

9


11 12

N/A P/L No

Confirm that all valves are greased and free to operate, with no handle clashes. Confirm that vessel internals are clean and undamaged and correct to specification. Execution of M01-B & M049-B have been completed.

6

10

OK

Check filter media is filled, distributed and at correct level. Confirm that all associated construction packs are signed off prior to starting any work. Confirm that the content of the accepted punch-lists will not impede commissioning.






Page 1 of 1

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SANITARY TREATMENT UNIT Project No. Project Title Facilities Tag no.

M16-B



OK

Mechanically complete and no subsequent damage occurred. Unit installed according to vendor instructions, with location and orientation correct, holding down arrangement complete and secure. Preservation removed and all facilities clean. All manual and control valves properly installed, tested, greased and ready for service. All instruments, safety devices and alarms tested and ready for service.

6

Electrical grounding installed as per specification.

7

Piping, tubing and cable connections complete and correct .

8

Relief valves fitted, tagged and certified with valid calibration date .

9

Lubricants filled and to vendors specification

10 11 12 13

N/A P/L No

Confirm that all associated construction packs are signed off prior to starting any work. Confirm that the content of the accepted punch-lists will not impede commissioning Carry out Vendor recommended pre-start up checks in accordance with Vendor Start Up and Operating Manual Confirm equipment is ready for dynamic commissioning as specified on relevant dynamic commissioning procedure






Page 1 of 1


GAS DEHYDRATION UNIT

M17-B


Tag no.


OK

N/A P/L No

Mechanically complete and no subsequent damage occurred. Unit installed according to vendor instructions, with location and orientation correct, holding down arrangement complete and secure.

3

Preservation removed and all facilities clean.

4

All manual and control valves properly installed, tested, greased and ready for service.

Ensure the following:-

5

Gassing of the Glycol Dehydration system up to Inlet MOVs on the Gas Metering Skid is done together with the gassing up of the Gas compression system. ii. Glycol Regeneration System has been started and is operating independently (isolated from the Glycol Contactor) and ready to feed lean TEG to the Glycol Contactor

6

Moisture Analyzer has been calibrated and is ready to be taken on line

7

All instruments, safety devices and alarms tested and ready for service.

8

Electrical grounding installed as per specification.

9

Piping, tubing and cable connections complete and correct .

i.

10

Relief valves fitted, tagged and certified with valid calibration date .

11

Lubricants filled and to vendors specification

12

Unit rotates freely (manually).

13

Couplings, belts and guards installed correctly.

14

Verify that all electrical installations are correct and ready for service: power cables, control cables, lighting systems, DC systems

15

Confirm that all associated construction packs are signed off prior to starting any work

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GAS DEHYDRATION UNIT 16 17 18

M17-B

Confirm that the content of the accepted punch-lists will not impede commissioning Carry out Vendor recommended pre-start up checks in accordance with Vendor Start Up and Operating Manual Confirm equipment is ready for dynamic commissioning as specified on relevant dynamic commissioning procedure






Page 2 of 2


SUBMERSIBLE PUMP

M18-B


Tag no.

INSPECTION / TEST 1

Verify ITR M18- A is complete and signed off

2

Check Preservation is removed.

3

Check that piping system is completed according to P & ID

4

Check Pump discharge is protected against over pressure.

5

If applicable, Check chemical dosing piping provided at pump suction area

6

Check motor to pump alignment

7

Check that unit is free to rotate by hand

8 9

10 11 12 13 14 15 16 17

OK

N/A P/L No

Check that cable termination to motor and glands are water and pressure tight and are without any damage Check that electric cables to motor do not foul pipes or rub against rough or sharp edges. Cable is free from external applied loads and properly secured with clamps against pump casing as recommended by the vendor installation manual Check that motor is fully filled with either inhibited distillated or mineral oil as appropriate and that mechanical seal is undamaged and leak free Treaded joints on rotating elements are tightened to the correct torque Check condition of suction mesh screen and its fixing arrangement Check that pump and riser pipe are installed satisfactorily inside caisson with adequate pump suction to caisson clearance and all riser center liners fitted properly Check all pump and risers joints have correct gasket/jointing compound fitted and all bolts, nuts and washers are of correct material and securely tighten (torque to vendors specification) Air release valve, non return valve and PSV are fitted and functional checked Motor cable is securely terminated in platform junction box with sufficient spare length to allow installation flexibility Electrical supply loop incorporates an ampere meter indicating normal amps (blue) and motor deteriorating amps (red)

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SUBMERSIBLE PUMP

M18-B

18

With the information on overall length of complete pump casing assembly and overall length of pump caisson, check that the pump suction submerged depth versus the lowest astronomical tide gives as a minimum the required NPSR + 2 meters

19

Perform no-load test




Verified by PMT Inspector PETRONAS Carigali

Accepted by Commissioning Engineer PETRONAS Carigali

Page 2 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRIC MOTOR DRIVEN PUMP (PD) M19-B Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem No.

INSPECTION / TEST

1 2

Confirm that all associated construction work packs are signed off prior to starting any work. Confirm that the content of the accepted punchlists will not impede commissioning. Confirm all certifying authority exception items complete or transferred to punchlist. Check that the skid is clean and all components are free from damage.

3


4

Confirm that all valves are greased and free to operate.

5

Lube oil system flushing complete and that all temporaries have been removed.

6

Confirm with Electrical commissioning that power is available.

7

Perform the uncoupled motor run and record: a) direction of motor rotation, b) bearing temperatures and c) Vibration Levels.

8 9

OK

N/A P/L No

Results are to be in accordance with manufacture specification and recorded on Electrical E-03B. Confirm alignment is acceptable and meets specification prior to reinstating coupling after uncoupled motor run. Confirm all guards are reinstated and secure.

10

Confirm that the correct lubrication has been applied to the bearings, seal glands and gearbox.

11

Confirm that equipment PSV's are installed.

12

Confirm the suction strainers are installed and clean.

13

Check pump discharge is protected against over pressurization.

14


15

For submersible pumps, confirm motors cooling water system installed correctly, water/inhibitor mix filled to correct level, hypochlorite dosing lines complete, and vacuum breaker valves installed & in service.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRIC MOTOR DRIVEN PUMP (PD)

16

17

M19-B

Review the manufacturers recommendation for preparation to start and confirm that no conflicts arise between that document and the commissioning procedure







Page 2 of 2


AIR COMPRESSOR

M20-B


Tag no.

INSPECTION / TEST 1

Verify ITR M20 -A is complete.

2

Confirm preservation has been removed.

3 4

OK

Verify the sump has been drained and refilled with correct grade lubricant. Verify pressure relief valves are fitted to the intermediate and discharge stages of the compressor.

5

Verify air intake filters are clean and fitted properly.

6

Verify all valves have been exercised and are operable.

7

Verify earthing strap is fitted.

8 9 10 11

12

N/A P/L No

Verify if motor has been tested and solo run per Electrical requirement; attach record Confirm that alignment is satisfactory done between driver and air compressor; check record Attach vendor’s FAT report Review the manufacturers recommendation for preparation to start and confirm that no conflicts arise between that document and the commissioning procedure Confirm equipment is ready for dynamic commissioning as specified on relevant dynamic commissioning procedure






Page 1 of 1


DIESEL ENGINE

M21-B


INSPECTION / TEST

1

Confirm that all associated construction packs are signed off prior to starting any work. Confirm that the content of the accepted punchlists will not impede commissioning.

2

Preservation removed and all facilities clean

3

Confirm that all shafts are free to turn by hand / barring device.

4

Confirm that all pumps suction strainer and filters are installed and clean.

5

Confirm that alignments have been completed.

6

7

8

9

OK

N/A P/L No

Confirm that all pumps under this package are mechanically ready for start up and functional test. Cooling System: a) Confirm that the engine cooling water system is complete, correct coolant mixture is filled up to required level and level gauges are installed. b) Confirm gearbox cooling water connections are complete. Air Start System: a) Check the air and electrical starting system has been installed and is ready for the functional test. b) Check that the air suction strainer is fitted & clean. c) Check and ensure that starter system instrument air reservoir is fully charged. Lube Oil System: a) Check that the lube oil system is complete, new filter elements installed, all components are free from damage, and filter changeover valve is operational. b) Check lube oil tank is filled with correct grade & quantity of lube oil. c) Check engine crank case lube oil heater connection is complete / operational.

Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B DIESEL ENGINE

10

11

12

13

14

15

M21-B

Fuel System: a) Check that the diesel fuel tank & feed lines to the engine have been installed correctly, flushed clean, new & correct filter elements installed, and ready for operation with all instrumentation in service. b) Check diesel tank filled with clean & correct grade of diesel. c) Check filling, overflow and drain lines are adequate and installed to specification. d) Check Remote shut-off valves are fitted and clearly identified outside engine compartment. Air Intake System: a) Confirm that the air intake filtration system is clean and filter elements are securely installed. Turbo Charger: a) Confirm Turbo Charger is installed correctly. b) Confirm sealing arrangements are in accordance with manufactures instructions. c) Operate lube oil priming pump and observe oil issuing from oil drain line (If oil supply line is from engine). d) Confirm oil level is correct. e) Confirm Vent line is not obstructed. Air Start: a) Confirm system is in accordance to manufactures instructions. b) Pressurize the system and check for leaks Exhaust System: a) Confirm the exhaust bellows are undamaged. b) Confirm the exhaust insulation is correct to specification and undamaged. c) Confirm that if sliding supports are installed they are free to move. d) Check if the flame arrestor is installed. Gear Box: a) Confirm that M04-B for the Gear Box is completed

Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B DIESEL ENGINE

16

M21-B

Overall Checks: a) Confirm if applicable, that the package enclosure is intact, undamaged, doors operational, ventilation system dampers operable and fire & gas system is operable. b) Conform that all instruments and engine controls are operable. c) Confirm that BPCS input / output functions are operable. d) Check that all the pre start up checks and preparation has been carried out as per the diesel engine / gear box vendor's recommendation. e) Confirm the package is ready for dynamic commissioning as specified on relevant SCP function test certificates.






Page 3 of 3


GAS TURBINE

M22-B


Tag no.

INSPECTION / TEST

OK

N/A P/L No

Lube oil system Design of the lube oil system is adequate for the gas turbine: • Flow rate of lube oil is sufficient 1 • Pressure form pump is sufficient • Heat duty of lube oil cooler is sufficient • Lube oil meets OEM requirements 2 Piping is complete and installed as per P&ID 3

Piping is undamaged, supports are secure and thermal insulation undamaged

4 Lube oil relieve valve and sight pop test certificate available 5 Lube oil level is at normal run down level 6 Lube oil filters are installed 7 Commissioning strainers are installed 8 Lube oil heater is functional 9 Lube oil piping has undergone acid cleaning and flushing 10 Lube oil piping has undergone hydrotest 11 Lube oil pump rotates in the right direction 12 Pump-motor coupling is protected with coupling guard 13 Continuity and resistance check conducted for wiring/cabling 14 Pump rotation check conducted 15 All related instruments are in place 16 Earthing system cables and connections are secure and undamaged

Page 1 of 7


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GAS TURBINE

M22-B

Starter system Variable Frequency Drive Motor: 1 The controls and instrumentation of electric motor is functional 2

Continuity check and resistance check conducted on relevant wiring and cabling

3 Current supply to VFD in accordance to OEM recommendation 4 Earthing system cables and connections are secure and undamaged 5 Rotational check and solo run of motor conducted 6 All instrumentation are installed and calibrated Hydraulic system: 1 There is no observable leakage 2

The grade of oil used for the hydraulic starter system is in accordance to manufacturer's specifications

3 The hydraulic pump is functional and rotates in the correct direction 4 The controls and instrumentation of hydraulic system is functional 5

Continuity check and resistance check conducted on relevant wiring and cabling

6 All instruments are installed and calibrated 7 Earthing system cables and connections are secure and undamaged 8 Hydraulic oil pressure is sufficient Pneumatic system: 1 The air pressure supplied is adequate 2

There is no observable leakage

3 The controls and instrumentation of pneumatic system is functional Continuity check and resistance check conducted on relevant wiring 4 and cabling 5 All instruments/transducers installed and calibrated. 6 Earthing system cables and connections are secure and undamaged

Page 2 of 7



M22-B

Fuel gas system 1 Gas filter is installed correctly 2 Fuel gas heater capacity is within the required limits 3 Vent off pipe leads to a safe area 4 All shutoff valves are fully functional 5 Fuel gas demister is functional The controls and instrumentation for the fuel gas system is 6 functional Continuity check and resistance check conducted on relevant wiring 7 and cabling All instruments/transducers are in place and terminal box covers are 8 correctly secured 9 Earthing system cables and connections are secure and undamaged Control system 1 All cables and wirings are connected to the right places 2 Hot loop check has been conducted 3 Continuity check/resistance check conducted 4 Latest version of control software is uploaded 5 Setting and constants of control system verified. Instrumentation 1 All necessary transducers/gauges have been correctly installed 2 All transmitters have been recalibrated 3 All field instruments have been recalibrated 4 Function check carried out for all protection devices 5 Protection devices calibrated and verified

Page 3 of 7



M22-B

6 Communication of vibration monitoring system is functional 7 Water wash system Wash water detergent is in accordance to manufacturer's 8 specifications 9 Pump and motor cart provided and functional 10 All pipework is complete, undamaged and supports are secure Continuity check and resistance check conducted on relevant wiring 11 and cabling All instruments/transducers are in place and terminal box covers are 12 correctly secured 13 Drainage system functional 14 Earthing system cables and connections are secure and undamaged 15 Enclosure ventilation system 16 Air filters have been installed correctly 17 Gas detector has been installed 18 Differential pressure gauge has been installed 19 Bearings of ventilation fans have been greased Dampers and louvers of air intake is functional and installed 20 correctly Package enclosure is intact, undamaged, dorrs operational, door 21 handles with lock are in good condition, door limit switches are installed correctly 22 Electric fans are functional Combustion air system 1 The air intake filters have been installed correctly 2 Gas detector has been installed 3 Exhaust insulation is intact Exhaust ducting is complete and sliding supports have been adjusted 4 for thermal expansion 5 Acoustic insulation is intact

Page 4 of 7



M22-B

6 Water seal pot is filled with water 7 Exhaust collector drainage is not clogged Continuity check and resistance check conducted on relevant wiring 8 and cabling All instruments/transducers are in place and terminal box covers are 9 correctly secured 10 Earthing system cables and connections are secure and undamaged Utility air system 1 Air filter has been correctly installed 2 There is no observable leakage The pressure measurements across the gas turbine falls within 3 expected limits when utility air system is pressurized 4 Pressurized air supply has been connected to utility air system 5 Fire and gas protection system 6 Gas detectors have been installed 7 IR flame detectors have been installed 8 Thermal/heat detectors have been installed 9 Fire dampers are functional Water mist system is functional: 10  Water tank is filled  Nitrogen pressure sufficient 11 Fire monitor layout have been reviewed Continuity check and resistance check conducted on relevant wiring 12 and cabling All instruments/transducers are in place and terminal box covers are 13 correctly secured 14 Earthing system cables and connections are secure and undamaged Skid and base 1 Levelness of skid falls within required codes and standards The thickness of the shimmings are in accordance to required codes 2 and standards

Page 5 of 7



M22-B

Thickness of the bearing pads are in accordance to required codes 3 and standards 4 The torque of the inter-skid tie bolts are adequate Vibration monitoring system 1

All vibration probes/ transducers/ accelerometers are installed correctly and functional

2 All instrumentation calibrated 3 Keyphasors have been set 4 Loop check on vibration monitoring system carried out Miscellaneous checks 1 Mechanical completion certificate available 2 Pre-commissioning, commissioning and start up procedure available 3 Operating and maintenance manual available 4 FAT reports and records available 5 All MOCs have been implemented and documentation up to date 6 All construction packs signed off 7 Inventory checklist has been conducted Content of all the accepted punch-lists will not impede 8 commissioning 9 Vendor supplied certification has been checked 10 Permit to work available for all relevant pre-commissioning activities Walk around performed to visually examine completeness of 11 installation 12 Equipment have been properly preserved Electrical power supply for various drives, heating and controls have 13 been installed correctly. 14 Inlet guide vanes move freely when forced manually 15 Bump test for rotor end test has been conducted 16 The bleed air piping has been installed correctly 17 Unit is piping stress free

Page 6 of 7



M22-B

Crank test 1 Tool box talk conducted 2 PTW issued and approved 3 All checklists and records available 4 All subsystem checks/miscellaneous checks have been conducted 5 Power supply is connected to necessary subsystems 6 Pressurized air supply connected to utility air system 7 All unit permissives indicate readiness for crank test 8 Enclosure ventilation system is operational 9 Electrical fans are rotating in the correct direction 10 Lube oil system is operational 11 Lube oil pump is rotating in the correct direction 12 Confirm that turbine/starter system rotates in the right direction Confirm that the instrument measurements are within expected 13 limits 14 No excessive vibration/noise is observed






Page 7 of 7

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B CENTRIFUGAL COMPRESSOR Project No. Project Title Facilities Tag no.

M23-B


INSPECTION / TEST

1 2 3 4 5

6

Confirm that all associated construction packs are signed off prior to starting any work. Confirm that the content of the accepted punchlists will not impede commissioning. Confirm all certifying authority exception items complete or transferred to punch-list. Confirm preservation removed and the preservation has been carried out in accordance with manufactures procedure. Visual check the entire compressor skid is complete as per drawing and ensure all connections are secured and intact Inspect compressor and confirm / record: Cleanliness satisfactory Condition of joint faces satisfactory No damage is found after sea transportation Check equipment alignment. If alignment values deviate from OEM recommended values, repeat alignment Auxiliary gearbox (if applicable) a. Check that all vibration probes/ transducers, accelerometers and temperature sensors are installed correctly, calibrated and functional b. Ensure that lubrication oil is of correct type and of sufficient quantity. Refer to gearbox OEM manual for correct lubrication and quantity to be used c. Ensure that coupling and coupling guards are installed correctly

OK

N/A P/L No

Page 1 of 5


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B CENTRIFUGAL COMPRESSOR

7

8

M23-B

Lube oil System a. Prior to filling lube oil system inspect Lube Oil Tank for Cleanliness and record on FM001 Function Test Certificate. b. Confirm that lube oil piping is complete as per P & ID, supports secure and thermal insulation undamaged c. Ensure that lube oil piping provided by fabricator has undergone acid cleaning, flushing and hydrotested d. Ensure that lube oil relieve valve has been tested and checked e. Check that lube oil pump-motor train coupling is guarded by coupling guard f. Perform rotational check for lube oil pump g. Verify that continuity check and resistance check has been conducted for the necessary wiring & cabling h. Check that all instruments are installed correctly as per P& ID i. Check that earthing system cables and connections are secured and undamaged j. Check lube oil system is complete. Check instrumentations are installed correctly and as per drawing. Check belt tension and alignment is complete Flushing of Lube Oil System: a. Perform final flushing with bypassing the connection to bearing b. Ensure reservoir/ lube oil tank is filled with clean lube oil c. Ensure that separation air is supplied to labyrinth seal before performing flushing d. Run the AC LO pump at normal operating condition. During this period, piping/equipment hammering should NOT be carried out e. Reservoir heaters can be turned ON to accelerate flushing f. Inspect filter screen after the first hour of flushing. Clear the filter screen and re-install back to repeat the flushing activities. Automatic particle counter can also be used to determine cleanliness of lubricant g. Repeat flushing until screens are clean or the samples are acceptable as per OEM recommendation h. Remove filter screens once flushing is complete i. After ensuring the interconnecting piping for lube oil system is clean, perform one more round of flushing with complete circuit to the bearing. Install mesh screen/API screen at the main bearing lube oil supply pipework. The screen installation must be as close as possible to the bearing connection. j. Repeat step c-h k. Remove mesh screens once flushing is complete

Page 2 of 5



9

10

11

12 13 14 15

M23-B

Check lube oil cooler system is functional. Check lube oil cooler fan is functional. Perform 2-hour test run on the fan and observe if motor is running normally at within rated speed. Record vibration and noise level and ensure levels are within acceptable limit. Seal Gas System: a. Check seal gas supply availability and confirm that seal gas filter is clean b. Confirm there is no liquid in seal gas system c. Perform stroke check on seal gas supply shutdown valve d. Ensure pressure at main seal gas supply header and alternate seal gas supply header is adequate and as per OEM settings. Adjust seal gas supply if necessary Instrumentation & Control: a. Perform loop test on all instrumentations against platforms DCS control b. Set points for controllers, switches, and transmitters shall be set and verified against OEM and Process settings c. Confirm that all temperature sensors are installed correctly, calibrated and functional d. Perform functional test for all alarm and trip set systems e. Ensure that all connections to module control panel (MCP) have been established and function correctly f. Ensure field instrumentations provide correct feedback to MCP display/ HMI monitor Conduct loop check on vibration monitoring system and ensure that all readings are correctly displayed at MCP Check that surge control valve can be positioned corresponding to the external order signal (25%, 50%, 75% and 100%) opening Confirm on the travel time of the anti-surge valve’s full stroke from “CLOSE” position to “OPEN” position Ensure that compressor suction strainer is installed correctly

Page 3 of 5



16

17 18 19

20

M23-B

Perform functionality check on process after coolers a. Fin Fan Coolers a.1. Energize fan motors and start motor and fan. Ensure fan is running at designated speed a.2. Check fan and motor rotation a.3. Monitor operation of motor and fan and ensure that both are running normally without abnormal noise or vibration a.4. Simulate high vibration to ensure the motor vibration protection function is working. Re-start motor and fan to confirm normal operation b. Cooling water system b.1. Ensure that required corrosion inhibitor is applied. Refer to project requirement on corrosion inhibitor specification b.2. Introduce seawater to seawater/fresh water heat exchanger b.3. Run cooling medium/ cooling water pump b.4. Confirm level in cooling water surge tank/expansion tank b.5. Confirm that flow and temperature of water cooling system is operating as per design Verify compressor discharge relief valves are fitted and have valid test certificates Check all couplings and guards are fitted.

Turn “ON” supply for buffer air for compressor. Check supply pressure for buffer air is as per OEM recommendation. Adjust supply if necessary. Supply lube oil to compressor package. Check supply pressure is sufficient as per requirement. Adjust lube oil supply pressure setting to ensure sufficient lube oil supply is achieved by the main lube oil pump and emergency lube oil pump.

Page 4 of 5



21

M23-B

Turn “ON” seal gas supply to compressor. Check seal gas pressure build-up period. Ensure that the period is within acceptable range. If the period is beyond normal range, check for any leakage. Otherwise, check supply pressure and flow at compressor skid and confirm they are as per requirement. Adjust if necessary






Page 5 of 5

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GAS ENGINE & RECIPROCATING COMPRESSOR M24-B PACKAGE Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem No.

INSPECTION / TEST

OK

N/A P/L No

CAUTION: Ensure that equipment including the associated piping, fittings, valves and instrumentation are physically installed, leveled and aligned as required by the appropriate recommendations. All electrical equipment and wiring is completed and the unit is ready to be powered up. A thorough physical inspection with reference to the P&IDs, piping arrangements, wiring diagrams and sub vendor installation manuals would be required for this purpose General Checks 1 2 3

Make a walk-through inspection around the equipment and check for any damages Check the entire compressor skid and ensure all connections are secured and intact Check that all couplings and guards are fitted Check that the compressor vents and drains are complete and spades / spectacle blinds 4 are fitted in the right orientation 5 Verify set-point values for various switches or other instrumentations as per data sheet Skid and Base Structure 1

Check skid weld down/hold down bolts

2

Check engine, gearbox and compressor hold down bolts

3 4

Perform skid levelness and soft foot check as recommended by OEM. Record readings Check that vibration dampeners (if required) is installed and tightened Check alignment between compressor-to-driver or compressor-to-auxiliary gearbox 5 (whichever applicable). Verify that the values are within vendor acceptable values and record readings 6 Check distance piece pre-loading reports 7 Remove any temporary stopper/shipping braces and etc 8 Check for visual oil leakage Gas Engine 1 2 3 4 5 6

Check radiator water level; ensure that coolant additives are filled with the correct ratio Check radiator fan, pulley alignment, belt tension and bearing lubrication Check the coolant level. Add coolant if necessary Check crankcase oil for contamination; check oil level Check for leaks at the following components; crankshaft seals, crankcase, engine oil filters, plugs for the engine oil gallery, sensors and valve covers Check the tubes, tee pieces and clamps on the crankcase breathers

Page 1 of 9


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GAS ENGINE & RECIPROCATING COMPRESSOR PACKAGE

M24-B

7 8 9 10 11

Check Check Check Check Check

12 13

Check air intake flame arrestor Check exhaust of gas starter is discharged to vent line Check that engine is provided with a spark arresting silencer and exhaust pipe is fully insulated Check turbo charger is covered with removable insulation blanket Check and test run pre-post lube oil pump Check coupling guard; ensure that it is non-sparking type Check engine cooling water pump, pulley alignment, belt tension and water piping Check the cooling system for leaks or loose connections. Check the condition of all the pipes for the cooling system and ensure that all connections are properly clamped Remove spark plugs and manual crank engine

14 15 16 17 18 19 20

the air cleaner service indicators. Service the air cleaner filter element if necessary that lube oil level control is installed at correct elevation any external bearing lubrication/greasing engine barring arrangement and bar engine over air intake filter element for cleanliness

Engine Fuel System 1 2 3 4

Inspect the fuel lines for loose fittings and leaks. Ensure that the fuel lines are properly clamped Ensure the fuel is supplied to the engine at the correct pressure for the application Check fuel gas filter element conditions and replace if necessary Check fuel gas shutdown valve and ensure vent is discharged to a safe area (with flame arrestor installed).

Auxiliary Gear Box 1 2 3 4 5 6

Check that all vibration probes, transducers, accelerometers and temperature sensors are installed correctly, calibrated and functional Ensure that lubrication oil is of correct type and of sufficient quantity Ensure that coupling guards are in place Check gearbox lube oil for water or dirt contamination; top-up or replace Check gearbox lube oil pipe and relief valve setting Turn gearbox input shaft to ensure it rotates freely

Compressor 1 2 3 4 5 6 7 8 9 10 11

Check suction strainer conditions Check and set the crosshead feeler gauge clearance Check that the on-skid piping and supports are adequate Check lube oil pump strainer conditions Check main lube oil filter conditions Check oil separator coalescing filter conditions Check lube / seal / injection / bearings / slide valve oil connections as per P&IDs Check that sufficient vents and drains are provided Check seal vent line properly vented to a safe area Check containment seal drain line connected to seal pot Fill oil separator with correct lubrication oil grade

Page 2 of 9



12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

M24-B

Check and switch on the lube oil heater(s) Circulate lube oil system and verify cleanliness Check lube oil level at oil separator – check for any leaks Check that the correct breather element is clean Check that the correct torque value has been applied Check rod packing Check the coupling bolts Check the crosshead guide support Check the crankcase and crossheads for cleanliness and ensure the crankcase is properly vented Check line up of vent and drain system of cylinder stuffing box and cylinder compartment distance pieces Check line up of purging system to cylinder stuffing box gland or cylinder compartment distance pieces Check the barring gear for correct functioning Check crankshaft deflection before and after coupling-up of driver Check the suction and discharge valve assembly and valve housing for cleanliness and check valve lift. Check that valves are assembled correctly. If valve unloaders are mounted, check correct functioning and sequence Check the piston travel clearance at both sides of each cylinder and piston/piston rod runout Check cylinder and suction volume bottle for cleanliness If clearance pockets for capacity control are installed, check proper functioning of this device Check cleanliness of the piston-rod seals at the cylinder stuffing box and the cylinder compartment distance pieces If the compressor is driven by means of V-belts, check the correct tension of these belts and the pulley alignment Check whether safety devices are properly installed and in accordance with the data sheets and flow diagram. Check that the safety/relief valve is installed and check set pressure Check that the crankcase contains oil up to the correct level Check that the lubricator is filled with oil and check proper supply to all lubricated points by rotating the crank by hand If an intermediate bearing is installed, check that the bearing housing contains oil or grease, and check for correct oil level If cylinders are cooled by thermosyphon cooling, check that the reservoir and cylinders are filled with glycol and check for correct level in the reservoir Check the proper functioning of all safety devices. Safety devices that cannot be tested when machine is not running should be checked during initial run

Page 3 of 9



M24-B

Lube Oil System 1 2

Confirm that lube oil piping is complete as per P&IDs; all supports are secured and thermal insulation undamaged Ensure that lube oil piping provided by fabricator has: 

Undergone acid cleaning and flushing.

 Undergone hydrotest Check lube oil relieve valve and sight pop test certificate Check that the lube oil filters are installed correctly at the lube oil flushing circuit Ensure that sufficient filter elements are available Perform lube oil flushing to ensure the entire system is clean. Ensure that lube oil particle 6 and water content is in accordance to ISO 4406 or NAS 1638 Fill lube oil into lube oil tank; ensure that the grade of lube oil is in accordance to OEM 1. specification. 7 Check that the lube oil level is at normal level; top-up if required 8 Check that commissioning strainers are installed correctly 9 Check that the lube oil heater is operational (only for internal skid). 10 Check that the pump-motor coupling is guarded by coupling guard Verify that continuity check and resistance check has been conducted for the necessary 11 wiring and cabling 12 Perform rotational check for lube oil pump 13 Check that all instruments are in place 14 Check that earthing system cables and connections are secure and undamaged Lube oil cooling system: 15  Ensure that flow rate of lube oil is sufficient for cooling purposes.  Ensure that pressure from pump is sufficient for cooling purposes. Electrical system 3 4 5

Inspect the wiring for the following conditions; i. Loose connections 1 ii. Wiring that is worn or frayed iii. Inspect the gauge panel and control panel for good condition. Reset any alarm or shut off components Verify that a complete operational test on all control, logic and power circuits have been 2 carried out Instrument/Control System 1 Verify instrument/control system is complete as per P&IDs. Verify that leak and loop check between local control panel and on-skid instrument have 2 been done 3 Conduct loop check between UCP and skid junction box 4 Check UCP and junction box grounding 5 Conduct function check for UCP 6 Dry test control panel and confirm start up valve opening sequence and timing 7 Carry out trip/fault simulation test for all safeguarding instruments.

Page 4 of 9



M24-B

Verify that electrical check on compressor pre-lube pump motor cable and MCC has been completed 9 Verify the instrumentation set points (control, alarm and fault) with site conditions 10 Verify that stroke test and Modbus check have been completed Seal Gas System 8

Check that system piping/tubing/instruments and other items are in healthy conditions 1 and fitted in correct position. 2 Verify that the system has been cleaned, flushed and blown with clean dry air. 3 Check that control valve of seal gas system has been function tested. 4 Check seal gas supply and seal gas filter is clean Ensure main seal gas supply and alternate seal gas supply pressure is adequate as per 5 OEM settings. Adjust supply if necessary Vibration Monitoring System Check that all vibration probes/transducers/accelerometers are installed correctly, 1 calibrated and functional. 2 Ensure that all keyphasors have been set correctly. 3 Conduct loop check on vibration monitoring system Cooling Water System (for compressor aftercoolers) 1 Check line-up of cooling water system and that it is in accordance with flow diagram. 2 Check that the cooling water system has been properly flushed and is clean. 3 Run cooling medium/cooling water pump 4 Confirm level in cooling water surge tank/expansion tank. 5 Confirm that flow and temperature of water cooling system is operating as per designed.

Page 5 of 9



M24-B

Skid Piping

1 Check process piping is constructed according to P&IDs. Ensure all lines have been tested and that radiographic examination and stress relief 2 (where applicable) is complete Ensure that the correct specification valve has been installed, greased (if applicable), will 3 easily open and close and sufficient packing is installed so that the packing gland nuts can be further tightened if required Ensure that check valves have been installed in the correct direction and if the internals 4 have been removed for hydrotesting or line flushing, they have been reinstalled Ensure that all control valves are installed in the correct direction, are in their fail-safe 5 position and their bypasses are closed Check safety valve installation, locking system tag, sight pop test certificates to confirm 6 correct setting Ensure that all strainers (permanent or temporary) are installed in the correct direction 7 and that the strainer element or basket has been reinstalled in all strainers Check that the correct number of studs and nuts are used on all flanges, that the nuts are 8 all tight and that at least two threads of the studs are showing past the nut Check that the piping is supported as per the drawings and anchors; guides and shoes are 9 correctly installed Check for sufficient clearance between piping to allow for movement and expansion during 10 start up 11 Ensure all blinds and jump overs installed during hydro testing are removed 12 Ensure oil and coolant level are correct Ensure all vent and drain connections have been unplugged and all hydro test fluid 13 drained out and lines have been blown dry. Replace all vents and drain plugs or caps Ensure all threaded connection on pipe, vessel and instruments are plugged. Observe the 14 plastic temporary shipping caps and covers; remove and replace them with the correct metal plug or cap 15 Check temporary/permanent suction strainer installed in spool 16 Conduct piping leak check 17 Purge the piping system with nitrogen

Page 6 of 9



M24-B

Instrument Air

Close all instrument isolation valves and purge lines using instrument air to check for instrument air availability Slowly open the instrument air inlet valve and blow out through a vent or available spare 2 nozzle at the other extreme end 3 Close the vent, pressurize and blow out once again The isolation valves may be opened after ensuring that the instrument air lines are free 4 from moisture and dirt Instrument and Actuated Valves 1

1 Stroke all automatic valves (SDV, BDV, PCV, LCV and etc.) 2 Check all instrument isolation valves are opened 3 Check PSU isolation valves are opened Air Inlet System 1 Ensure that the air inlet piping and the air filters are in place 2 Ensure that all clamps and connections are secured Scrubbers and Pulsation Bottles 1 Ensure that the internals are properly installed 2 Ensure that the piping and instrumentation is installed as per P&IDs For each suction scrubber vessel, fully open the liquid level controller isolation valves and 3 ensure that the bypass valves are fully closed. Check that the controller is correctly controlling the level for each level 4 Check the manual isolation for scrubber liquid drain is opened 5 Check pulsation bottles supports are loosen for hot alignment Cooler Check that the cooler fan motors are turning in the correct direction and the assembly is free to rotate 2 Check that the fan blades are installed correctly and are not damaged 3 Ensure that the louvers are in fully open position Drain 1

1 For manual drains, ensure all valves are shut 2 For automatic drains with level control valves, ensure that the isolation valves are open Liquid drain lines, including those beyond the skid limits, should be inspected to ascertain 3 that they are open

Page 7 of 9



M24-B

Gas Supply

1 Confirm that there is adequate supply of gas at required suction pressure Nitrogen Purging of the Unit CAUTION: The entire system must be purged to ensure an explosive air/hydrocarbon mix is avoided Ensure nitrogen purging has been carried out for the unit prior to initial start-up, or any 1 invasive maintenance or if unit being left in stand-by mode. Leak Testing Leak testing should be performed on all hydrocarbon containing pipe-work and equipment as part of the installation and pre-commissioning process Starting System 1

1 2 3 4

Ensure that the barring device is fully disengaged Drain moisture and sediment from the air tank and from any other piping Check the air pressure before starting Open the air supply valve for the starting motor


Page 8 of 9

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GAS ENGINE & RECIPROCATING COMPRESSOR PACKAGE COMPLETED BY VERIFIED BY Designation Contractor Representative PMT Inspector Company PETRONAS Carigali Name Signature Date

M24-B ACCEPTED BY Commissioning Engineer PETRONAS Carigali

Page 9 of 9

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MOTOR DRIVEN RECIPROCATING COMPRESSOR M25-B PACKAGE Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem No.

INSPECTION / TEST

OK

N/A P/L No

CAUTION: Ensure that equipment including the associated piping, fittings, valves and instrumentation are physically installed, leveled and aligned as required by the appropriate recommendations. All electrical equipment and wiring is completed and the unit is ready to be powered up. A thorough physical inspection with reference to the P&IDs, piping arrangements, wiring diagrams and sub vendor installation manuals would be required for this purpose General Checks 1 2 3

Make a walk-through inspection around the equipment and check for any damages Check the entire compressor skid and ensure all connections are secured and intact Check that all couplings and guards are fitted Check that the compressor vents and drains are complete and spades / spectacle blinds 4 are fitted in the right orientation 5 Verify set-point values for various switches or other instrumentations as per data sheet Skid and Base Structure 1

Check skid weld down/hold down bolts

2

Check motor, gearbox (if provided) and compressor hold down bolts

3 4

Perform skid levelness and soft foot check as recommended by OEM. Record readings Check that vibration dampeners (if required) is installed and tightened Check alignment between compressor-to-driver or compressor-to-auxiliary gearbox 5 (whichever applicable). Verify that the values are within vendor acceptable values and record readings 6 Check distance piece pre-loading reports 7 Remove any temporary stopper/shipping braces and etc. 8 Check for visual oil leakage and any external damage Motor 1 2 3 4 5 6

Ensure motor rotational direction is correct Check any external bearing lubrication/greasing Check that lube oil level is at correct elevation Check and test run pre-post lube oil pump Check coupling guard; ensure that it is non-sparking type Ensure that Electrical and Instrument interface to HMI (Local Control Panel) is establish and functioning properly

Page 1 of 9


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MOTOR DRIVEN RECIPROCATING COMPRESSOR PACKAGE

M25-B

Auxiliary Gear Box (If fitted) Check that all vibration probes, transducers, accelerometers and temperature sensors are installed correctly, calibrated and functional 2 Ensure that lubrication oil is of correct type and of sufficient quantity 3 Ensure that coupling guards are in place 4 Check gearbox lube oil for water or dirt contamination; top-up or replace 5 Check gearbox lube oil pipe and relief valve setting 6 Turn gearbox input shaft to ensure it rotates freely Compressor 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Check suction strainer conditions Check and set the crosshead feeler gauge clearance Check that the on-skid piping and supports are adequate Check lube oil pump strainer conditions Check main lube oil filter conditions Check oil separator coalescing filter conditions Check lube / seal / injection / bearings / slide valve oil connections as per P&IDs Check that sufficient vents and drains are provided Check seal vent line properly vented to a safe area Check containment seal drain line connected to seal pot Fill oil separator with correct lubrication oil grade Check and switch on the lube oil heater(s)- if applicable Circulate lube oil system and verify cleanliness Check lube oil level at oil separator – check for any leaks Check that the correct breather element is clean Check that the correct torque value has been applied Check rod packing Check the coupling bolts if all have the same weight and as per manufacturer specification Check the crosshead guide support Check the crankcase and crossheads for cleanliness and ensure the crankcase is properly vented Check line up of vent and drain system of cylinder stuffing box and cylinder compartment distance pieces Check line up of purging system to cylinder stuffing box gland or cylinder compartment distance pieces Check crankshaft deflection before and after coupling-up of driver Check the suction and discharge valve assembly and valve housing for cleanliness and check valve lift. Check that valves are assembled correctly. If valve unloaders are mounted, check correct functioning and sequence

Page 2 of 9



M25-B

Check the piston travel clearance at both sides of each cylinder and piston/piston rod runout is as per manufacturer specification 26 Check cylinder and suction volume bottle for cleanliness If clearance pockets for capacity control are installed, check proper functioning of this 27 device Check cleanliness of the piston-rod seals at the cylinder stuffing box and the cylinder 28 compartment distance pieces Check whether safety devices are properly installed and in accordance with the data 29 sheets and flow diagram. Check that the safety/relief valve is installed and check set pressure 30 Check that the crankcase contains oil up to the correct level 33 Check that the lubricator is filled with oil If an intermediate bearing is installed, check that the bearing housing contains oil or 34 grease, and check for correct oil level If cylinders are cooled by thermosyphon cooling, check that the reservoir and cylinders 35 are filled with glycol and check for correct level in the reservoir Check the proper functioning of all safety devices. Safety devices that cannot be tested 36 when machine is not running should be checked during initial run Lube Oil System 25

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Confirm that lube oil piping is complete as per P&IDs; all supports are secured and thermal insulation undamaged Ensure that lube oil piping provided by fabricator has: 

Undergone acid cleaning and flushing.

 Undergone hydrotest Check lube oil relief valve and sight pop test certificate Check that the lube oil filters are installed correctly at the lube oil flushing circuit Ensure that sufficient filter elements are available Perform lube oil flushing to ensure the entire system is clean. Ensure that lube oil particle and water content is in accordance to ISO 4406 or NAS 1638 Fill lube oil into lube oil tank; ensure that the grade of lube oil is in accordance to OEM specification. Check that the lube oil level is at normal level; top-up if required Check that commissioning strainers are installed correctly Check that the lube oil heater is operational (only for internal skid). Check that the pump-motor coupling is guarded by coupling guard Verify that continuity check and resistance check has been conducted for the necessary wiring and cabling Perform rotational check for lube oil pump Check that all instruments are in place Check that earthing system cables and connections are secure and undamaged Lube oil cooling system:  Ensure that flow rate of lube oil is sufficient for cooling purposes.  Ensure that pressure from pump is sufficient for cooling purposes.

Page 3 of 9



M25-B

Electrical system

Inspect the wiring for the following conditions; i. Loose connections 1 ii. Wiring that is worn or frayed iii. Inspect the gauge panel and control panel for good condition. Reset any alarm or shut off components Verify that a complete operational test on all control, logic and power circuits have been 2 carried out Instrument/Control System 1

Verify instrument/control system is complete as per P&IDs. Verify that leak and loop check between local control panel and on-skid instrument have 2 been done 3 Conduct loop check between UCP and skid junction box 4 Check UCP and junction box grounding 5 Conduct function check for UCP 6 Dry test control panel and confirm start up valve opening sequence and timing 7 Carry out trip/fault simulation test for all safeguarding instruments. Verify that electrical check on compressor pre-lube pump motor cable and MCC has been 8 completed 9 Verify the instrumentation set points (control, alarm and fault) with site conditions 10 Verify that stroke test and Modbus check have been completed Vibration Monitoring System 1

Check that all vibration probes/transducers/accelerometers are installed correctly, calibrated and functional.

2

Ensure that all keyphasors have been set correctly.

3

Conduct loop check on vibration monitoring system

Cooling Water System (for compressor aftercoolers) 1

Check line-up of cooling water system and that it is in accordance with flow diagram.

2

Check that the cooling water system has been properly flushed and is clean.

3

Run cooling medium/cooling water pump

4

Confirm level in cooling water surge tank/expansion tank.

5

Confirm that flow and temperature of water cooling system is operating as per designed.

Page 4 of 9



M25-B

Electrical system Inspect the wiring for the following conditions; i. Loose connections 1 ii. Wiring that is worn or frayed iii. Inspect the gauge panel and control panel for good condition. Reset any alarm or shut off components Verify that a complete operational test on all control, logic and power circuits have been 2 carried out Instrument/Control System 1



2


3




2


3


4


5


Page 5 of 9



M25-B

Electrical system

Inspect the wiring for the following conditions; i. Loose connections 1 ii. Wiring that is worn or frayed iii. Inspect the gauge panel and control panel for good condition. Reset any alarm or shut off components Verify that a complete operational test on all control, logic and power circuits have been 2 carried out Instrument/Control System 1



2


3




2


3


4


5


Page 6 of 9



M25-B

Skid Piping 1

Check process piping is constructed according to P&IDs.

2

Ensure all lines have been tested and that radiographic examination and stress relief (where applicable) is complete

3

Ensure that the correct specification valve has been installed, greased (if applicable), will easily open and close and sufficient packing is installed so that the packing gland nuts can be further tightened if required

4

Ensure that check valves have been installed in the correct direction and if the internals have been removed for hydrotesting or line flushing, they have been reinstalled

5

Ensure that all control valves are installed in the correct direction, are in their fail-safe position and their bypasses are closed

6

Check safety valve installation, locking system tag, sight pop test certificates to confirm correct setting

7

Ensure that all strainers (permanent or temporary) are installed in the correct direction and that the strainer element or basket has been reinstalled in all strainers

8

Check that the correct number of studs and nuts are used on all flanges, that the nuts are all tight and that at least two threads of the studs are showing past the nut

9

Check that the piping is supported as per the drawings and anchors; guides and shoes are correctly installed

10

Check for sufficient clearance between piping to allow for movement and expansion during start up

11

Ensure all blinds and jump overs installed during hydro testing are removed

12

Ensure oil and coolant level are correct

13

Ensure all vent and drain connections have been unplugged and all hydro test fluid drained out and lines have been blown dry. Replace all vents and drain plugs or caps

14

Ensure all threaded connection on pipe, vessel and instruments are plugged. Observe the plastic temporary shipping caps and covers; remove and replace them with the correct metal plug or cap

15

Check temporary/permanent suction strainer installed in spool

16

Conduct piping leak check

17

Purge the piping system with nitrogen

Page 7 of 9



M25-B

Instrument Air

Close all instrument isolation valves and purge lines using instrument air to check for instrument air availability Slowly open the instrument air inlet valve and blow out through a vent or available spare 2 nozzle at the other extreme end 3 Close the vent, pressurize and blow out once again The isolation valves may be opened after ensuring that the instrument air lines are free 4 from moisture and dirt Instrument and Actuated Valves 1

1 Stroke all automatic valves (SDV, BDV, PCV, LCV and etc.) 2 Check all instrument isolation valves are opened 3 Check PSU isolation valves are opened Air Inlet System 1 Ensure that the air inlet piping and the air filters are in place 2 Ensure that all clamps and connections are secured Scrubbers and Pulsation Bottles 1 2

Ensure that the internals are properly installed Ensure that the piping and instrumentation is installed as per P&IDs For each suction scrubber vessel, fully open the liquid level controller isolation valves and 3 ensure that the bypass valves are fully closed. Check that the controller is correctly controlling the level for each level 4 Check the manual isolation for scrubber liquid drain is opened 5 Check pulsation bottles supports are loosen for hot alignment Cooler Check that the cooler fan motors are turning in the correct direction and the assembly is free to rotate 2 Check that the fan blades are installed correctly and are not damaged 3 Ensure that the louvers are in fully open position Drain 1

1 2

For manual drains, ensure all valves are shut For automatic drains with level control valves, ensure that the isolation valves are open Liquid drain lines, including those beyond the skid limits, should be inspected to ascertain 3 that they are open Gas Supply 1

Confirm that there is adequate supply of gas at required suction pressure

Page 8 of 9



M25-B

Nitrogen Purging of the Unit CAUTION: The entire system must be purged to ensure an explosive air/hydrocarbon mix is avoided Ensure nitrogen purging has been carried out for the unit prior to initial start-up, or any 1 invasive maintenance or if unit being left in stand-by mode. Leak Testing 1

Leak testing should be performed on all hydrocarbon containing pipe-work and equipment as part of the installation and pre-commissioning process






Page 9 of 9

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRIC MOTOR DRIVEN CENTRIFUGAL PUMP M26-B Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem No.

INSPECTION / TEST

OK

N/A P/L No

Mechanical Rotating Subsystem 1

2

3

Remove all remaining preservation material from the pump set Check pump shaft seal/packing’s type, make and model are as per datasheet. Ensure pump’s API Plan for Mechanical Seal System is installed properly. Make certain that the mechanical seal has been correctly set and the drive collar setscrews tightened. Check the mechanical seal setting spacer is at ‘unlock’ position Check that the pump or motor shaft can rotates freely by hand. Rotate the coupling 2 or 3 times slowly

4

Check the leveling and soft foot

5

Make sure that the baseplate is correctly fixed by checking the ALL holding down bolts is torqued to correct value.

6

Check pump, gearbox and motor holding down bolts

7 8 9 10 11 12 13

Check distance between shaft ends (DBSE) is as per stated on General Arrangement (GA) drawing Check shaft alignment reading is within tolerance. Perform alignment if readings deviate from tolerance. Record the alignment readings after check or re-alignment Fit the hub bolts and locking washers by tighten it evenly Lube oil system (if any) and mechanical seal system piping have been flushed and meet the cleanliness requirement as per ISO 4406 or NAS 1638 Check level of buffer / burrier fluid tank for mechanical seal system (if any) Check motor and pump bearings are lubricated in accordance with manufacturer’s instructions Make sure that the volute casing and suction piping is completely full of liquid by priming the pump

Mechanical Piping Subsystem 1 2

Check all piping connection has been reinstated Check piping alignment to the pump nozzle has been performed

Page 1 of 4


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRIC MOTOR DRIVEN CENTRIFUGAL PUMP 3 4 5 6 7

M26-B

Ensure recycle line, ARV (if any) have been installed correctland check the setting of the ARV Ensure suction and discharge piping has been hydrostatic tested, flushed clean and blown dry Check suction strainer have been installed correctly and the mesh size is correct as per P&ID Check all bolted flanged connections are tight and make certain that all external connections have been made and function properly Visually check all associated valves and piping are correctly installed with appropriate gaskets, and adequately supported. Ensure all valves are operational. Any temporary blanks are removed

Electrical Subsystem Inspection 1 2 3 4 5 6 7 8

Check motor hold-down bolts. Be certain that the driver (motor) is properly installed in connection with the instructions provided by the manufacturer Check all electrical connections are correct and secure in the various terminal boxes, all in accordance with manufacturer’s wiring diagram Check the motor winding insulation resistance test using appropriate Megger Verify that electrical check on motor, cabling and motor control center has been done. Carry out static electrical checks of all circuits. Check supply voltages are correct. Check the setting of control, alarm and trip conditions Ensure Remote Control Unit (RCU) has been connected to the motor Just before the running test for the units driven by electric motor, the motor to be run for a moment to check for correct shaft rotation of the pump unit (Rotational check) through RCU (Local start-stop button) Ensure all electrical grounding have been installed properly and tested If the motor heaters are fitted and with the power available, they should be left ‘ON’ when the machine is out of service

Instrumentation Subsystem Inspection 1 2 3

All gauges at pump, motor, sealing system and other auxiliary systems have been calibrated and installed properly Check that all control and any instrumentation connections are complete Vibration and bearing temperature (if any) sensor /detection on the pump and motor have been wired and looped checked

Page 2 of 4


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRIC MOTOR DRIVEN CENTRIFUGAL PUMP

M26-B

Motor Solo Run Test 1

Remove the coupling spacer and confirm that coupling bolts are not fitted

2

Check motor shaft is free to turn by hand

3

For safety, temporarily fit coupling guard

4

Arrange for electrical power to be made available to motor

5 6

Start-up motor, check the direction of rotation is correct by referring to the general arrangement drawing or the rotation arrow on pump Run motor for 2 hours, carry out the following checks and record the data accordingly: 

Check motor ampere



Check for vibration using vibration meter.



Check for excessive noise using decibel meter



Check temperature of motor bearings using temperature gun



Check temperature rise of motor windings using temperature gun

7

Stop motor and isolate it from electrical supply

8

After the motor solo run test, re-check alignment and install coupling

Pump Test Run 1

Ensure coupling and coupling guard is fitted

2

Perform test run for the pump to confirm pump functionality. Recommended duration for the test is 2 hours. If the designed pumping medium is not available, check with OEM suitable test medium can be used

3

Observe any abnormal noise, vibration. Record vibration data

4

Perform preservation for offshore transportation according to OEM procedure and PTS70.10.70.11 - The Preservation of Old and New Equipment and Piping Standing Idle

Page 3 of 4


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ELECTRIC MOTOR DRIVEN CENTRIFUGAL PUMP COMMENT(S) AND ADDITIONAL INFORMATION:



M26-B



Page 4 of 4

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GAS ENGINE DRIVEN CENTRIFUGAL PUMP M27-B Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem No.

INSPECTION / TEST

OK

N/A P/L No

Mechanical Rotating Subsystem 1

2

3

Remove all remaining preservation material from the pump set Check pump shaft seal/packing’s type, make and model are as per datasheet. Ensure pump’s API Plan for Mechanical Seal System is installed properly. Make certain that the mechanical seal has been correctly set and the drive collar setscrews tightened. Check the mechanical seal setting spacer is at ‘unlock’ position Check that the pump shaft can rotates freely by hand. Rotate the coupling 2 or 3 times slowly

4

Check the leveling and soft foot condition

5

Make sure that the baseplate is correctly fixed by checking the ALL holding down bolts is torqued to correct value.

6

Check pump, gearbox and engine holding down bolts

7 8 9 10 11 12 13

Check distance between shaft ends (DBSE) is as per stated on General Arrangement (GA) drawing or manufacturer specification Check shaft alignment reading is within tolerance. Perform alignment if readings deviate from tolerance. Record the alignment readings after check or re-alignment Fit the hub bolts and locking washers by tighten it evenly Lube oil system (if any) and mechanical seal system piping have been flushed and meet the cleanliness requirement as per ISO 4406 or NAS 1638 Check level of buffer/barrier fluid tank for mechanical seal system (if any) Check engine and pump bearings are lubricated in accordance with manufacturer’s instructions Make sure that the volute casing and suction piping is completely full of liquid by priming the pump

Mechanical Piping Subsystem 1

Check all piping connection has been reinstated

2

Check piping alignment to the pump nozzle has been performed

Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GAS ENGINE DRIVEN CENTRIFUGAL PUMP 3 8 9 10 11

M27-B

Ensure recycle line, ARV (if any) have been installed correctly and check the setting of the ARV Ensure suction and discharge piping has been hydrostatic tested, flushed clean and blown dry Check suction strainer have been installed correctly and the mesh size is correct as per P&ID Check all bolted flanged connections are tight and make certain that all external connections have been made and function properly Visually check all associated valves and piping are correctly installed with appropriate gaskets, and adequately supported. Ensure all valves are operational. Any temporary blanks are removed

Electrical Subsystem Inspection 1 2 3

Check all electrical connections are correct and secure in the various terminal boxes, all in accordance with manufacturer’s wiring diagram Ensure all electrical grounding have been installed properly and tested Ensure that all Electrical deliverables is obtained; signed off with no critical punch list that will impede commissioning is recorded

Instrumentation Subsystem Inspection 1 2 3

All gauges at pump, sealing system and other auxiliary systems have been calibrated and installed properly Check that all control and any instrumentation connections are complete Vibration and bearing temperature (if any) sensor /detection on the pump and engine have been wired and looped checked

Engine Solo Run Test 1

Remove the coupling spacer and confirm that coupling bolts are not fitted

2

For safety, temporarily fit coupling guard

3

Run engine for 1-2 hours, carry out the following checks and record the data accordingly:

4



Check movement of engine shaft



Check for vibration using vibration meter.



Check for excessive noise using decibel meter



Check temperature of engine bearings using temperature gun

After the engine solo run test, re-check alignment and install coupling

Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B GAS ENGINE DRIVEN CENTRIFUGAL PUMP

M27-B

Pump Test Run 1

Ensure coupling and coupling guard is fitted

2

Perform test run for the pump to confirm pump functionality. Recommended duration for the test is 2 hours. If the designed pumping medium is not available, check with OEM suitable test medium can be used

3

Observe any abnormal noise, vibration. Record vibration data

4

Perform preservation for offshore transportation according to OEM procedure and PTS70.10.70.11 - The Preservation of Old and New Equipment and Piping Standing Idle






Page 3 of 3

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Fire Pump (Diesel engine driven) Project No. Project Title Facilities

Tag no.

M28-B


INSPECTION / TEST

1 2 3 4 5 6 7 8 9 10 11 12

Confirm that the Construction checksheet is completed prior to starting any work. Confirm that the content of the accepted punchlist will not impede the commissioning work Confirm that the preservation measures have been removed from the engine and auxiliary equipment

OK

N/A

Confirm that shaft alignment has been completed Confirm that all pumps under this package are mechanically ready for start-up and function test Confirm that engine cooling water system is complete, filled with correct mixture of coolant to required level and level gauges are fitted Confirm that gearbox connection is complete and pre-commissioning checksheet is signed off Hydraulic Start System Confirm that hydraulic and electrical system has been installed and ready for functional test Confirm that the hydraulic pump oil suction strainer is fitted and clean Check and ensure that starter system hydraulic oil reservoir is fully charged with correct oil Check pre-charge Nitrogen pressure in each hydraulic accumulator bladder Use hand pump to fully charge each of the hydraulic oil accumulator to the correct working pressure Lube Oil System Check that the lube oil system is complete, new filter elements installed , all component are free from damage and filter changeover valve is operational

13

Check lube oil tank is filled with correct grade & quantity of lube oil

14

Check engine crank case lube oil heater connection is complete / operational

Page 1 of 3

P/L No


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Fire Pump (Diesel engine driven)

M28-B

15

Fuel System Check that the diesel fuel tank & feed lines to the engine have been installed correctly, flushed clean , new & correct filter elements installed and ready for operation with all instrumentation in service

16

Check diesel tank filled with clean diesel

17 18 19 20 21 22

Check filing, overflow and drain lines are adequate and installed to specification Check Remote shut -off valves are fitted and clearly identified outside engine compartment Air Intake System Confirm that the air intake filtration system is clean and filter elements are securely Turbo Charger Confirm Turbo Charger is free to rotate Confirm sealing arrangement are in accordance with manufacturer's instructions Operate lube oil priming pump and observe oil issuing from oil drain line (If oil supply line is from engine)

23

Confirm oil level is correct

24

Confirm Vent line is not obstructed

25 26 27

Air start Pressurize the system and check for leaks Exhaust system Confirm exhaust bellows are undamaged Confirm the exhaust insulation is correct to specification and undamaged

28

Confirm that if sliding supports are installed they are free to move

29

Check if the flame arrestor is installed

30 31 32

Gear box Confirm the gear box installation is completed Check that all the pre-start up checks and preparation has been carried out as per the diesel engine / gear box vendor's recommendation Review the manufacturer's recommendations for preparation to start and confirm that no conflicts arise between that document and the commissioning procedure

33

Attached diesel engine performance test record

34

Record into mechanical punchlist for any incompleteness and deviation found during inspection

Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Fire Pump (Diesel engine driven) COMMENT(S) AND ADDITIONAL INFORMATION:



M28-B



Page 3 of 3

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B CHEMICAL METERING PUMP Project No. Project Title Facilities Tag no.

M29-B


INSPECTION / TEST

1

Check vendor’s instruction, ensure that manual and part list are available

2

Check equipment for any damage

3

Check for any sign of lack of preservation

4

Check pump holding down bolts

5

Check that pump material is as per specification

6

Check pump suction filter/strainer element (if provided)

7

Check pump discharge relief valve and test certificate

8

Check that discharge valve direction is correct

9 10 11 12

OK

N/A P/L No

Check that lubricant for pump is correct type. Lubricant type: Check that pressure gauge provided for the pump is of the correct range and has over pressure protection If electric motor, verify that electrical check on motor, cabling, and Motor Control Center has been done If pneumatic, check that air supply pressure is correct and lubricator is provided (If required)

13

Verify that coupling /belt rating is sufficient

14

Check alignment of coupling/pulley or belt tension

15


Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B CHEMICAL METERING PUMP COMMENT(S) AND ADDITIONAL INFORMATION:



M29-B



Page 2 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B CHEMICAL INJECTION PACKAGE Project No. Project Title Facilities Tag no.

M30-B


INSPECTION / TEST

1

Check vendor’s instruction, ensure that manual and part list are available

2

Check equipment for any damage

3

Check skid holding down bolts

4

Complete checksheet M01-A & B for all storage /mixing tank

5

Check and test mixing pump according to vendors procedure

6 7 8 9

OK

N/A P/L No

Check that circulation and fill piping are as per P & ID and approved drawing Check and test chemical metering pumps accordingly to vendors’ instruction Check that chemical header, discharge tubing are as per P & ID and approved drawing Leak check discharge tubing

10

Check and test mixer according to vendor procedure

11

Document all test and checks performed






Page 1 of 1

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B NITROGEN GAS GENERATOR Project No. Project Title Facilities Tag no.

M31-B


INSPECTION / TEST

1

Check manufacturer’s drawing, dossier, associated equipment catalogs and test certificates

2

Check vessel hold down bolts

3

Check that nameplate with details are provided

4

Check for any damage or dent

5

Check that internal & external painting are in accordance to approved specification

6

Check loading of molecular sieves and its cleanliness before charging

7 8 9 10 11

OK

N/A P/L No

Check vessel internal for cleanliness and issue final closure certificate Check relief valve installation, interlocking system and sight test certificate Check pressure test is completed and test certificate is signed off Check proper function of Programmable Logic Controls and the sequence of opening for PSA valves Check level instruments, level gauges and pressure gauges are properly installed

12

Check level switches are set at correct level

13

Test the functioning of actuated valves

14

Carry out pre-commissioning test as per vendor’s manufacturing procedure; Check for any abnormalities

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B NITROGEN GAS GENERATOR COMMENT(S) AND ADDITIONAL INFORMATION:



M31-B



Page 2 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SEWAGE TREATMENT UNIT Project No. Project Title Facilities Tag no.

M32-B


INSPECTION / TEST

OK

1

Confirm ITR-A completed and signed off. Essential punch list cleared

2

Confirm preservation has been removed

3

Verify and check for any external damage

4

5

Confirm all instrument: a. Confirm tubing connection tight and leak-free b. Confirm cable entry and termination is correct, neat, appropriately glanded, no excessive bend radius and properly earthed. Confirm all piping: a. Confirm piping adequately supported b. Confirm all flange joints properly mated with appropriate gaskets and leak-free (refer flange management procedure doc.) c. Insulations are correctly installed and not damage.

6

Confirm M01-B tank closure completed and signed off

7

Confirm Macerator pump test completed

8 9

N/A P/L No

Record into mechanical punchlist for any incompleteness and deviation found during inspection Carry out pre-commissioning test as per vendor’s manufacturing procedure; Check for any abnormalities






Page 1 of 1


WATER MAKER UNIT

M33-B


Tag no.

INSPECTION / TEST 1

Vendors instruction, manual and part list are available.

2

Check equipment for any damage.

3

Check that the on-skid piping and supports to be adequate.

4 5

Check lubrication / greasing of motor bearing; top-up if required.

7

Check that the correct grade of lube oil has been filled into the pump crankcase.

8

Check pump-to-motor alignment and align if required.

9

Check filters nameplates are provided with correct information.

10

Check the pressure rating of filter / strainer is correct.

11

Check all valves attached to the filter / strainers are not damaged.

12

Check that the correct specification of the filter is installed.

14

Check chemical storage tank nameplate is provided with the correct information. Check sight glass on storage tank is located at the correct level and easily visible.

15

Check plugs or blanks fitted to drain valves on storage tank.

16

Check nameplate is provided with correct information on media filter tank.

17

Check plugs or blanks fitted to drain valves on filter tank.

18 19

N/A P/L No

Check high pressure pump lube oil for any water or dirt contamination; top up or replace. Turn high pressure pump and motor shaft in the correct direction to ensure free rotation.

6

13

OK

Check that the correct media has been filled as per vendor specifications in filter tank. Check and ensure that the interconnection for instrument air, process pipeline, drains etc. is completed on the package. NOTE: Please refer to vendors’ operations manual for exact instructions.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B WATER MAKER UNIT

20

Carry out pre-commissioning test as per vendor’s manufacturing procedure; Check for any abnormalities. Record test parameters

M33-B






Page 2 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SUBSEA EQUIPMENT PACKAGE Project No. Project Title Facilities Tag no.

M34-B


INSPECTION / TEST

OK

1

Verify equipment against purchase order, record details

2

Check installation against manufacturers’ installation documentation

3

Verify that check-sheets and relevant procedures are provided by vendor

4

5

N/A P/L No

Verify that vendor System Integration Test (SIT) has been satisfactorily done and all document related to the test were provided by the vendor; attach System Integration Test (SIT) document Document all test and checks performed by the vendor and attach accordingly






Page 1 of 1

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MISCELLANEOUS EQUIPMENT Project No. Project Title Facilities Tag no.

M35-B


INSPECTION / TEST

OK

1

Items installed, calibrated and designed according to attached Project Design Specification.

2

Verify that ITR-A is signed off prior to starting any work

3

Check that control panel equipment is completely installed and functioning

4

Confirm the driver /gearbox/driven equipment is correctly aligned

5

Carry out manufacturers’ recommended Pre-commissioning and Start-up checks

6

Carry out manufacturers’ recommended No-load test (if applicable)

N/A P/L No






Page 1 of 1

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B VENDOR’S PACKAGED EQUIPMENT (SKID) M36-B Project No. Project Title Facilities INFORMATION Tag no. System/Subsystem No.

INSPECTION / TEST

1

Construction check sheets are complete & no subsequent damage occurred.

2

Confirm preservation removed.

3

All valves have been exercised and are operable.

4

Lube / Seal systems are flushed to spec.

5 6 7 8 9

Sum drained and refilled with the correct grade lubricant.

11

Gas sealing system is complete.

12

All temporary screens and filters have been removed.

13

Filters are clean and have the correct elements fitted.

14

Check that all vents and drains are complete and all spades / spec blinds are fitted in the correct orientation.

15

Equipment vibration mounts are free and set correctly.

17 18 19 20

N/A P/L No

Lube / Seal systems have been filled to the correct level with the correct specified lubricant. Fuel system complete, new filters fitted & system flushed to specification. Cooling system complete flushed and filled with correct coolant mixture. Ensure that all manufacturers’ static checks have been completed prior to commencing commissioning activities. Check gearbox is complete, clean and filled with the correct grade lubricant.

10

16

OK

Separate paring discs are set correctly to the manufacturer's specification. Vessels are clean and filled to the correct level with the correct fluid specified. Confirm dampers are correctly charged. Equipment is free to rotate and direction of rotation is clearly marked. Check all guards are fitted, skid is clean and free from debris prior to orientation.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B VENDOR’S PACKAGED EQUIPMENT (SKID) 21 22 23

M36-B

Check all support systems and auxiliary equipment are complete and available. Ensure permanent / temporary fire detection / protection systems are installed and operable. Ensure that all manufacturers’ installation / commissioning pre-start up check list have been completed.

24

Confirm ground bonding completed.

25

Carry out manufacturers’ recommended Pre-commissioning procedure and test






Page 2 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Project No. Project Title


Tag no. 1 COMPLETE PACKAGE Make & Model Serial No Capacity Unit Test Ref/Date 2 DRIVER Make & Model Serial No. Capacity HP (KW) Rated Speed Voltage/Current V-belt spec/Coupling 3 DRIVEN Make & Model Serial No Capacity HP (KW) 4 INTERMEDIATE Make & Model Serial No Gear Ratio HP (KW)

GENERAL INFORMATION System no./Subsystem no. Location Reference Drawing

INSPECTION/TEST

1

Mechanically complete and no subsequent damage occurred.

2


3 4 5 6

M37-B

OK

N/A P/L No

The Instrument air package is tested, operational and connected to all the relevant pneumatic instruments. The Nitrogen package is tested and operational Ensure field operating tools are available for Commissioning and Startup, e.g., Manual Valves Operating Key, SDV Junction box Keys, Instruments Manifold Venting Keys All LO/LC valves are as per their required positions as per P&ID and confirm status of all manual isolation valves, Padlock keys to be Page 1 of 3

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ACID GAS REMOVAL UNIT M37-B Project No. Project Title available at all the times for emergencies. All manual valves are lined up in their normal operating position (esp. 7 PSV’s upstream). All Restriction Orifices / Flow Orifice are in their correct positions and 8 their respective data sheets are cross checked for the Orifice hole ID size. All spectacle blinds, spacers/spades are in the normal operating 9 position and recorded in the spade list. 10 Catalysts are loaded in respective catalyst bed 11 All Membrane units filled with respective Membranes Static Equipment have been internally inspected, Internals are installed 12 and M049-B completed Ensure strainers on suction of all rotating equipment are installed 13 correctly. Ensure start-up mesh is installed upstream of all strainers on suction of 14 Pumps and Compressors. Correct grade of lube Oil is filled up to operating levels for pumping 15 equipment & Instrument Air compressor. Lube oil and Seal Oil lines are flushed and cleaned properly and the 16 lines are ensured to be free from debris All Panel / Cabinet / Console Installation and pre-commissioning 17 Acceptance check sheets completed, certified and signed off Power Supply Voltage to each Panels, Cabinets, Consoles are correct as 18 per Project Specifications Check all instruments are lined up through their root valves and 19 manifolds 20 All relief valves and pressure regulating valves are calibrated 21 Ensure all package SAT successfully carried out (where applicable) Complete function check of all fire, gas and safeguarding systems are 22 carried out and all items shown on Cause & Effect Drawings shall be tested and proven to ensure shut down protection is in place. ESD Push buttons are in Reset (Live) Positions (unless special 23 maintenance case) 24 Ensure that all DCS, ESD and F&G systems are functional. All ESD, PSD, EDV and control valves are in their fail-safe (de-energized) 25 position and in Auto Mode 26 Control Logic Philosophy operational as per Project Design 27 Communications with Safeguarding System correct as per Project Page 2 of 3

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B ACID GAS REMOVAL UNIT M37-B Project No. Project Title Specifications 28 INHIBIT LOGBOOK in place to monitor the status of INHIBITS. Ensure Electrical power is available to all the field electrically operated 29 equipment, control room, substation systems and all the consumers. All Motors have undergone pre-commissioning tests Solo Dynamic Run 30 and relevant test sheets are completed 31 Redundant Power Supply operating correctly 32 UPS system tested and available Emergency Diesel Generator Package is available for backup power 33 supply. 34






ACCEPTED BY Commissioning Engineer PCSB

Page 3 of 3

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B MERCURY REMOVAL UNIT

Project No. Project Title

P&ID No. Tag no. 1 COMPLETE PACKAGE Make & Model Serial No Capacity Unit Test Ref/Date 2 DRIVER Make & Model Serial No. Capacity HP (KW) Rated Speed Voltage/Current V-belt spec/Coupling 3 DRIVEN Make & Model Serial No Capacity HP (KW) 4 INTERMEDIATE Make & Model Serial No Gear Ratio HP (KW)

M38-B

GENERAL INFORMATION System no. /Subs-system No. Location

INSPECTION/TEST

1

Mechanically complete and no subsequent damage occurred.

2


3 4 5 6

OK

N/A P/L No

The Instrument air package is tested, operational and connected to all the relevant pneumatic instruments. The Nitrogen package is tested and operational Ensure field operating tools are available for Operation personnel for the start-up, e.g., Manual Valves Operating Key, SDV Junction box Keys, and Instruments Manifold Venting Keys. All LO/LC valves are as per their required positions as per P&ID and confirm status of all manual isolation valves, Padlock keys to be Page 1 of 3


M38-B

Project No. Project Title available at all the times for emergencies. All manual valves are lined up in their normal operating position (esp. 7 PSV’s upstream). All Restriction Orifices / Flow Orifice are in their correct positions and 8 their respective data sheets are cross checked for the Orifice hole ID size. All spectacle blinds, spacers/spades are in the normal operating 9 position and recorded in the spade list. 10 Catalysts are loaded in respective Mercury Removal bed. Static Equipment have been internally inspected, Internals are installed 11 and M049-B is completed. All Panel / Cabinet / Console Installation and pre-commissioning 12 Acceptance check sheets completed, certified and signed off Power Supply Voltage to each Panels, Cabinets, Consoles are correct as 13 per Project Specifications. Check all instruments are lined up through their root valves and 14 manifolds. 15 All relief valves and pressure regulating valves are calibrated. 16 Ensure all package SAT successfully carried out (where applicable). Complete function check of all fire, gas and safeguarding systems are 17 carried out and all items shown on Cause & Effect Drawings shall be tested and proven to ensure shut down protection is in place. ESD Push buttons are in Reset (Live) Positions (unless special 18 maintenance case) 19 Ensure that all DCS, ESD and F&G systems are functional. All ESD, PSD, EDV and control valves are in their fail-safe (de-energized) 20 position and in Auto Mode 21 Control Logic Philosophy operational as per Project Design Communications with Safeguarding System correct as per Project 22 Specifications 23 INHIBIT LOGBOOK in place to monitor the status of INHIBITS. Ensure Electrical power is available to all the field electrically operated 24 equipment, control room, substation systems and all the consumers. 25 Redundant Power Supply operating correctly 26 UPS system tested and available Emergency Diesel Generator Package is available for backup power 27 supply. 28


Page 2 of 3


M38-B







Page 3 of 3


FIN FAN COOLER

M39-B


Tag no.

INSPECTION / TEST 1

Check ITR M39-A has been completed.

2

Check vendors instruction, manuals and part list are available.

3


4

Check that sufficient vents and drains are provided.

5

Pressure relief valves installed as per project drawing.

6

Pressure relief valves have valid certification and are set to the correct values.

7

Verify sliding supports are free to move.

8

Check all valves associated with the heat exchanger for operability.

9

Check all spec blinds and spades are fitted and are in the correct orientation.

10 11 12

Check fan shaft bearing lubrication and ensure that remote greasing points are provided. Check tube, fin and header materials conform to purchase specifications. Check that tube fin is free of intermeshing and deformation.

14

Check coupling alignment and bolting.

15

Check fan blade angle and ensure correct tightness of blade bolting.

16

Rotate fan by hand to ensure that shaft and drive run freely.

18

N/A P/L No

Check nameplate details are correct.

13

17

OK

Check the clearance between the fan tip and the fan ring (fan tip clearance). Check the belt tension is in accordance to the manufacturers specifications.

19

Check motor / gearbox coupling alignment and bolting.

20

Check grease bearing.

21

Check that vibration switch is installed at the correct location.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B FIN FAN COOLER

M39-B

22

Turn Motor shaft by hand to ensure free rotation.

23

Start fan driver motor and check driver as outlined in the manufacturer’s instructions.

24

Check for any excessive vibration.

25

During the cooling fan running, record all the data for RPM, bearing temperature and vibration.

26

Check COOLER and HEATER condition

27

Check that the correct rating is as per the nameplate.

28

Check that the correct cable rating has been installed.






Page 2 of 2


ELEVATOR

M42-B


Tag no.

INSPECTION / TEST

OK

1

Check ITR M42-A has been completed.

2

Check vendors instruction, manuals and part list are available.

3


4

Manufacturers test certificates & FAT documentation available.

5

Verify that all electrical/instrument signal are completed.

6

Carry out Vendor recommended pre-start up checks in accordance with Vendor Start Up and Operating Manual.

7

8

N/A P/L No

Review the manufacturers recommendation for preparation to start and confirm that no conflicts arise between that document and the commissioning procedure Confirm equipment is ready for dynamic commissioning as specified on relevant dynamic commissioning procedure





Page 1 of 1


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B PULSATION DAMPENER Project No. Project Title Facilities

M44-B


Tag no.


OK

N/A P/L No

Ensure ITR M44-A has been completed and signed off Charge damper per manufacturer's specification and according to specifications.

3

Record recommended pre-charge pressure in bar g

4

Carry out manufacturers’ recommended Pre-commissioning procedure and test

5

Record any exceptions found






Page 1 of 1

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B COUPLING COLD ALIGNMENT Project No. Project Title Facilities Tag no.

M45-B



Carry out soft foot check and record.

4

Check all pipework is complete.

5

Loosen off all pipework to the driven equipment.

6

Split coupling, remove spacer (if fitted), bolts and guard.

7

Verify flange alignment is complete. Tighten up all pipework and recheck radial concentricity of each half coupling, axial alignment and radial concentricity. Coupling spacer free length = ______________ mm DBFF = _____________ mm Vendor specified cold offset:

8

Install Coupling and guard. Tension bolts as per spec.

9

Record distance between shaft ends.

11 12

N/A P/L No

Vendor test documentation complete & available. Confirm manufacturers figures for coupling alignment, record specified cold offsets below in comments box or attach record sheet.

3

10

OK

If Laser alignment device is to be used, ensure alignment device is properly calibrated Record alignment reading  As found: ____  Final :____ Perform final dowelling for Centrifugal Compressor once final alignment is achieved with vendor assistance

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B COUPLING COLD ALIGNMENT COMMENT(S) AND ADDITIONAL INFORMATION:



M45-B



Page 2 of 2


PIG TRAP

M46-B


Tag no.

INSPECTION / TEST

1 2

Confirm that all associated construction work packs are signed off prior to starting any work. Confirm that the content of the accepted punchlists are complete and no subsequent damage has occurred Check that the equipment is clean and all external components are installed

3

Confirm that all preservation accessories have been removed.

4

Check that the sliding support is free to move.

5

Check that all spades and spectacle blinds are in the correct orientation.

6

Confirm all connections are complete and as per vendors drawings.

7

8

9

OK

N/A P/L No

Confirm two pig signalers are installed one on each side of pig trap valve. If isolating joints are used in pig trap system the isolating joints shall be located so that no excessive bending moments are applied to the joint. Pipe supports between the overbend and the isolating joint shall be electrically isolated. Ensure Pig receivers are located so that they are orientated with their end closures pointing away from personnel areas and critical items of equipment, i.e. those containing hydrocarbons and/or toxic mmaterialmaterial or in safety service. material or in safety service

10

11 12

Check the requirements for pig handling depend on the type and mass of pig and the pipeline size: normal pigs with a mass less than 30 kg may be manually loaded into or out of the pig traps; typically, this will be the case in pipelines of nominal diameter 300 mm and smaller. Pig loading trolleys, cassettes or baskets enable heavier pigs to be properly loaded, aligned and retrieved from pig traps. Ensure enough space is provided beyond the end closure door of the pig trap for pig handling. Confirm Pressure Relief facilities are installed and interlocks are installed.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B PIG TRAP 13 14 15 16 17

M46-B

Confirm that all valves are greased and free to operate and all spare valves have flange connections blinded off. Confirm pig trap Internals have been installed in accordance with Vendor drawings and specifications

Verify earthing boss connection is in place. Confirm pig trap internal have been inspected by Commissioning and Final Closure certificate has been attached. Review the manufacturers’ recommendation for preparation to start up and confirm that no conflicts arise between that document and the commissioning procedure.






Page 2 of 2


STORAGE TANK

M47-B


INSPECTION / TEST

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Confirm that all associated construction work packs are signed off prior to starting any work. Confirm that the content of the accepted punchlists are complete and no subsequent damage has occurred Check that the equipment is clean and all external components are installed Ensure that storage tank hydrostatic pressure testing has been performed. Ensure all piping system connecting to the storage tanks and their associated facilities have been pressure tested. Reinstatement test shall be performed to confirm all joints including isolation valves, relief valves, and block valves are leak free. Ensure all piping system connecting to the storage tanks and their associated facilities have been properly drained, flushed and dry to ensure no debris/foreign objects are left in the system. Check all spacers and/or spectacle blinds are in the correct positions and all temporary blinds are removed.

OK

N/A P/L No

Ensure relief valves are tested and installed. Check all controls and instruments have undergone testing and confirmed to be functional and ready for service. Ensure TGS (Tank Gauging System) and level transmitters are calibrated and ready for operation. Ensure all firefighting facilities as per below are ready for operation: - Fire water system - Fire foam system - Firefighting equipment Verify biocide and corrosion inhibitor injection (if applicable) are in place as per vendor recommendation. Ensure all temporary connections are removed. Check instruments devices, MOVs, alarms, have all been calibrated and ready for operation. Ensure all electrical devices such as Retractable Grounding Assembly RGA, Catholic protection, earthling are ready for service. Ensure FGS (Fire and Gas System) and DCS (Distributed Control System) have been tested and checked.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B STORAGE TANK 17 18 19 20 21

M47-B

For floating roof storage tanks ensure degassing boot is in service in order to eliminate the traces of gases in the liquid phase before entering the storage tank. Confirm all manway covers are bolted up correctly with correct gaskets.

Verify earthing boss connection is in place. Confirm Vessels internal have been inspected and Final Closure certificate has been attached. Review the manufacturers’ recommendation for preparation to start up and confirm that no conflicts arise between that document and the commissioning procedure.






Page 2 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B FINAL CLOSURE CERTIFICATE Project No. Project Title Facilities Tag no.

Manufacturer Model No. Serial No. 1

2

3

4

M49-B

INFORMATION System/Subsystem No. Pressure Rating

INSPECTION / TEST

Vessel or Tank has now been fully installed and has been inspected by the designated Contractor, Operations and Inspecting Agency Vessel or Tank is confirmed as being in accordance with the relevant design documents and in full compliance with all the requirements as specified in the relevant project documents.

OK

N/A P/L No

All internal parts and sub-assemblies associated / applicable to this Vessel or Tank have been installed correctly with respect to all the drawings, confirming elevations All items on the Vessel / Tank punchlist have been duly completed

5

Tank is clean and dry and all temporary equipment, lighting, scaffolding, rags, trash, debris have been removed from Vessel/Tank

6

All proper manway gaskets and bolts are supplied and proper torque specification applied.

THIS IS TO CERTIFY THAT THE ABOVE VESSEL/ TANK HAS BEEN INSPECTED INTERNALLY AND FOUND TO BE SATISFACTORY. THE VESSEL/TANK MANWAY OR MANHOLE MAY NOW BE CLOSED. COMMENT(S) AND ADDITIONAL INFORMATION:





Page 1 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TURBO EXPANDAR & BOOSTER COMPRESSOR PACKAGE

Project No. Project Title Facilities Tag no.

Manufacturer Model No. Serial No.

M50-B

INFORMATION System/Subsystem No. Pressure Rating INSPECTION / TEST

OK

N/A

P/L No

CAUTION: Ensure that equipment including the associated piping, fittings, valves and instrumentation are physically installed, leveled and aligned as required by the appropriate recommendations. All electrical equipment and wiring is completed and the unit is ready to be powered up. A thorough physical inspection with reference to the P&IDs, piping arrangements, wiring diagrams and sub vendor installation manuals would be required for this purpose. General Checks Make a walk-through inspection around the equipment and check for any damages Check the entire compressor skid and ensure all connections 2 are secured and intact 3 Check that all couplings and guards are fitted Check that the compressor vents and drains are complete and 4 spades / spectacle blinds are fitted in the right orientation Verify set-point values for various switches or other 5 instrumentations as per data sheet. Skid and Base Structure 1

1

Check skid weld down/hold down bolts. Check The turbo expander, gearbox and compressor hold down 2 bolts Perform skid levelness and soft foot check as recommended by 3 OEM. Record readings. Check that vibration dampeners (if required) is installed and 4 tightened 5 Check distance piece pre-loading reports 6 Remove any temporary stopper/shipping braces and etc. Turbo Expander/Booster Compressor 1 2 3 4 5

Check Check Check Check Check

suction strainer conditions and set the crosshead feeler gauge clearance that the on-skid piping and supports are adequate that sufficient vents and drains are provided seal vent line properly vented to a safe area

Page 1 of 7

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TURBO EXPANDAR & BOOSTER M50-B COMPRESSOR PACKAGE 6 Check containment seal drain line connected to seal pot 7 Check that the correct breather element is clean 8 Check that the correct torque value has been applied 9 Check rod packing 10 Check the coupling bolts 11 Check the crosshead guide support Check the suction and discharge valve assembly and valve housing for cleanliness and check valve lift. Check that valves 12 are assembled correctly. If valve unloaders are mounted, check correct functioning and sequence If clearance pockets for capacity control are installed, check 13 proper functioning of this device 14 15 16

Verification of expander SDV (quick-closing valve) operation and timing Stroking and Verification of Turbo Expander bypass Valve. Verification of compressor surge control valve operation and timing

Check whether safety devices are properly installed and in accordance with the data sheets and flow diagram. Check that the safety/relief valve is installed and check set pressure Check the proper functioning of all safety devices. Safety 18 devices that cannot be tested when machine is not running should be checked during initial run Electrical system 17

Inspect the wiring for the following conditions; i. Loose connections 1 ii. Wiring that is worn or frayed iii. Inspect the gauge panel and control panel for good condition. Reset any alarm or shut off components Verify that a complete operational test on all control, logic and 2 power circuits have been carried out Instrument/Control System 1 2 3 4 5 6 7 8 9

Verify instrument/control system is complete as per P&IDs. Verify that leak and loop check between local control panel and on-skid instrument have been done Conduct loop check between UCP and skid junction box Check UCP and junction box grounding Conduct function check for UCP Dry test control panel and confirm start up valve opening sequence and timing Carry out trip/fault simulation test for all safeguarding instruments. Verify that electrical check on compressor pre-lube pump motor cable and MCC has been completed Verify the instrumentation set points (control, alarm and fault)

Page 2 of 7

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TURBO EXPANDAR & BOOSTER M50-B COMPRESSOR PACKAGE with site conditions. 10 Verify that stroke test and Modbus check have been completed. Active Magnetic Bearing(AMB) 1 2

Start Up logic testing by simulation 2 Final tuning and calibration of the optional magnetic bearing 3 control systems

Dry Gas Seal System 1

Check that system piping/tubing/instruments and other items are in healthy conditions and fitted in correct position.

2

Verify that the system has been cleaned, flushed and blown with clean dry air.

3

Check that control valve of seal gas system has been function tested.

4

Check seal gas supply and seal gas filter is clean

5

Ensure main seal gas supply and alternate seal gas supply pressure is adequate as per OEM settings. Adjust supply if necessary

Vibration Monitoring System 1


2


3


Skid Piping 1

Check process piping is constructed according to P&IDs.

2

Ensure all lines have been tested and that radiographic examination and stress relief (where applicable) is complete

3

Ensure that the correct specification valve has been installed, greased (if applicable), will easily open and close and sufficient packing is installed so that the packing gland nuts can be further tightened if required

4

Ensure that check valves have been installed in the correct direction and if the internals have been removed for hydro testing or line flushing, they have been reinstalled

5

Ensure that all control valves are installed in the correct direction, are in their fail-safe position and their bypasses are closed

6

Check safety valve installation, locking system tag, sight pop

Page 3 of 7

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TURBO EXPANDAR & BOOSTER COMPRESSOR PACKAGE test certificates to confirm correct setting

M50-B

7

Ensure that all strainers (permanent or temporary) are installed in the correct direction and that the strainer element or basket has been reinstalled in all strainers

8

Check that the correct number of studs and nuts are used on all flanges, that the nuts are all tight and that at least two threads of the studs are showing past the nut

9

Check that the piping is supported as per the drawings and anchors; guides and shoes are correctly installed

10

Check for sufficient clearance between piping to allow for movement and expansion during start up

11

Ensure all blinds and jump overs installed during hydro testing are removed

12

Ensure all vent and drain connections have been unplugged and all hydro test fluid drained out and lines have been blown dry. Replace all vents and drain plugs or caps

13

Ensure all threaded connection on pipe, vessel and instruments are plugged. Observe the plastic temporary shipping caps and covers; remove and replace them with the correct metal plug or cap

14

Check temporary/permanent suction strainer installed in spool

15

Conduct piping leak check

16

Purge the piping system with nitrogen

Instrument Air 1 2 3 4 5 6 7 8 9

Close all instrument isolation valves and purge lines using instrument air to check for instrument air availability Slowly open the instrument air inlet valve and blow out through a vent or available spare nozzle at the other extreme end Close the vent, pressurize and blow out once again The isolation valves may be opened after ensuring that the instrument air lines are free from moisture and dirt All alarm and shutdown functions will be simulated to verify proper operation of the annunciator display

Verification of functionality of the PLC or DCS program Confirmation of all start-up permissives Verification of start-up sequence Verification of all speed, temperature and pressure transmitters Verification of shut-down capabilities via ESD switches and 10 DCS commands. 11 C & E Matrix verification.

Page 4 of 7

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TURBO EXPANDAR & BOOSTER COMPRESSOR PACKAGE Instrument and Actuated Valves

M50-B

1 Stroke all automatic valves (SDV, BDV, PCV, LCV and etc.) 2 Check all instrument isolation valves are opened 3 Check PSU isolation valves are opened Scrubbers 6

Ensure that the internals are properly installed Ensure that the piping and instrumentation is installed as per 1 P&IDs For each suction scrubber vessel, fully open the liquid level controller isolation valves and ensure that the bypass valves are 2 fully closed. Check that the controller is correctly controlling the level for each level 3 Check the manual isolation for scrubber liquid drain is opened 4 Check pulsation bottles supports are loosen for hot alignment Drain 1

For manual drains, ensure all valves are shut For automatic drains with level control valves, ensure that the 2 isolation valves are open Liquid drain lines, including those beyond the skid limits, should 3 be inspected to ascertain that they are open Gas Supply Confirm that there is adequate supply of gas at required suction pressure Nitrogen Purging of the Unit 1

CAUTION: The entire system must be purged to ensure an explosive air/hydrocarbon mix is avoided Ensure nitrogen purging has been carried out for the unit 1 prior to initial start-up, or any invasive maintenance or if unit being left in stand-by mode. Leak Testing Leak testing should be performed on all hydrocarbon 1 containing pipe-work and equipment as part of the installation and pre-commissioning process Starting System 1 2 3

Drain moisture and sediment from the TE & BC casing and from any other piping Check the air pressure before starting Open the air supply valve for the starting motor. COMMENT(S) AND ADDITIONAL INFORMATION:

Page 5 of 7

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TURBO EXPANDAR & BOOSTER COMPRESSOR PACKAGE

Designation Company

Name Signature Date


M50-B



Page 6 of 7

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B RE-INSTATEMENT LEAK TEST Project No. Project Title Facilities Test Package No System no. Sub System Location

1 2 3 4 5 6 7 8 9 10 11 12

P04-B1

INFORMATION Test Pressure Test Medium Test Duration Test Date INSPECTION / TEST

OK

N/ A

P/L No

Flushing and hydrostatic testing have been satisfactorily completed and recorded. Check that drying of lines is complete. Verify that all in line units have been reinstated as per latest P &ID Correct bolts and gaskets are installed at all mechanical joints. Bolts are torqued / tensioned to correct specification. Check all manual valves are in opened position (recommended) and smoothly turned. All temporary spades, bobbins, vents and drains have been removed, and openings closed in accordance with specification. Support Gags are removed where applicable (it may be required to leave some in place for removal offshore). All process blinds, spades, valves and inline equipment have been correctly installed as per P&ID. Check/ ensure that lines are resting firmly/ properly on its support (not floating) Extended spindles and chain wheels for specified valves have been correctly installed. All locking devices and interlocks for specified valves have been correctly installed. Piping, instruments, mechanical equipment and specialty items are reinstated in accordance with the P&ID. Verify the items against pretest list. Verify earthing strap / connection if required. Verify the Base Line Survey for Corrosion Management completed COMMENT(S) AND ADDITIONAL INFORMATION

Page 1 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - A RE-INSTATEMENT LEAK TEST P04-B2 COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C REINSTATEMENT LEAK TEST Project No. Project Title Facilities

P04-C

INFORMATION Test Package No Test Pressure System Test Medium Sub System Test Duration Location Test Date INSPECTION / TEST The Leak Test has been Completed and Accepted as per company 1 Procedure. Leak Test Result :Leak Rate =……… ..Scf/yr 2 Maximum permitted Leak Rate = ………. Scf/yr (Standard cubic feet per year). The completed System has been depressurized and all signs and 3 barriers have been removed. All test equipment has been removed and line re-instated using 4 witness joint procedure. 5 All associated P & IDs have been red lined As-Built. The completed system shall be preserved with Nitrogen (N²) gas at one 6 (1) barg of pressure. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No

CONFIRMED BY Commissioning Engineer PETRONAS Carigali

Page 1 of 1

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B WITNESSED JOINT

P14-B


1 2 3 4 5 6 7 8 9

INFORMATION Isometric Dwg Flanges Tag

INSPECTION / TEST Prior to conducting reinstatement leak test, the following checks will be made: Flange faces examined and seen to be clean and damage free. Gaskets are correct type and size. Nuts and stud bolts examined and seen to be undamaged and correct size and type. Flange faces parallel. Joint pulled up evenly on diametrically opposing stud bolts. All nuts pulled up to required tightness. No visible damage to gasket when joint completed. Minimum allowable of two threads through each nut. No excessive length of stud bolt protruding through each nut. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No

CONFIRMED BY Commissioning Engineer PETRONAS Carigali

Page 1 of 1

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B FLANGES MANAGEMENT

P06-B

Project No. Project Title Facilities INFORMATION Test Package No Test Pressure System no. Test Medium Sub System Test Duration Location Test Date INSPECTION / TEST Verify the check sheet P06-A ( Flanges Alignment) and P09-A (Bolt 1 tensioning/Tourqing) have been completed and approved Correct bolts and gaskets are installed at all flanges joints. Bolts are 2 torqued / tensioned to correct specification and certified

OK

N/A

All the flanges have been tagged, identified in data based ensure that the following items are corrected. 

All of Flanges data: Flange connection number.



Drawing number.



Isometric Line Number.



Sub-system No:



Alignment Check (date and signature).



Cleanliness Check after hydrotest or flushing (date and signature).



Gasket type and rating.



Bolt type, diameter and length.



Brand of lubricant applied.



Used tool (number and type).



Torque value or tensioning pressure (when applicable).



Date of execution.



Name of the operator.

3

Page 1 of 2

P/L No


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B FLANGES MANAGEMENT P06-B COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix II-VII PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SERVICE TEST

P10-B

Project No. Project Title Facilities INFORMATION Test Package No Test/OP Pressure System Test Medium Sub System Test Duration Location Test Date INSPECTION / TEST Verify to ensure that all construction / installation activities have been 1 completed. The Service Test has been Completed and Accepted as per company 2 Procedure. Service Test Result :3 Leak Rate : The completed System has been depressurized and all signs and 4 barriers have been removed. All test equipment has been removed and line re-instated using 5 witness joint procedure. 6 All associated P & IDs have been red lined As-Built.

OK

N/A P/L No

Service Test record the following:

7

Duration 0 Min 15 Min 30 Min 45 Min 60 Min

Op/Tp Press

Temperature

Remark






Page 1 of 1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B LUBE OIL FLUSHING

P15-B

Project No. Project Title Facilities INFORMATION Flushing Flow rate Lube Oil Brand Flushing Duration Flushing Date INSPECTION / TEST Marked up drawing / P&ID attached equipment / bearing bypassed and blinded. Pipe / equipment chemically cleaned / de scaled. Correct type of flushing medium used. Laboratory analysis satisfactory, details attached. Correct cleanliness level as documented. Oil reservoir clean after flushing. New, correct filters installed. System / equipment labeled. System / equipment re-instated. System / equipment blinded off. Record the number and size of particles after the four-hour run. Install fine mesh filter screens at oil inlets to all bearing. Verify removal of filter screens and temporary filters. Preservation carried out and recorded in preservation log. COMMENT(S) AND ADDITIONAL INFORMATION

Test Package No System Sub System Location 1 2 3 4 5 6 7 8 9 10 11 12 13 14




OK

N/A P/L No


Page 1 of 1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B SAFETY SHOWER / EYEWASH Project No. Project Title

Tag no. Area Ref. Drawing nos. 1 2 3 4 5

S02-B

INFORMATION System no. Location

INSPECTION / TEST Ensure A check list and A punch list items completed & no subsequent damage occurred. Check portable eye wash stations are filed with sterilized water. Check water quality (cleanliness) of the shower/ eyewash station (piped). Test the functioning of each shower station. Test the functioning of eye wash stations. COMMENT(S) AND ADDITIONAL INFORMATION:




OK

N/A P/L No

ACCEPTED Commissioning Engineer PCSB

Page 1 of 1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B Project No. Project Title

Tag no.

1 2 3

SURVIVAL EQUIPMENT

S03-B

INFORMATION System/Subsyste m No.

INSPECTION / TEST Ensure A check list and A punch list items completed & no subsequent damage occurred. Conduct thorough visual inspection of survival equipment, checking for damage, deterioration and deficiencies since onshore certification. Confirm that all loose item supplied with the survival equipment is in accordance with the equipment drawing as detailed in the O & M Manual COMMENT(S) AND ADDITIONAL INFORMATION:



OK

N/A P/L No

VERIFIED BY PMT Inspector

ACCEPTED BY Commissioning Engineer

PCSB

PCSB

Page 1 of 1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B FIREWATER/ FOAM SYSTEM Project No. Project Title

Tag no. Area Ref. Drawing nos 1 2

S10-B


INSPECTION / TEST Ensure A check list and A punch list items completed & no subsequent damage occurred. Check location / quantities of firefighting equipment is as per Escape

OK

N/A

P/L No

Route, Fire Fighting, Safety and Life Saving Equipment layout

drawings. FIREWATER PUMP Ref. Specification/ Datasheet No.: 3 Ensure Mechanical ITR-B for Diesel Engine Fire Pump is completed. Name plate/tag details correct & in accordance with approved design 4 data sheet. Manufacturers test certificates & SAT documentation available. FIREWATER RING MAIN Ref. Specification/ Datasheet No.: 5 Ensure Piping ITR B for Firewater Ring Main is completed. 6 Check piping/ ring main for signs of damage. Ensure system flushing is conducted as per flushing procedures. 7 (Ensure gauges liable to be damaged at test pressure and during flushing operations are removed and stored in instrument store). 8 Check flow at drains and any test connections. 9 Complete Certificate of Flushing after performing flushing operation. Conduct hydrostatic testing as per approved project specifications and record details of the hydrostatic test report. Attach copies of: - Isometric sketch showing as built condition, test limits and scope 10 - Test equipment calibration certificates - Certificate of pressure test - Pressure chart and temperature chart - Test report COMMENT(S) AND ADDITIONAL INFORMATION (List the approved specification and datasheet reference number)

Page 1 of 2

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B FIREWATER/ FOAM SYSTEM



S10-B



Page 2 of 2

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B FIRE SUPPRESSION SYSTEM/ TOTAL FLOODING SYSTEM Project No. Project Title

Tag no. Area Ref. Drawing nos

S11-B

INFORMATION System no. Location INSPECTION / TEST

OK

1

Ensure A check list and A punch list items completed & no subsequent damage occurred.

2

Check fire suppression/ total flooding system is connected to the fire panel (including status display).

N/A P/L No






Page 1 of 1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B DECK INTEGRATED FIRE FIGHTING SYSTEM Project No. Project Title


S15-B


INSPECTION / TEST Ensure A check list and A punch list items completed & no subsequent damage occurred. Ensure Fire and Gas Device Loop Test (Instrument ITR I16-B) is completed for DIFFS COMMENT(S) AND ADDITIONAL INFORMATION:




OK

N/A P/L No


Page 1 of 1

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B T03-B

CCTV Project No. Project Title Platform/ Plant name Sys Number

Sys Description GENERAL INFORMATION

OK N/A P/L 1 Confirm that all preservation materials have been removed. 2 Confirm pan function operates correctly. 3 Confirm tilt function operates correctly. 4 Confirm zoom and focus function from as per specification range. 5 Confirm auto iris properly functioning. (if applicable) 6 Confirm variable speed function correct. (if applicable) 7 Confirm pre-set position properly functioning. (if applicable) 8 Confirm wiper / wash unit properly functioning. (if applicable) OTHER OBSERVATION / REMARKS





Page 1 of 1

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B PAGA SYSTEM/ECHO STATION/STROBELIGHT Project No. Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating

1 2 3 4 5 6 7 8 9 1 2

T04-B


DEVICE INSPECTION & TESTING (LOADSPEAKER & STROBELIGHT) Confirm that all preservation materials have been removed Confirm orientation of speakers acceptable. Confirm transformer tap selected as specified. Confirm sound output level acceptable. Confirm sound output acceptable. Confirm beacons / lights operate correctly when energised. Confirm beacons / lights flashing frequency correct. Confirm beacons / lights go off when de-energized. Confirm beacons flashing without any obstruction. DEVICE INSPECTION & TESTING (LOUDSPEAKER & STROBE LIGHT) Confirm that all preservation materials have been removed. Confirm station / ext. number correct against Facility Telephone Directory. Ext. No:_______

OK N/A P/L

OK N/A P/L

Confirm acoustic hood installation requirement.key board correct No:______& connection of the corresponding Confirm dial tone when hand set off the hook. Confirm ring back on dialing other extension. Confirm speech quality and sound level acceptable. 7 Confirm incoming call causes ringing and Flashing Light/Beacon (if applicable). 3 4 5 6

Page 1 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B T04-B PAGA SYSTEM/ECHO STATION/STROBELIGHT Confirm flashing Light / Beacon extinguishes when incoming call is answered (if 8 applicable). 9 Confirm any other features on the phone operate satisfactorily. 10 Confirm audible alert operates satisfactorily. 11 Confirm headset operates satisfactorily. OBSERVATION / REMARKS



Verified by PMT Inspector

Accepted by Commissioning Engineer

PETRONAS Carigali

PETRONAS Carigali

Page 2 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TELEPHONE/LAN PORT VERIFICATION& CABLE TEST Project No. Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating

T05-B

Sys Description INSTRUMENT DATA System Number Manufacturer Location Model Number Area Serial Number Unit Temp. Class Gas Group ACCEPTANCE CRITERIA (ERROR %) OK N/A P/L

1 Confirm correct colour code according to TIA/EIA - 568 B STANDARD 2 Confirm (link) cable is run less than 90 metres in total. Cable testing result. TEST RESULT

PASS

FAIL

Wire Map Test

3

Attenuation NEXT ( Near End Crosstalk) RL (Return Loss) ACR (Attenuation to Crosstalk)

DEVICE INSPECTION & TESTING 1 Confirm that all preservation materials have been removed Confirm station / extension number correct against Facility Telephone Directory. 2 Ext No. 3 Confirm (link) cable is run less than 90 metres in total. 4 Confirm acoustic hood installation requirement. Page 1 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TELEPHONE/LAN PORT VERIFICATION& CABLE TEST 5 Confirm dial tone when hand set off the hook. 6 Confirm ring back on dialing other extension. 7 Confirm speech quality and sound level acceptable 3 4 5 6 7

T05-B

Confirm acoustic hood installation requirement. Confirm dial tone when hand set off the hook. Confirm ring back on dialing other extension. Confirm speech quality and sound level acceptable. Confirm any other features on the phone operate satisfactorily.

8 Confirm any other features on the phone operate satisfactorily. 9 Confirm headset operates satisfactorily. OBSERVATION / REMARKS





Signature Date

Page 2 of 2


TELECOMMUNICATION PANEL Project No. Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating


1 Prove manual operation of isolators, switches, pushbuttons. 2 Confirm local indicators operate correctly and lamps are correctly rated 3 Energise panel supplies and check voltage as per requirement. 4 Energise the cooling fan and confirm the operation of the thermostat. OBSERVATION / REMARKS





PETRONAS Carigali

PETRONAS Carigali

Page 1 of 1


RADIO COMMUNICATION TEST Project No. Project Title Platform/ Plant name Sys Number Tag Number Type Service IP rating EX rating


1 Check the radio frequencies have been set as per specification 2 Ensure correct sequence channel setting. Test simplex/duplex communication between portable to portable/portable to 3 base station Ensure portable/base station able to receive signal with quality signal & clear 4 voice for every channel 5 All the radio features function as per requirement (if applicable). OBSERVATION / REMARKS





PETRONAS Carigali

PETRONAS Carigali

Page 1 of 1


TELECOMS FIBRE OPTIC CABLES TEST Project No. Project Title Platform/ Plant name Sys Number 1 2 3 4 5

Sys Description GENERAL INFORMATION Cable from Cable to Pair /Core & Size Cable type Termination drawing ACCEPTANCE CRITERIA (ERROR %) OK N/A P/L

Perform cable length measurement fiber fracture inspection and construction defect inspection using Optical Time Domain Reflectometer (OTDR). 2 Perform connector integrity test using OTDR. Cable attenuation loss measurement from both ends of cable with optical power 3 loss test set. (if applicable) 1

4 Attached OTDR & power loss test result (if applicable) for reference. REFERENCE DRAWINGS

TEST EQUIPMENT Type

Manufacturer

Model

Serial Number


Page 1 of 2

CSP-20 rev.01 Appendix I-X PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - B TELECOMS FIBRE OPTIC CABLES TEST OBSERVATION / REMARKS




T12-B


Signature Date Page 2 of 2


ENTERTAINMENT SYSTEM Project No. Project Title Platform/ Plant name Sys Number

Sys Description GENERAL INFORMATION

OK N/A P/L 1 Confirm that all preservation materials have been removed. 2 Follow manufacturer's recommendations for system check out. Confirm all visual indicators at master station and remote stations are 3 operational. 4 Confirm all remote volume controls operate satisfactorily. 5 Confirm orientation of speakers acceptable. 6 Confirm transformer tap selected as specified (if applicable). 7 Confirm sound output quality acceptable. 8 Confirm visual output quality acceptable. 9 Full panel test & system functionally will cover under commissioning procedure OTHER OBSERVATION / REMARKS





PETRONAS Carigali

PETRONAS Carigali

Page 1 of 1

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 10.0 APPENDIX III: ITR- C (COMMISSIONING) 10.1

APPENDIX III-I: Architecture (A)- NA

10.2

APPENDIX III-II: Civil (C)- NA

10.3

APPENDIX III-III: Electrical (E)

10.4

APPENDIX III-IV: HVAC (H)

10.5

APPENDIX III-V: Instrumentation (I)

10.6

APPENDIX III-VI: Mechanical (M)

10.7

APPENDIX III-VII: Piping (P)

10.8

APPENDIX III-VIII: Safety (S)

10.9

APPENDIX III-IX: Structural (ST)- NA

10.10

APPENDIX III-X: Telecommunication (T)


CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C GAS TURBINE GENERATOR

E01-C

Project No. Project Title Facilities Tag no. Frequency Manufacturer Model No. Serial No. 1

2

INFORMATION System / Sub System no. Voltage Rating Ref. Drawing nos. Location INSPECTION / TEST OK

N/A

P/L No

Documents required: a) Precom check-sheet and punch list status for turbine, alternator and all related auxiliary systems b) Precom check-sheet for the generator Incoming feeder c) Key single line diagram d) Generator control panel schematic diagram e) Pre-commissioning check sheets for ENMC system f) Start-up/commissioning procedure g) FAT report Carry out IR test on the following circuits. (Test voltage shall be 500V DC for LV (up to 1kV) system and 5kV DC for HV (3.3kV and above) system. Attach report. Description Alternator Stator Winding Space heater circuits

IR (MΩ)

Minimum insulation value shall be 10*(kV+1) MΩ. Compare the results with those obtained during pre-commissioning. Any variation of more than 20% needs to be investigated prior to start-up. IR test on the following circuits shall be conducted after consultation with OEM with regard to test voltage, procedure and acceptable IR values. Description Exciter Stator Winding Diode Bridge Assembly (Short out diodes) Insulated Bearings

IR (MΩ)

Page 1 of 2

CSP-20 rev. 01 Appendix III-III

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C 3 4

5

GAS TURBINE GENERATOR E01-C Perform all functional checks of protection system (electrical and mechanical) including ESD and record results. Start-up the GTG as per start-up procedure / manufacturer instructions and perform load test as per requirements of PTS63.10.08.11. Test results to be attached to this check sheet. Record any defects/shortcomings in the system punch-list.

COMMENT(S) AND ADDITIONAL INFORMATION - This check sheet shall be used as the cover sheet for detailed start-up and commissioning tests conducted on the GTG.





Page 2 of 2

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C MICRO TURBINE GENERATOR Project No. Project Title Facilities Tag no. Frequency Manufacturer Ref. Drawing nos Type

E02-C

INFORMATION System / Sub System no. Location Power Rating Serial no. Voltage INSPECTION / TEST OK

N/A

P/L No

1

Documents required: a) Precom check-sheet and punch list status for MTG and all related auxiliary systems b) Precom check-sheet for the MTG Incoming feeder c) Key single line diagram d) Start-up/commissioning procedure e) FAT report 2 Perform all functional checks of protection system (electrical and mechanical) including ESD and record results 3 Start-up the MTG as per start-up procedure / manufacturer instructions and perform load test as per requirements of PTS63.10.08.11. Test results to be attached to this check sheet. 4 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation 5 surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 6 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION - This check sheet shall be used as the cover sheet for detailed start-up and commissioning tests conducted on the MTG.





Page 1 of 1

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C GAS ENGINE GENERATOR

E03-C

Project No. Project Title Facilities Tag no. Frequency Manufacturer Ref. Drawing nos Type 1

2


N/A

P/L No

Documents required: a) Precom check-sheet and punch list status for engine, alternator and all related auxiliary systems b) Precom check-sheet for the generator Incoming feeder c) Key single line diagram d) Generator control panel schematic diagram e) Pre-commissioning check sheets for ENMC system f) Start-up/commissioning procedure g) FAT report Carry out IR test on the following circuits. (Test voltage shall be 500V DC for LV (up to 1kV) system and 5kV DC for HV (3.3kV and above) system. Attach report. Description Alternator Stator Winding Space heater circuits

IR (MΩ)


IR (MΩ)

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C 3 4

5

GAS ENGINE GENERATOR E03-C Perform all functional checks of protection system (electrical and mechanical) including ESD and record results. Start-up the GEG as per start-up procedure / manufacturer instructions and perform load test as per requirements of PTS63.10.08.11. Test results to be attached to this check sheet. Record any defects/shortcomings in the system punch-list.

Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 7 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION - This check sheet shall be used as the cover sheet for detailed start-up and commissioning tests conducted on the GEG. 6





Page 2 of 2

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C DIESEL ENGINE GENERATOR Project No. Project Title Facilities Tag no. Frequency Manufacturer Ref. Drawing nos. Type

E04-C


1

Documents required: a) Precom check-sheet and punch list status for the engine, alternator and all related auxiliary systems b) Precom check-sheet for the generator Incoming feeder c) Key single line diagram d) Generator control panel schematic diagram e) Pre-commissioning check sheets for ENMC system f) Start-up/commissioning procedure g) FAT report

2

Carry out IR test on the following circuits. (Test voltage shall be 500V DC for LV (up to 1kV) system and 5kV DC for HV (3.3kV and above) system. Attach report. Description Alternator Stator Winding Space heater circuits

N/A

P/L No

IR (MΩ)


IR (MΩ)

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C DIESEL ENGINE GENERATOR E04-C 3 Perform all functional checks of protection system (electrical and mechanical) including ESD and record results. 4 Start-up the DEG as per start-up procedure / manufacturer instructions and perform load test as per requirements of PTS63.10.08.11. Test results to be attached to this check sheet. 5 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation 6 surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 7 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION - This check sheet shall be used as the cover sheet for detailed start-up and commissioning tests conducted on the DEG.





Page 2 of 2

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C SOLAR PANEL

E07-C

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Frequency Location Manufacturer Power Rating Ref. Drawing nos. Serial no. Type Voltage INSPECTION / TEST OK N/A P/L No 1 Documents required for verification. a. Solar panel Datasheet and manufacturer’s operating manual b. Completed and signed-off pre-com check-sheet and punch list status c. FAT report / Routine test report 2 Perform functional test of the solar panel and the charge controller system by simulating the fault conditions. 3 Follow manufacturer instruction and start-up the solar panel system. 4 If the battery is fully discharged, charge the same through a temporary power supply and energize the charge controller. 5 Check the battery status and confirm state of charge is 100%. Perform battery discharge test. (Refer to battery commissioning check-sheet). 6 After completing the discharge test, perform the charging of battery through the solar panel and record the charging current and duration. (Refer to battery commissioning check-sheet). Allow the battery to be charged by the solar panel for 3 days with the load still connected. Record the parameters. Start the test on a morning in order to allow the solar panel deliver the load current. Time

Output Voltage(A)

Load current(A)

Battery Voltage(V)

Battery current(A)

Remarks

0 15 m. 30 m. 1 Hr. 2 Hr. 4 Hr. 8 Hr. 12 Hr. 24 Hr. 36 Hr. 48 Hr. 60 Hr. 72 Hr. Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C SOLAR PANEL E07-C 7 Verify and confirm the correct operation of timers (if applicable) during discharge test and record the operation in remarks column. 8 Verify and confirm correct operation of the battery MCCB at reaching the voltage threshold for low battery voltage. 9 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 10 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 11 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION This check-sheet shall always be used together with the battery commissioning check-sheet.





Page 2 of 2

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C TRANSFORMER (DRY TYPE)

E09-C

Project No. Project Title Facilities Tag no. Rated kVA Frequency Manufacturer Ref. Drawing nos Vector Group Voltage Secondary


1

2

3 4

OK

N/A

P/L No

Documents required: f) Precom check-sheet and punch list status g) Precom check-sheet for the outgoing transformer feeder h) Precom check-sheet for incoming feeder from transformer i) Key single line diagram j) FAT report Perform insulation resistance test. Take insulation resistance measurements from high voltage side to low voltage side, from low voltage side to ground and from high voltage side to ground. Test voltage shall be 500V DC for LV (up to 1kV) system, 2.5kV DC for HV up to 4.2kV system voltage and 5kV DC for HV above 4.2kV of system voltage. Compare the results with the values during precommissioning. With transformer energized at rated voltage record the tap position and secondary open circuit voltage. Simulate trip test on transformer primary and secondary side circuit breakers

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C 5

TRANSFORMER (DRY TYPE) E09-C Perform soak test. Keep the transformer energized at no-load for a minimum of 24 hours. At the end of soak test load the transformer gradually, based on available load. Voltage Time

6 7 8

Pri.

Sec.

Amb.

Temperature Pri. Cable Sec. Cable Winding box box

Tank

Remarks

0 15mnt 30mnt 45mnt 60mnt 2 Hr. 6 Hr. 12 Hr. 24 Hr. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C TRANSFORMER (OIL TYPE) Project No. Project Title Facilities Tag no. Rated kVA Frequency Manufacturer Ref. Drawing nos Vector Group Voltage Secondary 1

2

3 4

E10-C

INFORMATION System / Sub System no. Area Classification Location Insulation class Type Voltage Primary Percentage Impedance INSPECTION / TEST OK

N/A

P/L No

Documents required: a) Precom check-sheet and punch list status b) Precom check-sheet for the outgoing transformer feeder c) Precom check-sheet for incoming feeder from transformer d) Key single line diagram e) FAT report Perform insulation resistance test. Take insulation resistance measurements from high voltage side to low voltage side, from low voltage side to ground and from high voltage side to ground. Test voltage shall be 500V DC for LV (up to 1kV) system, 2.5kV DC for HV up to 4.2kV system voltage and 5kV DC for HV above 4.2kV of system voltage. Compare the results with the values during precommissioning. With transformer energized at rated voltage record the tap position and secondary open circuit voltage. Simulate trip test on transformer primary and secondary side circuit breakers

Page 1 of 2



TRANSFORMER (OIL TYPE) E10-C Perform soak test. Keep the transformer energized at no-load for a minimum of 24 hours. At the end of soak test load the transformer gradually, based on available load. Voltage Time

6 7 8

Pri.

Sec.

Amb.

Temperature Pri. Cable Sec. Cable Winding box box

Tank

Remarks

0 15mnt 30mnt 45mnt 60mnt 2 Hr. 6 Hr. 12 Hr. 24 Hr. Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C HIGH VOLTAGE SWITCHBOARD Project No. Project Title Facilities Tag no. Bus Bar Rating Frequency Short Circuit Rating/time Model / Type Serial no. 1

2 3

4 5

6

E11-C

INFORMATION System / Sub System no. IP Rating Voltage Ref. Drawing Location Manufacturer INSPECTION / TEST OK

N/A

P/L No

Documents required: a) Precom check-sheet and punch list status b) Key single line diagram c) Switchboard single line diagram d) FAT report Verify and confirm switchboard earthing is intact Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes/bus-duct flanges, bushing cracks, corrosion, sign of water ingress / moisture condensation, painting damage etc. Inspect all doors, panels and sections for corrosion, dents, scratches, correct fit and missing hardware. Visually verify the torque markings on the bolted connections. Retorque, if required. Perform contact resistance test (Ductor test) for all bolted connections and attach the test record to this check sheet. Resistances should be in micro-ohms. For identical connections, the measured values shall not differ by more than 20% from each other for different phases in same circuit. Further, the test results to be compared against pre-commissioning test values and any variation more than 20% from pre-commissioning test results shall be investigated. Perform IR test on the switchboard incomer and bus-bar. Test voltage shall be 2.5kV DC for HV up to 4.2kV system voltage and 5kV DC for HV above 4.2kV of system voltage. Test point Insulation Resistance Remarks R-YBE Y-RBE B-RYE Minimum acceptable insulation value shall be 200 MΩ.

Page 1 of 3



HIGH VOLTAGE SWITCHBOARD E11-C Perform Hi-Pot test on the bus-bar with all the circuit breakers (except bus-tie) OPEN and record the leakage current. Test Duration 1 minute Test Voltage (select from table below) Max. Syste Voltage Test Voltage

3.6

7.2

12

17.5

24

36

0

20

8

38

50

70

Leakage current R-YBE Y-RBE

8

10

11 12 13 14

Remarks

Difference in leakage currents shall not differ by more than 20% for different phases in same circuit. Further, the test results to be compared against pre-commissioning test values and any variation of more than 20% from the pre-commissioning test results shall be investigated. Repeat the IR test after hi-pot test and record values. Test point R-YBE Y-RBE B-RYE

9

B-RYE


Remarks

Minimum acceptable insulation value shall be 200 MΩ. Reconnect all electronic equipment after insulation resistance and hipot testing. Re-install PT drawers, fuses and all relays. Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Energize the switchgear as per energisation procedure and record the required values. Attach report to this check-sheet. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C HIGH VOLTAGE SWITCHBOARD E11-C COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C LOW VOLTAGE SWITCHBOARD / MCC E14-C Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Bus Bar Rating IP Rating Frequency Voltage Short Circuit Rating/time Ref. Drawing Model / Type Location Serial no. Manufacturer INSPECTION / TEST OK 1 Documents required: a) Precom check-sheet and punch list status b) Key single line diagram c) Switchboard single line diagram d) FAT report 2 Verify and confirm switchboard earthing is intact. 3 Verify and confirm that there's no mechanical damage. Check especially for damage to terminal boxes/bus-duct flanges, bushing cracks, corrosion, sign of water ingress / moisture condensation, painting damage etc. 4 5

N/A

P/L No

Inspect all doors, panels and sections for corrosion, dents, scratches, correct fit and missing hardware. Visually verify the torque markings on the bolted connections. Retorque, if required. Perform contact resistance test (Ductor test) for all bolted connections and attach the test record to this check sheet. Resistances should be in micro-ohms. For identical connections, the measured values shall not differ by more than 20% from each other for different phases in same circuit. Further, the test results to be compared against pre-commissioning test values and any variation more than 20% from pre-commissioning test results shall be investigated.

Page 1 of 2



7 8

9 10 11 12

LOW VOLTAGE SWITCHBOARD / MCC E14-C Perform IR test on the switchboard incomer and bus-bar. Test voltage shall be 500 V DC Test point Insulation Resistance Remarks R-YBNE Y-RBNE B-RYNE N-RYB Minimum acceptable insulation value shall be 20 MΩ. Compare the IR test values against those of pre-commissioning. Any deviation of more than 20% from pre-commissioning report needs to be investigated. Reconnect all electronic equipment after insulation resistance and. Re-install fuses and all relays. Reconnect all cables, remove any temporary test links installed and put back all the shorting links to design condition at the completion of the pre-commissioning tests. Energize the switchgear as per energisation procedure and record the required values. Attach report to this check-sheet. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 2

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C CAPACITOR BANK AND SERIES REACTOR E26-C Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Model / Type IP Rating Serial no. Manufacturer Location Ref. Drawing nos. INSPECTION / TEST OK 1 Documents required: a) Capacitor Bank and reactor datasheet and GA drawing b) Single line diagram of associated switchgear c) Completed and signed-off pre-commissioning check-sheet for the capacitor bank with punch list status and precommissioning check-sheet of the associated switchgear. d) FAT report 2 Verify the cleanliness of panel internals and confirm the panel is free from dust, dirt, all loose wires, packing material etc. 3 Confirm earthing of the panel is intact. 4 Energize the control circuit and apply load on the switchgear. 5 Verify the operation of APFC relay and step control contactors either by varying the load power factor (if load bank is available) or by adjusting the target power factor (if actual plant load is used). During the test, temperature of the capacitor banks and series reactors to be checked using a thermal scanner or temperature gun. At the end of the test, confirm that the settings are put back to the correct values. 6 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation 7 surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 8 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION




N/A

P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C AC UPS

E28-C

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Amperes Frequency Location Manufacturer Ref. Drawing nos. Serial no. Type Voltage INSPECTION / TEST OK N/A P/L No 1 Documents required for verification. d. UPS Datasheet and manufacturer’s operating manual e. Completed and signed-off pre-com check-sheet for the subject UPS & battery and punch list status f. FAT report / Routine test report 2 Energize the UPS incoming power feed and verify correct AC input voltage. Input voltage ______ Volts 3 Follow manufacturer instruction and start-up the UPS system 4 Perform functional test of the UPS system by simulating loss of incoming supply, static by-pass operation and manual bypass operation. 5 Conduct performance test on UPS for 72 hours at full load and record the parameters.

Time

Load current (A)

Battery current (A)

Voltage (V) Input Output

Frequency (Hz) Input Output

Remarks

0 15 m. 30 m. 1 Hr. 2 Hr. 4 Hr. 8 Hr. 12 Hr. 24 Hr. 36 Hr. 48 Hr. 60 Hr. 72 Hr. During load test check for any abnormal conditions like high noise or high temperature. Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C AC UPS E28-C 6 Check the UPS battery status and confirm state of charge is 100%. Perform battery discharge test. (Refer to battery commissioning checksheet) 7 Verify and confirm the correct operation of timers (if applicable) during discharge test and record the operation in remarks column. 8 Verify and confirm correct operation of the battery MCCB at reaching the voltage thresh hold for low battery voltage. 9 After completing the discharge test, perform the charging of battery and record the charging time and current. (Refer to battery commissioning check-sheet) 10 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 11 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 12 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION This check-sheet shall always be used together with the battery commissioning check-sheet.





Page 2 of 3

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C DC CHARGER

E29-C

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Amperes Frequency Location Manufacturer Ref. Drawing nos. Serial no. Type Voltage INSPECTION / TEST OK N/A 1 Documents required for verification. a. Charger Datasheet and manufacturer’s operating manual b. Completed and signed-off pre-com check-sheet for the subject Charger, battery and punch list status c. FAT report / Routine test report 2 Energize the Charger incoming power feed and verify correct AC input voltage. Input voltage ______ Volts 3 Follow manufacturer instruction and start-up the Charger. 4 Perform functional test of the Charger by simulating loss of incoming supply. 5 Conduct performance test on the charger for 72 hours at full load and record the parameters.

Time

Load current (A)

Battery current (A)


P/L No

Remarks

0 15 m. 30 m. 1 Hr. 2 Hr. 4 Hr. 8 Hr. 12 Hr. 24 Hr. 36 Hr. 48 Hr. 60 Hr. 72 Hr. During load test check for any abnormal conditions like high noise or high temperature. Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C DC CHARGER E29-C 6 Check the battery status and confirm state of charge is 100%. Perform battery discharge test. (Refer to battery commissioning check-sheet) 7 Verify and confirm the correct operation of timers (if applicable) during discharge test and record the operation in remarks column. 8 Verify and confirm correct operation of the battery MCCB at reaching the voltage thresh hold for low battery voltage. 9 After completing the discharge test, perform the charging of battery and record the charging time and current. (Refer to battery commissioning check-sheet) 10 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 11 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 12 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION This check-sheet shall always be used together with the battery commissioning check-sheet.





Page 2 of 3

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRICAL POWER UNIT (EPU) Project No. Project Title Facilities

E30-C

INFORMATION Tag no. System / Sub System no. Amperes Frequency Location Manufacturer Ref. Drawing nos. Serial no. Type Voltage INSPECTION / TEST OK N/A 1 Documents required for verification. a. Charger Datasheet and manufacturer’s operating manual b. Completed and signed-off pre-com check-sheet for the subject Charger and battery and punch list status c. FAT report / Routine test report 2 Energize the Charger incoming power feed and verify correct AC input voltage. Input voltage ______ Volts 3 Follow manufacturer instruction and start-up the Charger. 4 Perform functional test of the Charger by simulating loss of incoming supply. 5 Conduct performance test on the charger for 72 hours at full load and record the parameters.

Time

Load current (A)

Battery current (A)


P/L No

Remarks

0 15 mnt. 30 Mnt. 1 Hr. 2 Hr. 4 Hr. 8 Hr. 12 Hr. 24 Hr. 36 Hr. 48 Hr. 60 Hr. 72 Hr. During load test check for any abnormal conditions like high noise or high temperature. Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRICAL POWER UNIT (EPU) E30-C 6 Check the battery status and confirm state of charge is 100%. Perform battery discharge test. (Refer to battery commissioning check-sheet) 7 Verify and confirm the correct operation of timers (if applicable) during discharge test and record the operation in remarks column. 8 Verify and confirm correct operation of the battery MCCB at reaching the voltage thresh hold for low battery voltage. 9 After completing the discharge test, perform the charging of battery and record the charging time and current. (Refer to battery commissioning check-sheet) 10 Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces 11 are clean. Verify Instruments & its Accessories /Electrical equipment/Panel 12 externally clean. COMMENT(S) AND ADDITIONAL INFORMATION This check-sheet shall always be used together with the battery commissioning check-sheet.





Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C BATTERY

E31-C

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. Ampere Hour Location System Voltage No. of cells Type of Battery Electrolyte Float Voltage Boost Voltage Manufacturer Ref. Drawing INSPECTION / TEST OK 1 Documents required for verification. a. Battery Datasheet and battery rack drawing b. UPS/Charger drawings showing battery connection c. Completed and signed-off pre-commissioning check-sheet for the subject battery and punch list status d. FAT report of battery (if applicable) or charge / discharge test report of prototype. 2 Inspect batteries for physical and mechanical condition. 3 Verify and confirm battery room / enclosure ventilation is working correctly. 4 Inspect for evidence of corrosion at terminal, connections, racks or cabinets. 5 Verify correct electrolyte levels of each cell (not applicable for sealed battery). 6 Energize the UPS/charger and allow the battery to be charged to full capacity. 7 Conduct discharge test of the battery and measure the discharge current and battery voltage. Time

Discharge current

Battery voltage

Battery voltage at end of discharge

N/A

P/L No

Remarks

____________ Volt Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C BATTERY Actual End cell voltage ____________ Volt Remaining capacity at end of discharge _____________% 8

After completing the discharge test, perform the charging (both boost charge-if applicable, and float charge) of battery and record the charging time and current. Time (Min)

9 10 11

E31-C

Charging current (I)

Charging voltage (V)

Capacity (%)

Remarks

Time to recharge up to 80% capacity ______________ Hours Time to recharge up to 100% capacity ______________ Hours Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 3

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C VARIABLE SPEED DRIVE SYSTEM Project No. Project Title Facilities Tag no. Amperes KW/HP Rating Manufacturer Ref. Drawing nos. Voltage 1

2

4 5

INFORMATION System / Sub System no. Frequency Location Overload setting Serial no.

INSPECTION / TEST Documents required for verification. a. VSD Datasheet and manufacturer’s operating manual b. Completed and signed-off pre-com check-sheet for the subject VSD and punch list status c. Pre-commissioning check sheet for associated motor and switchgear feeder d. Pre-commissioning check sheet for associated power and control cables e. FAT report / Routine test report Perform IR test on the power circuits. Test voltage shall be 500V DC for LV (up to 1kV) system, 2.5kV DC for HV up to 4.2kV system voltage and 5kV DC for HV above 4.2kV of system voltage. Minimum resistance shall be 10(kV+1) MΩ-kV is the system voltage. Test point R-YBNE Y-RBNE B-RYNE

3

E35-C


OK

N/A

P/L No

Remarks

Any deviation of more than 20% from pre-commissioning results to be investigated prior to energisation. Energize the VSD incoming power feed and verify correct AC input voltage. Input voltage ______ Volts Follow manufacturer instruction and start-up the VSD. Perform functional test of the VSD by simulating the control and protection functions.

Page 1 of 3



VARIABLE SPEED DRIVE SYSTEM E35-C Carry out load test for a minimum period of 4 hours or until temperature readings stabilizes, subject to process conditions.

Motor starting current Starting Time Maximum speed Normal running speed Minimum speed Coasting /Stopping time Time (Min)

Motor speed (rpm)

Load Current (A)

Temperature (o C) Ambient VSD Motor power Frame Bearing cards

Remarks

0 5 10 20 30 40 50 60 75 90 120 150 180 210 240 Speed shall be set at normal running speed for the first two hours, maximum speed for the next one hour and minimum speed for the last one hour. Some motors may not be able to be run for long duration due to process limitations. In such cases, the available test duration shall be divided into the three speed ranges.

Page 2 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C 7 8 9 10

VARIABLE SPEED DRIVE SYSTEM E35-C Record final VSD parameter settings. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 3 of 3

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C HIGH VOLTAGE MOTOR

E37-C

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. KW Rating EX Rating / IP FLC Insulation Class Frequency Location Voltage Ref. Drawing nos. RPM Serial no. Connection (Y/∆) Manufacturer Fed from (MCC) Time te (For Ex’e’ motors) INSPECTION / TEST OK 1 Documents required for verification. a. Motor Datasheet b. Driven equipment data sheet c. Completed and signed-off pre-com check-sheet for the subject motor and punch list status d. FAT report / Routine test report 2 Perform insulation resistance test of windings including the cables from MCC side. Test voltage shall be 2.5kV DC for voltages up to 4.2kV system and 5kV DC for above 4.2kV system. R-Y 3

R-B

Y-B

R-G

Y-G

N/A

P/L No

B-G

Test and record insulation resistance of space heater, where applicable. Test voltage shall be 500V DC. Insulation resistance __________ MΩ

4

Minimum acceptable value is 10MΩ. Carry out load test for a minimum period of 4 hours or until temperature readings stabilizes, subject to process conditions. Starting current Starting Tie Normal running speed Coasting /Stopping time

Note:Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C HIGH VOLTAGE MOTOR E37-C The load test duration shall be agreed based on process conditions. Some motors may not be able to be run for long due to process limitations (eg. Sump pump motor due to low level) and the tests shall be limited to available process load.

Time (Min)

Load Current (A)

Temperature (o C) Ambient Frame/ Bearing winding DE NDE

Remarks

0 5 10 20 30 40 50 60 75 90 120 150 180 210 240

5 6 7

Record the final setting of thermal overload relay Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 3

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C LOW VOLTAGE MOTOR

E38-C

Project No. Project Title Facilities INFORMATION System / Sub System no. EX Rating / IP Insulation Class Location Ref. Drawing nos. Serial no. Manufacturer Time te (For Ex’e’ motors) INSPECTION / TEST OK Documents required for verification. a. Motor Datasheet b. Driven equipment data sheet c. Completed and signed-off pre-com check-sheet for the subject motor and punch list status d. FAT report / Routine test report

Tag no. KW Rating FLC Frequency Voltage RPM Connection (Y/∆) Fed from (MCC) 1

2

P/L No

Perform insulation resistance test of windings including the cables from MCC side. Test voltage shall be 2.5kV DC for voltages up to 4.2kV system and 5kV DC for above 4.2kV system. R-Y

3

N/A

R-B

Y-B

R-G

Y-G

B-G

Test and record insulation resistance of space heater, where applicable. Test voltage shall be 500V DC. Insulation resistance __________ MΩ

4

Minimum acceptable value is 10MΩ. Carry out load test for a minimum period of 4 hours or until temperature readings stabilizes, subject to process conditions. Starting current Stating Time Normal runnng speed oasting/Stopping time

Note:Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C LOW VOLTAGE MOTOR E38-C The load test duration shall be agreed based on process conditions. Some motors may not be able to be run for long due to process limitations (eg. Sump pump motor due to low level) and the tests shall be limited to available process load.

Time (Min)

Load Current (A)

Temperature (o C) Ambient Frame Bearing DE NDE

Remarks

0 5 10 20 30 40 50 60 75 90 120 150 180 210 240

5 6 7

Record the final setting of thermal overload relay Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION





Page 2 of 3

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRICAL HEATER

E39-C

Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. KW/HP Rating Voltage Amperes Frequency Manufacturer No. of Bundles Ref. Drawing Nos. Model No. Location Serial no. INSPECTION / TEST 1 Documents required for verification. a. Heater Datasheet b. Completed and signed-off pre-com check-sheet for the subject heater and punch list status c. FAT report / Routine test report 2 Perform insulation resistance test at 500 V and record the IR values. Minimum resistance shall be 10MΩ Bundle 1 2 3 4

R-YBE

Y-RBE

B-RYE

OK

N/A

P/L No

Remarks

Compare the values against the results of pre-commissioning and any variation more than 20% shall be investigated prior to energisation. 3

Energize the heater according to manufacturer instructions and energisation procedure and attach the report to this check sheet. Record the load current from the MCC at various loads as dictated by process / mechanical requirements. Flow rate

Temperature setting

Load current

Remarks

Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C 4 5 6

ELECTRICAL HEATER Record any defects/shortcomings in the system punch-list.

E39-C

Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 3

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRICAL HEAT TRACING Project No. Project Title Facilities

E40-C

INFORMATION Tag no. System / Sub System no. Voltage Frequency Oper. Temperature Location Type of Tracer Overload setting Ref. Drawing nos. Distr. Board No. Manufacturer Area Classification INSPECTION / TEST 1 Documents required for verification. a. Isometric drawing of heat traced lines b. Datasheet and distribution drawing c. Completed and signed-off pre-commissioning check-sheet for the subject tracing system and punch list status d. FAT report (if applicable) or routine test reports from manufacturer 2 Confirm warning labels have been fitted on cladding as per manufacturer's recommendations. 3 Confirm continuity of trace heating tape is satisfactory. 4 Carry out IR test on heat tracing circuit including the tracing tape. 5 Confirm rating of each MCB / RCCD against design drawings. 6 Disconnect circuit, close MCB and confirm RCD test button trips MCB. 7 Confirm MCB / ECLB has been tested. 8 Energize the circuit and record the following: Cold tape: Current : ____________ Amp Ambient air temp : ____________ Amp Tape surface temp : ____________ Amp After 24 hours: Current : ____________ Amp Ambient air temp : ____________ Amp Tape surface temp : ____________ Amp

9 10 11 12

OK

N/A

P/L No

Confirm that the individual circuit current and total DB current are within the MCB/MCCB ratings when the cold tapes are switched ON (Inrush current). Confirm surface temperature of heating tape is within design temperature specification. Check all cover and guards are present and no bolts missing. Make safe tape and isolate as appropriate. Record defects/shortcomings, if any, in the system punch-list. Page 1 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C

13 14

ELECTRICAL HEAT TRACING E40-C Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 3

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C IMPRESSED CURRENT CATHODIC PROTECTION E41-C SYSTEM Project No. Project Title Facilities INFORMATION Tag no. System / Sub System no. TR Unit Rating (A) Voltage Location Manufacturer Serial no. Model No. INSPECTION / TEST OK N/A P/L No 1 Documents required: a) Completed and signed-off pre-commissioning check–sheet for the ICCP system and punch list status b) Vendor datasheet and wiring diagram for the ICCP system c) List of protected equipment / structures 2 Commissioning tests of the ICCP system shall be performed by a qualified CP specialist as per the manufacturer recommendation. The test report shall be attached to this check sheet. 3 As a minimum, the instant OFF potential, pipe to soil potential and the rectifier current to achieve the required pipe-soil potential to be measured and recorded. Structure/pipe

4 5 6

Instant-Off potential

Structure-Soil Potential

Rectifier current

Remarks

Record defects/shortcomings, if any, in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION:





Page 1 of 1

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C MOTOR OPERATED VALVE

E42-C

Project No. Project Title Facilities Tag no. Voltage KW/HP Rating Valve size Manufacturer Ref. Drawing nos. 1

2 3 4 5 6 7 8 9

INFORMATION System / Sub System no. Frequency Location Overload setting Serial no.

INSPECTION / TEST Documents required for verification. a. MOV Datasheet b. Completed and signed-off pre-com check-sheet for the subject MOV and punch list status c. FAT report / Routine test report Verify the operation of limit switch. Verify the operation of torque switch. Start Current: ______ Amps Running Current: ______ Amps Total stroke time: ______ Seconds Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. COMMENT(S) AND ADDITIONAL INFORMATION:




OK

N/A

P/L No


Page 1 of 1

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C NORMAL LIGHTING (CIRCUIT / FIXTURES) Project No. Project Title Facilities INFORMATION Area / Location System no. Ref. Drawing nos. Sub System no.

1

2

E43-C

INSPECTION / TEST OK N/A P/L No Documents required for verification. a. Pre-commissioning check sheets for all associated circuits b. Lighting layout drawing c. Lighting calculation / Illumination requirements Using a suitable calibrated lux meter, confirm lighting levels are within requirements stipulated in design documents. Record lighting levels at five points for every location and arrive at the mean illumination. The selected point shall include the location of expected maximum and minimum illumination values.

Location

1 (Ma x)

2

3

4

5 (Mi n)

Mean (Measur ed)

Mean (Requir ed)

Remarks

Compressor Area (Drawing No – XXXXXX)

Locations to be marked in the latest available drawing and attached to this check sheet. 3

Using a clamp-on ammeter record the full load current, of circuit from the distribution board. Circuit No.

4 5 6

Load Current

Remarks

Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C NORMAL LIGHTING (CIRCUIT / FIXTURES) E43-C COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 2

CSP-20 rev. 01 Appendix III-III PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C EMERGENCY LIGHTING (CIRCUIT / FIXTURES) E44-C Project No. Project Title Facilities INFORMATION Area / Location System no. Ref. Drawing nos. Sub System no. INSPECTION / TEST OK N/A P/L No 1 Documents required for verification. a. Pre-commissioning check sheets for all associated circuits b. Lighting layout drawing c. Lighting calculation / Illumination requirements 2 When luminaries emergency batteries are fully charged (see manufacturer's instructions), isolate the main power source. Using a suitable calibrated lux meter, confirm lighting levels are within requirements stipulated in design documents. Record lighting levels at five points for every location and arrive at the mean illumination. The selected point shall include the location of expected maximum and minimum illumination values. Location

1 (Ma x)

2

3

4

5 (Mi n)

Mean (Measur ed)

Mean (Requir ed)

Remarks

Compressor Area (Drawing No – XXXXXX)

Locations to be marked in the latest available drawing and attached to this check sheet. 3

Using a clamp-on ammeter record the full load current, of circuit from the distribution board. Circuit No.

4 5 6 7

Load Current

Remarks

Note the battery back-up time of individual fixtures and confirm the same is as per design requirements. Record any defects/shortcomings in the system punch-list. Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean.

Page 1 of 2


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C EMERGENCY LIGHTING (CIRCUIT / FIXTURES) E44-C COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 2

CSP-20 rev. 01 Appendix III-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C HEATING, VENTILATION AND AIR CONDITIONING H21-C (HVAC) Contract No. Project Title Facilities INFORMATION Tag no. System/Sub-system no. Location RELIABILITY TEST OK Verify that ITR-B is complete and signed off by relevant parties prior to 1 starting any work; ensure that all ancillary equipment are tested and pre-commissioned 2 Ensure that sufficient commissioning spares are available on site Confirm that all functional checks are done and satisfactorily 3 completed 4 Start up first pressurization fan and verify fan rotation is correct Check for any excessive vibration or noise; check motor ampere 5 running amp Check control panel indication, allow the fan to run for at least 30 6 minutes and check fan capacity Start-up second pressurization fan and carry out similar check and test 7 as the first fan Start-up air cooled condensing unit and air handling system and verify 8 that motor rotation is correct 9 Check for any excessive vibration or noise 10 Check refrigeration tubing for any leakage 11 Check and verify air handling fan capacity 12 Check running ampere of all electric motor 13 Start electric duct heater 14 Verify control panel indicating lights 15 Adjust volume damper to achieve air balancing 16 Adjust thermostat to verify temperature control functioning 17 Carry out the 72-hour continuous test run and document all test results 18 Attach the 72- hour vendor’s log and test parameters COMMENT(S) AND ADDITIONAL INFORMATION

N/A

P/L No

Page 1 of 2

CSP-20 rev. 01 Appendix III-IV PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C HEATING, VENTILATION AND AIR CONDITIONING (HVAC)




H21-C


Page 2 of 2

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C PNEUMATIC INSTRUMENT CONTROL PANEL (ICP)/ESD STATION TEST

I08-C

Project No. Project Title GENERAL Platform/ Plant name Sys Description

Sys Number Tag Number Type Service IP rating

INSTRUMENT CONTROL PANEL (ICP) DATA Signal Range Manufacturer Dial/Chart Model Number Range Data Sheet Serial Number EX rating

Pneumatic Supply:  Instr. Air  Instr. Gas

Panel Type:  P

P–E

P: Pneumatic, E: Electronic PRE-COMMISSIONING CHECK Verify I08-B: Pneumatic Instrument Control Panel (ICP)/ESD Station Test Checksheet. Verify the availability of ICP Vendor Commissioning / SAT Procedure Verify the panel pneumatic supply is connected and leak soap tested Verify the panel electric power supply is connected Verify the panel input and output signals are connected Verify the panel and WHCP are ready for commissioning Verify all affected outputs on every individual input signal actuation as per Cause & Effect Verify noMatrix dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Cause & Effect Matrix 2 Panel Schematic Drawings OBSERVATION / REMARKS 1 2 3 4 5 6 7 8 9

OK N/A

P/L NO

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C PNEUMATIC INSTRUMENT CONTROL PANEL (ICP)/ESD STATION TEST




I08-C


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C Instrument Loop Check

I11-C


Facilities GENERAL Platform/ Plant name Sys Number

Sys Description INSTRUMENT DATA Signal Range Dial/Chart Range Data Sheet Line of Equip Valve No Action

Controller Tag Number Initiator Tag Number Service Loop Number Controller Action

Manufacturer Model Number Serial Number Loop Diag No Final Element Tag number OK N/A P/L No

COMMISSIONING CHECK 1

Verify to ensure that all the pre commissioning activities have been completed and all punch list closed as per I11-B

2

Verify each Instrument Equipment is calibrated and confirm the duration of the calibration certificate from vendor are still valid

3

Test and ensure that loop is configured and functioning as per Control Narrative (Controller Action Auto Manual changeover, split range etc.)

4 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 5 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. Note: If functional test of the full loop has been successfully completed during onshore pre-commissioning, loop verification with current injection can be done to complete the loop check for offshore commissioning Type

Manufacturer




I11-C

LOOP TEST INSTRUMENTS INCLUDED IN THIS LOOP CHECK Tag No Tag No Tag No Tag No Tag No Tag No Tag No Tag No Tag No Tag No Tag No Tag No (Note2) ANALOG TRANSMITTER MODEL NO: SERIAL NO: TRANSMITTER TAG NO: LOCAL INSTR.TAG NO PANEL DCS Tag No: (RANGE: ) : INSTR.TAG NO:Reading Input Input(HART) Output Reading Reading 0% Reading 50% 100% DIGITAL SWITCH(Note2) MODEL NO: SERIAL NO: PANEL LOCAL SWITCH/TRIP ALARM TAG VALVE ACTION TAG DCS Tag No: LEVEL OF SHUTDOWN AMPLIFIER TAG NO: NO : NO: SET POINT

READING

ACTION

ALARM

HH H L LL MODEL NO: Controller Tag No: Output 0% 50% 100%

I/P Transducer

ANALOG CONTROLLER SERIAL NO: Valve Valve LIMIT SWITCH Positioner Position

N N N

SE SE SE

DCS


I11-C

FIELDBUS CHECKLIST(Note 1) The FOUNDATION Fieldbus shall be tested using a proven Fieldbus Wiring Monitor that can test the voltage, signal levels and wiring noise. The test shall comply with FOUNDATION™ Fieldbus System Engineering Guidelines (AG-181) SEGMENT MEASUREMENT Voltage Lowest Device Signal Lowest Device Signal Address Lowest Device Signal Date/Time Avg Fieldbus Frequency Noise (940kHz) Peak Fieldbus Frequency Noise (940kHz) Peak Fieldbus Frequency Noise Date/Time Avg Low Frequency Noise (50Hz4kHz)Low Frequency Noise (50HzPeak 4kHz)Low Frequency Noise Peak Date/Time Avg High Frequency Noise (50Hz4kHz)High Frequency Noise (50HzPeak 4kHz)High Frequency Noise Peak Date/Time Shield Short LAS Address Most Recent Add/Drop Address Device Add or Drop Date/Time of Device Add/Drop Number of Active Devices

DATA

DEVICE MEASUREMENTS Device Address Signal Level Added/Dropped

ACCEPTANCE VALUES 9.0V Minimum 150-1200mV N/A N/A 75mV Maximum 75mV Maximum N/A 150mV Maximum 150mV Maximum N/A 150mV Maximum 150mV Maximum N/A No Shorts N/A N/A None Added/Dropped N/A N/A N/A N/A N/A 150-1200mV Not Added/Dropped

Retransmits

0


I11-C REFERENCE DRAWINGS

1 2 3 4 5 6 7 8 9

Control Narrative (if applicable) Shutdown Narrative (if applicable) Hook Up Drawings Logic Diagram Cause & Effect Matrix Diagram Alarm List Panel Drawings Loop Diagram Test Equipment Certificate

10 Calibration Certificate OBSERVATION / REMARKS





PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C MISCELLANEOUS PROCESS ANALYZER TEST

I13-C


Facilities GENERAL Platform/ Plant name Sys Number Tag Number Type Service Area Classification

Sys Description ANALYZER DATA Signal Range Dial/Chart Range Data Sheet


ACCEPTANCE CRITERIA Check the performance requirement from the datasheet of respective analyzers. COMMISSIONING CHECK

OK N/A P/L No

1 Verify the analyzer has been installed as per check sheet I13-A and completed Functional check of the instrument, flow computer, HMI and interface of the host 2 system 3 Visually inspect equipment for any external damage 4 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 5 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. TEST EQUIPMENT/CALIBRATION GAS DATA Type Manufacturer Model Serial Number Calibration Expiry Date


Analyzer Datasheet Vendor SAT procedure Manufacturer Calibration Cert (including Calibration gas) Vendor Drawings

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C MISCELLANEOUS PROCESS ANALYZER TEST OBSERVATION / REMARKS




I13-C


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C FIRE & GAS DEVICE LOOP TEST

I16-C

Project No. Project Title Facilities GENERAL Platform/ Plant name System Number Type of Detector  Heat Tag Number Method of detection Area Protected IP rating

System FIRE & GASDescription DEVICE DATA  Flam  Gas  Breakglass  Smoke  Other (To specify):______________ Signal Range e Manufacturer Classifying Authority

Model Number

EX Protection Data Sheet

Serial Number Loop Drawing

COMMISSIONING CHECK 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3

Verify completeness of pre-commissioning checksheet I16-B Verify no damage to the Fire & Gas device during transportation (offshore) Verify all cables are secured and no damage Verify the Junction Boxes are secured and no damage Verify the correct electric power supply is connected to the Fire and Gas panel Verify all tools/equipment/test kits for the loop test are available Verify local indication/display (if applicable), are correctly activated upon testing of the loop Verify all theindication/display in FGS Panel are correctly activated upon testing of the loop Verify the indication/display in DCS (if applicable) are correctly activated upon testing of the loop Verify the indication/display and actions in Shutdown Systems (if applicable) are correctly activated upon testing of the loop as per cause and effect matrix Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS Loop Drawings FGS Cause & Effect Matrix (if applicable) Vendor Drawings

OK N/A

P/L No






PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C CAUSE AND EFFECT MATRIX (CEM) TESTING AND VERIFICATION Project No. Project Title Facilities GENERAL Platform/ Plant name System Number

I18-C

System Description ACCEPTANCE CRITERIA

Functionality as per approved CEM COMMISSIONING CHECK 1 2 3 4 5 1 2 3 4 5

OK N/A

Verify completion of I18-B Verify CEM is the final approved revision Perform CEM testing and verification as per final approved revision of CEM Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS Instrument Location Plan Instrument Installation Detail Hook Up Drawings Panel Drawings CEM - Process & FGS OBSERVATION / REMARKS





P/L No

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C Well Head Control Panel (WHCP) Test Project No. Project Title Facilities GENERAL Platform/ Plant name Sys Description Sys Number

I20-C

Well Head Control Panel (WHCP) DATA Tag Number Signal Range Manufacturer Dial/Chart Type Model Number Range Service Data Sheet Serial Number IP rating EX rating Pneumatic Supply:  Instr. Air  Instr. Panel Type:  P-H E–H Gas P: Pneumatic, E: Electronic, H:Hydraulic COMMISSIONING CHECK 1 2 3 4 5 6 7 8 9 10 11 12

Verify I20-B: Well Head Control Panel (WHCP) Test Check sheet Verify the availability of WHCP Vendor Commissioning /SAT Procedure Verify the panel pneumatic supply is connected and leak soap tested Verify the panel electric power supply is connected Verify the panel hydraulic reservoir is ready for operation Verify the panel hydraulic accumulator is pre-charged and ready for operation Verify the ICP, control system and shutdown system are ready for WHCP commissioning Run hydraulic pump and adjust the regulator to the required operating pressure and check for leakage Verify individual opening and closing of WV, SSV and SCSSV, time delay and status in the control system Verify individual closing of WV and SSV and the status in the control system due to actuation of flow line Hi-Lo pilot Verify the closing all of WV and SSV due to actuation of push button from control system Verify the closing all of WV and SSV due to actuation of local push button from WHCP

P–E–H

OK N/A

P/L No

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C

13 14 15 1 2

I20-C Well Head Control Panel (WHCP) Test Verify the closing all of WV, SSV and SCSSV due to actuation of ESD push button from WHCP and control room Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS Cause & Effect Matrix WHCP Schematic Drawings OBSERVATION / REMARKS





PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C METERING SKID TEST

I23 - C

Project No. Project Title Facilities INFORMATION Tag Number Type Area Protected

Flow Range


COMMISSIONING CHECK

OK N/A P/L No

1 Verify the skid has been installed as per ITR I23-A and completed. 2 Verify completeness of Pre-commissioning as per ITR I23-B. 3 Verify the availability of Approved Vendor Commissioning / SAT Procedure. Verify that the SAT is carried out as per the approved SAT procedure and check 4 sheets are filled in and signed off. Confirm that validation ITR (by vendor) are duly filled in and signed Off. 6 Verify and confirm that previous punchlist are cleared. 7 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 8 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Location Layout 2 Isometric Drawing 3 Instrument Cable Loading Layout 4 Termination Drawing 5 Pre-commissioning and commissioning procedure 6 Validation ITR OBSERVATION / REMARKS 5





PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C TANK GAUGING SYSTEMS

I26 - C

Project No. Project Title Facilities INFORMATION  Float  Displacer  Other (To specify):_________________

Type of Sensor  Radar  Servo No. of Tank No of JB Gauges Type of Level IP rating Sensor Area Type of Classification Signal Tank Local Interconnect Indication ion (Field to TGS) COMMISSIONING CHECK

Manufacturer Ex protection Type of Temperature Sensor

1 Verify the skid has been installed as per ITR I26-A and completed. 2 Verify completeness of Pre-commissioning as per ITR I26-B. 3 Verify the availability of Approved Vendor Commissioning / SAT Procedure. Verify that the SAT is carried out as per the approved SAT procedure and check 4 sheets are filled in and signed off. 5 Confirm that validation ITR (by vendor) are duly filled in and signed .off 6 Verify and confirm that previous punchlist are cleared. 7 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 8 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 2 3 4 5

Loop Drawings Panel Schematic Drawings Tank Strapping Table P&ID Vendor Drawings OBSERVATION / REMARKS

OK N/A P/L No

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C TANK GAUGING SYSTEMS



I26 - C



PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C MULTIPHASE FLOW METER (MPFM) TEST

I27 - C

Project No. Project Title Facilities INFORMATION Tag Number

Flow Range

Manufacturer

Type

Model Number

Area Protected

Serial Number OK N/A P/L No

COMMISSIONING CHECK 1 Verify completeness of Pre-commissioning as per ITR I26-B. 2 Verify the availability of Vendor Commissioning / SAT Procedure. Verify that the SAT is carried out as per the approved SAT procedure and check 3 sheets are filled in and signed off. Confirm that validation ITR (by vendor) are duly filled in and signed 4 Off. 5 Verify no dust inside Enclosure /Cabinet / Panel and insulation surfaces are clean. 6 Verify Instruments & its Accessories /Electrical equipment/Panel externally clean. REFERENCE DRAWINGS 1 Location Layout 2 Isometric Drawing 3 Instrument Cable Loading Layout 4 Termination Drawing OBSERVATION / REMARKS





CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C Project No. Project Title Facilities

PRESSURE VESSEL

M01-C

GENERAL INFORMATION Tag no. System no./Sub-system No. Make & Model Reference drawing Serial No Location RELIABILITY TEST 1 Verify M01-B is complete and signed off by relevant parties Check/ inspect installation and hook-up of all associated instruments in 2 the system and ensure all shutdown valves are locked closed Ensure that all tie-ins or open flanges are blinded. line –up the whole 3 system Open the isolation valve and introduce medium onto the vessel; 4 pressurize up the vessel according to operating condition on AUTO mode Attach the logging parameters such as gauges & analyzers’ reading. On5 site readings shall be cross-referenced to PNID & DCS for analysis and performance assessment 6 Print copy or snapshots from DCS as proof for acceptance Compile Handover Certificates. As-built drawings (P & ID) and 7 outstanding work list for the system (if any) and issue to Operations for acceptance COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C Project No. Project Title Tag no. 1

2

1

2 3 4 5 6

PEDESTAL CRANE

M08-C

GENERAL INFORMATION System no. /Subsystem No. Location

CRANE Make & Model Serial No. Boom Length Extension Jib Length Maximum Main Block Radius (meter) Minimum Main Block Radius (meter) Main Block Rope Size (millimeter) Main Block Capacity (metric ton) Maximum Auxiliary Block Radius (meter) Minimum Auxiliary Block Radius (meter) Auxiliary Block Rope Size (millimeter) Auxiliary Block Capacity (metric ton) Boom Hoist Rope Size Crane Test Ref/Date POWER PACK ENGINE/MOTOR Make & Model Serial No. Horsepower (KW) Rated Speed, RPM RELIABILITY TEST Documents required: a. Signed off Pre-com check-sheet and accepted punchlist b. Reference Drawing c. Commissioning procedure (No.) d. No load, Static test report and other Test Certificate e. Equipment manual Verify hydraulic hose interconnection between power pack, control station winch, hydraulic actuator and drive gear Pedestal crane function test and load test shall be witnessed by PCSB approved 3rd party Surveyor Perform running test of the combustion engine for minimum of 4 hours Perform no-load test of the motor driven hydraulic pump Perform no-load function test of the crane which include ONLY slewing and luffing

OK

N/A P/L No

Page 2 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C PEDESTAL CRANE

M08-C

Project No. Project Title 7 Carry out other commissioning activities according to vendor’s manual COMMENT(S) AND ADDITIONAL INFORMATION:



VERIFIED BY Commissioning Engineer PCSB

ACCEPTED BY Operation PCSB

Page 3 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C MONORAIL /TROLLEY HOIST M09-C Project No. Project Title GENERAL INFORMATION Tag no. System no./Sub-system No. Manufacturer Location Model Serial No Type: Electric/ Air/ Manual Rated Capacity Test Reference / Date RELIABILITY TEST OK Documents required: a. Signed off Pre-com check-sheet and accepted punchlist b. Reference Drawing 1 c. Commissioning procedure (No.) d. Static test report and other test certificate e. Equipment manual Ensure that no obstacles, i.e. piping, scaffolding or any other local 2 operations which will impede Monorail/Trolley hoist test operations Demonstrate lifting and travelling of the hoist & trolley per 3 requirement; test overhead cut off 4 Test limit switches functioning at least 3 times 5 Carry out test at 125% rate load and issue certificate of fitness 6 With the proof load, travel the trolley across the entire monorail 7 For electric motor driven, bump test to confirm rotation COMMENT(S) AND ADDITIONAL INFORMATION:



Verified by Commissioning Engineer PCSB

N/A P/L No

Accepted by Operation PCSB

Page 1 of 1

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C Project No. Project Title

GANTRY/BRIDGE CRANE

Tag no. Manufacturer Model Serial No. Type: Electric/ Air/ Manual Gantry Span Lifting Capacity Test reference/ Date Trolley details

M10-C

GENERAL INFORMATION System no./Sub-system No. Location

RELIABILITY TEST

Documents required: a. Signed off Pre-com check-sheet and accepted punchlist 1 b. Reference Drawing c. Commissioning procedure (No.) d. Static test report and other test certificate Ensure that no obstacles, i.e. piping, scaffolding or any other local 2 operations which will impede Gantry/Bridge Crane test operations. Lower block and lift block without load and test at least three times the 3 overhoist cut off switch function Move trolley to and fro the entire gantry and test at least three times 4 the limit switches at hook end 5 Lift rated load and test break capacity, check lifting speed 6 Move the load around and ensure operation is smooth 7 THIRD PARTY –WITNESSED LOAD TEST 7.1 Perform test at 125 % rated load (load at mid-span of gantry) and issue certificate of fitness COMMENT(S) AND ADDITIONAL INFORMATION:



Verified by Commissioning Engineer PCSB

OK

N/A P/L No

Accepted by Operation PCSB

Page 1 of 1

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C FLARES/FLARE TIPS Project No.: Project Description: P&ID No. Tag no. 1

2

3

1

M11-C

GENERAL INFORMATION System no./Subsystem no. Location

COMPLETE PACKAGE Make & Model Serial No Capacity Unit Test Ref/Date DRIVER Make & Model Serial No. Capacity HP (KW) Rated Speed Voltage/Current V-belt spec/Coupling DRIVEN Make & Model Serial No Capacity HP (KW) RELIABILITY TEST Documents required: a. Signed off Pre-commissioning Check-sheet b. Accepted Punch list c. Ignition System FAT reports d. Relevant test report e. Commissioning and Start-up procedure (No. XXXX) f. Operation & Maintenance Procedures (No. XXXX)

OK

N/A

P/L No

PRE-INITIAL START-UP CHECKS 2 3

4

5 6 7

Confirm that all Commissioning spares and operating spares are available. Check that the preservation records have been maintained and preservation removed wherever required. Carry out final inspection, verify / check that the precommissioning checks are complete as per pre-commissioning check sheet and ensure no critical punch list items. Check flare tip has been installed to manufacturer's instructions. Check flare tip is installed to relevant PIDs/vendor specification. Check flare tip to flare pipe valve bolted up to spec. w/correct size

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C FLARES/FLARE TIPS Project No.: Project Description: of bolt & torque value) 8 9 10 11 12 13 14 15 16 17 18

M11-C

Check wind shield is correctly oriented to drawings and spec. Check flare pilot assembly is complete supply system. Check pilot gas and ignition pipework flushed and dried. Check access for flare tip removal is adequate. Check flare tip for damage. Check provision has been made for fitting flare tip removal equipment. Check painting and corrosion protection. Check welding & post weld heat treating. Check flame front generation system ignition is provided. Check air seal assemblies, as per designed. Check piping, valve, instrument gauges as per specification TESTING

19

Test igniter as per vendor data & specification.

Carry out commissioning as per vendors commissioning and startup procedure COMMENT(S) AND ADDITIONAL INFORMATION: 20



VERIFIED BY Commissioning Engineer

ACCEPTED BY Operation

Page 2 of 2


LIFEBOAT AND DAVIT

Tag no. 1 WINCH MOTOR Make & Model Serial No. HP (KW) Rated Speed (RPM) Voltage /Amp 2 WINCH GEARBOX Make & Model Type/Gear ratio 3 LIFE BOAT Make & Model Capacity SOLAS Standard Unit Test Ref/Date 4 DIESEL ENGINE Make & Model Serial No HP (KW) Rated Speed (RPM)

M12-C

INFORMATION System no./Sub-system No.

RELIABILITY TEST

Documents required: a. Signed off Pre-commissioning check-sheet 1 b. Accepted punch-list c. Relevant Certificate, i.e., load test & other test certificate d. Critical Procedure 2 Launch life boat offshore and test run the boat for one (1) hour 3 Check function of spraying system and other features 4 Recover boat after testing; check boat engine and refuel COMMENT(S) AND ADDITIONAL INFORMATION:

OK

N/A P/L No

Page 1 of 2



LIFEBOAT AND DAVIT


M12-C



Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C MIXERS AND AGITATORS M14-C Project No. Project Title GENERAL INFORMATION Tag no. System no./ Sub-system No. 1 MIXER/AGITATOR Make & Model Serial No. Body Material Propeller Diameter 2 ELECTRIC MOTOR Make & Model Serial No. HP (KW) Rated Speed, RPM Voltage/Ampere 3 GEARBOX Make & Model Serial No Type/ Gear Ratio Type of Lube Oil/Qty RELIABILITY TEST OK Documents required: a. Signed off Pre-com check-sheets and punchlist status 1 b. Reference drawings c. Commissioning and Start-up procedure (No.) d. FAT report 2 Ensure Start-up spares are available 3 Start-up the unit as per vendor recommended procedure 4 Check motor running ampere 5 Check for any excessive vibration & noise 6 Observe liquid mixing action and see if it is satisfactory 7 Perform the required run if designed for continuous operation 8 Record or log operating parameters COMMENT(S) AND ADDITIONAL INFORMATION:

N/A P/L No

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C MIXERS AND AGITATORS Project No. Project Title



M14-C



Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRO-CHLORINATION UNIT M15-C Project No. Project Title GENERAL INFORMATION Tag no. System no./ Sub-system No. 1 COMPLETE PACKAGE Location Make & Model 4 ELECTROLYSER/ RECTIFIER Serial No Make & Model Capacity Serial No. Unit Test Ref/Date Output Capacity, cm/h 2 AIR BLOWER Flowrate, liters/hr Make & Model Instrument Air Press Serial No. Instrument Air Temp Motor Make & 5 TRANSFORMER/ Model RECTIFIER Motor HP (KW) Load Motor Speed, RPM DC Output Voltage Voltage/Current V-belt Spec 3 CHLORINE DOSING PUMP Make & Model Serial No. Capacity, CFM Motor Make & Model Motor HP (KW) Motor Speed, RPM Voltage/Current V-belt spec/Coupling RELIABILITY TEST OK Documents required: a. Signed off Pre-com check-sheets and punchlist status 1 b. Reference drawings c. Commissioning and Start-up procedure (No.) d. FAT report 2 Ensure availability of critical commissioning and start-up spares 3 Verify that Initial Start-up is carried out as follows: 2.1 Bump fan motor to verify correct rotation

N/A

P/L No

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRO-CHLORINATION UNIT M15-C Project No. Project Title 2.2 Bump chlorine pump to ensure correct rotation 2.3 Prepare valve positions as per vendor instructions 2.4 Introduce seawater and allow it to flush through the systems for at least ten minutes 2.5 Normalize power supply and check panel indicating lights 2.6 Start the package following vendor’s instruction 2.7 Monitor for excessive noise and or vibration 2.8 Test manual shutdown features by ramping down the current slowly to zero 2.9 Allow five minutes delay for the duty fan to stop and remove hydrogen collected in the tank 4 Perform the required test run duration, say 24 hour Record operating data every 2 hour intervals; record: a. Current b. Load 5 c. Temperature d. Dosing rate e. Voltage COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C SANITARY TREATMENT UNIT M16-C Project No.: Project Description: GENERAL INFORMATION P&ID No. Tag no. System no./Subsystem no. 1 COMPLETE PACKAGE Location Make & Model Serial No Capacity Unit Test Ref/Date 2 DRIVER Make & Model Serial No. Capacity HP (KW) Rated Speed Voltage/Current V-belt spec/Coupling 3 DRIVEN Make & Model Serial No Capacity HP (KW) 4 INTERMEDIATE Make & Model Serial No Gear Ratio HP (KW) RELIABILITY TEST OK Documents required: a. Signed off Pre-commissioning Check-sheet b. Accepted Punch list 1 c. FAT reports d. Commissioning and Start-up procedure (No. XXXX) e. Operation & Maintenance Procedures (No. XXXX) Verify equipment release note signed and all vendor and 2 equipment receipt punch-list items are cleared. Confirm that all Commissioning spares and operating spares are 3 available. 4 Ensure all preservation has been removed wherever applicable 5 Ensure that Electrical system Energized and tested Ensure all vendor data books, installation, operating, and 6 maintenance manual are available. Confirm all operating and / or safety instruction tags / labels are 7 attached. 8 Commissioning the system as per Vendor Instruction

N/A

P/L No


Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C SANITARY TREATMENT UNIT Project No.: Project Description:



M16-C



Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C GAS DEHYDRATION UNIT Project No. Project Title

M17-C

GENERAL INFORMATION System no. /Sub-system No. Location

Tag no. 1 MOTOR Make & Model Serial No. HP (KW) Rated Speed Voltage/Current Factory Test Ref/ Date 2 GEARBOX OR DRIVE BELT Make & Model Serial No Type/ Gear Ratio Lubricant type/ Quantity Belt Size/ Length Factory Test Ref/ Date 3 PUMP Make & Model Serial No Lubricant type/ Quantity Factory Test Ref/ Date RELIABILITY TEST Documents required: a. Signed off Pre-commissioning Check-sheet b. Accepted Punchlist 1 c. FAT report d. Relevant test report e. Commissioning and Start-up procedure (No.) 2 Ensure availability of critical commissioning and start-up spares Ensure the following:-

OK

N/A P/L No

Gassing of the Glycol Dehydration system up to Inlet MOVs on the Gas Metering Skid is done together with the gassing up of the Gas compression system. ii. Glycol Regeneration System has been started and is operating independently (isolated from the Glycol Contactor) and ready to feed lean TEG to the Glycol Contactor i.

3

Page 1 of 4

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C GAS DEHYDRATION UNIT M17-C Project No. Project Title Ensure that all the instruments have been taken on line prior to or 4 during gassing up. 5 6 7

Ensure Moisture Analyser has been calibrated and is ready to be taken on line Ensure valve positions are as per the Valve Status Checklist Ensure that pressurization of the Gas Dehydration system has been achieved. TEG to the Glycol Contactor will be introduced after Compressor Train has been started.

8

Ensure that Gas compressor Train has been started and has reached its minimum governable speed (Verify with Vendor Data) and the pressure at Glycol Contactor is stabilized at the discharge pressure of the Compressor Train (as per design operating conditions).

9

Where possible, set LIC at the Glycol Contactor glycol section to ‘AUTO’

10

Confirm that TDIC is set at 5.5°C and that TIA (outlet line of Glycol Cooler) is indicating approximately 5°C higher than TI (gas outlet from Glycol Contactor). Open Shutdown Valve (SDV) on glycol inlet to the Glycol Contactor

11

Flow of TEG now starts to the Glycol Contactor. Ensure TEG levels are made-up and balanced accordingly in Glycol regeneration system.

12

Keep an inventory of glycol make up in the Glycol Surge Vessel V from the time SDV is opened

13

Ensure TEG flow at FIA is stabilized as per OPM.

14

Ensure that indication light for FIAL as ’OFF’ at the PMCS.

15

Ensure that LZALL indication light has ‘OFF’ at PMCS when TEG level is higher than normal.

16

As soon as TEG reaches normal level visible, line-up rich TEG outlet from Glycol Contactor to the Glycol Regeneration System.

17

When level of TEG crosses 50%, ensures that LIC/LCV functions properly and controls the level at this value. Refer to Glycol Regeneration System Section to complete glycol regeneration start-up. TEG, which has now picked up moisture from the gas (known as rich Page 2 of 4

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C GAS DEHYDRATION UNIT Project No. Project Title TEG), will start flowing to the Glycol Regeneration system. 18

M17-C

Ensure the temperature of TEG supply to Glycol Contactor is 5.5°C above the gas inlet temperature to the Glycol contactor. Notes:

19

20

a. Flow of Glycol to Glycol Contactor remains the same from Turn down to design flow of the gas through the Glycol Contactor. b. During startup, forward flow to Gas Metering and Export is established after stabilizing the conditions at Glycol Contactor and after gas has been dried to its dry gas. c. Gas flow to Fuel gas system from the Glycol Contactor gas outlet is, however, lined up after gassing up. Take Moisture Analyzer) on line (refer to vendor’s operating manual for the Moisture Analyzer). Confirm that moisture in the gas is as per specifications. This can be cross-checked by separately analyzing a sample in the laboratory and comparing it with the local indicator.

21

Further pressurization of Gas metering Skid can now be started.

22

Gas, after start up of the Metering system, shall be transported to the export pipeline via the combined Condensate and Gas Export Header.

23

The system is ready to send dry gas for the Fuel Gas system

24

The system is ready to export dry gas after the gas Metering system has been started up

25

Carry out the 72 hour test run and measure critical parameters including motor amps, bearing temperature and vibration readings for glycol pumps

26

Attach vendor’s commissioning log and test parameters to this checksheet


Page 3 of 4

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C GAS DEHYDRATION UNIT Project No. Project Title



M17-C



Page 4 of 4


SUBMERSIBLE PUMP

Tag no. 1 PUMP Make & Model Serial No Rated Discharge Head Design Flow Rate Design Pump Elevation Liquid Specific Gravity 2 MOTOR Make & Model Serial No Horsepower (KW) Rated Speed, RPM Voltage /Rated Amp

M18-C

INFORMATION System No./Sub-system No. Location

RELIABILITY TEST

1

2 3 4

5

Documents required: a) Signed off Pre-com check-sheet and punch list status for motor, pump and all related auxiliary system b) Reference drawings c) Commissioning & Start-up procedure (No.) d) FAT report e) No load test report Verify that initial Start-up & Test run has been carried out according to Operation Procedure and Manual (OPM) and vendor’s instruction Carry out the 72 hours continuous endurance test run Observe for any abnormalities (high noise, high ampere, etc.)

OK

N/A P/L No

Measure and record operating data in Commissioning Log Sheet every 2 hours interval: a. Pump flow rate b. Discharge pressure c. Motor starting and running ampere d. Motor supply voltage, frequency, ampere, speed

Page 1 of 2



SUBMERSIBLE PUMP

M18-C





Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRIC MOTOR DRIVEN PUMP (PISTON DISPLACEMENT) M19-C Project No. Project Title GENERAL INFORMATION Tag no. System no./Sub- system No. 1 PUMP Location Make & Model Reference drawing Serial No. Type 4 FLEXIBLE DRIVE COUPLING/ BELT Max Operating Press Make & Model Capacity Serial No. Lubricant Type/Qty Belt Size Factory Test Ref/Date 2 PRIME MOVER Make & Model Serial No. Horsepower (KW) Rated Speed RPM Power / Air Supply Press 3 GEARBOX Make & Model Serial No. Type/Gear Ratio Lubricant Type/Qty RELIABILITY TEST OK N/A P/L No Documents required: a) Signed off Pre-com check-sheet and punch list status 1 b) Commissioning & Start-up procedure (No.) c) FAT report d) No load test report 2 Ensure availability of critical commissioning and start-up spares 3 Start-up of pump train in accordance with OEM’s instruction Check for any abnormal noise, high motor temperature, low pump 4 discharge pressure, high vibration: stop the unit as necessary 5 Carry out the 72-hr test run During the Endurance test (72-hr), measure and record operating data in Commissioning Log Sheet every 2 hours interval: 6 a. Pump flow rate b. Suction and discharge pressure c. Motor and pump vibration Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRIC MOTOR DRIVEN PUMP (PISTON DISPLACEMENT) Project No. Project Title d. Motor starting and running ampere e. Motor supply voltage, frequency, speed f. Temperature at pump and motor bearings 7 Check for any leaks in pump bearing lubrication; rectified if required 8 Bleed off air pocket trapped in suction or discharge line (if necessary) 9 Record lube oil differential pressure (if available) 10 Record suction and discharge dampener pressure 11 Observe suction and discharge piping vibration 12 Record pump speed 13 Confirm results are in accordance with manufacturer's specifications.

M19-C






Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRIC MOTOR DRIVEN AIR COMPRESSOR M20-C Project No. Project Title GENERAL INFORMATION TAG NO SYSTEM NO/ Sub-system No 1 COMPRESSOR Reference drawing Make & Model Location Serial No Max Operating Press Capacity 2 MOTOR Make and Model Horsepower (KW) Voltage/Current 3 FLEXIBLE COUPLING Make & Model Serial No RELIABILITY TEST OK Documents required: a. Signed off Pre-com check-sheet and punch list status for motor, 1 compressor and all related auxiliary system b. Commissioning & Start-up procedure (No.) c. FAT report 2 Ensure critical commissioning/start-up spares are available Provide assistance to the start-up of instrument air compressor train in 3 accordance with vendor instruction Check for any abnormal noise, excessive lube oil leak and high 4 vibration; stop the unit if required 5 Check and record air filter differential pressure 6 Record motor ampere Carry out the 72-hr continuous endurance test run and record the following at 2 hour interval: a. Motor DE & NDE bearing casing vibration level b. Compressor DE & NDE bearing casing vibration level c. Motor DE & NDE bearing casing temperature reading 7 d. Compressor DE & NDE bearing casing temperature reading e. Lube oil inlet and outlet pressure plus differential pressure f. Discharge Pressure (loading) g. Ambient temperature (deg C) h. Discharge flow

N/A P/L No

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRIC MOTOR DRIVEN AIR COMPRESSOR M20-C Project No. Project Title 8 Confirm results if in accordance with manufacturer recommendation COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C DIESEL/GAS ENGINE GENERATOR M21-C Project No. Project Title GENERAL INFORMATION Tag no. System no./Sub-system No. 1 DIESEL/GAS ENGINE Location Make & Model Serial No HP (KW) Rated Speed Factory test ref/Date 2 GENERATOR Make & Model Serial No Rating Voltage/ Amp Factory test ref/Date 3 GOVERNOR Make & Model Serial No Supply Voltage Overspeed Setting RELIABILITY TEST OK Documents required: a) Signed Pre-com check-sheet and punchlist for the engine, alternator/Generator and all related auxiliary systems 1 b) Reference drawing c) Commissioning and Start-up procedure (No.) d) FAT report e) No load test report Ensure critical Commissioning & Start-up spares are available prior to 2 DEG Start-up Start-up the DEG as per Start-up procedure and manufacturer’s 3 instruction Check for any abnormal noise, lube oil /water leakage and high 4 vibration; stop the unit when required Carry out the 72-hr endurance run at maximum platform load and record the following parameters on regular interval. i.e., every 2 hours 5 for diesel and one and half hour for gas engine a. Engine Lube oil pressure b. Engine Lube oil differential pressure

N/A P/L No

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C DIESEL/GAS ENGINE GENERATOR M21-C Project No. Project Title c. Engine and Alternator/Generator Casing vibration d. Engine Fuel pressure e. Engine Exhaust temperatures f. Engine Right and Left bank Cylinders temperatures g. Generator/ Alternator load h. Alternator/Generator Voltage, Frequency & Ampere i. Alternator/Generator bearing temperatures 6 Record other critical parameters listed in OEM procedure 7 Confirm results if in accordance with manufacturer’s specification COMMENT(S) AND ADDITIONAL INFORMATION:




ACCEPTED BY Operations PCSB

Page 2 of 2


Gas Turbine Generator

Tag no. 1 GAS GENERATOR Make & Model Serial No. HP (KW) Operating Speed Type of Lube Oil/ Qty Factory test ref/Date 2 TURBINE Make & Model Serial No HP (KW) Operating Speed Type of Lube Oil/ Qty Factory test ref/Date 3 GEARBOX Make & Model Serial No Type /Gear Ratio Type of Lube Oil/Qty 4 DRIVE COUPLING Make & Model Serial No

1

2 3 4

M22-C

INFORMATION System no. /Sub-system No. Location 5 GENERATOR Make & Model Serial No Rating Volt Rating Amp Factory test ref /Date 6 TURBINE CONTROL Make & Model Serial No Supply Voltage Overspeed Setting

RELIABILITY TEST

Documents required: a. Signed off Pre-com check-sheet and accepted punchlist for gas turbine generator train and all ancillary system b. Reference Drawing c. Start-up and Commissioning procedure (No.) d. FAT report / String test report e. No load test report f. Lube oil test report Ensure availability of Start-up & Commissioning spares Perform final line walk to ensure system is safe and ready to run with manual valves lined-up per P&ID GAS TURBINE:

OK

N/A P/L No

Page 1 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C Gas Turbine Generator

M22-C

Project No. Project Title a. Perform Lube Oil system check b. Check Quality of fuel, i.e. dryness & cleanliness c. Verify if pressurized air supply is able to provide sufficient pressure for gas turbine operation d. Alignment of driver to driven equipment is acceptable e. Verify that Fire & Gas system is healthy f. Check that all unit permissive indicates readiness for start-up Push the “Start” button to begin the automated start-up Ensure the following sequence is followed: a. The lube oil pump starts and run for a period of time according to OEM specification b. The enclosure vent system starts c. The enclosure vent system will purge the enclosure for period of time d. The seal gas system starts e. Starter system starts and warms up based on ambient temperature f. Rotation of starter commences g. Engine driven lube oil pump starts h. Starter system reaches a certain NGP, GG is purged for a period of time i. At the end of GG purge, GG igniters are energized and fuel valves open j. Starter system stops k. Power turbine starts rotating at breakaway speed and increases in speed Check that GG and Generator oil temperatures and pressure during 5 warm up and start-up period falls within normal starting limits Check that GG temperatures and vibrations are within normal starting 6 limits When PT speed reaches 100%, driven equipment is made ready for 7 endurance test Record the following Gas Turbine parameters during endurance test: a. GP/GG speed b. PT speed 8 c. Fuel pressure d. Pcd/Cdp e. T5 temperature

Page 2 of 3


9 10

11

12

13

Gas Turbine Generator

M22-C

f. Lube oil temperature g. Bearings temperature h. Bearing Vibration level Conduct manual shutdown; ensure that post lube oil cycle commences Once post lube oil cycle is complete, check commissioning strainers for the presence of any sediments/ particles GENERATOR: Test the following function:a. Manual shutdown b. Manual synchronization c. Parallel operation d. Auto start-up and synchronization 11.1 Check and confirm status of indication lights 11.2 Test load sharing of generators 11.3 Check and confirm Distributed Control System signals are correct On 72 hours continuous test run; record the following at generator maximum platform operating load: a. Generator bearings temperature b. Generator bearings vibration level c. Generator load d. Generator bearing lube oil temperature e. Other critical operating data Confirm results if acceptable and within Vendor’s specification






Page 3 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C TURBINE DRIVEN CENTRIFUGAL COMPRESSOR M23-C Project No. Project Title GENERAL INFORMATION TAG NO. SYSTEM NO. /Sub-system No. 1 GAS GENERATOR Reference Drawing Make & Model Location Serial No 7 TURBINE LUBE OIL SYSTEM HP (KW) Pump Make & Model Operating Speed Serial No. Type of lube oil/Qty Capacity (Liters/min) Factory test ref/Date Motor Make & Model 2 POWER TURBINE Serial No. Make & Model Motor HP Serial No Speed (RPM) HP (KW) 8 COMPRESSOR & GEARBOX LO SYSTEM Operating RPM Pump Make & Model Type of lube oil/Qty Serial No Factory test ref/Date Capacity 3 GEARBOX Motor Make & Model Make & Model Serial No Serial No Motor HP (KW) & RPM Operating RPM Type of Lube Oil/Qty Factory test ref/Date 4 COMPRESSOR Stage 1 Stage 2 Stage 3 Make & Model Capacity Type of Lube Oil/Qty Serial No No of Impellers Suction Press Discharge Press HP (KW) Factory test ref/Date 5 COUPLING Turbine- Gearbox Compressor-Compressor Gearbox -Comp Make & Model Serial No Page 1 of 5

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C TURBINE DRIVEN CENTRIFUGAL COMPRESSOR M23-C Project No. Project Title 6 TURBINE/ CONTROL MODULE Make & Model Serial No Supply Volt Overspeed Setting RELIABILITY TEST OK Documents required: a. Signed off Pre-com check-sheet and accepted punchlist for turbine compressor train and all ancillary system 1 b. Start-up and Commissioning procedure (No.) c. FAT report/String test d. No load test report e. Lube oil test report 2 Ensure Start-up spares are available Perform final line walk to ensure system is safe and ready to run with 3 manual valves lined-up per P&ID GAS TURBINE: a. Perform Lube Oil system check b. Check Quality of fuel, i.e. dryness & cleanliness c. Verify if pressurized air supply is able to provide sufficient pressure for gas turbine operation d. Alignment of driver to driven equipment is acceptable e. Verify that Fire & Gas system is healthy f. Check that all unit permissive indicates readiness for start-up Push the “Start” button to begin the automated start-up Ensure the following sequence is followed: a. The lube oil pump starts and run for a period of time according 4 to OEM specification b. The enclosure vent system starts c. The enclosure vent system will purge the enclosure for period of time d. The seal gas system starts e. Starter system starts and warms up based on ambient temperature f. Rotation of starter commences g. Engine driven lube oil pump starts h. Starter system reaches a certain NGP, GG is purged for a period of time

N/A P/L No

Page 2 of 5

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C TURBINE DRIVEN CENTRIFUGAL COMPRESSOR M23-C Project No. Project Title i. At the end of GG purge, GG igniters are energized and fuel valves open j. Starter system stops k. Power turbine starts rotating at breakaway speed and increases in speed Check that GG and Compressor oil temperatures and pressure during 5 warm up and start-up period falls within normal starting limits Check that GG temperatures and vibrations are within normal starting 6 limits When PT speed reaches 100%, driven equipment is made ready for 7 endurance test Record the following Gas Turbine parameters during endurance test: a. GP/GG speed b. PT speed c. Fuel pressure 8 d. Pcd/Cdp e. T5 temperature f. Lube oil temperature g. Bearings temperature h. Bearing Vibration level COMPRESSOR: During compressor is on operation, observe and record the following: a. Compressor lube oil temperature and pressure b. Gearbox lube oil temperature and pressure c. Compressor bearing temperature and pressure d. Gearbox bearing temperature and pressure e. Compressor inlet & outlet pressure and temperature f. Vibration level at 9  Compressor DE & NDE plus gap voltage  Gearbox DE & NDE plus gap voltage  Process piping g. Seal gas pressure & flow

10 11

Compare recorded data with normal or design values; determine cause and rectify if values deviates Check for any leakage and abnormal noise Perform emergency shutdown test as follows: a. Confirm that ESD button is functional b. All BDV and SDV in compression system reacts as per design Page 3 of 5

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C TURBINE DRIVEN CENTRIFUGAL COMPRESSOR M23-C Project No. Project Title c. Confirm that lube oil supply for post lube is available during shutdown d. Confirm anti-surge valve functions as per design Confirm anti-surge test is conducted by OEM representative. This is to 12 verify surge limit line and map surge points On surge test, ensure the following requirement are available: 13 a. Gas is sufficient and that actual gas properties is given b. Stroke test for anti-surge valve is carried out During surge test: a. Ensure that surge control valve is in fully open position whilst compressor is running b. Close the discharge manual valve fully and the valve shall be kept closed during surge test c. Set compressor speed to minimum operating speed d. Gradually close the anti-surge valve by manual operation to bring the operating point as close as possible to surge e. Record flow rate, suction pressure & temperature, discharge 14 pressure and temperature at this condition f. Open the surge control valve g. Increase the speed and verify next surge point according to the compressor map provided. As a minimum, 3 points shall be verified. Recommend to test at 90%,95%, and 100% speed h. Adjust surge control line per findings from surge test i. Perform surge test again to verify new control line j. Confirm on the surge control valve respond time. Surge control shall be put on AUTO mode during this test Carry out 72 hour endurance test at the following conditions: a. Minimum load b. Partial load 15 c. Full load Verify the operating points are as per tested compressor performance map Log operating data at 2 hours interval During endurance test, confirm the following are within designed values and does not trigger any alarm: a. Compressor suction and discharge pressure & temperature 16 b. Vibration level c. Noise level (1 meter away from compressor) d. Bearing temperature Page 4 of 5

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C TURBINE DRIVEN CENTRIFUGAL COMPRESSOR M23-C Project No. Project Title e. Lube oil temperature f. Seal supply & seal vent pressure and flow Check lube oil commissioning strainers for presence of any sediments/ 17 particles and remove commissioning strainer on compressor suction as required COMMENT(S) AND ADDITIONAL INFORMATION:





Page 5 of 5

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C GAS ENGINE DRIVEN RECIPROCATING COMPRESSOR M24-C Project No. Project Title GENERAL INFORMATION Tag no. System no./Sub-system No. 1 GAS ENGINE Location Make and Model Serial No 5 GEARBOX (IF FITTED) Horsepower (KW) Make & Model Rated RPM Serial No Lube Oil type/Qty Type and Gear Ratio Factory Test Ref/Date Type of Lube Oil/Qty 2 ENGINE CONTROL Factory Test Ref/Date Governor Make and Model Overspeed trip setting 3 COUPLING Make and Model Serial No 4 COMPRESSOR Make & Model Serial No. No. of Stages /No of throw Bore & stroke for Throw 1 Throw 2 Throw 3 Throw 4 Rated Suction/Discharge P Rated Capacity, MMSCFD Rated RPM Compressor Frame LO type Cylinder and Rod lubricant type Test Certificate Ref/ Date RELIABILITY TEST OK Documents required: a. Signed off pre-com check-sheets and accepted punchlist for engine & compressor train and all related ancillary 1 system b. Reference drawings c. Commissioning and Start-up procedure (No.)

N/A

P/L No

Page 1 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C GAS ENGINE DRIVEN RECIPROCATING COMPRESSOR M24-C Project No. Project Title d. FAT report e. Lube oil test report 2 Ensure availability of critical commissioning and start-up spares 3 Start-Up and No Load Test Run Crank the engine with all engine spark plugs and fifty (50) percent of f. compressor suction valves removed Perform intermittent no-load run of five (5), ten (10) and twenty (20) minutes using bottled gas and observe the following: a. Abnormal noise or vibration b. Leakage of lube oil or water c. Engine, gearbox and compressor lube oil immediate pressure build up d. Force feed lubrication function e. Feed g. rate shall be adjusted as per requirement f. Check control panel for any alarm/trips and correct status indication g. Check all cylinder head temperature h. Check auxiliary/jacket water temperature i. Check engine air inlet for any pressure drop j. Check engine fuel filter for any pressure drop k. Check engine lube oil filter differential pressure 4 Check that Distributed Control System signals are correct Carry out four (4) hour continuous no-load run and log operating data 5 at every thirty (30) minutes interval 6 Test and record engine overspeed shutdown 7 Document all tests and checks performed Commissioning (Continuous Running Test) 1 Line-up and check all valves ready for start-up 2 Purge piping and scrubbers with nitrogen 3 Start-up compressor at minimum speed at no load conditions 4 Check for any vibration / abnormal noise 5 Check control panel and record any alarm / trips Load compressor and log operating data at regular intervals and proceed to carry out the 72 hours continuous running test with critical 6 parameters being recorded, i.e., vibration, temperature, suction and discharge pressure, 7 Observe that liquid dumping of all scrubbers are functioning properly 8 Check and confirm all Distributed Control System signals are correct Page 2 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C GAS ENGINE DRIVEN RECIPROCATING COMPRESSOR Project No. Project Title 9 Observe gas cooler condition for any abnormalities 10 Compare log result if within acceptable limit or vendor specification Vendor checklist with 72 hour run data has to be collated and 11 consolidated to the overall report

M24-C



COMPLETED Contractor Representative



Page 3 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRIC MOTOR DRIVEN RECIPROCATING COMPRESSOR M25-C Project No. Project Title GENERAL INFORMATION Tag no. System no./Sub-system No. 1 ELECTRIC MOTOR Location Make and Model Serial No 4 GEARBOX (IF FITTED) Horsepower (KW) Make & Model Rated RPM Serial No Lube Oil type/Qty Type and Gear Ratio Rated Voltage/Ampere Type of Lube Oil/Qty Factory Test Ref/Date Factory Test Ref/Date 2 COUPLING Make and Model Serial No 3 COMPRESSOR Make & Model Serial No. No. of Stages /No of throw Bore & stroke for Throw 1 Throw 2 Throw 3 Throw 4 Rated Suction/Discharge P Rated Capacity, MMSCFD Rated RPM Compressor Frame LO type Cylinder and Rod lubricant type Test Certificate Ref/ Date RELIABILITY TEST OK N/A Documents required: a. Signed off pre-com check-sheets and accepted punchlist for motor & compressor train and all related ancillary system 1 b. Reference drawings c. Commissioning and Start-up procedure (No.) d. FAT report e. Lube oil test report

P/L No

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRIC MOTOR DRIVEN RECIPROCATING COMPRESSOR Project No. Project Title 2 Ensure availability of critical commissioning and start-up spares Start-Up and No Load Test Run 3.1 Functional test of pre/post lube pump 3.2 Functional test cooling water pump 3.3 Bump test motor to ensure correct motor rotation 3.4 Perform intermittent no-load run of five (5), ten (10) and twenty (20) minutes using bottled gas and observe the following: a. Abnormal noise or vibration 3 b. Leakage of lube oil or water c. Did Gearbox and Compressor lube oil pressure build up immediately? d. Is Force feed lubrication function properly? e. Feed rate shall be adjusted as per requirement f. Check control panel for any alarm/trips and correct status indication g. Compressor lube oil filter differential pressure 3.5 Check that Distributed Control System signals are correct 3.6 Carry out four (4) hour continuous no-load run and log operating data at every thirty (30) minutes interval 3.7 Test and record engine overspeed shutdown 3.8 Document all tests and checks performed Commissioning (Continuous Running Test) 4.1 Line-up and check all valves ready for start-up 4.2 Purge piping and scrubbers with nitrogen 4.3 Start-up compressor at minimum speed at no load condition 4.4 Check for any vibration/ abnormal noise 4 4.5 Check control panel and record any alarm / trips 4.6 Load compressor and log operating data at regular intervals and proceed to carry out the 72 hours continuous running test with critical parameters being recorded, i.e., vibration, temperature, suction and discharge pressure 5 Observe that liquid dumping of all scrubbers are functioning properly 6 Check and confirm all Distributed Control System signals are correct 7 Observe gas cooler condition for any abnormalities 8 Compare log result if within acceptable limit or vendor specification Vendor checklist with 72 hour run data has to be collated and 9 consolidated to the overall report COMMENT(S) AND ADDITIONAL INFORMATION:

M25-C

Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRIC MOTOR DRIVEN RECIPROCATING COMPRESSOR Project No. Project Title


COMPLETED Contractor Representative


M25-C


Page 3 of 2

CSP-20 rev 01 Appendix III-VI

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRIC MOTOR DRIVEN CENTRIFUGAL PUMP M26-C Project No. Project Title GENERAL INFORMATION Tag no. System no./ Sub-system No. 1 PUMP Location Make & Model Serial No. No of Stages Head/Capacity Rated RPM Mech Seal Make & Model Factory Test Ref/Date 2 ELECTRIC MOTOR Make & Model Serial No HP (KW) Rated RPM Voltage/Rated Amp 3 GEARBOX Make & Model Serial No. Type/Gear ratio Lube oil type/Qty 4 FLEXIBLE DRIVE Motor -Gearbox Gearbox- Pump COUPLING Make & Model Serial No. RELIABILITY TEST OK Documents required: a. Signed off pre-com check-sheets and accepted punchlist for motor & pump train and all related ancillary system b. Reference drawings 1 c. Commissioning and Start-up procedure (No.) d. FAT report e. No load test report f. Lube oil test report 2 Ensure availability of critical commissioning and start-up spares

N/A P/L No

Page 4 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRIC MOTOR DRIVEN CENTRIFUGAL PUMP M26-C Project No. Project Title 3 Remove all remaining preservation material from the pump set Check level of buffer / burrier fluid tank for mechanical seal system (if 4 any) Check motor and pump bearings are lubricated in accordance with 5 manufacturer’s instructions Make sure that the volute casing and suction piping is completely full 6 of liquid by priming the pumping system 7 Check suction strainer or temporary strainer has been installed Visually check all associated valves and piping are correctly installed 8 with appropriate gaskets, and adequately supported. Ensure all valves are operational. Any temporary blanks are removed 9 Ensure instrumentation and control systems are fully functional Check that suction system is filled to working level and all suction 10 system valves are open 11 Ensure that pump drain valves are closed Run the motor through local stop-start button to check correct shaft 12 rotation 13 Start-up and test manual and remote shutdown function Continue to slowly open the discharge valve until the system pressure 14 stabilizes and the pump discharge valve is fully open Check the gearbox lube oil pressure build up immediately and that the 15 operating pressure is as per stated in OEM manual 16 Check control panel indication lights and motor running 17 Check and confirm correct Distributed Control System signal 18 Fill-up surge tank / vessel with water and test for automatic start-up Simulate tank / vessel and function test level and recirculation control 19 valve 20 Test lead and lag operation of pump if equipped Conduct performance test for pump to ensure that pump performs as design. a. Run pump at these conditions: 1) shutoff (no vibration data required), 21 2) minimum continuous stable flow, 3) midway between minimum and rated flow, 4) rated flow, Page 5 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ELECTRIC MOTOR DRIVEN CENTRIFUGAL PUMP M26-C Project No. Project Title 5) maximum allowable flow (as a minimum, 120 % of BEP) b. Test result should be within acceptable region as per PTS and API 610 Record discharge pressure, motor running ampere and vibration level 22 at the tested points 23

Run the pump for seventy-two (72) hours continuous endurance test Measure and record operating data in Commissioning Log Sheet every 2 hours interval: d. Pump flow rate e. Suction and discharge pressure 24 f. Motor and pump vibration g. Motor starting and running ampere h. Motor supply voltage, frequency, speed i. Temperature at pump and motor bearings 25 Check for any leakage, either in skid or piping connections 26 Recheck the integrity of all holding down bolts COMMENT(S) AND ADDITIONAL INFORMATION:





Page 6 of 2

CSP-20 rev 01 Appendix III-VI

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ENGINE DRIVEN CENTRIFUGAL PUMP M27-C Project No. Project Title GENERAL INFORMATION Tag no. System no. /Sub-system No. 1 PUMP Location Make & Model Serial No. No of Stages Head/Capacity Rated RPM Mech Seal Make & Model Factory Test Ref/Date 2 GAS/DIESEL ENGINE 5 GOVERNOR Make & Model Make & Model Serial No Serial No. HP (KW) Overspeed setting Rated RPM Lube Oil Type/Qty Factory Test Ref/Date 3 GEARBOX (IF FITTED) Make & Model Serial No. Type/Gear ratio Lube oil type/Qty Factory Test Ref/Date 4 FLEXIBLE DRIVE Motor -Gearbox Gearbox- Pump COUPLING Make & Model Serial No. RELIABILITY TEST OK Documents required: a. Signed off pre-com check-sheets and accepted punchlist for engine & pump train and all related ancillary system 1 b. Reference drawings c. Commissioning and Start-up procedure (No.) d. FAT report e. No load test report

N/A P/L No

Page 7 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ENGINE DRIVEN CENTRIFUGAL PUMP M27-C Project No. Project Title 2 Ensure availability of critical commissioning and start-up spares 3 Remove all remaining preservation material from the pump set Check level of buffer / burrier fluid tank for mechanical seal system (if 4 any) Check engine and pump bearings are lubricated in accordance with 5 manufacturer’s instructions Make sure that the volute casing and suction piping is completely full 6 of liquid by priming the pumping system 7 Check suction strainer or temporary strainer has been installed Visually check all associated valves and piping are correctly installed 8 with appropriate gaskets, and adequately supported. Ensure all valves are operational. Any temporary blanks are removed 9 Ensure instrumentation and control systems are fully functional Check that suction system is filled to working level and all suction 10 system valves are open 11 Ensure that pump drain valves are closed Run the engine through local stop-start button to check correct shaft 12 rotation 13 Start-up and test manual and remote shutdown function Continue to slowly open the discharge valve until the system pressure 14 stabilizes and the pump discharge valve is fully open Check the gearbox lube oil pressure build up immediately and that the 15 operating pressure is as per stated in OEM manual 16 Check control panel indication lights and engine running 17 Check and confirm correct Distributed Control System signal Simulate tank / vessel and function test level and recirculation control 18 valve 19 Test lead and lag operation of pump if equipped Conduct performance test for pump to ensure that pump performs as design. a. Run pump at these conditions: 1) shutoff (no vibration data required), 20 2) minimum continuous stable flow, 3) midway between minimum and rated flow, 4) rated flow, Page 8 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ENGINE DRIVEN CENTRIFUGAL PUMP M27-C Project No. Project Title 5) maximum allowable flow (as a minimum, 120 % of BEP) b. Test result should be within acceptable region as per PTS and API 610 Record discharge pressure, motor running ampere and vibration level 21 at the tested points 22

23

24 25

Run the pump for seventy-two (72) hours continuous endurance test Measure and record operating data in Commissioning Log Sheet every 2 hours interval: j. Pump flow rate k. Suction and discharge pressure l. Engine and pump vibration at running speed m. Lube oil pressure and temperature n. Pump bearings temperature o. Gearbox vibration and temperature (if fitted) Check for any leakage, either in skid or piping connections Recheck the integrity of all holding down bolts






Page 9 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C DIESEL ENGINE DRIVEN FIRE PUMP M28-C Project No. Project Title GENERAL INFORMATION Tag No. System no./Sub-system No. 1 ENGINE Location Make & Model 4 PUMP Serial No. Make & Model Horsepower (KW) Serial No. Rated Speed, RPM No of Stages Lube Oil Type/ Qty Rated Flow Rate 2 DRIVE COUPLING Rated Discharge Press Make & Model Design Submergence Serial No. Rated Speed, RPM 3 GEARBOX Seal Type/Make /Model Make & Model Factory Test Ref/Date Serial No 5 ENGINE CONTROLLER Type/Gear Ratio Make & Model Lube Oil Type/Qty Serial No. Supply Voltage RELIABILITY TEST OK Documents required: a. Signed off Pre-com check-sheet and punchlist status 1 b. Reference drawing c. Commissioning and Start-up procedure (No.) d. FAT report 2 Ensure availability of critical commissioning & start-up spares Initial Start-up and No-load Run 2.1 Uncouple engine from gearbox and start-up engine manually 2.2 Test manual shutdown of engine 3 2.3 Check and confirm light indication status 2.4 Carry out 4 hours continuous no load run of engine and log operating data at 1 hour interval Test engine overspeed shutdown Continuous Running Test 3.1 Test manual and automatic start-up of fire pump 3.2 Carry out 3 hours continuous running of the pump and record 4 operating data 3.3 Take pressure and flow rate to confirm pump operates within specification 3.4 Check for any sign of lube oil leak, pressure drop, abnormal sound

N/A P/L No

Page 10 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ENGINE DRIVEN CENTRIFUGAL PUMP M27-C Project No. Project Title at gearbox, etc. 3.5 Check and verify DCS signal and signal to fire control panel Document test results and make comparison with manufacturer’s 5 recommended value COMMENT(S) AND ADDITIONAL INFORMATION:





Page 11 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C CHEMICAL METERING PUMP M29-C Project No. Project Title GENERAL INFORMATION Tag no. System no. /Sub-system No. 1 PUMP Location Make & Model Serial No Type Max Disch Press Capacity Range Factory Test Ref/Date 2 PRIME MOVER Type Make & Model Serial No HP (KW) Rated Speed Power Supply Air Supply Pressure RELIABILITY TEST

1

2 3 4 5 6 7 8 9 10 11

OK

N/A P/L No

Documents required: a) Signed Pre-com check-sheet and punch list status for Chemical metering pump skid and all related auxiliary system b) Reference drawing c) Commissioning & Start-up procedure (No.) d) FAT report Ensure availability of Start-up & Commissioning spares Ensure that pump is primed Start-up pump per vendor’s instruction Test manual and remote shutdown Check discharge pressure is sufficient for injection Check, vary and set dosing rate Check that motor running amps is within specification Perform the 72 hour continuous test run Observe for any abnormalities Log operating data at regular interval

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C CHEMICAL METERING PUMP Project No. Project Title COMMENT(S) AND ADDITIONAL INFORMATION:



M29-C



Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C CHEMICAL INJECTION PACKAGE M30-C Project No. Project Title GENERAL INFORMATION Tag no. System no. /Sub-system No. Make and Model Location Serial No Test Ref/ Date RELIABILITY TEST OK Documents required: a. Signed off Pre-com check-sheet and punchlist status for Chemical Injection and all related ancillary system 1 b. Commissioning and Start-up procedure (No.) c. Reference drawing d. FAT report 2 Start-up chemical injection skid per manufacturer’s instruction 3 Check for any leakage in discharge tubing 4 Perform the required test run duration 5 Check discharge pressure is sufficient for injection 6 Check, vary and set dosing rate 7 Log operating data at regular interval 8 Check and record for any abnormalities

N/A P/L No






Page 3 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C NITROGEN GAS GENERATOR M31-C Project No. Project Title GENERAL INFORMATION Tag no. System no. /Subs-system No. Manufacturer/Date Tank No Serial No Location Capacity/Dimension Design Code Max Allow Working Press RELIABILITY TEST OK N/A P/L No Documents required: a. Signed off Pre-com check-sheet and punchlist status for Nitrogen Gas Generator and all related ancillary system 1 b. Commissioning and Start-up procedure (No.) c. Reference drawing a. FAT report 2 Ensure availability of start –up & commissioning spares 3 Start-up in accordance with manufacturer’s instruction 4 Check for any leakage and any abnormalities on initial start-up 5 Ensure sufficient volume and pressure of instrument air supply Ensure timely sequence for opening of PSA valves is according to the 6 enclosed time sequence 7 Open air inlet valve and close the nitrogen product valve 8 Check the pressure and temperature of air for the desired value Switch on the breaker to energize PLC and all PSA valves start 9 operating Continue operation until nitrogen receiver pressure and oxygen 10 percentage reach the required value Verify nitrogen purity and pressure are achieved and then open the 11 product line valve to the end-users Carry out 72 hours continuous test run and record operating data at 2 hours interval. Record the following: 12 a. Nitrogen flow rate b. Nitrogen Discharge Pressure c. O2 Content COMMENT(S) AND ADDITIONAL INFORMATION:

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C NITROGEN GAS GENERATOR Project No. Project Title



M31-C



Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C SEWAGE TREATMENT UNIT


M32-C

GENERAL INFORMATION System no./Sub-system No. Location

Tag no. 1 PACKAGE Make & Model Serial No. Capacity 2 COMINUTOR Make & Model Serial No. Motor Make/Model Motor KW/RPM Motor Rated Voltage/ Amp 3 AERATOR Make & Model Serial No. Motor Make/Model Serial No Motor KW/RPM Rated Voltage/Ampere 4 CHLORINATION UNIT Pump Make & Model RELIABILITY TEST Documents required: b. Signed off Pre-com check-sheet and punchlist status 1 c. Commissioning and Start-up procedure (No.) d. Reference drawing e. FAT report 2 Ensure availability of critical commissioning & start –up spares 3 Initial start-up in accordance with manufacturer’s instruction 4 Check for any leak on initial filling of sewage tank 5 Bump test cominutor motor to ensure correct rotation Start-up cominutor, observe for any excessive noise or vibration and 6 test shutdown function 7 Bump test mechanical aerator to ensure correct rotation Start-up mechanical aerator; observe for any excessive noise or 8 vibration; check aeration 9 Check aeration of air diffuser 10 Perform 24 hour continuous test run of complete package

OK

N/A P/L No

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C SEWAGE TREATMENT UNIT

Project No. Project Title 11 Record operating parameters

M32-C






Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C WATERMAKER UNIT (VAPOR COMPRESSOR TYPE) M33-C Project No. Project Title GENERAL INFORMATION TAG NO. SYSTEM NO./Sub-system No. 1 PACKAGE Reference Drawing Make & Model Serial No Location Capacity (GPM) Unit test ref/Date 2 COMPRESSOR 4 DISTILLATE PUMP Make & Model Make & Model Serial No Serial No 2.1 MOTOR Motor Make & Model Make & Model Motor HP (KW) Serial No Motor Rated Speed HP (KW) Voltage/Ampere Rated Speed V-belt spec Voltage/Amp 5 CHEMICAL FEED V-belt spec Pump Make & Model 2.2 Lube Oil Pump Pump Serial No Make & Model Pump Motor HP Serial No Pump Motor Voltage Motor M & Model Motor HP Motor Speed Voltage Current 3 RECIRCULATION PUMP Make & Model Serial No 3.1 MOTOR Make & Model Serial No. HP (KW) Rated Speed V-belt spec RELIABILITY TEST OK Documents required: 1 a) Signed off Pre-com check-sheet and punch list status for vapour

N/A

P/L No

Page 1 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C WATERMAKER UNIT (VAPOR COMPRESSOR TYPE) M33-C Project No. Project Title compression water maker skid and all related auxiliary system b) Commissioning & Start-up procedure (No.) c) FAT report d) Lube oil test report 2 Ensure availability of critical commissioning and start-up spares Verify that initial start-up & test run has been carried out according to Operation Procedure and Maintenance (OPM) and vendor’s instruction Following vendor’s procedure on start-up; observe for excessive noise or vibration & test manual shut down of:3 a. Compressor lube oil pump and compressor (if applicable) b. Distillate pump c. Circulation pump d. Chemical feed pump 3.1 Check for any sign of lube oil or water leakage 3.2 Check that distillate, blowdown & boiler temperatures are as per vendor’s specification 3.3 Check that desalination meter is set correctly & test diverter valve 3.4 Check panel indication lights are as per specifications 3.5 Check cold flushing function 3.6 Test unit shutdown on:  Low compressor lube oil pressure  Low shell pressure  High shell pressure  High compressor lube oil temp Carry out 72 hours continuous test and record operating data at 2 4 hours interval Compare results are in accordance with manufacturers 5 recommendation COMMENT(S) AND ADDITIONAL INFORMATION:

Page 2 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C WATERMAKER UNIT (VAPOR COMPRESSOR TYPE) Project No. Project Title




M33-C


Page 3 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C SUBSEA EQUIPMENT PACKAGE M34-C Project No. Project Title GENERAL INFORMATION Tag no. System no./Sub-system No. CHEMICAL INJECTION UNIT Location 1 MOTOR Make & Model Serial No. Horsepower (KW) Rated Speed, RPM Rated Voltage/Ampere Factory Test Ref/ Date 2 GEARBOX Make & Model Serial No. Gear Ratio Type of Lube Oil/Qty Factory Test Ref/Date 3 PUMP Make & Model Serial No. Capacity Rated RPM Factory Test Ref/Date RELIABILITY TEST OK Documents required: a. Signed Pre-com ITR and punchlist status b. Manufacturer’s Operating & Maintenance Manual (OMM) 1 c. Reference drawings d. Start-up and Commissioning procedure (No.) e. FAT report f. SIT report 2 Confirm that all functional check is satisfactorily completed Ensure that all system/sub-system related to Hydrocarbon introduction 3 are complete and signed off and that the accepted punchlist will not impede commissioning work Ensure availability of Start-up spares & first fill for Chemical Injection 4 Unit (CIU) Provide assistance to the start-up of Subsea Equipment package per 5 vendor instruction

N/A P/L No

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C SUBSEA EQUIPMENT PACKAGE M34-C Project No. Project Title Check for any abnormalities such as leakage, high vibration and noise 6 of Chemical Injection pump during the introduction of Hydrocarbon 7 Carry out the 72-hour continuous test run Monitor and log critical parameters on Chemical Injection Skid on 8 regular interval and print screen DCS & manifold control module data 9 Attach vendor check-sheets used during the entire test, if any COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C MISCELLANEOUS EQUIPMENT Project No. Project Title Tag no.

M35-C

INFORMATION System no./Sub-system No.

RELIABILITY TEST 1 Verify that ITR M 35-B is complete and signed off Verify that the no-load test is carried out with satisfactory result (if 2 applicable) 3 Carry out manufacturers’ recommended pre-initial Start-up inspection 4 Start-up equipment skid following manufacturer’s instruction 5 Carry out the 72-hour continuous test run Check for any abnormalities (abnormal noise, leakage and high 6 vibration 7 Record critical operating parameters on regular interval 8 Confirm result if within manufacturer’s recommendation COMMENT(S) AND ADDITIONAL INFORMATION:




OK

N/A P/L No


Page 1 of 1

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C VENDOR’S PACKAGE EQUIPMENT (SKID) M36-C Project No. Project Title GENERAL INFORMATION Tag no. System no. /Sub-system No. 1 COMPLETE PACKAGE Location Make & Model Serial No Capacity Unit Test Ref/Date 2 DRIVER Make & Model Serial No. Capacity HP (KW) Rated Speed Voltage/Current V-belt spec/Coupling 3 DRIVEN Make & Model Serial No Capacity HP (KW) 4 INTERMEDIATE Make & Model Serial No Gear Ratio HP (KW) RELIABILITY TEST OK Documents required: f. Signed off Pre-commissioning Check-sheet g. Accepted Punchlist 1 h. FAT report i. Relevant test report j. Commissioning and Start-up procedure (No.) 2 Ensure availability of critical commissioning and start-up spares Perform final line walk to ensure system is safe and ready to run with 3 manual valves lined-up per P&ID Check the entire equipment skid and ensure all connections are 4 secured and intact 5 Start-up equipment skid per manufacturer’s instruction or in

N/A P/L No

Page 1 of 2

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C VENDOR’S PACKAGE EQUIPMENT (SKID) M36-C Project No. Project Title accordance with operating manual Observe and record any abnormalities such as high pitch/roaring noise 6 and excessive vibration; stop the unit when necessary 7 Carry out 72-hour continuous test run Record all operating parameters at regular interval during the entire 8 endurance test 9 Confirm results are in accordance with vendor’s specification 10 Attach vendor’s check-sheets used during the 72-hr test run, if any COMMENT(S) AND ADDITIONAL INFORMATION:





Page 2 of 2



Tag no. 1 COMPLETE PACKAGE Make & Model Serial No Capacity Unit Test Ref/Date 2 DRIVER Make & Model Serial No. Capacity HP (KW) Rated Speed Voltage/Current V-belt spec/Coupling 3 DRIVEN Make & Model Serial No Capacity HP (KW) 4 INTERMEDIATE Make & Model Serial No Gear Ratio HP (KW)

1

2 3

M37-C

GENERAL INFORMATION System no./Subsystem no. Location Reference Drawing

RELIABILITY TEST Documents required: a. Signed off Pre-commissioning Check-sheet b. Accepted Punchlist c. FAT/SAT reports d. Relevant test report e. Lube Oil flushing and lab test report is available f. Commissioning and Start-up procedure (No. XXXX) g. Operation & Maintenance Procedures (No. XXXX) Confirm that all Commissioning spares and operating spares are available. Check that the preservation records have been maintained and removed wherever required.

OK

N/A P/L No

Page 1 of 4

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ACID GAS REMOVAL UNIT M37-C Project No. Project Title The Instrument air package is tested, operational and connected to all 4 the relevant pneumatic instruments. 5 The Nitrogen package is tested and operational 6 Export/Downstream Plant is ready to receive hydrocarbons/Product Leak-tested with N2/He to maximum operating pressure and under N2 7 blanket with O2 level below 4 % Ensure field operating tools are available for Operation personnel 8 during start-up e.g., Manual Valves Operating Key, SDV Junction box Keys, Instruments Manifold Venting Keys All LO/LC valves are as per their required positions as per P&ID and 9 confirm status of all manual isolation valves, Padlock keys to be available at all the times for emergencies. All manual valves are lined up in their normal operating position (esp. 10 PSV’s upstream). All Restriction Orifices / Flow Orifice are in their correct positions and 11 their respective data sheets are cross checked for the Orifice hole ID size. All spectacle blinds, spacers/spades are in the normal operating 12 position and recorded in the spade list. 13 Catalysts are loaded in respective catalyst bed 14 All Membrane units filled with respective Membranes Static Equipment have been internally inspected, Internals are installed 15 e.g. Demister Pads, Vein Packs, etc. Ensure strainers on suction of all rotating equipment are installed 16 correctly. Ensure start-up mesh is installed upstream of all strainers on suction of 17 Pumps and Compressors. Correct grade of lube Oil is filled up to operating levels for pumping 18 equipment & Instrument Air compressor. Lube oil and Seal Oil lines are flushed and cleaned properly and the 19 lines are ensured to be free from debris All Panel / Cabinet / Console Installation and pre-commissioning 20 Acceptance check sheets completed, certified and signed off Power Supply Voltage to each Panels, Cabinets, Consoles etc correct as 21 per Project Specifications Check all instruments are lined up through their root valves and 22 manifolds 23 All relief valves and pressure regulating valves are calibrated Page 2 of 4

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C ACID GAS REMOVAL UNIT M37-C Project No. Project Title 24 Ensure all package SAT successfully carried out (where applicable) Complete function check of all fire, gas and safeguarding systems are 25 carried out and all items shown on Cause & Effect Drawings shall be tested and proven to ensure shut down protection is in place. ESD Push buttons are in Reset (Live) Positions (unless special 26 maintenance case) Final ESD test to be carried out and valve positions to be checked and 27 signed off Ensure that all DCS, ESD and F&G systems are commissioned and 28 functional. All ESD, PSD, EDV and control valves are in their fail-safe (de-energized) 29 position and in Auto Mode 30 Control Logic Philosophy operational as per Project Design Communications with Safeguarding System correct as per Project 31 Specifications 32 INHIBIT LOGBOOK in place to monitor the status of INHIBITS. Ensure Electrical power is available to all the field electrically operated 33 equipment, control room, substation systems and all the consumers. All Motors have undergone pre-commissioning tests Solo Dynamic Run 34 and relevant test sheets are completed 35 Redundant Power Supply operating correctly 36 UPS system tested and available Emergency Diesel Generator Package is available for backup power 37 supply. 38 Carry out 72-hour continuous test run Record all operating parameters at regular interval during the entire 39 endurance test ; Confirm if result is within manufacturer’s specification Attach test and log parameters taken by the vendor including snap 40 shots of DCS screen with this check-sheets COMMENT(S) AND ADDITIONAL INFORMATION:

Page 3 of 4





M37-C



Page 4 of 4

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C MERCURY REMOVAL UNIT


P&ID No. Tag no. 1 COMPLETE PACKAGE Make & Model Serial No Capacity Unit Test Ref/Date 2 DRIVER Make & Model Serial No. Capacity HP (KW) Rated Speed Voltage/Current V-belt spec/Coupling 3 DRIVEN Make & Model Serial No Capacity HP (KW) 4 INTERMEDIATE Make & Model Serial No Gear Ratio HP (KW)

1

2 3

M38-C

GENERAL INFORMATION System no. /Subs-system No. Location

RELIABILITY TEST

OK

N/A P/L No

Documents required: a. Signed off Pre-commissioning Check-sheet b. Accepted Punch list c. FAT/SAT reports d. Relevant test report e. Commissioning and Start-up procedure (No. XXXX) f. Operation & Maintenance Procedures (No. XXXX) Confirm that all Commissioning spares and operating spares are available. Check that the preservation records have been maintained and removed wherever required. Page 1 of 4


M38-C

Project No. Project Title 4 Ensure all preservation has been removed wherever applicable The Instrument air package is tested, operational and connected to all 5 the relevant pneumatic instruments. 6 The Nitrogen package is tested and operational 7 Export/Downstream Plant is ready to receive hydrocarbons/Product Leak-tested with N2/He to maximum operating pressure and under N2 8 blanket with O2 level below 4 % Ensure field operating tools are available for Operation personnel 9 during the start-up, e.g., Manual Valves Operating Key, SDV Junction box Keys, Instruments Manifold Venting Keys. All LO/LC valves are as per their required positions as per P&ID and 10 confirm status of all manual isolation valves, Padlock keys to be available at all the times for emergencies. All manual valves are lined up in their normal operating position (esp. 11 PSV’s upstream). All Restriction Orifices / Flow Orifice are in their correct positions and 12 their respective data sheets are cross checked for the Orifice hole ID size. All spectacle blinds, spacers/spades are in the normal operating 13 position and recorded in the spade list. 14 Catalysts are loaded in respective Mercury Removal bed. Static Equipment have been internally inspected, Internals are installed 15 e.g. Demister Pads, Vein Packs, etc. All Panel / Cabinet / Console Installation and pre-commissioning 16 Acceptance check sheets completed, certified and signed off. Power Supply Voltage to each Panels, Cabinets, Consoles etc correct as 17 per Project Specifications. Check all instruments are lined up through their root valves and 18 manifolds. 19 All relief valves and pressure regulating valves are calibrated. 20 Ensure all package SAT successfully carried out (where applicable). Complete function check of all fire, gas and safeguarding systems are 21 carried out and all items shown on Cause & Effect Drawings shall be tested and proven to ensure shut down protection is in place. ESD Push buttons are in Reset (Live) Positions (unless special 22 maintenance case) Final ESD test to be carried out and valve positions to be checked and 23 signed off

Page 2 of 4


M38-C

Project No. Project Title Ensure that all DCS, ESD and F&G systems are commissioned and 24 functional. All ESD, PSD, EDV and control valves are in their fail-safe (de-energized) 25 position and in Auto Mode 26 Control Logic Philosophy operational as per Project Design Communications with Safeguarding System correct as per Project 27 Specifications 28 INHIBIT LOGBOOK in place to monitor the status of INHIBITS. Ensure Electrical power is available to all the field electrically operated 29 equipment, control room, substation systems and all the consumers. 30 Redundant Power Supply operating correctly 31 UPS system tested and available Emergency Diesel Generator Package is available for backup power 32 supply. 33 Carry out 72-hour continuous test run Record all operating parameters at regular interval during the entire 34 endurance test ; Confirm if result is within manufacturer’s specification Attach test and log parameters taken by the vendor including snap 35 shots of DCS screen with this check-sheets COMMENT(S) AND ADDITIONAL INFORMATION:

Page 3 of 4





M38-C



Page 4 of 4


ELEVATORS

M42-C

GENERAL INFORMATION Tag no. System no./Sub-system No. Make & Model Reference drawing Serial No Location RELIABILITY TEST 1 Verify ITR-B is complete and signed off by relevant parties Check/ inspect installation and hook-up of all associated instruments in 2 the system. Carry out Commissioning activities as per vendor’s Commissioning 3 procedure with vendors assistance Refer to the Operation Procedure & Manual (OPM) for detailed 4 Operation and Maintenance Attach the logging parameters, it shall be cross-referenced to 5 manufacturer’s specification Compile Handover Certificates, as-built drawings (P & ID) and 6 outstanding work list for the system (if any) and issue to Operations for acceptance. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1


Pig Trap

M46-C

GENERAL INFORMATION Tag no. System no./Sub-system No. Make & Model Reference drawing Serial No Location RELIABILITY TEST 1 Verify ITR-B is complete and signed off by relevant parties Check/ inspect installation and hook-up of all associated instruments in 2 the system and ensure all shutdown valves are locked closed. 3 Ensure that all tie-ins or open flanges are blinded. if spectacle blind are required for isolation of the pig trap from the pipeline, the spectacle blinds shall be located on the pig trap side of the 4 pig trap valve, kicker valve, isolation valve on the pressurising line (if fitted) and on any vent and drain lines which are connected to other facilities. Open the isolation valve and introduce medium into the pig trap; 5 pressurize up the vessel according to operating condition. Refer to the Operation Procedure & Manual (OPM) for detailed 6 Endurance and Performance Test run. Attach the logging parameters such as gauges and analyzers’ reading. 7 On-site readings shall be cross-referenced to P&ID and DCS for analysis and performance assessment. 8 Print copy or snapshots from DCS as proof for acceptance. Compile Handover Certificates, as-built drawings (P & ID) and 9 outstanding work list for the system (if any) and issue to Operations for acceptance. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1


STORAGE TANK

M47-C

GENERAL INFORMATION Tag no. System no./Sub-system No. Make & Model Reference drawing Serial No Location RELIABILITY TEST 1 Verify ITR-B is complete and signed off by relevant parties Check/ inspect installation and hook-up of all associated instruments in 2 the system and ensure all shutdown valves are locked closed. For hydrocarbon system ensure nitrogen blanketing have been 3 performed to reduce oxygen content from the hydrocarbon systems prior to introduction of the hydrocarbon. 4 Ensure that all tie-ins or open flanges are blinded. Ensure all utilities including instrument air supply and power supply are 5 in service. Open the isolation valve and introduce medium onto the tank; fill up 6 the tank according to commissioning and start up manual. Attach the logging parameters such as gauges and analyzers’ reading. 7 On-site readings shall be cross-referenced to P&ID and DCS for analysis and performance assessment. 8 Print copy or snapshots from DCS as proof for acceptance. Compile Handover Certificates, as-built drawings (P & ID) and 9 outstanding work list for the system (if any) and issue to Operations for acceptance. COMMENT(S) AND ADDITIONAL INFORMATION




OK

N/A P/L No


Page 1 of 1

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C Turbo Expander/Booster Compressor

Project No. Project Title Facilities TAG NO. 1

Turbo Expander Make & Model Serial No HP (KW) Operating Speed

M50-C

GENERAL INFORMATION SYSTEM NO. /Sub-system No.

Factory test ref/Date 2

3

4

1

Magnetic Bearing Make & Model Serial No HP (KW) Operating Speed Factory test ref/Date Make & Model GEARBOX Make & Model Serial No Operating RPM Factory test ref/Date COMPRESSOR Make & Model Capacity Type of Lube Oil/Qty Serial No No of Impellers Suction Press Discharge Press HP (KW) Factory test ref/Date RELIABILITY TEST Documents required: a. Signed off Pre-com check-sheet and accepted punchlist and all ancillary system b. Start-up and Commissioning procedure (No. xxxx) c. FAT report/String test d. No load test report

2

Ensure Start-up spares are available

3

Perform final line walk to ensure system is safe and ready to run with manual valves lined-up per P&ID

OK

N/A

P/L No

Page 1 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C 4

4

7 8 10

11

12 13

14

Turbo Expander/Booster Compressor M50-C Turbo Expander/Booster Compressor suction and discharge piping pressurized with fuel gas up to recommended pressure. Turbo Expander: a. Check dryness & cleanliness b. Verify that Fire & Gas system is healthy Push the “Start” button to begin the automated start-up Ensure the following sequence is followed: a. Required Minimum fuel gas flow is available for commissioning. b. The enclosure vent system starts c. The enclosure vent system will purge the enclosure for period of time and ensure oxygen concentration <6.0 % d. Pressurize the casing and Active Bearing casing more than 2.5 barg. e. The seal gas system starts f. Levitate Active Magnetic Bearing(AMB) g. Suction and Discharge SDV’s are open except Quick Shut Down valve at Turbo Expander suction. h. Ensure Anti surge Valve is full open i. Starter system stops Follow the Vendor recommended start up sequence Ramp the speed as per vendor recommendation Check for any leakage and abnormal noise Perform emergency shutdown test as follows: a. Confirm that ESD button is functional b. All BDV and SDV in compression system reacts as per design c. Confirm that lube oil supply for post lube is available during shutdown d. Confirm anti-surge valve functions as per design Confirm anti-surge test is conducted by Vendor representative. This is to verify surge limit line and map surge points On surge test, ensure the following requirement are available: a. Gas is sufficient and that actual gas properties is given b. Stroke test for anti-surge valve is carried out During surge test: a. Ensure that surge control valve is in fully open position whilst compressor is running b. Close the discharge manual valve fully and the valve shall be kept closed during surge test c. Set compressor speed to minimum operating speed d. Gradually close the anti-surge valve by manual operation to bring the operating point as close as possible to surge e. Record flow rate, suction pressure & temperature, discharge pressure and temperature at this condition f. Open the surge control valve g. Increase the speed and verify next surge point according to the compressor map provided. As a minimum, 3 points

Page 2 of 3

CSP-20 rev 01 Appendix III-VI PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C Turbo Expander/Booster Compressor M50-C shall be verified. Recommend to test at 90%,95%, and 100% speed h. Adjust surge control line per findings from surge test i. Perform surge test again to verify new control line j. Confirm on the surge control valve respond time. Surge control shall be put on AUTO mode during this test Carry out 72 hour endurance test at the following conditions: a. Minimum load b. Partial load 15 c. Full load Verify the operating points are as per tested compressor performance map Log operating data at 2 hours interval During endurance test, confirm the following are within designed values and does not trigger any alarm: a. Compressor suction and discharge pressure & temperature b. Cold Recovery vessel out temperature 16 c. Vibration level d. Noise level (1 meter away from compressor) e. Bearing temperature f. Seal supply & seal vent pressure and flow COMMENT(S) AND ADDITIONAL INFORMATION:

Designation Company

Name Signature Date




Page 3 of 3


PETRONAS CARIGALI SDN. BHD. INSPECTION TEST RECORD (ITR) - C NITROGEN PURGING

P16-C

Project No. Project Title Facilities INFORMATION Purging Medium Purging Duration

Test Packages No System Sub System Location 1

INSPECTION / TEST Verify the Reinstatement Leak Test for the system/sub system /test package above have been completed and accepted THE SYSTEM SHOWN ON THE ATTACHED P&ID (TEST PACKAGE) HAS BEEN PURGED ANCHIVED 7% O2 CONTENT. Signature:

OK

N/A

P/L No

Name: 2

Title:- Site Representative Company: Date: COMMENT(S) AND ADDITIONAL INFORMATION




CONFIRMED BY Operation PETRONAS Carigali

Page 1 of 1

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST REPORT ITR-C FIREWATER/FOAM SYSTEM Project No. Project Title


3 4 5 6

7 8

9 10 11

12

13

S10-C


INSPECTION / TEST Ensure ITR B check list completed & no subsequent damage occurred. Check firewater/ foam system equipment is located as indicated by the Escape Route, Fire Fighting, Safety and Life Saving Equipment layout drawing. FIREWATER PUMP Ref. Specification/ Datasheet No.:

OK

N/A P/L No

Ensure Mechanical ITR-C for Firewater Pump is completed. Check vibration of the Firewater pump. Check starting logic sequence and operation. Ensure pump curve performance record is available. Discharge pressure of each pump speed at 0%, 50%, 100%, 125%, and 150% flow. FIRE WATER/ FOAM MONITORS AND HYDRANTS Ref. Specification/ Datasheet No.: Check flow capability at each monitor and hydrant. Check straight stream/ spray and throw range on all monitor and handheld equipment nozzles. FOAM TANK Ref. Specification/ Datasheet No.: Check proportioning accuracy at operating flow rates. Check foam expansion and drainage time in accordance with specifications. Ensure foam concentrate tank is full after system testing. Foam Systems - Instrument air supply commissioned. - Firewater supply commissioned. - Fire & Gas interface commissioned. - Foam system commissioned. DELUGE SYSTEM Ref. Specification/ Datasheet No.: Ensure that all deluge nozzles are clear from blockage during flow test. Page 1 of 3

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST REPORT ITR-C

14 15 16 17

18 19 20 21 22

23

FIREWATER/FOAM SYSTEM S10-C (Note: Please ensure that spray deluge spray heads are available prior to any tests being performed on the system). Check that pressures at most remote deluge nozzles conform to hydraulic calculations. Check that no dry areas occur on protected equipment during discharge. Check the minimum pneumatic pressure required to open the deluge valves. Deluge & Sprinkle Systems - Instrument air supply commissioned. - Firewater supply commissioned. - Fire & Gas interface commissioned. WATERMIST SYSTEM Ref. Specification/ Datasheet No.: Check quality of water in system. Check location and flow rate of all water mist nozzles. Check time and sequence of discharge. Check that all nozzles flow freely. Check that discharge patterns of nozzles overlap. Fire Watermist Systems - Firewater reservoirs filled. - Air / N2 cylinders charged. - Instrument air supply commissioned. - Fire & Gas interface commissioned. FIRE PANEL Ref. Specification/ Datasheet No.:

24 25 26

Ensure Fire Panel is connected to BOMBA (for onshore). Ensure the fire panel connection and status lights are functioning. FIRE AND GAS SYSTEM Ensure the firefighting system is connected to the fire and gas system. Carry out other commissioning activities according to vendor’s manual

COMMENT(S) AND ADDITIONAL INFORMATION (List the approved specification and datasheet reference number)

Page 2 of 3

PETRONAS CARIGALI SDN. BHD. INSPECTION TEST REPORT ITR-C FIREWATER/FOAM SYSTEM



S10-C

Verified by PMT Inspector PCSB

Accepted by Operations PCSB

Page 3 of 3

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 11.0 APPENDIX IV: ITR OVERVIEW


TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE ARCHITECTURE ITR OVERVIEW FOR CONSTRUCTION

SYSTEM 800-MISCELLANEOUS

SUB SYSTEM 820-ARCHITECTURAL

SUB-SUB SYSTEM 821 822 823 824 825

PROCEDURE NO: CSP-20 REVISION : 01

CONSTRUCTION CHECK SHEET ( A)

DESCRIPTION GENERAL ACCOMODATION SPACES GALLEY / MESS HALL OFFICES COLD ROOM SICK BAY

A01-A X X X X X

A02-A X X X X X

A03-A X X X X X

A04-A X X X X X

A05-A X X X X X

A06-A

A07-A X

X

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE CIVIL ITR OVERVIEW FOR CONSTRUCTION


SUB SYSTEM 860-CIVIL

SUB-SUB SYSTEM 861 862 863 864


DESCRIPTION Process Area ( Inside Battery Limit ) Non Process Area ( Outside Battery Limit) Receiving Area Launching/Export Area

C01-A X X

CONSTRUCTION CHECK SHEET ( A) C02-A C03-A C04-A C05-A X X X X X X X X X X X X X X X X


TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE ELECTRICAL ITR OVERVIEW FOR CONSTRUCTION Sub-Sub System Number

Description

511

Main Power Generation

512

Emergency Power Generation

513

ENMC/PMS

521

Transformers

522

HV switchgear and MCC

523

LV switchgear and MCC

524

Integrated Motor Control System (IMCS) Overhead Line / High Voltage Cable

525

E-01

E-02

E-03

X

X

X

E-04

E-05

E-06

E-07

E-08

E-09

E-10

E-11

E-12

E-13

E-14

E-15

E-16

E-17

E-18

E-19

E-20

E-21

E-22

E-23

E-24

X X X X

X X

E-25

E-26

E-27

E-28

E-29

E-30

E-31

E-32

E-33

E-34

E-35

E-36

E-39

E-40

E-41

E-43

E-44

E-45

E-46

E-47

E-48

E-49

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X

X

526

Capacitor/Reactor

531

AC UPS

532

DC UPS

533

EPU

541

Emergency Distribution Board

X

X

X

X

542

Normal Distribution Board

X

X

X

X

543

X X X

X X X X

Navigation Aid

X 551

Earthing

552

Lightning Protection

561

Variable Speed Drive (VSD)

562

Heater Control System

571

Electric Heaters

572

Heat Tracing System

573

Aux Distribution

574

ICCP System

575

Lighting

576

Sockets

X X X

X

X

X

X

X

X

X

X

X

X

X

X

X

CHECKED / WITNESSED BY CONSTRUCTION CONTRACTOR Representative CARIGALI Inspector CARIGALI Representative

X

X

X X X

X X

X

X X

X X

X

X

X

X

X

X

X

X

X

X

NAME / SIGNATURE / DATE PRECOMMISSIONING NA NA NA

X

X

X

X

X

X

X

X

E-50

TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE ELECTRICAL ITR OVERVIEW FOR PRECOMMISSIONING


Sub-Sub System Number

Description

511


512


513

ENMC/PMS

521

Transformers

522

HV Switchgear and MCC

523

LV Switchgear and MCC

524


525

E-01 E-02 E-03 E-04 E-05 E-06 E-07 E-08 E-09 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-21 E-22 E-23 E-24 E-25 E-26 E-27 E-28 E-29 E-30 E-31 E-32 E-33 E-34 E-35 E-36 E-37 E-38 E-39 E-40 E-41 E-42 E-43 E-44 E-45 E-46 E-47 E-48 E-49 E-50

X

X

X

X X X X

X X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

526

Capacitor/Reactor

531

AC UPS

532

DC UPS

533

EPU

541


X

X

X


X

X

X

542 551

Earthing

552


561


562


571

Electric Heaters

572

Heat Tracing System

573

Aux Distribution

574

ICCP System

575

Lighting

576

Sockets

X X X

X X X X

X

X

X

X

X

X

X X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

CHECKED / WITNESSED BY CONTRACTOR Representative CARIGALI Inspector CARIGALI Representative

X

X

CONSTRUCTION NA NA NA

X

X X

X X

X

X

X

X

X

X

X

X

X

X

X

NAME / SIGNATURE / DATE PRECOMMISSIONING

COMMISSIONING NA NA NA

X

TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE ELECTRICAL ITR OVERVIEW FOR COMMISSIONING



Description

511


512


513

ENMC/PMS

521

Transformers

522

HV Switchgear and MCC

523

LV Switchgear and MCC

524


525

526

Capacitor/Reactor

531

AC UPS

532

DC UPS

533

EPU

541


542


551

Earthing

552


561


562


571

Electric Heaters

572

Heat Tracing System

573

Aux Distribution

574

ICCP System

575

Lighting

576

Sockets

E-01 E-02 E-03 E-04 E-05 E-06 E-07 E-08 E-09 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-21 E-22 E-23 E-24 E-25 E-26 E-27 E-28 E-29 E-30 E-31 E-32 E-33 E-34 E-35 E-36 E-37 E-38 E-39 E-40 E-41 E-42 E-43 E-44 E-45 E-46 E-47 E-48 E-49 E-50

X

X

X

X

X

X

X

X

X X X

X X X

X X

X

X X X

X X

X

CHECKED / WITNESSED BY CONTRACTOR Representative CARIGALI Inspector CARIGALI Representative OPR/Maint Representative

X

CONSTRUCTION NA NA NA NA

NAME / SIGNATURE / DATE PRECOMMISSIONING NA NA NA NA

X

X

X

X

COMMISSIONING

TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE HVAC ITR OVERVIEW

HVAC CHECK SHEET

500-POWER

600-CONTROL AND SAFEGUARDING

700- TELECOMMUNICATION

510- POWER GENERATION

512 513 514

MAIN POWER GENERATION EMERGENCY POWER GENERATION PMS

H21

H20

H19

H18

H17

H16

H15

H14

H13

H12

H11

H10

H09

H08

H07

H06

H05

H04

DESCRIPTION

H03

SUB-SUB SYSTEM

H02

SUB SYSTEM

H01

SYSTEM

X X X

520- DISTRIBUTION

X

530 - UPS

X

610- PROCESS CONTROL

X

620- SAFEGUARDING SYSTEM

X

710- MAIN BACKBONE LINK

X

720- RADIO COMMUNICATION SYSTEM

X

730- VOICE AND DATA COMMUNICATION 740 COMMUNICATION EQUIPMENT


X X

BDV/SDV/XV

Blowdown Valve/Shutdown Valve/Actuated Ball Valve

Instr. Installation

Instr. Tubing Installation & Pressure Testing

Instr. Panel (Electronic) Installation

Instr. Junction Box Installation

Pneumatic Instr. Control Panel (ICP)/ESD Station

CV/SDV/BDV Installation & Calibration

PSV Inspection & Test

Instr. Closed Loop Check

(Reserved for Future Use)

Miscellaneous Process Analyzers Test

Fire & Gas Device Calibration & Installation

Cable Tray Installation Check (Note 11)

Fire and Gas Device Loop Test

Fusible Plug Loop & Panel Installation

Cause & Effect Matrix Verification

N/A

WHCP

N/A

HSSD(VESDA) Installation

Metering Skid

Conduit Installation Check (Note 11)

N/A

Tank Gauging System

MPFM

(Reserved for Future Use)

I-01

I-02

I-03

I-04

I-05

I-06

I-07

I-08

I-09

I-10

I-11

I-12

I-13

I-14

I-15

I-16

I-17

I-18

I-19

I-20

I-21

I-22

I-23

I-24

I-25

I-26

I-27

I-28

X

SY PI/PG PSV PSL

Solenoid Valve Pressure Indicator/Gauge

X

Pressure Safety Valve

X

PSH PSLL

Pressure Switch High

PSHH

Pressure Switch High High

PT

Pressure Transmitter

PR

Pressure Recorder

PIC PY PDI/PDG PDIS PDSL PDSH PDT XGSO TI/TG

Pressure Switch Low

Pressure Switch Low Low

Temperature Switch Low

TSHH

Temperature Switch High High

Temperature Switch High Temperature Switch Low Low

X

X X X

X

X

X

X

X

X

X

X

X

(Note 3)

X

X

X

X

(Note 3)

X

X

X

(Note 3)

X

X

X

X

(Note 3)

X

X

X

(Note 3)

X

X

X

X

(Note 3)

X

X

X

(Note 3)

X

X

X

X

(Note 3)

X

X

X

(Note 3)

X

X

X

X

(Note 3)

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Temperature Indicator/Gauge

TSL TSH TSLL

X

X

Pressure Indication Controller Pressure Relay (I/P) or I/P Converter Pressure Differential Indicator/Gauge Pressure Differential Indicator Switch Pressure Differential Switch Low Pressure Differential Switch High Pressure Differential Transmitter Limit Switch

X

X X

X

X X

X X

X X

X X

X X

X X

X

X

X

X

X

X

X

X

X

X

X

X

Vendor Specification Checksheet

Instr. Calibration

Description

Instr. Fiber Optic Installation & Testing

Instrument Tag No


Instr. Cable Installation & Testing

DE

SC

RI P

TI O

N

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE INSTRUMENTATION ITR OVERVIEW FOR CONSTRUCTION, PRE-COMMISSIONING AND COMMISSIONING

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE INSTRUMENTATION ITR OVERVIEW FOR CONSTRUCTION, PRE-COMMISSIONING AND COMMISSIONING TE/TT TR TIC TY TDSL TDSH TDT LI LG LSL LSH LSLL LSHH LT LIC LY FI/FG FSL FSH FSLL FSHH FE FT FIC FY

Temperature Element/Transmitter Temperature Recorder Temperature Indication Controller Temperature Relay (I/P) or I/P Converter Temperature Differential Switch Low Temperature Differential Switch High Temperature Differential Transmitter Level Indicator Level Switch Low Level Switch High Level Switch Low Low Level Switch High High Level Transmitter

X X X X X

Level Relay (I/P) or I/P Converter Flow Indicator Flow Switch Low Flow Switch High Flow Switch Low Low Flow Switch High High

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X X X X X X

X X X X X X X

X X X X X

X

X

X

X

X

X

X

X X X X

X X X X X X X

X X X X X X X X

X

X

X X X X X

X X X X X

X X

X X X X X

(Note 3) (Note 3) (Note 3) (Note 3) (Note 3)

Flow Element Flow Transmitter

X

(Note 3)

Flow Indication Controller Flow Relay (I/P) or I/P Converter Pig Signaller

Oil Mist Detector Auto Sampler Control Valve + Positioner Position Transmitter Actuated Valve

X X X

(Note 3) (Note 3)

X X X X X X

Shutdown Relay Position Switch

X

Position Indicator Valve Leak Monitoring System

PST MOV

X

Level Indication Controller

Analyzer

SDY ZS ZL

X

Level Gauge

Sand Detector

CV

X

Partial Stroke Testing Motor Operated Valve

X

X

X X

X X X X X X X X X X

Regulator

ESD BDY

End Station

X X

X

Blowdown Relay Key Phasor Velocity Probes Proximity Probes Acceleration Probes Proximeter

X X X X X

X X X X X

X


X X

X

X

X X X X X

X X X X X

(Note 3) (Note 3) (Note 3) (Note 3) (Note 3)

X X X X

X X X X X X

X

X

X

X X X X

X X X X

X X

(Note 3)

X X X

X X X X

(Note 3)

X X X X X X

X X

X X

X X

(Note 3)

X X X X X

(Note 3) (Note 3)

X X X X X X

X X

X

X

X

X X

X X X

X X

X X X X X X X

X

X X X X X X X

X X X X X X

X X X X X

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE INSTRUMENTATION ITR OVERVIEW FOR CONSTRUCTION, PRE-COMMISSIONING AND COMMISSIONING Typical System -113 Well Testing MPFM Wet Gas Meter Test Separator


X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X

X X X

X X

X X

X X

X

X X X

X X X

X X X

X X X

X

X X

X X X

X X X

Typical System -124 Process Liquid Metering and Export/Offloading Metering Package Meter Prover Auto Sampler Typical System -133 Process Gas Metering and Export/Offloading Metering Package Gas Chromatography Densitometer

X X X

Typical System -412 Fire Suppression and Extinguishers (applicable to all suppresion agent)

CSW CSP CDS SW SW PSH XY CAA CVL

Storage Bank Selector Main/Reserve CO2 System Auto Inhibited At MCR CO2 Discharge Station CO2 Manual Release At Fire and Gas Panel Inhibit Key-Switch CO2 System Solenoid AT MCR CO2 Released Pressure Switch CO2 Release Solenoid Valve CO2 Predischarge Horn At MCR CO2 Predischarge Beacon At MCR

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Typical System -413 Deluge Sprinkler

DVS PSH SY FSH SW SW

Deluge Valve Panel Deluge Valve Pressure Switch Deluge Solenoid Flow Switch High - Sprinkler System Deluge Manual Release Pushbutton Inhibit Key-Switch Deluge System Solenoid Typical System -611 Distributed Control System (DCS)

X

(Note 3)

X

X

X

(Note 3)

X

X

(Note 3)

X

X

X

(Note 3)

X

X

(Note 3)

X

(Note 3)

X

X

X

(Note 3)

X

X

(Note 3)

X

(Note 3)

X

X

X

X

X

(Note 3)

X

X

(Note 3)

X

(Note 3)

X

X

(Note 3)

X

X

X

(Note 3)

X

X

(Note 3)

X

(Note 3)

X

X

X

(Note 3)

X

X

X

(Note 3)

X

X

(Note 3)

X

(Note 3)

X

X

X

(Note 3)

X

X

(Note 3)

X

X

(Note 3)

X

(Note 3)

X

X



System Architecture/Block Diagram Power Distribution/Grounding

X X X X

Network Architecture Subsystem Interfaces Typical System -612 Supervisory Control And Data Acquisition (SCADA) System Architecture/Block Diagram Power Distribution/Grounding

X X X X

Network Architecture Subsystem Interfaces Typical System -613 Information Management System (IMS) System Architecture

X X X

PC/Server Interfacing Typical System -621 Safety Instrumented System (SIS) System Architecture/Block Diagram Power Distribution/Grounding

X X X X

Network Architecture Subsystem Interfaces Typical System -622 Fire and Gas System

HD SD FD GD

HSSD (VESDA)

Heat Detector (NOTE 8)

Gas Detector (NOTE 8)

X X X X

Manual Callpoint/Breakglass (NOTE 8)

X

Beacon (NOTE 8)

X

X

High sensitive smoke detection apparatus

X

X

Smoke Detector (NOTE 8) Flame Detector (NOTE 8)

X X X X

X X X X

X X X X

X

X X X X

X

X X X X

X X X X

(Note 4)

X

X

(Note 4)

X

X (Note 4) X (Note 4)

(Note 4) (Note 4) (Note 4)

Typical System -623 Fusible Plug Loops

FP HA PSL

Fusible Plugs Kill Knobs Pressure Switch Low

X

X

X X X

X X X

X X

X

X X X

X X X

X



Typical System -624 High Integrity Pressure Protection System (HIPPS) Safety Controller

X

Typical System -625 Wellhead Control Panel (WHCP)

PSH/PSL PSD ESD SCSSV SSV HS

High-Low Pilot

X

X

Process S/D Signal Emergency S/D Signal Subsurface Safety Valve (Hyd. Tubing Lines) Surface Safety Lines (Hyd. Tubing Lines) Open/Close Hand Switch

X X X

X

X X X

X X X

X X X

X

X

X

X

X

X

X

X

X

X

X X

Typical System -626 Instrument Control Panel (ICP)

PSH/PSL PSD ESD HS

High-Low Pilot Process S/D Signal Emergency S/D Signal Open/Close Hand Switch

X

X

X X X

X X X X

CHECKED / WITNESSED BY CONSTRUCTION

X

X X X X NAME / SIGNATURE / DATE PRECOMMISSIONING

X X X

COMMISSIONING

CONTRACTOR Representative CARIGALI Inspector CARIGALI Representative OPR/Maint Representative Notes:1. The above checksheet overview identifies only typical instruments and typical loops. CONTRATOR shall be responsible to identify the applicable instrument loops and compiled them in the blank Instrument Checksheet Overview in system basis 2. System number and its description including instrument tagging shall be indicated as applicable for the specific projects or works. 3. Applicable for electric-type instruments only. 4. For Fire and Gas devices, Fire and Gas Cause and Effect Matrix shall be used. 5. I01, I02, I03, I04, I05, I06, I07, I09, I10, I14 ,I15, I17 ,I22 and I24 shall be completed during Construction phase. 6. I11, I16, I18 and I22 shall be completed during Pre-commissioning and Commissioning phase. 7. I8, I13, I20, I23, I26 and I27 shall be completed during Pre-commissioning and Commissioning phase. 8. Inclusive addressable. 9. Ensure completed and approved checksheet of proceeding stage is available attached before proceeding with the next stage. Eg: For Pre-commissioning stage, ensure construction checksheet is attached. 10. Checksheet overview shall be used as a reference to monitor the check sheet status. 11. ITR will only be utilized when applicable.

TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE MECHANICAL ITR OVERVIEW

100-PROCESS

110 -FULL WELL STREAM

111 112 113

WELLHEADS (DRY TREES) WELLHEADS (WET TREES) WELL TESTING

121 122 123 124

PL COLLECTION AND RECEIVING PL SEPARATION (OIL FACILITIES) PL TRANSFER / STORAGE SYSTEM PL METERING AND EXPORT / OFFLOADING

X X

130-PROCESS GAS

131 132 133

PG COLLECTION AND RECEIVING PG SEPARATION (GAS FACILITIES) PG METERING

X X

140-GAS COMPRESSION

141 142 143 144 145

SUCTION MANIFOLD EXPORT COMPRESSION TRAIN DISCHARGE MANIFOLD EXPORT / DOWNHOLE INJECTION TURBO EXPANDER

151

ABSORPTION (GLYCOL DEHYDRATION TRAIN-1… X) ADSORPTION DIRECT COOLING (HYDROCARBON DEW POINT)

120 - PROCESS LIQUID

150-GAS DEHYDRATION

152 153

160-WATER INJECTION

200-PROCESS UTILITIES

M49

M48

M47

M46

M45

M44

M43

M42

M41

M40

M39

M38

M37

M36

M35

M34

M33

M32

M31

M30

M29

M28

M27

M26

M25

M24

M23

M21

M20

M19

M18

M17

M16

M15

M14

M13

M12

M11

M10

M09

M08

M07

M06

M05

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

180-CONTAMINATE REMOVAL 181

MERCURY REMOVAL UNIT

X

210-UTILITY GAS

211 212


X X

221 222

NITROGEN (Nitrogen Generation & Nitrogen Bottles) SPENT GAS

231 232

ATMOSPHERIC VENT FLARE

241 242


250-DRAIN

251 252 253 254


260-PROCESS HEATING

261

Waste heat Recovery /Hot Oil /Warm Oil Sub-subsystem

270-CHEMICAL DOSING

271 272 273 274 275 276 277 278 279-1 279-2 279-3 279-4

SODIUM HYPOCHLORITE POLYELECTROLYTE COROSSION INHIBITOR DIESEL GLYCOL ANTIFOAM SCALE INHIBITOR DEMULSIFIER REVERSE DEMULSIFIER PH MODIFIER BIOCIDE METHANOL

X

X

X


240-PRODUCED WATER

X

X X X X X

171

230-VENTING

X X X X


220-INERT GAS

M04

X

161 162 163 164 165

170-ACID GAS REMOVAL

M22

MECHANICAL CHECK SHEET

DESCRIPTION

M03

SUB-SUB SYSTEM

M02

SUB SYSTEM

M01

SYSTEM


X

X

X

X

X

X

X

X

X

X

X

X X

X X

X X

X X

X X

X

X X X X X

X

X

X

X

X X

X

X X

X X

X

X

X

X X

X

X

X

X X X X X X X X X X X X



TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE MECHANICAL ITR OVERVIEW

300-GENERAL UTILITIES

279-5

PPD

X

X

311

DIESEL FUEL

X

X

312 313

JET FUEL LUBRICATION OIL

X

321 322 323

INSTRUMENT AIR UTILITY AIR BLACK START/STARTING AIR

331 332 333 334 335 336

SERVICE WATER FRESH AND DISTILLED WATER FEED WATER POTABLE WATER HOT WATER COOLING WATER

340-STEAM

341 342 343


410- FIREFIGHTING

411 412 413

FIREWATER DELUGE AND SPRINKLER TOTAL FLOODING FIRE SUPRESSION

510- POWER GENERATION

512 513 514

MAIN POWER GENERATION EMERGENCY POWER GENERATION PMS

811 812 813 814

PEDESTAL CRANE OVERHEAD/GANTRY CRANE MONORAIL/TROLLEY HOIST ELEVATORS

832

AVIATION REFUELLING

310-FUEL AND LUBRICATION

320-COMPRESSED AIR

330-WATER

400-SAFETY

500-POWER

800-MISCELLEANOUS


810- MATERIAL HANDLING

830-AVIATION

X

X X X

X X

X X

X

X X X X X X

X X X X X

X

X X

X

X X

X

X X X X X

X X X

X X

TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE PIPING ITR OVERVIEW

X X X

X X X

X X X

X X X

X X X

120 - PROCESS LIQUID

121 122 123 124 125 126

PL COLLECTION AND RECEIVING PL SEPARATION (OIL FACILITIES) CRUDE OIL STABILISATION CONDENSATE STABILISATION PL TRANSFER / STORAGE SYSTEM PL METERING AND EXPORT / OFFLOADING

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

130-PROCESS GAS

131 132 133

PG COLLECTION AND RECEIVING PG SEPARATION (GAS FACILITIES) PG METERING

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

140-GAS COMPRESSION

141 142

SUCTION MANIFOLD OFF GAS COMPRESSOR

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

143 144 145

COMPRESSOR TRAIN (BOOSTER/ EXPORT/GAS LIFT/GAS INJECTION) DISCHARGE MANIFOLD EXPORT / DOWNHOLE INJECTION

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

151

GAS DEHYDRATION TRAIN (WATER DEW POINT)ADSORPTION

X

X

X

X

X

X

X

X

X

X

X

X

X

152 153 154

TURBO EXPANDER(WATER DEW POINT) DIRECT COOLING (HYDROCARBON DEW POINT) (HYDROCARBON DEW POINT)

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

160-WATER INJECTION

161 162 163 164 165


X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

X X X X X

170-ACID GAS REMOVAL

171


X

X

X

X

X

X

X

X

X

X

X

X

X

X

180-CONTAMINATE REMOVAL

181

MERCURY REMOVAL UNIT(ADSORPTION)

X

X

X

X

X

X

X

X

X

X

X

X

X

X

210-UTILITY GAS

211 212


X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

220-INERT GAS

221

NITROGEN (Nitrogen Generation & Nitrogen Bottles)

X

X

X

X

X

X

X

X

X

X

X

X

222

SPENT GAS

X

X

X

X

X

X

X

X

X

X

X

X

231 232

ATMOSPHERIC VENT HP FLARE LP FLARE

X X X

X X X

X X X

X X

X X X

X X X

X X X

X X X

X X X

X X

X X

X X X

240-PRODUCED WATER

241 242


X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

250-DRAIN

251 252 253 254


X X X X

X X X X

X X X X

X X X X

X X X X

X X X X

X X X X

X X X X

260-PROCESS HEATING

261 262

HOT OIL WARM OIL

X X

X X

X X

X X

X X

X X

X X

X X

X X

270-CHEMICAL DOSING

271 272 273 274 275 276 277 278 279-1 279-2 279-3 279-4 279-5

SODIUM HYPOCHLORITE POLYELECTROLYTE COROSSION INHIBITOR DIESEL GLYCOL ANTIFOAM SCALE INHIBITOR DEMULSIFIER REVERSE DEMULSIFIER PH MODIFIER BIOCIDE METHANOL POUR POINT DEPRESSANT (PPD)

X X X X X X X X X X X X X








310-FUEL AND LUBRICATION

311 312 313

DIESEL FUEL JET FUEL LUBRICATION OIL

X X X

X X X

X X X

X X X

X X X

X X X

X X X

320-COMPRESSED AIR

321 322 323

INSTRUMENT AIR UTILITY AIR BLACK START/STARTING AIR

X X X

X X X

X X X

X X X

X X X

X X X

330-WATER

331 332 333 334 335 336

SERVICE WATER FRESH AND DISTILLED WATER FEED WATER POTABLE WATER HOT WATER COOLING WATER

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

340-STEAM

341 342 343


X X X

X X X

X X X

X X X

410 FIREFIGHTING

411 412

FIREWATER DELUGE AND SPRINKLER

X X

X X

X X

512 513

MAIN POWER GENERATION & ENMC EMERGENCY POWER GENERATION

X X

X X

832

AVIATION REFUELING

X

X

230-VENTING

830- AVIATION

X

X

X X

X

X X

X X

X X





X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X X

X

X

X

X

X

X

X

X

X

X

X X X

X

X X

X

X X X X

P16-C Nitrogen Purging

X X X

P15-B Lube Oil Flushing

P06-B Flanges Management

X X X

P14-B Witness Joint

P04-B2 Re-instatement Leak Test

X X X

P10-B Service Test

P04-B1 Reinstatement Work

X X X

P13-A Cretical Valve Leak Test

X X X

P12-A Pipe Insulation

P07-A Bolt Tensioning/Torqing

X X X

P11-A Painting /Coating /Marking

P06-A Flanges Alignment

X X X

P10-A Service Test

P05-A Blowing/Draying

X X X

P09-A Re-installation Work

P04-A Pressure Test

WELLHEADS (DRY X-MAS TREES) WELLHEADS (WET TREES) WELL TESTING

P08-AChemical Cleaning

P03-A Flushing

PRECOMM ITR ( B )

111 112 113

200-PROCESS UTILITIES

400-SAFETY

CONSTRUCTION ITR ( A)

DESCRIPTION

110 -FULL WELL STREAM

150-GAS DEW POINTING

300-GENERAL UTILITIES

SUB-SUB SYSTEM

P02-A Pre-Test

100-PROCESS

SUB SYSTEM

P01-A Pipe Work Completion

SYSTEM


X X X X

X X X

X X X

X

X


Escape Routes and Signs

Safety Shower/Eyewash

Survival Equipment

Breathing Apparatus

Fire hose and Monitor

Portable & Wheeled Fire Extinguisher

Fireman Outfit Cabinet

Miscellaenous Safety Equipment

Liferaft

Firewater /Foam system

Fire Suppression/Total Flooding System

Escape and Evauation Equipment

LEV

Sickbay

Deck Integrated Fire Fighting System

DE

SC

RI

PT I

ON

TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE SAFETY ITR OVERVIEW FOR CONSTRUCTION

S-01

S-02

S-03

S-04

S-05

S-06

S-07

S-08

S-09

S-10

S-11

S-12

S-13

S-14

S-15


Description

411

Firewater/ Foam System

412

Total Flooding and Fire Suppression System

413

Portable/ Wheeled Fire Extinguisher

414

Deck Integrated Fire Fighting System (DIFFS)

421

Liferafts

422

Lifeboat/ Survival Craft/ TEMPSC Use M 12- ITR

423

Escape and Evacuation

424

Safety Equipments

X X X X X

X

X X

X

CHECKED / WITNESSED BY

NAME / SIGNATURE / DATE CONSTRUCTION

CONTRACTOR Representative CARIGALI Inspector CARIGALI Representative OPR/Maint Representative Notes:1. This overview is ONLY a generic sample for projects to follow. Every project to produce a detailed check sheet over view for each project stage (construction/installation-A, precommissioning-B and commissioning-C) based actual equipment installed and the overview shall include the equipment tagging as well. 2. Checksheet overview shall summarise all the tagged items and shall be used for monitoring of the check sheet status. 3. Ensure completed and approved checksheet of proceeding stage is available attached before proceeding with the next stage. Eg: For Pre-commissioning stage, ensure construction checksheet overview is attached.



Liferaft

Lifeboat/ Survival Craft/ TEMPSC

Escape and Evaucation Equipments

Safety Equipments

Safety Shower/ Eyewash

Intrument ITR - Fire and Gas Loop

S-03

S-04

S-05

S-06

S-07

S-08

S-09

I-16

Mechanical ITR - Survival Craft and Davit

Portable/ Wheeled Fire Extinguishers

S-02

Mechanical ITR - Fire Water Pump

Fire Suppression

S-01

Piping ITR - Firewater Ringmain


DE

SC RI PT IO

N

TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE SAFETY ITR OVERVIEW FOR PRE-COMMISSIONING


Description

411


412


413


414


421

Liferafts

422


423

Escape ande Evacuation

424

Safety Equipments


X

X X

M-18

X

X

X

X

X

X

X NAME / SIGNATURE / DATE PRE-COMMISSIONING




Liferaft


Escape and Evaucation Equipments

Safety Equipments

Safety Shower/ Eyewash

Intrument ITR - Fire and Gas Loop

S-03

S-04

S-05

S-06

S-07

S-08

S-09

I-16

Mechanical ITR - Survival Craft and Davit

Portable/ Wheeled Fire Extinguishers

S-02

Mechanical ITR - Fire Water Pump

Fire Suppression

S-01

Piping ITR - Firewater Ringmain


DE

SC RI P

TI

ON

TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE SAFETY ITR OVERVIEW FOR COMMISSIONING


Description

411


412


413


414


421

Liferafts

422


423

Escape ande Evacuation

424

Safety Equipments


X

X

M-18

X

X

X

NAME / SIGNATURE / DATE COMMISSIONING


TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE STRUCTURAL ITR OVERVIEW FOR CONSTRUCTION


SUB SYSTEM 850-Structure

SUB-SUB SYSTEM 851 852 853 854 855


DESCRIPTION Topside Jacket Living Quarters (LQ) Bridges Telecom Tower

S01-A X X X X X

S02-A X X X X X

S03-A X

CONSTRUCTION CHECK SHEET ( A) S04-A S05-A S06-A S07-A X

X

X

S08-A X X

S09-A X X

X

X

X X

TESTING, PRECOMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE TELECOM ITR OVERVIEW

X

X

X

X

730- VOICE AND DATA COMMUNICATION

732 733 734 740- SURVEILLANCE AND SAFETY SYSTEM

750- COMMUNICATION EQUIPMENT

741 742 743

PABX & TELEPHONE (ANALOG/DIGITAL) CCTV METEOROGICAL SYSTEM

751

ENTERTAINMENT SYSTEM

X X X

X X X

X X

X X

X

X

X

X

X

X

X X X X X

X X X X X

X X

X X

X X

X X

X X

X X

X

X

X

X

X X

X X

X

X

X

X X X

X

X

X

X

X

X X

X X

X

X

X X

X

X X X

X

X

T13-B Entertainment System

X

T12-B Telecom Fibre Optic Cable Test

T11-B Radio Communication Test

PABX & TELEPHONE (ANALOG/DIGITAL) LAN & WAN NETWORK MANAGEMENT SYSTEM (NMS) MOBILE BROADBAND

T06-B Telecom Panel

731

720- RADIO COMMUNICATION

T05-B Telephone /LAN port Verification & Cable Test

VHF/AM (AVIONICS) HF/SSB RADIO SYSTEM NON-DIRECTIONAL BEACON (NDB) DIGITAL TRUNK RADIO WIRELESS SYSTEM

X

T04-B PAGA

722 723 724 725 726

X

T03-B CCTV

VHF/FM (MARINE)

X

T10-A LAN/WAN

721

X

T09-A VHF AM

713 714 715

VERY SMALL APERTURE TERMINAL (VSAT) SATELITE SYSTEM FIBRRE OPTIC TRANSMISSION UHF RADIO LINK TROPOSCATTER RADIO SYSTEM

X

T08-A VHF FM

712

T07-A Telecom Junction box

MAIN MICROWAVE RADIO (DMR)

T05-A Indoor/Outdoor Telephone

711

PRECOMM CHECK SHEET ( B )

T06-A Telecom Panel

SYSTEM 700TELECOMMUNICATION

T04-A PAGA

710 - MAIN BACKBONE LINK

CONSTRUCTION CHECK SHEET ( A)

DESCRIPTION

T03-A CCTV

SUB-SUB SYSTEM

T02-A Fibre Optic

SUB SYSTEM

T01-A Telecommunication Cable

SYSTEM


X X X X

X

X X X

TESTING, PRE-COMMISSIONING AND COMMISSIONING GUIDELINE CARIGALI STANDARD PROCEDURE 12.0 APPENDIX V: OVERALL SYSTEM DESCRIPTION


GENERIC SYSTEM OVERVIEW - DESCRIPTOR AND MAJOR EQUIPMENT SYSTEM L1 100

PROCESS

SUB SYSTEM L2 110

FULL WELL STREAM

SUB SUB SYSTEM L3 111

112

113

120

121

BRIEF DESCRIPTOR (Boundary & Purpose)

Major Equipment (List of Major Equipment in the System)

WELLHEAD (DRY X- A Wellhead is the component at the surface of an oil or gas well that provides MAS TREES) the structural and pressure-containing interface for the drilling and production equipment. Chrismas (X-mas) tree is an assembly of valves, spools, and fittings used for an oil well, gas well, water injection well, water disposal well, gas injection well, condensate well and other types of wells. Dry X-mas trees are installed on the surface. Offshore, where a wellhead is located on the production platform it is called a surface wellhead

The major components covered by Topside Contractor are: • Production Choke Valve (PCV) • Position Transducer (ZT) • Downstream Pressure/ Temperature (DPT)

WELLHEADS (WET The subsea X-mas tree sits on top of the subsea wellhead and provides a means TREES) to monitor and control oil or gas production from well, or injection of water or gas into a well. A subsea Xmas tree maybe a vertical type or a horizontal type depending on valve configuration

The major components are: • Tubing Retrievable Surface Controlled Subsurface Safety Valve (TRSCSSV) / Surface Controlled Subsurface Safety Valve (SCSSV) • Annulus Master Valve (AMV) • Annulus Access Valve (CIV) • Methanol Injection Valve (MIV) • Crossover Valve (XOV) • Production Master Valve (PMV) • Production Wing Valve (PWV) • Production Choke Valve (PCV) • Downhole Pressure /Temperature Gauge (DHPTG) • Annulus Pressure/Temperature (APT) • Upstream Pressure/ Temperature (UPT) • Subsea Multiphase/Wet Gas Flow Meter (MPFM/WGFM) • Position Transducer (ZT) • Downstream Pressure/Temperature (DPT) • Acoustic Sand Detector (ASD) • Subsea Control Module (SCM). Other associated equipment for subsea production system (SPS) may include but not limited to: • Jumper • Manifold • Pipeline End Termination (PLET)/Pipeline End Manifold (PLEM) • Flowline • Umbilical/Hydraulic Flying Leads (HFL)/Electrical Fling Leads (EFL) • Subsea Umbilical Termination Assembly (SUTA)

WELL TESTING

The major components covered by Drilling Contractor • Annulus Master Valve (AMV) • Annulus Access Valve (AAV) • Chemical Injection Valve (CIV) • Production Master Valve (PMV) • Production Wing Valve (PWV) • Downhole Pressure /Temperature Gauge (DHPTG) • Annulus Pressure/Temperature (APT) • Upstream Pressure/ Temperature (UPT)

The Sub Sub-System is generally associated with its boundaries defined from the Test Separator, Multiphase Flow Meter (MPFM) , Wet Gas Meter (WGM) Test headers to the well testing facilities. It includes equipment such as Test Separator, Multi phase flow meter (MPFM) Wet Gas Meter (WGM) for well testing which is located at each individual flowline also included in this sub subsystem. Each of the Well flow lines is provided with a connection to Test header. During testing of a well, the corresponding flow line is opened into the Test separator via the test header and its connection to the production header is isolated. Only one flow line is opened into the Test separator at a time. The instruments on the Test Separator are level transmitters to control the flow rate of water and oil, pressure transmitter, local temperature gauge, level gauges and pressure gauges.

PROCESS LIQUID This sub-sub-system is generally associated with process crude with its (PL) COLLECTION boundaries defined from the wellheads to the respective collection headers AND RECEIVING and/or from a receiving pipeline riser to the inlet of a separator vessel

Typical Schematic

Equipment in the sub-sub-system includes production headers, test headers, flowlines from the production wells, choke valves and production manifold. It also includes associated instruments such as pressure and temperature gauges and transmitters.

V-CONE TYPE BDS

H FM

TEST SEPARATOR

L

FQI

FROM TEST MANIFOLD

SDV

PC

P-12

WCM

FI PCV

BDV

PT

TT FT

SDV

S

PDT

LC

PT

FT

TC

WET GAS METER COMPUTER (FMC)

FI LCV

TT

SDV

H FLA

L

VENTURI TYPE FE

GENERIC SYSTEM OVERVIEW - DESCRIPTOR AND MAJOR EQUIPMENT SYSTEM L1

SUB SYSTEM L2 PROCESS LIQUID


123

130


PROCESS LIQUID Separation Vessel are equipped with internal weirs; baffle plate, etc/ to (PL) SEPARATION segregate crude, gas and water. Gas being the lightest would be release at the (OIL FACILITIES) top of the vessel whereas water and crude outlets are generally located at the bottom of the vessel.

CRUDE OIL STABILISATION

Crude oil received from Separator is fed to crude oil stabilization unit for removing the light gas along with hydrogen sulfide before the oil is stored and transporting for downstream uses. The crude stabilization process sweetens the Sour crude and reduces the vapor pressure to make safe for shipments.


Typical Schematic

HP/MP/LP Production Separator, Free Water Knockout (FWKO), Exchanger/Heater, Crude stabilizing unit (CSU). It also involve associate instrument such as relief valves, pressure and temperature gauge and transmitter, level indicators and flow elements.

Comprises of Flash Drum, Desalter, Dehydration Vessel, Crude Stabilization Column, Kettle Reboiler, Pumps etc. It includes the extensive pipework and instruments like Shutdown valves, Control valves for various application, Analyzers, transmitters and indicators.

124

PL TRANSFER / The cargo system associates with FPSO/FSO are PFS/Spar facilities that normally Cargo tank, Cargo pump-steam driven, Stripping pump, Hydraulic Operated STORAGE SYSTEM consists of Cargo tanks, cargo pumps, cargo eductors. It cover storage for crude valves, Tank Gauging, Heat tracing,/Exchanger/Heater, Crude Oil Washing oil, crude offloading/export, crude oil washing and crude stripping facilities. The (COW), Eductor cargo tank is normally equipped with tank gauging using radar sensor / guided microwave sensor to monitor and analyze level content of cargo oil tank and slop tank. It also fitted with temperature sensor to monitor the fluid temperature.

125

PROCESS LIQUID Inclusive of several skid equipment originating from the disharge nozzle of a (PL) METERING separator or surge vessel through a pumping and metering sub-subsystem AND EXPORT / before ending at the shutdown valve downstream of scraper launcher. OFFLOADING

131

PROCESS GAS (PG) Process gas is collected and received in a manner identical to liquid collection COLLECTION AND and receiving system. It comprises of Production Gas Header, Riser shutdown RECEIVING valve, receiver and associated piping and instrumentation

Crude Oil Transfer Pump (COTP), Metering runs, flow element (e.g turbine, orifice), Metering Control System, Meter Prover, Auto sampling station, Export launcher, Heat tracing/Exchanger/Heater

Production Gas Header, Riser shutdown valve, Slug Catcher HIGH PRESSURE FLARE (HPF)

HPF SCRAPER LAUN CHER

SCRAP ER RECEI VER PROD UCTION HEAD ER

PROCESS GAS

132

PROCESS GAS (PG) Slugcatcher is used to saperate liquid in the gas. As gas passes through the SEPARATION (GAS vessel, an arrangement of baffle plates reduces velocity of the incoming gas FACILITIES) thus providing opportunity for the heavier hydrocarbon component to precipitate into liquid. This liquid is called condensate. There is also a possibility of other forms of liquid such as water to be present that requires removal as well.

HPF

Slug Catcher, Production Separator, Surge vessel, pressure relief subsystem, associated piping and instrumentation SLUGCATCHER

GAS WELL

Figure 2.4 Process Schematics for Gas Receiving and Collection

GENERIC SYSTEM OVERVIEW - DESCRIPTOR AND MAJOR EQUIPMENT SUB SYSTEM L2


134

CONDENSATE STABILISATION

BRIEF DESCRIPTOR (Boundary & Purpose) Condensate received from slug catcher and Knockout drum is fed to stabilization unit to reach the required specification for transportation of condensate or for the use of the condensate in drown stream process. The stability is specified in True Vapor Pressure or Reid Vapor Pressure (TVP or RVP).

PROCESS GAS (PG) On a gas processing facility, gas export sub-sub-system boundary begins from METERING the discharge of a liquid knockout vessel or a separator to the riser shutdown valve at the export pipeline. However, on a gas compression facility the boundary for gas transfer and metering sub-sub-system is identified from the end of the discharge manifold system (see sub-sub-system 145) to the riser shutdown valve of the particular export pipeline.


Typical Schematic

Comprises of Surge Drum, Filter Coalescer, Stabilization column, Pumps, Exchangers and Re-boiler etc. It includes the extensive pipework and instruments like Shutdown valves, Control valves for various application, Analyzers, transmitters and indicators.

Gas metering runs, flow element (e.g ultrasonic meter, orifice), Metering Control System, Gas Chomatograph, Auto sampling station, Export launcher

GAS SAMPLING AND ANALYZER CABINET (OFFSKID)

SSC

MANUAL SPOT SAMPLING

SSC GC PRIMARY SAMPLE CONDITIONING SYSTEM

GC SECONDARY CONDITIONING SYSTEM

GAS CHROMATOGAR PH (PAY)

GC PRIMARY SAMPLE CONDITIONING SYSTEM

GC SECONDARY SAMPLE CONDITIONING SYSTEM

GAS CHROMATOGRA PH (CHECK)

MOISTURE ANALYZER

M

M

M

M

QT

PG

TG

TT

TW M

M

M

M

M

M

M

M

M

PT

FT

SSV M

PT

FT

QT

PG

TG

TT

TW

M

SSV

M

SYSTEM L1

140

141

SUCTION MANIFOLD

Suction manifold is pipework from gas outlet of Separator or Slug catcher to the Suction manifold, shutdown valves, gauges, transmitters and indicators inlet of a compressor scrubber or a heat exchanger.

PT

FT

SSV

QT

SURGE CONT ROL VALVE

SDV

INLET SCRUBBER

TT

TW

2ND ST AGE COOLER

1ST ST AGE COOLER

INT ERST AGE SCRUBBER COMP RESSOR (FIRST STAGE)

GAS

TG


SUCT ION HEADER INLET COOLER

PG

COMP RESSOR (SECOND ST AGE)

SUPPLY

T EMP ERAT URE MIXING VALVE MODULE RECYCLE VALVES (INT ERST AGE)

GLYCOL CONT ACT OR

LOW P RESSURE SEP ARAT OR

GAS/ GLYCOL EXCHANGER

HIGH P RESSURE SEP ARAT OR DISCHARGE SCRUBBER

DISCHARGE COOLER

TO INJECT ION HEADER

COMP RESSOR (T HIRD STAGE)

MODULE RECYCLE VALVES (DISCHARGE) DISCHARGE HEADER

Figure 2.5 Process Schematics for Gas Compression consisting of Suction Manifold, Compression Train and Discharge Manifold Sub-subsystems

GAS COMPRESSION

142

OFF GAS COMPRESSOR

The combined off gas streams from Crude/Condensate stabiliser, Surge Drum and acid gas of GSU are compressed by two stages centrifugal compressors. Off gas compressor are driven by fixed/variable speed motor. Each stage is equipped with its own Anti-surge/Recylce control valve designed for full flow condition. The main components of the system are shown in the Fig XX below.

Off Gas Compressor train Sub-subsystem is divided into smaller components such as: i) Prime movers for compressors is electric motor, ii) Speed reducing gearbox, iii) Centrifugal Compressors iv) Scrubber vessels, v) Control panels, and vi) Ancillary subsystems; for example Dry gas seal, fuel gas, diesel, air inlet filtration, start system, etc. It also includes numerous instrumentations. Usually, a gas compression system is equipped with its own control system and it is linked to other control systems such as DCS, SIS and FGS.

143

COMPRESSION TRAIN (EXPORT/GAS LIFT/GAS INJECTION)

Inclusive where applicable of prime movers (Turbine or ICE or EM), Gearbox, compressor (Centrifugal or Recip), heat exchanger, scrubber/vessels, control panels, and ancilliary equipment. It also includes numerious instrumentations. Usually, a gas compression system is equipped with its own control system and it is linked to other control systems such as DCS, SIS and FGS.

Prime mover, gearbox, Compressor, Ancilliaries such as fuel gas, lube oil, dry gas seal and Anti-surge system Compressor control panel

144

DISCHARGE MANIFOLD

Sub subsystem starts at the outlet of the discharge scrubber or a heat exchanger of the compressor train and ends at the inlet nozzle to the lift gas distribution network

Discharge manifold, Shutdown valve, gauges transmitters and indicators



SUCT ION HEADER INLET COOLER SDV

GAS

2ND ST AGE COOLER

1ST ST AGE COOLER

INLET SCRUBBER

INT ERST AGE SCRUBBER COMP RESSOR (FIRST STAGE)

COMP RESSOR (SECOND ST AGE)

SUPPLY

T EMP ERAT URE MIXING VALVE MODULE RECYCLE VALVES (INT ERST AGE)

LOW P RESSURE SEP ARAT OR

GLYCOL CONT ACT OR GAS/ GLYCOL EXCHANGER

HIGH P RESSURE SEP ARAT OR DISCHARGE SCRUBBER

DISCHARGE COOLER

TO INJECT ION HEADER

COMP RESSOR (T HIRD STAGE)

MODULE RECYCLE VALVES (DISCHARGE) DISCHARGE HEADER

Figure 2.5 Process Schematics for Gas Compression consisting of Suction Manifold, Compression Train and Discharge Manifold Sub-subsystems


SUB SYSTEM L2


EXPORT / DOWNHOLE INJECTION



Every installation after processing of oil or gas is required to be exported to next Export Launcher, Injection Well, FPSO offloading facilities, pipelines user. Oil and/ or gas is exported through long pipelines from offshore installation to onshore plant. Pipelines are normally provided with pig launcher in this case called Export Launcher. Note: To modify description (suggest to separate into 2 subsystem) 1. Export 2. Downhole Injection For the reservoir maintenance and ultimate more oil recovery, reservoir is flooded with gas or water. Thus water or gas is injected in the reservoir. The injection is done through X-mas trees. Normally X-mas tree is on the surface but water or gas through X-mas tree is injected in the reservoir and sometimes called downhole injection.

150

GAS DEW POINTING

151

GAS DEHYDRATION TRAIN(WATER DEW POINT)

152

ADSORPTION (WATER DEW POINT)

153

TURBO EXPANDER/BOOST ER COMPRESSOR (HYDROCARBON DEW POINT)

Removing water vapor from the gas is important because it prevents hydrates from forming when the gas is cooled in the transmission and distribution systems and prevents water vapor from condensing that create corrosion problem. Glycol contactor is a pressure vessel used in gas dehydration process. It is a vertical vessel equipped with several trays of small outlets that are methodically situated. Instead of trays Glycol Contactor can have structured packing also. As wet gas or gas laden with water vapor travels from bottom of the vessel upwards, it meets with the glycol that is sprayed from the top. As glycol has a very high affinity for water, water vapor is extracted from the gas thus making the gas dry.

Glycol contactor, glycol/gas heat exchanger, glycol storage vessel, The major equipment are Glycol contactor, glycol/gas heat exchanger, glycol storage vessel, glycol transfer pumps, complete glycol regeneration package (re-boiler, skimmer vessel, charcoal/glycol filters, heat exchangers, glycol trim cooler/fan and electrical motor drivers etc.), anti-foam chemical injection system, local control panel, thyristor control panel, dew point analyzer and all associated piping, valves, instrumentation, moisture analyzer, tubing, instrument/electrical cabling and junction boxes. The Sub-Subsystem comprises of a contactor vessel and regeneration skid and its associated piping and instrumentation.

Adsorption is the adhesion of water molecules from a gas, liquid, or dissolved Adsorption bed, Regereation unit, heat exchanger, cooler, LCP, Dew point solid to a surface. This process creates a film of the adsorbate on the surface of analyser and all associated piping, valves, instruments, moisture analyser, the adsorbent . Note that adsorption is a surface-based process while tubing, electrical cabling and JB. absorption involves the whole volume of the material. Solid desiccants, Molecular sieves used as adsorbents.

The turbo expander / Booster Compressor unit is used to provide refrigeration for the sales gas purification/treatment process in a hydrocarbon processing plant. It is representative of a natural gas dew point control process where the low pressure ratio expander cools the gas only enough to lower the hydrocarbon dew point to be appropriate for pipeline transmission of the gas. Expander outlet liquid fractions are usually in the range of 2 to 8% by weight.

Turbo expander/Booster Compressor is equipped with following:

i) Quick Shut off Valve ii) Joule-Thompson Control Valve iii) Anti-Surge Controller iv) Variable guide Vane v) Dry Gas Seal The expansion turbine is of the radial inflow type with advanced aerodynamic vi) Active Magnetic Bearing(AMB) design maximizing the isentropic efficiency. The machine is of a proven cartridge vii) Automatic Thrust Balancing Unit concept which allows a quick replacement of the machinery capsule including viii) Cold Vessel Recovery Unit rotating parts without interference with expander process pipes. ix) Suction and Discharge Knockout Drums x) Magnetic Bearing Control System A high efficiency compressor wheel is utilized as a loading device, recovering the mechanical energy from the expander. A vane diffuser ensures optimum efficiency and head flow characteristic.

Typical Schematic


SUB SYSTEM L2


160

161

WATER INJECTION

162


DIRECT COOLING Hydrocarbon Dew Point system is designed to inhibit the formation of solid (HYDROCARBON hydrates in the gas stream i.e. to perform a level of dehydration. DEW POINT)

The major equipment are Refrigeration Compression package, Dew point control package. The system includes the refrigeration system. This is achieved through the injection of a liquid agent directly into the gas stream. The liquid agent is selected based on low viscosity and low freezing temperature rather than dehydration ability.

SEAWATER INTAKE Normally found only on water injection facilities, seawater intake sub-subThe Sub-Subsystem includes one or more electric-motor-driven submerged system starts from the submersible "lift" pump to the inlet of a coarse filtration centrifugal pumps, vacuum relief valves, discharge pipings, Sea Water Lift unit. Installation of the pumps are frequently performed offshore as it requires Pump (SWLP), Electro- chlorination package and associated instrumentations. pre-installation of its "caissons"; tubular structures where the pumps are protected from the surrounding oceanic environment. However, the respective discharge pipings and control instrumentation are preinstalled in the fabrication yard.

FILTRATION

There are two types of filtration equipment provided for in this sub-subsystem. One is called "coarse" filtration and the other "fine" filtration. Coarse filters are essentially vessels equipped with internal elements that provide filtration of particles of 100 microns or more. The filter elements are rotated with the assistance of an electric motor to shake the trapped particles out of the elements whereby the particles are then released into the drain. This sequence is called a "backwash". In the fine filtration equipment, filter vessels are filled with different layers of filter media. The media are normally made of garnet and anthracite. As dirty water flows through the media from the top, particles bigger than 2 microns are trapped thus provided very clean water. Unlike coarse filters, trapped particles are removed on a fixed period by reversing the flow. This process is also helpful in restoring the media fluffiness for another cycle of filtration.

163


DEAERATION

The Sub-Subsystem starts at the inlets of the coarse filters and ends at the outlet of the fine filters. It comprises of pressure vessels, motor-driven mixers and blowers, butterfly valves, control valves and other associated piping and instrumentations. Injection pumps and all associated drive equipment and accessories and local control panels. All conditioning equipment, including suction filters and dedicated chemical injection systems, all suction and discharge piping and headers, valves, instrumentation, tubing and any electrical/instrument cabling and junction boxes.

Deaeration is a process of oxygen removal from the water. It is mostly Deaeration package (vessel/ tower, electric motor driven pump, vacuum achieveable through two processes; gas stripping and vacuum. Under gas ejector set) stripping, process gas passes through water droplets and "strips" the oxygen from the water molecules. Under vacuum, a separate equipment is required to create the necessary vacuum thus allowing the oxygen molecules to separate from the water molecules. The whole process occurs in a tower vessel called a "deaerator tower". Inside a deaerator tower, packings are randomly arranged with the sole purpose of increasing the contact between two phases i.e. water and gas, thus removing oxygen under vacuum condition.

164

TREATED WATER Treated water pressure is increased prior to injection into the wells by Low pressure booster pump, high pressure multi-stage pump (turbine or diesel PUMPING employing different sets of pumps. For low pressure requirements, a 'booster" /gas engine drive) ancilliary equipment. Shutdown valves control valves, pump is sufficient to meet the needs. It also could be used to maintain inlet blowdown valves, gauges and transmitters suction pressure for the high pressure pump. It is normally a single-stage centrifugal pump driven by an electric motor

Typical Schematic


SUB SYSTEM L2

170

SUB SUB SYSTEM L3



165

TREATED WATER It starts from the discharge of the injection pump and ends at the gate valves to Discharge manifold, riser shutdown valves, mobile scraper launcher and EXPORT / the water injection wells. receiver (if applicable), injection water header, flowlines to water injection DOWNHOLE wells, associated piping and instrumentations INJECTION

171


ACID GAS REMOVAL

In case of high H2S, where it may not be suitable to re-inject or flare the acid Main equipment involved are Absorber, tanks and vessels, reboiler, pumps, gas, further treatment would be required by introducing acid gas to Acid Gas reflux drum, associated piping and instruments. Enrichment Unit (AGEU) to selectively remove H2S over CO2 in order to produce an acid gas composition which enables acceptable operating conditions for Sulphur Recovery Unit (SRU). The Sulphur Recovery Unit consists of modified Claus Units with catalytic stages with common degasser and incinerator where acid gas is pre-heated to around 195 °C. Elemental sulphur is produced which is routed to sulphur blocking area and the tail gas routed to incinerator to convert remaining sulphur species to SO2. This is also known as gas sweetening and acid gas removal in downstream plants referring to processes that use aqueous solutions of various amines to remove H2S and CO2 from gases.

180

181 MERCURY REMOVAL UNIT

Also known as demercurization in downstream plants found after the Major equipment involved is Packed Bed columns, Tanks, vessels and dehydration process where mercury is removed from gas by absorption using associated piping & instrumentation. activated carbon beds or other technology such as silver-doped molecular sieve, sulfur impregnated carbon, copper sulfide and the like.

CONTAMINATE REMOVAL

182 MERCAPTAN REMOVAL UNIT (ADSORPTION)

Natural gas having contaminants Mercaptans which is a sulphur-containing The Mecaptans Removal Unit consists of: compound defined as RSH where R represents radical, and having an extremely i) Mercaptan Unit Gas/Gas Exchanger offensive, garlicky odor. ii) Molesieve Chiller Package, iii) Three (3) Molecular Sieve Vessels Dew point Gas is feed to the unit from the Mercury Removal Bed. The incoming iv) Molecular Sieve After Filter gas is first cooled in the Mecaptan Unit Gas/Gas Exchanger and then by the v) Regeneration Gas Heater Chiller Package. It is then feed into the Molecular Sieve Vessels. Two (2) out of vi) Regeneration Gas Cooler the three (3) Molecular Sieve Vessels will be online at any one time. The vessels vii) Regeneration Gas Filter have a duty time of 16 hours before entering an eight (8) hour regeneration cycle. The regeneration cycles are staggered to ensure two (2) vessels are always online. The conditioned gas exits the Molecular Sieve Vessels with a total sulphur content of <5mgS/Nm³. The stream passes through the Molecular Sieve after Filter and onto the Mercaptan Unit Gas/Gas Exchanger to cool incoming gas from the Mercury Removal Bed. The gas stream then flows to the pipeline for export. After 16 hours of online duty time, the Molecular Sieve Vessel enters a regeneration cycle. In this cycle, the bed is heated to 300ºC to regenerate the desiccant.

200

210

211

FUEL GAS SYSTEM Fuel gas system will provide for gas driven prime movers such as Gas Turbine Generator to drive Gas Compressor and other miscellaneous load such as compressor seal gas requirement and vessel blanketing.

Inclusive where applicable of Fuel gas scrubbers, filters/scrubbers, preheaters, superheaters and all associated level control systems and pressure control valves, control panels, thyristor panels and all line piping, headers, valves and instrumentation, tubing and any electrical /instrument cabling and junction boxes

Typical Schematic

GENERIC SYSTEM OVERVIEW - DESCRIPTOR AND MAJOR EQUIPMENT SYSTEM L1 PROCESS UTILITIES

SUB SYSTEM L2

SUB SUB SYSTEM L3

UTILITY GAS

212

220

221


INSTRUMENT GAS The gas extracted from the wells for use as instrument supply medium is inherently wet and waxy such that this has to go through a system to slightly enhance the gas to be used for instrumentation.

NITROGEN (NITROGEN GENERATION & NITROGEN BOTTLES)

INERT GAS

222

SPENT GAS

230

231

ATMOSPHERIC VENT

VENTING

232

FLARE

240

241

PRODUCED WATER SYSTEM

PRODUCED WATER

242

DISCHARGED WATER TREATMENT

Inert gas such as nitrogen which contain low oxygen is blown distributed into process system to make the inert atmosphere in the tanks so that explosion may not occur even if any ignition source is generated.

Major Equipment (List of Major Equipment in the System) Inclusive where applicable of gas scrubbers, filters and associated level control systems, pressure monitoring loop, control valves, all line piping, tubing, headers, valves and other associated instrumentation.

Generator, absorption vessels, receivers, distribution header & control panels

As alternate, nitrogen bottle is normally provided as back-up for purging and blanketing where it distributed to the FG system, HP/LP flare, produce water degasser, stripping and blanket gas to glycol generator.

One method to get the spent gas source is from flue gas taken from the boiler Fan uptake after it is washed, cleaned and cooled. The boiler provides a plentiful Scrubber supply of flue gas and the only additional equipment required is that associated Instrument control with processing of the gas before it is delivered to the cargo tanks.

Atmospheric vent system or low pressure vent generally implies venting of gas or pneumatic air to the atmosphere. The system starts at the discharge of particular equipment like a compressor or a vessel such as a knockout drum. It comprises of pipeworks and minimal equipment like flame arrestors and rupture disks. The purpose of the Flare and Vent Systems is to provide safe discharge and disposal of gases and liquids resulting from different systems handling oil and gas. The systems are typically divided into a High Pressure (HP) Flare and a Low Pressure (LP) flare system. The LP system is operated marginally above atmospheric pressure to prevent atmospheric gases such as Oxygen to flow back into the vent and flare system and generate a combustible mixture. With low gas flow, inert gas is injected at the flare nozzle to prevent air ingress. The flare system consists of flare header and sub headers, flare KO drums and pumps, smokeless flare stack with ignition panel, velocity seal and air blowers.

Discharge outlet of equipment, knockout drum, flame arrestors and rupture disks

Produced Water from the separators / dehydrators/ cyclones is routed to a common header. This common header routes produced water from the trains to the Produced Water Skimming vessel. Skimmed oil Flow through the system is by gravity to avoid the formation of an emulsion. Oil recovered from the Produced Water Skimming vessel is routed to a common Oil Recovery Sump. The skimmed oil is returned to each of the production trains upstream of the Crude Heater via the Oil Recovery Pumps.

Hydro cyclones, pumps and associated drive equipment and accessories. All conditioning equipment, exchangers, vessels including pre-filters, filtration, oil analyzer and dedicated discharge system, all suction and discharge piping and headers, valves, instrumentation and associated tubing and any electrical/instrument cabling and junction boxes

It treats the process effluent water to acceptable specification of the end user.

Various methods deployed in treating the water such as hydrocyclones, gas floatation, corrugated plate interceptors, Reverse osmosis, Submerged Ultra Filtration, Bio-treating, etc.

The major equipment are liquid knock-out drums, flame arrestors, molecular seals, flare tips and any associated piping valves, instrumentation and flare gas meter.

Typical Schematic


SUB SYSTEM L2

SUB SUB SYSTEM L3



250

251

DRAIN

252

OPEN DRAIN (HAZARDOUS)

The function of Hazardous Drain System is to collect hazardous liquid or waste Hazardous drain system and headers media which could contaminate the environment. The system will collect from various area drain lines and headers from topside to hull/marine.

253

CLOSED DRAIN

Closed drain, sometimes called pressurised drain or hazardous drain, is meant to handle waste media which could contaminate the environment. A distinctive feature of the system is that it involves a waste collector called a "sump caisson". Pumping equipment called "sump pump" is provided to recycle hydrocarbon waste material back into the process system for further extraction

Closed drain system may contain equipment such as closed drain drum, caison, relief valves, a pump, a prime mover in the form of an electric or pneumatic motor. It also involves associated piping and instrumentation including indicators

254

SEWAGE

The sewage system is designed to treat the grey and black water. Black water from toilets, urinals and all discharged from living quarters, workshop, administration building will be treated in the biological type sewage treatment unit before disposal overboard.

All toilets and other foul water drains, sewerage and sewage treatment systems including all pumps, drives, control panelsand associated instrumentation and cabling. Also including compactor machines and all associated hydraulic systems and controls NOTE: LAST LINE STRIKED IN RED TO BE CONFIRMED

261

WASTE HEAT RECOVERY

This is an energy recovery heat exchanger that recovers heat from hot streams with potential high energy content, such as hot flue gases from a diesel/ gas turbine generator or other heat sources or exhaust units.

Heating coils, exhaust unit system of boiler, steam generator or hot oil. Associated piping and instrumentation NOTE: Circulation pump to be considered under major equipment

262

HOT OIL

Hot oil is used on facilities where continuous heating of the process crude to prevent it from hardening is necessary. Hot oil is circulated with the assistance of a pumping facility and distributed around pressure vessels and other users

263

WARM OIL

260

PROCESS HEATING

OPEN DRAIN (NON- Open drain system, sometimes called "non-hazardous drain", involves drainage Drain sump/caisson, drain pump, Open drain line & headers HAZARDOUS) of wastes overboard of the facility. A good example of an open drain is the "downcomer" line for disposal of drilling mud. Sometimes, it is synanymous with atmospheric or non-pressurised drain lines. This sub-sub-system is generally associated with pipeworks only.

Warm oil subsystem is tapped from the hot oil facilities and it is used for similar The system consists of equipment such as electric-motor-driven centrifugal purposes in hot oil. Warm oil is circulated with the assistance of a pumping pumps for circulation, strainers, associated piping and instrumentations. subsystem.

Typical Schematic


SUB SYSTEM L2

SUB SUB SYSTEM L3

270

271

CHEMICAL (DOSING) INJECTION/TREAT MENT

272

SODIUM HYPOCHLORITE



Hypochlorite is essentially pure chlorine. Hypochlorite (NaOCl) is obtained hydrogen disengagement tank, motor-driven air blowers, motor-driven from the electrolysis of seawater (NaCl) into hypochlorite and hydrogen gas. It pumps, rectifiers, control panel and associated piping and instrumentations is colorless and corrosive in nature. The concentration of hypochlorite is proportional to the amount of electric current passing through the electrolysers or rectifiers. Hypochlorite is used in water treatment plant at lift pumps suction area to prevent ingress of sea growth, bacteria and unwanted water life which if not applied could cause clogging at the pump suction

POLYELECTROLYTE Polyelectrolyte is injected upstream of filters to assist removal of very small particles in water treatment plant. It is colorless, very viscous and corrosive in nature. When mixed with water, polyelectrolyte tends to settle at the bottom thus it appears to have higher density or "heavier" than water. It is normally diluted with water in a mixing tank to achieve the required concentration before it is injected into the process

Chemical storage tank, a water tank, a mixing tank, dosing pumps, mixers, strainers, power cables, Hand-Off-Auto (HOA) switches and associated piping. It also includes instrumentations such as indicators, shutdown valves, control valves and transmitters.

273

COROSSION INHIBITOR

Scale and corrosion inhibitors are injected to prevent formation of scales and to Storage Tank, transfer pumps, calibration gauge, injection pumps and lessen the corrosion inside the piping. It commonly applied when carbon steel associated instruments. piping is specified for water treatment plant as carbon steel tends to corrode in seawater

274

DIESEL

Diesel injection sub-sub-system contains of equipments such as injection pumps, Storage Tank, transfer pumps, calibration gauge, injection pumps and electric motors, power cable and relief valves. associated instruments.

275

GLYCOL

Glycol is injected at the compression recycle lines and upstream of pressure Storage Tank, transfer pumps, calibration gauge, injection pumps and control valves to prevent hydrate formation when gas is recycled. This sub- associated instruments. subsystem contains equipments such as motor-driven injection pumps, calibration gauges, power cable, injection fittings and relief valves.

Typical Schematic


SUB SYSTEM L2


277

ANTIFOAM



Antifoam is used to prevent the formation of foam during the preparation of a Storage Tank, transfer pumps, calibration gauge, injection pumps and treatment fluid or slurries at surface. Excess foam created during the mixing associated instruments. process may cause handling and pumping difficulties and may interfere with the performance or quality control of the mixed fluid. Antifoam agents may also be used to break foams returned from the wellbore, following a treatment, in preparation for disposal of the fluids.

SCALE INHIBITOR Scale Inhibitor is used to control or prevent scale deposition in the production Storage Tank, transfer pumps, calibration gauge, injection pumps and conduit or completion system. The chemicals may be continuously injected associated instruments. through a down hole injection point in the completion, or periodic squeeze treatments may be undertaken to place the inhibitor in the reservoir matrix for subsequent commingling with produced fluids

278

DEMULSIFIER

Demulsifier is used to enhance the separation of water from oil in the FWKO Storage Tank, transfer pumps, calibration gauge, injection pumps and drums and heater treaters. it act to neutralize the effect of emulsifying agent. It associated instruments. is injected to the crude upstream of the heat exchangers

279

REVERSE DEMULSIFIER

Reverse Demulsifier is designed to separate oil emulsions into three phases:Storage Tank, transfer pumps, calibration gauge, injection pumps and • Oil Phase associated instruments. • Biological • Solid Without the use of Reverse Demulsifier, disposal of waste oil-in water emulsion would be environmentally unfriendly. Oil-in-water emulsion are treated at ambient temperature. Treatment should be added at a point of high turbulence for complete dispersion within the treatment tank. After dosing, all dosing and pumping equipment should be switched off to allow phase separation to take place in a turbulence free environment.

Diesel is used as backup fuel for equipment such as generators, compressor drivers, engine-driven pumps, etc. should fuel gas system malfunction or shutdown.

Diesel storage vessels, day tank, transfer pumps, filters, valves,associated piping, electrical and instrumentation

Facilities that are frequently visited by helicopter may be equipped with refueling equipment. A jet fuel sub-sub-system consist of equipment such as a fuel storage tank, motor-driven pumps, fuel filters, pipeworks and gauges

Portable storage tank, fuel pumps, filter separators, monitors, dispensers, associated flexible hoses and valves

300

310

311

DIESEL FUEL

GENERAL UTILITIES

FUEL AND LUBRICATION

312

JET FUEL

313

LUBRICATION OIL Some facilities, several major equipment may share the same lubrication oil supply thus it requires a big volume of lubrication oil to be stored. Under such circumstances, a separate equipment skid facility may be provided to cater for the needs.

Oil storage tank, fill pumps and drivers, filters & valves, associated piping and instrumentation

Typical Schematic


SUB SYSTEM L2

SUB SUB SYSTEM L3

320

321

COMPRESSED AIR

322

323


INSTRUMENT AIR Compressed air for instrument and utility applications is provided by two (2) compressors. The compressors are set up to operate one as a lead and the other as a standby unit. A dedicated controller is provided at each compressor for automatic loading and unloading

UTILITY AIR DISTRIBUTION HEADER

Utility air is tapped from the Utility Air Receiver discharge without going through any filtration and drying. Utility air serves various users such as sump pump, maintenance tools and it also pressurises starting air sub-subsystem. Self actuated control valve ensures the air supply pressure is maintained i.e. the control valve would completely shut when upstream pressure is lower than the pressure setting. BLACK Starting air is used for equipment that is started up using pneumatic starters; for START/STARTING example starters on internal combustion engines. Starting air compressor is AIR driven by a diesel engine which could be started manually or using hydraulic starter. During "black start", there is no compressed air from the utility header until power supply is available. Thus, start air provides for the required facility to start up the power generator. Start air could also be used as instrument air as the discharge piping is connected to the inlet of the air driers.

Major Equipment (List of Major Equipment in the System) Air compressors and all associated drive equipment and accessories (including all on skid scrubbers, coolers and air intake equipment, etc) and local control panel. Instrument air dryer and control panel, valves, moisture analyzer, and junction boxes

This includes air compressors and all associated drive equipment and accessories (including all on skid scrubbers, coolers and air intake equipment, etc.) and local control panel. Instrument air dryer and control panel, valves, moisture analyzer, and junction boxes.

Starting air compressor (diesel engine driven), Air intake filter

330

331

SERVICE WATER Service water application is for cleaning,hypochlorination generation, potable The major equipment are water cooler and water treatment skid consisting of water maker and fire water system of deck areas thus, seawater is normally filtration and chlorination units i.e. RO/Water Maker. used. Seawater is pumped up from the ocean by the service water pump, routed into the service for hypochlorination generation, potable water maker and fire water system. The rest of the system is only pipeworks.

WATER

332

FRESH AND DISTILL WATER

333

FEED WATER

Fresh water is generated by having fresh water generator where sea water is Fresh Water Generator desalinated seawater (vapor compression) and distill water is formed. Fresh Fresh/Distill Water Tank water is then generated from the distill water after gone thru clorine dozing unit Pump and re-hardening filter. Fresh water system will supply water to accommodation and input to feed water and potable water system. Fresh water to accommodation will further treated with hydrophore system.

The function of feed water system is to supply feed water to boilers. This feed water is used by the boilers to generate steam. Condensate and distill water is the main source for feed water system.

Cascade tank with inspection/observation tank, transfer pumps and boiler chemical dosing unit

Typical Schematic


SUB SYSTEM L2


335

336



POTABLE WATER Potable water is obtained from watermakers where seawater is desalinated into Water maker skid ( pumps, filters, tanks & instrumentation) fresh water for use in living quarters and any other application that requires use of fresh water. Watermakers normally comes on a skid in the form of a vaporcompression type or a reverse osmosis. Both types require use of chemicals and the skid would include smaller items such as filters, pumps, some tanks and instrumentations

HOT WATER

Hot water is required at accommodation for sinks, showers, washer, ice maker and etc. It is generated from fresh water via electric chalorifier system. Input water comes from fresh water system and after being treated by fresh water hydrophore and decholirinator filter.

Chalorifier/Heater Hot Water Tank Pump

COOLING WATER Cooling water systems absorb heat from the processes they are designed to Heat exchanger(PCHE,PHE, S&T HE),Chalorifier/cool Water Tank,Pump. cool (Printed Circuit Heat Exchanger-PCHE). In HVAC systems, the condenser cooling water absorbs heat from the refrigerant through a heat exchanger. In process cooling water systems the cooling water absorbs heat from the process stream that needs cooling. The re-circulating water in cooling water systems is usually cooled by the evaporation of a small amount of the re-circulating flow (typically 1-2%). This evaporation takes place as water flows over and through cooling towers, fluid coolers or evaporative condensers.

340

341

STEAM GENERATION

The steam generation can generally be classified into two principal type fired boiler system and waste heat system. The primarily purpose of steam generation is to generated steam under the conditions (Flow rate and pressures) required for systems and end-used requirement.

Boiler or heat source, steam drum heating coils, piping and associated instrumentation.

STEAM

342

STEAM DISTRIBUTION

The steam distribution system contributes the produced steam from steam generation system i.e. boiler and been distributed to each station including power generation and processing plant facilities.

Piping,Steam Traps and associated instruments,

343

STEAM CONDENSATE

The steam condensate system is the final stage of steam cycle. The condensate Steam condesate system discharged from equipment will then be recycling to cascade tank. It is normally comes from all condensers and steam traps. This includes a steam condensate system (condensate receiving tank & condensate pumps).

350

351

DIRECT Direct expansion type air handling units with air cooled condensing unit Air handling unit, compressor/condenser unit,HVAC Control panel & duct EXPANSION UNIT maintain appropriate quality of air, room temperature and relative humidity to provide human comfort as well as to protect electronic and electrical equipment from excessive operating temperature and prevent corrosion and deterioration due to air contamination. It maintains positive pressure within the room to prevent ingress of flamable/toxic gasses and achieve non-hazardous area classification

Typical Schematic


SUB SYSTEM L2 HEATING, VENTILATION AND AIRCONDITIONIN G


353

360


CHILLED WATER The condenser water absorbs heat from the refrigerant in the condenser barrel Inclusive of chillers, cooling towers, pumps, electrical control equipment, UNIT of the water chiller, and is then sent via return lines to a cooling tower, which is instrumentation, associated piping and valves. a heat exchange device used to transfer waste heat to the atmosphere. The extent to which the cooling tower decreases the temperature depends upon the outside temperature, the relative humidity and the atmospheric pressure. The water in the chilled water circuit will be lowered to the Wet-bulb temperature or dry-bulb temperature before proceeding to the water chiller, where it is cooled to between 4° and 7°C and pumped to the air handler, where the cycle is repeated.

FORCED AIR The purpose of the system is to rovide sufficient air ventilation to required room Supply Fan VENTILATION UNIT such as engine room, emergency generator room, fire pump room, steering Exhaust Fan gear engine room, purifier space and auxiliary mechinery room. Type of ventilation are mushroom, gooseneck, storm hood and cowl head type. The equipment involved are supply fan and exhaust fan

361

HYDRAULICS POWER UNIT (HPU)

370

371

BALLAST

MARINE SYSTEM

372

BILGE AND SLUDGE

373

WATERTIGHT DOOR

374

TURRET & MOORING

HYDRAULICS


The purpose of Hydraulics Power Unit (HPU) is to provide hydraulic power HPU supply tank, return tank, pumps, valves and bulkhead connection to TUTU needed i.e. for subsea control system and subsea valve. The system operates using a liquid base biodegradable control fluid such as McDermid Ocenic HW443 or Castrol Transaqua HT, at fluid cleanliness SAE AS4059 Class 6B-F or better

The Ballast and Bilge systems are critical to safety and life and must function reliably over a broad range of environmental, global response and damage conditions. The Ballast System is design to ballast, de-ballast and trim the vessel semoultanuesly over a wide range of vessel stability and trim conditions, and accommodate emergency bilge suctions

The purpose of the bilge system is to pump out bilge (water pounding or The Bilge and Sludge System collected water) on all decks board, hull access, pump room or void compartment in the event of flooding. According to ABS Steel Vessel 2004 Part 4 mention that the bilge system is intended to dispose of water which may accumulate in space within the vessel due to condensation, leakage, washing, fire fighting etc. it is to be capable of controlling flooding in the propulsion machinery space as a result of limited damage to piping system

Hull of a floating structure consists of various watertight doors or hatches that Watertight door types are hydraulic operated sliding doors, manual hinged provide access into and out of various rooms and compartment while watertight doors, hydraulic assisted watertight hatches and manual watertight maintaining watertight integrity between them. The basic intent of the doors is hatch to provide the means of access for personnel, but to prevent progressive flooding between rooms and compartments when they are not in use.

A turret mooring system is composed of a fixed turret column supported by an internal or external vessel structure via a bearing arrangement. The vesselbound components can therefore freely weather vane around the turret, which is fixed via a number or anchor lines to the seabed. This turret arrangement allows the FPSO to adopt the direction of the least resistance against waves, wind and currents. Toroidal swivels allows for the transfer of fluids across the rotary interface while the FPSO is weathervaning. Above deck level, located between the fixed turret column and the swivel stack, is a structure that supports the piping manifolds. These manifolds comingle the fluids (oil, gas, water, etc.) and thus reduce the number of fluid paths in the swivel stack

A turret mooring system consists of 5 main components: 1. A number of anchor lines, to keep the vessel on station 2. A turret column, to connect the anchor lines to the vessel 3. A bearing arrangement, to allow the vessel to weather vane 4. A vessel structure to support the bearing arrangement 5. The fluid transfer system consisting of an underwater fluid transfer system, a manifold, a toroidal swivel stack, and vessel piping arrangement.

Typical Schematic


SUB SYSTEM L2

SUB SUB SYSTEM L3

400

410

411

FIREWATER

SAFETY

FIREFIGHTING

412

DELUGE AND SPRINKLER

413

TOTAL FLOODING FIRE SUPRESSION & FIRE EXTINGUISHER

420

421

LIFERAFTS

LIFESAVING EQUIPMENT

422

423



Inclusive where applicable of all fire water and all associated drive equipment This sub-sub-system includes a diesel engine, a gearbox, ancillary equipment, and accessories including jockey pumps. All local control panels and copper nickel piping and associated instrumentations. It also includes fire instrumentation, electrical instrumentation cabling and all associated caissons, monitors, fire hose reels and foam hose reel. suction piping, discharge piping and fire mains, deluge system, valves, monitors, hoses and nozzles. All foam generation equipment.

For fighting fire outdoors around equipment areas such as compressor station, wellheads, launcher and receiver areas, pressure vessels etc., deluge or sprinkler is installed.

All deluge and sprinkler system and all associated drive equipment and accessories

CO2 is now use in areas where fire suppression using water or Halon gas as Fire fighting in the form of CO2 and associated equipments such as gas medium is not permissible, CO2 discharge is triggered by fire and Gas Detection cylinders,storage cabinet,discharge manifold, release valve solenoid and and also by manual operation.When fire is detected in a certain area, the sensor discharge nozzles. will send signal to the fire alarm panel which in turn would open the release valve. A timer delay is installed to allow for personnel inside the control room to leave the premises before the CO2 is release.

Liferafts normally come in an enclosed and pressurised container whereby to release the liferaft a tug line is pulled and the container would burst.

Liferaft in an enclosed container

SURVIVAL CRAFTS The most essential lifesaving equipment on any platform, survival crafts and the Survival craft engine driven and support frame support frame are normally installed offshore. Survival crafts are driven by a diesel engine and the engine is usually air-started. A craft is equipped with survival kits, an air cylinder, a hand pump, safety belts and pneumatic or hydraulic controls, to mention a few.

ESCAPE AND RESCUE EQUIPMENT

Other lifesaving equipment includes lifebuoys, Jacobs ladder, safety netting, lifejackets, fire blankets and portable fire extinguishers, to mention a few

Lifebuoys, Jacobs ladder, safety netting, lifejackets, fire blankets and portable fire extinguishers

Typical Schematic


500

SUB SYSTEM L2

510

SUB SUB SYSTEM L3

511

MAIN POWER GENERATION


Sub-Subsystem 511 consists of single/dual-fuel-fired turbine-driven generators and the turbine ancillaries such as electro-hydraulic starter motor, pre/post lube oil pump, backup direct current (DC) lube oil pump, diesel fuel pump motor, lube oil cooler fans and turbine enclosure fans. For smaller systems, Micro Turbine Generators (MTG), Gas Engine Generators (GEG) or Diesel Engine Generators (DEG) may be used. In case of GEG and DEG, the pre-commissioning and commissioning requirements shall follow SubSubsystem 512 Emergency Power Generator Unit. As for the MTG, reference shall be made to specific vendor recommendations and the check sheets.

POWER

POWER GENERATION/SU PPLY

512

EMERGENCY POWER GENERATION

513

ENMC/PMS

Sub-Subsystem 512 consists of gas or diesel fired engine driven generators and auxiliaries such as electric /hydraulic starters, enclosure fans, fuel system etc.


It also includes a control console consisting of a programmable-logic microprocessor-based control system, controls and indicators for turbine enclosure Fire and Gas detection and suppression system, a turbine local control panel, a voltage regulator panel, a vibration monitoring system and a circuit breaker panel. It also involves electrical power supply cables and main junction box, on-skid and off-skid instruments, turbine engine gage panel, turbine exhaust, turbine air intake, exhaust system, fuel system, valves and associated piping.

It also includes a control console consisting of a programmable-logic microprocessor-based control system, controls and indicators for enclosure Fire and Gas detection and suppression system, an engine control panel, generator control panel and a voltage regulator. It also involves electrical power supply cables and main junction box, on-skid and off-skid instruments, engine gage panel, air intake and exhaust system, fuel system, valves and associated piping.

This covers the Electrical Network Monitoring and Control system covering load ENMC / PMS panels and associated interface cabling to sharing/load shedding controls/Power management System etc. This usually is Generators/GCP/switchgears. It includes a control console consisting of packaged together with the main generation package programmable-logic microprocessor-based control systems, PC based network control systems, data acquisition systems, interface cabling and human machine interfaces.

520

521

TRANSFORMERS This system covers all the power/distribution transformers (Except the main It consists of power/distribution transformers, Neutral Earthing Resistors power transformer for grid intake/export), associated equipments and incoming (NERs), On Load Tap Changers (OLTC), Remote Tap changing Cubicles (RTCC), cables/busducts to the transformers local isolators and incoming cables/busducts.

DISTRIBUTION

522

HIGH VOLTAGE This covers the high voltage switchgear and high voltage motor control centre SWITCHGEAR AND up to the outgoing feeders. All incoming cables/busduct to the respective MOTOR CONTROL switchgear shall be part of this system CENTER

Sub-Subsystem 522 includes High Voltage Switchboard and a Motor Control Center which consist mainly of the main bus-bar, vacuum circuit breakers (VCB) or Gas insulated switchgear - GIS (e.g. SF6 circuit breakers) , distribution feeder, high voltage motor starter feeders, high voltage supply cables, control cables, protection relays, metering, potential and current transformers. A typical single line diagram is shown under Sub-Subsystem 522.

523

LOW VOLTAGE This covers the low voltage switchgear and low voltage motor control centre up SWITCHGEAR AND to the outgoing feeders. All incoming cables/busduct to the respective MOTOR CONTROL switchgear shall be part of this system. CENTER

Sub-Subsystem 523 includes 415 volts Switchboard / Motor Control Center which consist mainly of a main bus-bar system, 415 volts utilization feeders, 415 volts motor starter feeders, supply cables, control cables, protection relays, metering, potential and current transformerss

Typical Schematic


SUB SYSTEM L2

SUB SUB SYSTEM L3



524

INTEGRATED This system covers the IMCS panels, workstations, Human Machine Interfaces MOTOR CONTROL (HMIs) all intefaces between switchgear/DCS/PMCS/other package eqipments SYSTEM (IMCS) and the IMCS including any fibre optic links.

525

OVERHEAD LINE / This system covers the Overhead line / cable for power intake from grid / export Sub-Subsystem 525 consists of all power transmission systems including CABLE to grid transmission lines, transmission towers, lightning arrestors, power transmission cables (both land based and submarine) and associated termination arrangements. CAPACITOR / This System covers the capacitor banks / Reactors for power quality Sub-Subsystem 526 consists of all power capacitors and reactors including the REACTOR improvement power factor correction relays, cabling and interconnecting cabling.

526

Sub-Subsystem 524 includes the intelligent electronic devices (IED) on all the switchgears, interface with third party systems including DCS/PMCS, all communication cabling and interfaces, Human Machine Interfaces (HMI), control/monitoring consoles, sequence of event recorders etc. as shown in the project functional schematic diagram.

530

531

AC UPS SYSTEM

The AC UPS System provides a continuous, uninterruptible and clean alternating Rectifier/Inverter system, battery, battery isolators, distribution boards, current (VAC) power supply to the AC UPS distribution board from the battery Cabling charger and also when charger is not in use, the distribution board is supplied through the isolation transformer. The purpose of onshore pre-commissioning and commissioning is to confirm that the system can operate to the desired design specification which involve electrical cable/control check and function/run test if required to demonstrate the system operation.

UNINTERRUPTIBL E POWER SUPPLY

532

DC UPS SYSTEM

The DC UPS System provides a continuous, uninterruptible and clean direct Chargers, battery, battery isolators, distribution boards, Cabling current (VDC) power supply to the DC UPS Distribution Board. The DC UPS System consists of two (2) charges which are independent of each other that supply to a common distribution board. Since the two (2) charges/batteries are independent of each other, they are linked via the distribution board to the other. When normal mode, both charges will maintain the battery charge at float mode and will supply the distribution board. When at AC supply fail mode, if only one (1) charger fails, the other charger will continue to feed the load, but if both charger supplies fail, both chargers are stopped and the batteries will take over and feed the load. The purpose of onshore pre-commissioning and commissioning is to confirm that the system can operate to the desired design specification which involve electrical cable/control check and function/run test if required to demonstrate the system operation.

533

ELECTRICAL POWER UNIT (EPU)

The Electrical Power Unit provides a continuous, uninterruptible and clean power supply to the various instrument loads for subsea control system. The EPU is a fully self-contained unit complete with the UPS, Battery, chargers, interconnecting cables etc. The purpose of onshore pre-commissioning and commissioning is to confirm that the system can operate to the desired design specification which involve electrical cable/control check and function/run test if required to demonstrate the system operation.

EPU and associated cabling

540

541

EMERGENCY DISTRIBUTION BOARD

The emergency small power and lighting distribution system consists of the emergency distribution boards for both small power and lighting, cabling from emergency MCC to emergency distribution boards and the outgoing circuits of the distribution boards.

Distribution boards, Cables

SMALL POWER AND LIGHTING

542

NORMAL DISTRIBUTION BOARD

The normal small power and lighting distribution system consists of the normal Distribution boards, Cables distribution boards for both small power and lighting, cabling from normal MCC to the normal distribution boards and the outgoing circuits of the distribution

Typical Schematic


SMALL POWER SUB SYSTEM AND LIGHTING L2

SUB SUB SYSTEM L3



543

NAVIGATIONAL AIDS

Sub-sub-system 533 provides 24 volts of direct current (DC) power supply to Navigational aids, batteries, solar panels and juction boxes navigational aids lanterns. The major components of the system are battery charger, battery bank, DC distribution board and power distribution cables. The battery charger derives its alternating current (AC) power from Low Voltage Motor Control Center and Switchgear.

550

551

EARTHING

EARTHING & LIGHTNING PROTECTION

552

LIGHTNING PROTECTION

560

561

DRIVES AND CONTROLLERS

562

HEATER CONTROL Covers the electrical system from incoming cable to the heater control panel SYSTEM upto the outgoing cable to the electric heater.

Sub-Subsystem 562 includes the thyristor based control system for heater control consisting input/output transformers, thyristor controllers, contactor controllers, harmonic filters, Human Machine Interfaces (HMI) and all interconnecting power and control/communication cables.

570

571

ELECTRIC HEATERS This covers the electric heater, RCU/Safety switch and the cables from MCC to Heater Panel/respective equipment/component of this system.

Electric heater, RCU, Safety switch, Power and control cables from heater panel upto the heater/RCU/Safety switch/Thermister etc.

CONSUMERS

572

HEAT TRACING SYSTEM

This covers the heat tracing system from the incoming cabling to heat tracing panel upto the tracing tapes.

Heat tracing panels, distribution boards, JBs, Heating tapes and all associated cabling.

573

AUX DISTRIBUTION

This covers the cables from the Auxiliary distribution board to the individual load (MOV/Level Gauge lighting/Auxiliary panels etc).

Power and control cables from the aux distribution board upto the respective auxiliary equipment (MOV/Level Gauge lighting/Auxiliary panels etc).

574

IMPRESSED CURRENT CATHODIC PROTECTION (ICCP) SYSTEM

This covers the Impressed Current Cathodic Protection (ICCP) system from the incoming cabling to the cathodic protection distribution panel / transformer rectifier unit until the anodes.

Cathodic protection distribution panel, Transformer rectifier unit, anode and cathode junction boxes and all associated cabling.

575

LIGHTING

This covers the lighting circuits and fixtures (normal and emergency) from cabling from the DB up to individual lighting fixture

Cabling, Junction boxes, lighting fixtures

576

SOCKETS

This covers the small power/welding socket circuits and sockets (welding Cabling, Junction boxes, socket outlets/plugs /convinient/handlamp socket) from cabling from the DB up to individual socket

This system covers the overall earthing of the plant/platform. However, individual equipment earthing shall be part of the respectieve equipment. Only the main earth grid and connections to the platform are considered as part of this system. Alternating current (AC) system neutrals for power generation and distribution systems (namely High Voltage and Low Voltage generators, transformers, reactors, switchboards, motors and Uninterruptible Power Supply unit) are connected to one common earth grid up to the jacket leg or as per design requirements. Equipments are bonded to the platform structure. Screens of signal cables which are connected to instrument earth and intrinsically safe earth maybe looped together to a common or separate earth grid and connected to the jacket leg or as per design requirements. Lightning conductor system complete with air termination are interconnected together to have a separate grid extending up to the jacket leg.

Sub-Subsystem 551 consists of Earth Electrodes, earthing ring and branch conductors, earthing bar, earthing resistors, earthing boss, cable wire armour bonding and junction boxes. Steelworks of the structural legs which are buried into the seabed are considered to be the Earth Electrode for offshore platforms.

Lightning protection system and Bonding. Steelworks of the structural legs which are buried into the seabed are considered to be the Earth Electrode for offshore platforms.

Sub-Subsystem 552 consists of Earth Electrodes and earthing ring. Lightning conductor system complete with air termination (where applicable) are interconnected together to have a separate grid.

VARIABLE SPEED Covers the electrical system from incoming cable to the VSD upto the outgoing DRIVE (VSD) cable to the respective motor.

Sub-Subsystem 561 includes the variable speed drive system for motor control consisting input/output transformers, variable speed drives, harmonic filters, Human Machine Interfaces (HMI) and all interconnecting power and control/communication cables.

Typical Schematic


SUB SYSTEM L2

SUB SUB SYSTEM L3



Typical Schematic

GENERIC SYSTEM OVERVIEW - DESCRIPTOR AND MAJOR EQUIPMENT SYSTEM L1 600

SUB SYSTEM L2 610


612


DISTRIBUTED Consists of a microprocessor-based Distributed Control System (DCS) which CONTROL SYSTEM utilizes distributed processors to perform loop and sequence controls, interfacing to input and output (I/O) points from field devices on local and remote location (platforms, sub-station). Also interface with third party systems (Safety Instrumented System, Telecommunication System, Fire and Gas System, etc) and Human Machine Interface.

SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA)


Typical Schematic

System Cabinets (includes Power supply units, controller, I/O cards, serial cards, communication card etc), Marshalling Cabinets (includes field termination, barriers, etc ), RIOS (Remote Input / output) panels, HMI, Printers, Networking devices. etc.

SCADA system consists of Main Terminal Units (MTU) comprises of servers/HMI Master Terminal Unit (MTU), Remote Terminal Unit (RTU). and one or more field data interface devices, usually RTU’s or PLC’s, which Communication/networking equipment interface to field sensing devices and valves actuators/final control devices.

PSTN ISDN WAN

Field I/O

ModBus

RTU20

Remote Data Concentrator DNP 3.0

RTU20

ModBus

RTU20

RTU20

DNP 3.0 ModBus RTU20

ModBus

Field I/O

ModBus

Flow Computer

IED

Intelligent Instrumentation

PROCESS CONTROLS

613

INFORMATION MANAGEMENT SYSTEM (IMS)

IMS covers all the systems that acquire data from all facets of a business and Communication server, networking equipment, IMS software package (PMSsubsequent transformation of that data into easily usable, high value and widely Plant Management System, Historian Data server, CBMS-Condition Base distributed information for the management. Monitoring System software, Object Linking & Embedding (OLE) Process Control (OPC) server, Sequence of Events Recorder-SER) etc.

ASSET MANAGEMENT CLIENT

World Wide Web

Business VALVE LEAK MONITOR / PST DIAGNOSTICS

ALARM MANAGEMENT

PST DIAGNOSTICS

WEB SERVER

Services

AMS DEVICE MANAGER

OPC SERVER / HISTORIAN

PMCS

Control Network

Sub-system

PMCS CONTROLLER

SIS

FGS

HART

FF

614

SUBSEA CONTROL The topside part of the subsea production control system provides the following Master Control Station (MCS) SYSTEMS functions Electrical Power Unit (EPU) Hydraulic Power Unit (HPU) 1. Providing electrical power and communications to the control modules Topside Umbilical Termination Assembly (TUTA) subsea Chemical Injection Unit (CIU) *CIU may be supplied by others 2. Supply hydraulic power (pressure) to subsea for actuating valves. Interconnecting cables and tubing 3. Monitoring and controlling of the above topside SPCS equipment Interface to PMCS (PMCS supplied by others) 4. In some cases control of chemical injection skid. Interface to SIS (SIS supplied by others) Interface to UPS (UPS supplied by others) The topside equipment includes electrical power and communications Interface to MCC (MCC supplied by others) equipment, hydraulic power equipment and, in some cases, chemical injection equipment. (Chemical injection facilities normally come under topside supplied process equipment, but in some projects the CIU may come under subsea scope of supply). In addition to the equipment items, there are also some critical interfaces to the host facility and also suport systems that need to be provided by the host facility (e.g. MCC, UPS etc.)

620

621

SAFETY Safety Instrumented System (SIS) provides the emergency shutdown function INSTRUMENTED for the entire facility. It continuously monitors the process variables and SYSTEM (SIS) automatically initiates shutdown and blowdown if any of the variables is outside the predetermined safe limit. However, it is not intended for process control purposes.

Logic solver (CPU), I/Os card, initiating elements and final control elements, System Cabinets (includes Power supply units, serial cards, communication card etc), Marshalling Cabinets (includes field termination, barriers, etc ), Printers, SER, pushbutton, MOS (Maintenance Override Switch), IRP (Interposing Relay Panel), Networking devices. etc.

Logic Solver

DO

AI

24 VDC 4- 20 mA

Solenoid Valve Pressure Transmitter Process Line SDV

PLC Network

PLC

RTU20

CONTROL AND SAFEGUARD ING

PLC

ModBus

MTU/SCD

FoxScada P6008

RTU20

SCADA Master Station


SUB SYSTEM L2


FIRE AND GAS SYSTEM (FGS)



The system consist of Fire and Gas panel monitoring all fire detection devices and controls the automatic release of fixed fire extinguishing mediums (CO2, FM200, chemical powder, firewater, foams, etc.) on the facilities and interface with other sub-systems for shutdown and alarms. This sub-sub-system is also interfaced to third party systems such as PMCS and SIS. The Fire and Gas System (FGS) may be conventional or addressable system.

Gas/smoke/thermal/flame/heat detectors, fusible plug, fire & gas panel, purge panel for CO2 discharge system, deluge, firewater monitor, associated control panels, warning lights, junction boxes, break glass stations, manual stations, fire dampers, instrumentation, audible/visible alarms

Typical Schematic Serial Link to Other System Hardwired to Other System

FD

GD

FGS

CP

SD Tx

Rx 100% LFL Cloud

Process line

Control Valve

SAFEGUARDING SYSTEM

623

FUSIBLE PLUG LOOPS

Fusible plug loops is used for monitoring fire in strategic locations throughout the facility by means of pressurised system in a closed loop and the fusible plug melts when the temperature exceeds the melting point. Fusible plug loops are normally hook-up to the FGS or deluge valve panel (pneumatic system) which as an input for fire detection. Deluge valve panel senses the release of fusible plug loop pressure by means of change pressure switch low and send it as an input signal to Fire and Gas Panel which sends output to de-energize deluge valve solenoid to open the deluge valve and discharge water to the sprinkler system. Deluge valve panel in turn will send feedback signal to Fire and Gas Panel when deluge is activated. Electronic transmitter also may be provided in some installations to monitor charge pressure and connected to FGS for operation of fire water pump and deluge system.

Initiating elements(Fusible plugs) and final control elements, complete with associated cabling, tubing and junction boxes, Fusible loop charge panel , kill knobs and other pneumatic sensors, interface with the Shutdown System / Safety Instrumented System.

FPL PANEL

REGULATOR

PNEUMATIC RELAY RESTRICTION ORIFICE S-1

I.A.S

Fusible Plug Loop (FPL)

CHARGE VALVE

624

HIGH INTEGRITY PRESSURE PROTECTION SYSTEM (HIPPS)

HIPPS systems are applied to prevent over-pressurisation of a plant / Pipe line Logic solver, initiating elements and final control elements, complete with system by shutting-off the source of the high pressure and isolation /protection associated cabling, tubing and junction boxes. of other parts. It has a complete functional loop consisting of the sensors, logic solver and final elements

625

WELLHEAD Consists of a Wellhead Control Panel to provide controls and status indication of Logic devices, initiating elements and final control elements, complete with CONTROL PANEL individual wellhead Surface controlled Sub-Surface Safety Valve (SCSSV), Wing associated instrumentation, cable, tubing, junction boxes, pumps, hydraulic (WHCP) Valve (WV) and Surface Safety Valve (SSV). reservoir and etc.

WHCP

PSLL

ICP

HS

PSHH

PALL

PAHH

LALL

ESD

PSD

USD

LAHH

SDV

LSLL

LSHH BDV

ESD FUSIBLE PLUGS

FPP

626

INSTRUMENT Provide pneumatic or Electronic for control and safeguarding system to control Pneumatic or Electronic panel containing functional logics connected to CONTROL PANEL and protect the production facilities from process abnormalities and provide initiators and final control elements, complete with necessary shutdown functions and status indication, including the interface with Fire & instrumentation, cable, tubing, junction boxes, and etc. Gas and Emergency Shutdown System.

HS CLOSE

HS OPEN

WHCP FUNCTION LOGIC IN SIS

HS

SCSSV

SSV

WV

WV

SSV

SCSSV

OPEN

HS CLOSE

WV USD SSV

PSD SCSSV ESD

700

710

711

DIGITAL MICROWAVE RADIO (DMR) SYSTEM

Provides point-to-point or point-to-multipoint telecommunication network for data and voice comm between platforms and shores. DMR link requires line-ofsight (LOS) clearance, and pathloss analysis needs to be carried out prior to designing a DMR link

This system consists of (and not limited to) antenna, feeder, radio unit, cabling, junction box, telecom tower (if necessary, based on patloss analysis, with availability of 99.995%). Interface with other systems such as LAN, PABX, CCTV, DCS, etc is possible

700

710


TELECOMM UNICATION

SUB SYSTEM L2

MAIN BACKBONE LINK

720

RADIO COMMUNICATIO NS SYSTEM

SUB SUB SYSTEM L3 VERY SMALL APERTURE TERMINAL (VSAT) SATELITE SYSTEM

713

FIBER OPTIC TRANSMISSION SYSTEM

714

UHF RADIO LINK UHF radio link provides telecommunication network between platforms and shore base (for relatively short distance). Usually being used for low capacity data transmission

This system consists of antenna, radio unit, cabling and junction box. Interface with other systems such as PABX, LAN, DCS, etc is possible

715

TROPOSCATTER RADIO SYSTEM

This system consists of (and not limited to) antenna, RF unit, modem, amplifier, IDU, ODU, cabling and junction box.Interface with other systems such as LAN, PABX, CCTV, DCS, etc is possible

Troposcatter can bridge up to 400km without a repeater by illuminating a volume of the troposphere, using high-power transmitters and large antennas. Troposcatter is economic for systems up to 8Mbps and bridging up to 250km, where it is impossible or expensive to provide repeaters and there is no requirement for communication at intermediate points

VHF/FM (MARINE A multi-channel VHF marine band radiotelephone shall be provided for routine COMMUNICATION communications with nearby shipping and other installations, and for ) emergency voice comm on the marine dustress frequency of 156.8 MHz (channel 16). The control unit should be located in the radio room and/or control room so that it's always monitored, and handheld units are dedicated for key personnel

722

VHF/AM (AVIONICS COMMUNICATION )

723

HF/SSB RADIO SYSTEM

This system consists of antenna, base station, handheld unit, cabling and junction box. Digital selective calling (DSC) is required to comply with SOLAS requirement

VHF-AM is used to assist chopper operation, and shall be provided for routine This system consists of antenna, base station, handheld unit, cabling and and emergency communications. VHF AM base station should be located in the junction box radio room and/or control room, and handheld unit is dedicated for helicopter chopper landing (HLO) HF/SSB provides long range communication between the platform and nearby ship/vessels or onshore base. It also serves as emergency

NON-DIRECTIONAL NDB should be provided on one or more platforms in a field, where scheduled BEACON (NDB) helicopter operation is present. NDB is used to assist chopper landing by SYSTEM sending Morse code signal to chopper

DIGITAL TRUNK RADIO

This system consists of (and not limited to) antenna (gyro-stabilised antenna for moving FPSO or FSO), RF unit, satellite modem, indoor unit (IDU), outdoor unit (ODU) cabling and junction box. Interface with other systems such as LAN, PABX, CCTV, DCS, etc is possible

Submarine fiber optic cable (SFOC) is selected to be the main backbone link if a This system consists of submarine fiber optic cable, patch panel, optical new pipeline or a submarine power cable will be laid. SFOC provides very high amplifier and repeater (if needed, for long distance link). Interface with other bandwidth, and doesn't depend on LOS. Installation and repair cost might be systems such as LAN, PABX, CCTV, DCS, etc is possible high

721

725

VOICE AND DATA COMMUNICATIO N

VSAT uses microwave frequencies and free space propagation to link ground terminals to the satellite, and it requires LOS. We prefer to operate VSAT in Cband, since rain attenuation is significant. VSAT has a limited bandwidth of 2Mbps, and usually being used at a very remote location


712

724

730


Digital trunk radio system (DTRS) is normally used for onshore terminal. It provides the necessary flexibility and a framework for growth. It shall have a minimum of one base station transceivers (BTS) to cover a single site.

This system consists of antenna, antenna tuning unit (ATU), base station, cabling and junction box

This system consists of antenna (for offshore platforms, preferably to use long wire antenna), antenna tuning unit (ATU), base station and cabling.

This system consists of antenna, BTS, handheld units, radio operator console and cabling. Interface with PABX and PAGA is possible

726

WIRELESS SYSTEM Inlusive where applicable of RFID, Wi Max, GSM/UTMS & CDMA

RFID, WiMax, GSM/UTMS & CDMA

731

PABX AND TELEPHONE SYSTEM (ANALOG & DIGITAL)

PABX system is the primary voice communication network on the platform or at This system consists of indoor and/or outdoor telephone sets, distribution onshore terminal/office. It supports indoor (IP & digital) and outdoor telephone frame and boards, hotline, private access branch exchange. Integration with sets . PABX features are voice paging, telephone service, data and fax other systems such as LAN and PAGA is possible communication

732

LOCAL AREA NETWORK (LAN)/WIDE AREA NETWORK (WAN)

LAN/WAN system provides data communication for connection between This system requires integrated service router (ISR), switch, servers, UPS, PCs, platforms to onshore gas terminal/office and also to outside network. WAN has CPUs and cabling. Interface with other systems for monitoring purpose is similar fucntions as LAN except WAN covers broad area (normally connects 2 or possible more LAN by means of router

733

NETWORK MANAGEMENT SYSTEM (NMS)

NMS and engineering service features shall be provided for local monitoring This system requires server, PCs, CPUs, and cabling. Interface with other functionalities on the central site. NMS shall incorporate at a minimum systems such as LAN, PABX and main backbone link is possible capability to perform system configuration, maintenance and administration, and performance monitoring. The features shall not be limited to the following: - system link monitoring - alarm monitoring - configuration troubleshooting and fault finding

Typical Schematic

VOICE AND DATA COMMUNICATIO N


SUB SYSTEM L2

740

SUB SUB SYSTEM L3



734

MOBILE Mobile broadband is wireless internet access through a portable modem, BROADBAND mobile phone, USB wireless modem, or other mobile devices. Bit rates of (New Technology) broadband support voice and video as well as other data access

This system requires PCs or laptops, USB stick (dongles) and USB modems

741

PUBLIC ADDRESS Offshore platforms which have LQ shall be provided with PAGA system. It is GENERAL ALARM used for paging and general announcements (including azan). It should be (PAGA) SYSTEM entirely solid state and have facilities to centrally monitor the operational status of the component parts and to generate an alarm on detection of any failure. For noisy area, beacons shall be installed to assist on any alarm announcement

This system consists of PA console, distribution panels and boards, loudspeakers, beacons (if necessary based on noise mapping), access panel, amplifiers, cabling and junction box. Interface with other systems such as PABX, CCTV, DCS, etc is possible via it's master control unit

742

CCTV AND INTRUSION SYSTEM

The CCTV system operates as surveillance system at platforms and onshore terminal, and shall be designed for continuous duty. A pan, tilt, zoom (PTZ) camera is preferred to cover almost 360° coverage. The monitoring station should be located at the control room

This system comprises of CCTV camera, IR detector (if necessary), monitoring station, transmission cable (FO), cabinet, video amplifier, control panel and CPU

SURVEILLANCE AND SAFETY SYSTEM

743

METEOROGICAL Also know as weather monitoring system (WMS), it provides local weather and SYSTEM sea condition for navigational aid. The monitoring station should be located at the control room

This system consists of meteorological system (wind speed, wind direction, rainfall, air pressur, temperature, relative humidity sensors) and hydrological system (tidal wave monitoring, where it measures current conditions at a medium range)

750

751

ENTERTAINMENT Entertainment systems on manned platforms should consist of an This system consists of televison, decoder, central equipment rack, DVD SYSTEMS entertainment package feeding a distribution network. The possible player, satellite TV receiver, projector and bedhead entertainment units entertainment sources are satellite television receiver, broadcast radio receiver and DVD players

811

PEDESTAL CRANE Pedestal crane is available on most manned facilities as it provides the main Pedestal cranes and all associated engine/motor driven hydraulic system, capability for lifting and transfer of personnel. Supported on a vertical column, accessories and safety systems. All associated controls, cabling and junction the crane comes in a variety of capacities and sizes depending upon the lifting boxes requirements on the facility. The main structures are the boom, the A-frame and prime mover console. The crane rotates on the vertical column with the assistance of a slew bearing which also bear most of the load during lifting

COMMUNICATIO NS EQUIPMENT

800

MISCELLAN EOUS

810

MATERIAL HANDLING

820

812

OVERHEAD / GANTRY CRANE

Overhead gantry crane, at times also called "jib" crane, is operated manually or Overhead gantry crane, chain blocks and all associated controls, cablings and with the assistance of an air-operated or a gas-operated winch. Air or gas to junction boxes power the winch is tapped from utility air or utility gas system using flexible hose or tubings. Its system consists of equipment like the supporting structure, pneumatic motor and wire rope.

813

MONORAIL / TROLLEY HOIST

Monorail hoist sub-sub-system comes in two forms: manual and automated. In Monorail/trolley hoist, chain blocks and all associated controls. Pendants, manual mode of operation, monorail hoist includes use of trolleys whereby its cabling and junction boxes travel and lifting capabilties are dependent upon operator’s skill and power. In automated form, hoist travel and lifting capabilities are derived from an electrical motor that powers a winch and the operator could control movement from a remote location

814

ELEVATORS

821

822

Elevators (lift) is use to move personnel between floors. Some major component of an elevators will equipped with car module, mast, base frame, drive unit, cable guiding system, landing assemblies with call boxes, mast attachment hardware and some applicable controls

Car module, mast, base frame, drive unit, cable guiding system, landing assemblies with call boxes, mast attachment hardware and some applicable controls.

GENERAL This sub-sub system relates to the various equipment found in living quarters Kitchen & Laundry appliances ACCOMODATION such as kitchen and laundry appliances. SPACES GALLEY / MESS HALL

It relates to various equipments in living quarters kitchen, laundry appliances and mess hall facilities.

Cooking equipment, Cold room/Chiller, Laundry equipment and Mesh hall

Typical Schematic


SUB SYSTEM L2 FURNITURE / APPLIANCES

SUB SUB SYSTEM L3



823

OFFICES

824

COLD ROOM

830

831

HELIDECK

AVIATION

832

AVIATION REFUELING

840

841

SACRIFICIAL Sacrificial Anodes are highly active metals that are used to prevent a less active ANODE CATHODIC material surface from corroding. Sacrificial Anodes are created from a metal PROTECTION alloy with a more negative electrochemical potential than the other metal it will be used to protect. The sacrificial anode will be consumed in place of the metal it is protecting, which is why it is referred to as a "sacrificial" anode. When metal surfaces come into contact with electrolytes, they undergo an electrochemical reaction known as corrosion. Corrosion is the process of returning a metal to its natural state as an ore and in this process, causing the metal to disintegrate and its structure to grow weak. These metal surfaces are used all around us -- from pipelines to buildings to ships. It is important to ensure that these metals last as long as they can and thus necessitates what is known as cathode protection. Sacrificial anodes are among several forms of cathode protection. Other forms of cathode protection are plating, galvanization, and the formation of alloys. Metal in seawater is one such example with the iron metal coming into contact with electrolytes. Under normal circumstances, the iron metal would react with the electrolytes and begin to corrode, growing weaker in structure and disintegrating. The addition of zinc, a sacrificial anode, would prevent the iron metal from "corroding". According to the table of Standard Reduction Potentials, the standard reduction potential of zinc is about -0.76 volts. The standard reduction potential of iron is about -0.44 volts. This difference in reduction potential means that Zinc would oxidize much faster than iron would. In fact, zinc would oxidize completely before iron would begin to react. Note: Ensure there are no construction punchlist prior to load out.

842

MARINE GROWTH The Marine Growth Prevention System will be used to protect the sea water Hydropac-M units, Transformer rectifier, Tank, Blower and hypo dosing pump PREVENTION systems against biological fouling. The system comprises of Hypopac-M units which include a transformer rectifier, an electrolyser, a hypo tank, a dilution air blower and hypo dosing pump. The system is designed to create sodium hypochlorite directly from seawater once it has been distributed to the sea chests and into the seawater system it reverts to salt and water

MARINE AND CORROSSION PROTECTION

843

DE-HUMIDIFIER SYSTEM

850

851

Topside

852

Jacket

This sub-sub-system relates to the various office equipment; namely personal Personal computer, Photocopy machine, Fax machine computers, walkie-talkies, photocopy machine, fax machine, etc. The system generally covers areas such as lobby room, vegetable room, meat room and fish room at the living quarters

Air condenser and coolers. refrigerant, switches valves and power supply

The helideck is a landing area or platform for helicopters. The helideck surface is Perimeter lighting, safety net, fire protection, refueling package, rescue non-slip, painted and clean. It has perimeter lighting, safety net and fire equipment protection system. Safety notices are visibly in place with refueling system available Inclusive where applicable of portable storage tanks, fuel pumps, filter Portable storage tanks, fuel pumps, filter separators, monitors, dispensers and separators, monitors, dispensers and all associated flexible hoses, piping, valves, all associated flexible hoses, piping, valves, instrumentation, tubing and instrumentation, tubing and cabling cabling

Ballast dehumudifier system is designed to reduce moisture inside the ballast Dehumidifier unit tank. It normally consist of dehumidfying and regeneration zone. High moisture process air is drawn into humidyfing zone of the wheel which absorbes the moisture from the process air. The moisture laden -section of the wheel rotor then rotate as dessicant wheel is roughes through the regeneration zone where the hot spurts of regeneration air is passed through the rotor and expelledremoving moisture from the rotor

The topeside structure is designed to carry out the weigth of the dead and The topside consist of Cellar Deck, Sub Cellar Deck Mezzanine Deck, Main variable equipment loads. Live loads,eviroment loads,briges raction ,earthquake Deck , Venting /Flaring boom loads,accidental loads fromdropped object and future facilities.

The jaket structure is designed to support the topside structure ,a rescue boat The Jacket consist of Spider Deck, Boat fenders, Risser guards, Bollards, Caged landing ,risser,J-tube and other appurtennance accordance with API RP 2A-WSD ladder from apider deck to cellar deck or level 1, Sea escape ladders and . The jacket to be assumed with 4,6 of 8 legged pile supported structure alowing Caissons. a float over installation or modular of topside .

Typical Schematic


SUB SYSTEM L2 STRUCTURAL

SUB SUB SYSTEM L3


853

Living Quarters (LQ)

854

Bridges

855

Telecom Tower

Telecom tower is the structure that used for diffrent applications such as internal communication, telemetry systems, telecommunication networks and external communication to the operational centre onshore.

860

861

Process Area ( Inside Battery Limit )

An area designed for processing unit , including control room, electrical sub station ,analyzer house , pipe rack etc

CIVIL

862

863

864

Living quarter is an essential requirement for the safe operational and life support requirements for personnel in the offshore. It consists of recreation room, offices/meeting room, kitchen room, bathroom and shower facilities.

Mess hall (kitchen & galley), entertainment room, office/meeting room, document filing room, bathroom & shower facilities.

Th bredges is structure to connect the patform to platform with using triangular structure or rectanular strucure.The bridges shall be equipet by bearing support as part of instaallation part, bridges access stairway and handrails.

Non Process Area ( An area designed for all non process civil facilities which may include Outside Battery administration building, workshop, laundries, warehouse ,material yard, storage Limit) tank compunds, cooling tower, utility pump station,flare , fire-fighting station,training grounds,cooling water intake, pipe rack etc

Receiving Area


An area designed for hydrocarbon receiving weather from offshore or onshore. The receiving facilities consist of civil facilities for Receiver, Control building, Fancing etc

Launching/ Export An area designed for hydrocarbon export weather from offshore or onshore. Area The export facilities consist of civil facilities for Launcher, Control building, Fancing etc

The telocom tower consist of Batteries for telecommunication , Transmitter room , Helitower , Reception ,Central control room (CCR) and Antenna tower

Typical Schematic





13.0 APPENDIX VI: ENDURANCE & PERFORMANCE TESTING CRITICAL PARAMETERS RR TAGS A26AMA A26CPDE A26CPIB A26CPNE A26CPOB A26EVGTA A26GBHDE1 A26GBHNE1 A26GBLDE1 A26GBLIB1 A26GBLNE1 A26GBLOB1 A26GG05A A26GG05B A26GG05C A26PG1D1 A26PG1S1 A26PG2D1 A26PG2S1 A26PTDE1 A26PTDE2 A26PTNE1 A26PTNE2 A26PTRC1A A26PTRC1B A26PTRC2A A26PTRC2B A26PTTB1 A26PTTB2 A26QGBCSA A26QGBFSA A26QGBRSA A26QGTA A26QGTB A26QMA A26QMTA A26SRCA A26UCP A39CPDEX A39CPDEY A39CPNEX A39CPNEY A39CPTA A39GBC1 A39GBC2 A39GBHDEX A39GBHDEY A39GBHNEX A39GBHNEY A39GBLA1 A39GBLA2 A39GBLDEX

DESCRIPTION Ambient Air Temp Compr DE Bearing Temp Compr Inboard Thrust Bearing Temp Compr NDE Bearing Temp Compr Outboard Thrust Bearing Temp GT Encl Temp Gear HS DE Bearing Temp Gear HS NDE Bearing Temp Gear LS DE Bearing Temp Gear LS Inboard Thrust Bearing Temp Gear LS NDE Bearing Temp Gear LS Outboard Thrust Bearing Temp GG 05 Module Temp A GG 05 Module Temp B GG 05 Module Temp C LP Discharge Temp LP Suction Temp HP Discharge Temp HP Suction Temp PT DE Bearing Temp 1 PT DE Bearing Temp 2 PT NDE Bearing Temp 1 PT NDE Bearing Temp 2 PT Stage 1 Rim Cooling Temp A PT Stage 1 Rim Cooling Temp B PT Stage 2 Rim Cooling Temp A PT Stage 2 Rim Cooling Temp B PT Thrust Bearing Temp 1 PT Thrust Bearing Temp 2 GG L.O. Center Bearing Scavenge Temp A (UHM) GG L.O. Front Bearing Scavenge Temp A (UHM) GG L.O. Rear Bearing Scavenge Temp A (UHM) GG L.O. Tank Temp A GG L.O. Tank Temp B Mineral L.O. Supply Temp A Mineral L.O. Reservoir Temp 1 Hyd Starter Coolant Return Temp UCP Internal Temp Compr DE X Vibration Compr DE Y Vibration Compr NDE X Vibration Compr NDE Y Vibration Compr Axial Displacement Gear Casing Vibration HS Gear Casing Vibration LS Gear HS DE X Vibration Gear HS DE Y Vibration Gear HS NDE X Vibration Gear HS NDE Y Vibration Gear LS Axial 1 Displacement Gear LS Axial 2 Displacement Gear LS DE X Vibration

9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 0:00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 -62 -62 -62 -62 -62 -62 62.7 62.9 62.8 62.9 62.7 62.7 54.6 54.7 54.8 54.8 54.7 54.6 63.2 63.3 63.3 63.3 63.2 63.2 57.4 57.6 57.6 57.7 57.6 57.4 30.4 30.4 30.4 30.3 30.2 30.2 60.1 60.1 60.1 60.2 60.1 60 61.8 61.8 61.9 61.8 61.8 61.8 60 60.1 60.2 60.1 60.1 60.1 60.5 60.6 60.7 60.7 60.5 60.4 60.6 60.6 60.7 60.7 60.6 60.5 53.6 53.7 53.8 53.8 53.8 53.7 155.6 155.7 155.6 155.5 155.3 155.3 155.7 155.7 155.8 155.6 155.4 155.4 155.5 155.6 155.5 155.4 155.3 155.2 41.975 41.975 42.225 42.175 41.775 42.15 36.325 36.3 36.638 36.525 36.1 36.525 34.406 34.375 34.781 34.469 34.188 34.719 29.7 29.7 30.1 29.738 29.475 30.025 68.4 68.6 68.6 68.6 68.7 68.5 64.9 65.1 65.1 65.1 65 65 68.9 68.9 69 68.9 68.9 68.8 68.3 68.6 68.5 68.6 68.3 68.3 309.3 309.6 309.4 309.2 309 308.9 297.6 297.7 297.6 297.4 297.4 297.4 244.7 244.8 244.8 244.6 244.5 244.3 244 243.8 244.1 244.2 243.9 243.8 55.3 55.3 55.5 55.5 55.3 55.3 54.9 55 54.9 55.1 54.9 54.8 74.1 74.2 74.3 74.3 73.9 74.1 58.2 58.3 58.4 58.3 58.2 58 81.6 81.8 81.8 81.8 81.5 81.4 55.8 56.2 56.4 56.4 55.8 55.7 55.6 55.9 56.1 56.3 55.6 55.6 52 52 52.2 52.2 52 51.9 53.7 53.7 53.9 53.9 53.7 53.7 32.5 32.6 32.7 32.6 32.5 32.5 26.3 26.4 26.5 26.6 26.6 26.7 7.073 7.024 7.073 7.024 7.024 7.121 6.734 6.734 6.783 6.734 6.734 6.734 4.07 4.215 4.117 4.166 4.215 4.07 3.584 3.633 3.633 3.633 3.633 3.633 0.025 0.025 0.025 0.025 0.025 0.025 0.126 0.133 0.141 0.133 0.13 0.133 0.099 0.103 0.103 0.103 0.099 0.103 15.889 15.841 15.841 15.889 15.889 15.889 12.209 12.161 12.062 12.209 12.161 12.161 9.398 9.398 9.446 9.35 9.398 9.302 9.494 9.494 9.446 9.446 9.398 9.545 -0.08 -0.081 -0.081 -0.08 -0.079 -0.079 -0.077 -0.077 -0.077 -0.076 -0.075 -0.076 8.43 8.43 8.235 8.235 8.332 8.526


RR TAGS A39GBLDEY A39GBLNEX A39GBLNEY A39GGC A39GGI A39GGT A39PTA1 A39PTA2 A39PTDEX A39PTDEY A39PTNEX A39PTNEY A63AM A63EVJAM A63EVJF A63FGS A63GG20 A63GG20J0 A63GG25 A63GG455 A63GGBA A63GTAA A63IFJ A63PG1D1 A63PG1JSF A63PG1S1 A63PG2D1 A63PG2JSF A63PG2S1 A63PGJD A63PGJS A63QG A63QGHJF A63QGHP A63QGJF A63QM A63QMJBA A63QMJF A63QMP1 A63QMP2 A63SGBA A63SGJBD A63SGJBF A63SGJBN A63SGJDE A63SGJF A63SGJNE A63SGJS A63SGJVDE A63SGJVNE A71QMRDT

DESCRIPTION Gear LS DE Y Vibration Gear LS NDE X Vibration Gear LS NDE Y Vibration GG Center Vibration GG Inlet Vibration GG Turbine Vibration PT Axial Displacement 1 PT Axial Displacement 2 PT DE X Vibration PT DE Y Vibration PT NDE X Vibration PT NDE Y Vibration Ambient Air Press GT Encl/Atmosphere dP Vent Filter House dP Fuel Gas Supply Press GG IP Compr Inlet Press GG Inlet Flare Atmospheric dP GG IP Compr Discharge Press GG Exhaust Press GG Bearing Cooling Air Press Aux Air Supply Press Combustion Air Filter dP LP Discharge Press LP Suction Filter Strainer dP LP Suction Press HP Discharge Press HP Suction Filter Strainer dP HP Suction Press Discharge Valve dP Suction Valve dP GG L.O. Supply Press GG Hydraulic Oil Filter dP GG L.O. Hydraulic Pump Press GG L.O. Filter dP Mineral L.O. Supply Press PT Seal Air dP Mineral L.O. Filter dP Mineral L.O. Pump 1 Discharge Press Mineral L.O. Pump 2 Discharge Press Dry Gas Seal Buffer Air Supply Press Dry Gas Seal Buffer Air dP DE Dry Gas Seal Buffer Air Filter dP Dry Gas Seal Buffer Air dP NDE Seal Gas dP DE Seal Gas Filter dP Seal Gas dP NDE Seal Gas Supply To Ref Signal dP Dry Gas Seal Primary Vent dP DE Dry Gas Seal Primary Vent dP NDE Mineral L.O. Rundown Tank Level


9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 0:00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 7.75 7.654 7.75 7.798 7.849 7.75 17.199 17.004 16.908 17.004 17.004 17.199 16.423 16.375 16.423 16.375 16.327 16.375 1.163 1.163 1.163 1.163 1.143 1.163 2.519 2.519 2.48 2.499 2.519 2.499 1.473 1.492 1.492 1.492 1.473 1.511 0.005 0.005 0.005 0.006 0.004 0.005 -0.013 -0.013 -0.013 -0.012 -0.013 -0.013 6.539 6.539 6.491 6.539 6.587 6.491 6.539 6.395 6.443 6.539 6.443 6.443 5.715 5.619 5.763 5.667 5.667 5.715 5.667 5.667 5.814 5.619 5.715 5.715 0 0 0 0 0 0 0.388 0.386 0.383 0.402 0.399 0.392 124.063 121.938 120.813 125.125 126.813 125.063 3874.781 3875.212 3875.212 3877.8 3876.938 3873.056 99.637 99.613 99.55 99.487 99.5 99.55 0.126 0.128 0.128 0.128 0.128 0.129 33.337 33.3 33.225 33.3 33.3 33.3 14.738 14.7 14.738 14.738 14.738 14.7 0 0 0 0 0 0 761.25 763.25 761.125 761.375 762.687 762.75 105.938 106.25 104.688 106.25 107.812 106.875 3519.375 3521.25 3521.25 3521.25 3517.5 3523.125 13.287 12.994 12.956 13.012 13.031 13.131 3373.125 3373.125 3372.5 3371.25 3370 3376.25 3746.875 3746.875 3746.875 3750 3743.75 3750 7.388 7.169 7.3 7.313 7.225 7.212 3523.125 3523.125 3523.125 3523.125 3521.25 3523.125 4625 4635.938 4659.375 4665.625 4671.875 4679.688 -3.75 -3.75 -3.75 -3.75 -3.75 -3.125 151.688 151 151.25 151.063 151.875 151.438 6.487 6.338 6.3 6.3 6.487 6.45 4861.25 4861.25 4860 4858.125 4863.125 4862.5 42.787 42.375 42.225 42.15 42.825 42.825 138.6 138.313 138.425 138.425 138.4 138.387 0.113 0.112 0.115 0.111 0.112 0.112 36.438 36.338 36.438 36.35 36.375 36.625 1.969 2.156 2.344 2.625 2.719 3 371.156 371.438 371.25 371.813 371.156 371.438 104.85 105.175 105.163 105.012 104.9 105.337 64.688 65.05 65.281 65.113 64.737 64.975 0 0 0 0 0 0 66.069 66.425 66.481 66.344 66.263 66.431 31.344 31.344 30.328 31.25 31.578 30.656 6.781 6.891 6.672 6.859 6.844 7.047 34.297 34.578 34.406 34.484 34.594 33.891 208.406 209.156 208.5 209.438 210.375 207.844 2.766 2.531 2.375 2.609 2.844 2.734 1.016 0.828 0.828 0.922 1.062 1.078 1490.672 1490.672 1489.95 1488.3 1488.609 1487.887




RR TAGS A71QMT A80PG1A A80PG2A A97AMHUM_1A A99GGNH1 A99GGNH2 A99GGNL1 A99GGNL2 A99GGNS A99PT1 A99PT2 A99PTRSP C99N3 KFGPT_HMI V26GG05 V26PTRC1 V26PTRC2 V26QGT V99COMPR A26FGRA A26GG10_1A A26GG25A A26GG25B A26GG25C A26GG31_2C A26GG31A A26GG31B A26GG455_01A A26GG455_02A A26GG455_03A A26GG455_03B A26GG455_04A A26GG455_05A A26GG455_05B A26GG455_06A A26GG455_07A A26GG455_08A A26GG455_09A A26GG455_10A A26GG455_11A A26GG455_12A A26GG455_13A A26GG455_14A A26GG455_15A A26GG455_16A A26GG455_17A A26GG455B A26GG455C A26QGA A26QGB A63FGM A63FGR A63GG30

DESCRIPTION Mineral L.O. Reservoir Level LP Stage Suction Flow High Span HP Stage Suction Flow High Span Ambient Air Humidity 1A GG NH Speed 1 (ECS) GG NH Speed 2 (ECS) GG NL Speed 1 (ECS) GG NL Speed 2 (ECS) GG Starter Speed (ECS) PT N3 Speed 1 (ECS) PT N3 Speed 2 (ECS) PT Remote Speed Setpt PT N3 Speed Output To Anti-Surge Control Ext. Fuel Gas Piping Purge Timer Preset from HMI GG 05 Module Temp (Median Voted) PT Stage 1 Rim Cooling Temperature (LSS) PT Stage 2 Rim Cooling Temperature (LSS) GG L.O. Tank Temp (LSS) Calculated Compressor Speed Fuel Gas Regulated Temp A GG Inlet Air Temperature A GG IP Compressor Discharge Temp 1 - UHM ONLY GG IP Compressor Discharge Temp 2 - UHM ONLY GG IP Compressor Discharge Temp 3 - UHM ONLY GG HP (T31) Compr Disch Temp #6 GG Combustion Inlet Temp 1 - UHM ONLY GG Combustion Inlet Temp 2 - UHM ONLY T455 Exhaust Temperature Input 1 T455 Exhaust Temperature Input 2 T455 Exhaust Temperature Input 3 GG Exhaust Temp 3B T455 Exhaust Temperature Input 4 T455 Exhaust Temperature Input 5 GG Exhaust Temp 5B T455 Exhaust Temperature Input 6 T455 Exhaust Temperature Input 7 T455 Exhaust Temperature Input 8 T455 Exhaust Temperature Input 9 T455 Exhaust Temperature Input 10 T455 Exhaust Temperature Input 11 T455 Exhaust Temperature Input 12 T455 Exhaust Temperature Input 13 T455 Exhaust Temperature Input 14 T455 Exhaust Temperature Input 15 T455 Exhaust Temperature Input 16 T455 Exhaust Temperature Input 17 GG Exhaust Temperature Average B GG Exhaust Temperature Average 1-17C GG Lube Oil Temperature A GG LO Supply Temp B Fuel Gas Manifold Pressure Fuel Gas Regulated Pressure GG H.P. Compressor Discharge Pressure

9/14/2011 9/14/2011 9/14/2011 9/14/2011 0:00:00 1:00:00 2:00:00 3:00:00 450.246 450.246 451.211 450.246 134.25 133.875 132 135 91.875 91.25 91.25 81.875 0 0 0 0 6680 6680 6680 6680 6680 6676.667 6676.667 6680 3251.111 3248.889 3248.889 3251.111 3251.111 3248.889 3248.889 3251.111 0 0 0 0 1367.619 1367.619 1367.619 1368.571 1367.619 1367.619 1367.619 1367.619 0 0 0 0 1367.619 1367.619 1367.619 1368.571 1200 1200 1200 1200 155.6 155.7 155.6 155.5 297.6 297.7 297.6 297.4 244 243.8 244.1 244.2 55.6 55.9 56.1 56.3 RPM RPM RPM RPM 67.7 68.5 68.6 68.3 28.3 28.3 28.3 28.2 66.7 66.7 66.7 66.5 66.8 66.8 66.8 66.7 66.7 66.7 66.8 66.7 45 45 45 45 197.9 197.7 197.8 197.7 199.4 199.4 199.6 199.3 375.3 375.5 375.6 375.4 385.1 384.3 384.5 385.2 363.9 364 363.7 364 1093 1093 1093 1093 364.9 364.4 364.8 364.3 363.7 363.2 363.2 362.2 278.457 277.821 277.276 278.184 354.8 355.8 355.3 356.2 369.7 371.1 369.7 370.9 352.6 350.7 351.5 350.4 382.4 381.7 381.6 380.9 351.9 352 352.2 352.3 389.7 390.1 389.3 389.4 328.1 326.9 327.3 326.9 360.3 359.4 360.2 360 373.2 373.2 372 372.3 366.7 365.9 367.6 366.6 346.9 346.1 346.1 346.4 378.6 377.9 378.2 378.8 375.6 376.1 376.1 375.9 364.7 364.4 364.3 364.5 55.2 55.6 55.7 55.8 56.2 56.4 56.6 56.7 305.325 304.031 304.462 305.325 3883.837 3884.269 3883.837 3883.837 278.457 277.821 277.276 278.184


9/14/2011 9/14/2011 4:00:00 5:00:00 451.184 450.246 131.25 135.75 92.5 89.375 0 0 6680 6676.667 6680 6676.667 3251.111 3248.889 3251.111 3248.889 0 0 1367.619 1367.619 1368.571 1367.619 0 0 1368.571 1367.619 1200 1200 155.3 155.3 297.4 297.4 243.9 243.8 55.6 55.6 RPM RPM 67.6 67.4 28.1 28.1 66.4 66.6 66.6 66.7 66.5 66.6 45 45 197.6 197.6 199.3 199.3 375.1 374.8 384.1 384.1 363.5 363.5 1093 1093 364.2 363.8 363 362.4 278.093 277.276 355.3 355.1 369.7 369.8 351.7 351.1 381.7 381.7 352.1 351.8 389.4 388.3 327.3 326.6 360.4 359.2 372.3 372.3 364.8 364.8 345.9 345.4 379.4 379 375.7 375.1 364.2 363.9 55.3 55.3 56.2 56.2 304.894 304.462 3884.7 3882.112 278.093 277.276


RR TAGS A63QGCS A63QGHS A63QGJCV A63QGJGG A63SRM A65FCRSP A65FCUCP A71QGT A75GGIGVF1 A75GGIGVF2 A75QGCVF A99GGNH1 A99GGNH2 A99GGNL1 A99GGNL2 A99GGNS A99PT1 A99PT2 ACT01 ACT02 ACT03 ACT04 ACT05 ACT06 ACT07 ACT08 ACT09 ACT10 ACT100 ACT101 ACT102 ACT103 ACT104 ACT105 ACT106 ACT107 ACT108 ACT209 ACT11 ACT110 ACT111 ACT112 ACT113 ACT114 ACT115 ACT116 ACT117 ACT118 ACT119 ACT12 ACT120 ACT121

DESCRIPTION GG Lube Oil Center Scavenge Pressure GG Lube Oil Hydraulic Supply Pressure GG Lube Oil Control Valve DP GG Lube Oil Center Bearing DP Hydraulic Starter Motor Supply Pressure Remote PT Speed Setpoint To Fuel Control (Comp Onl UCP Software Hand Shake Time GG Lube Oil Tank Level GG IGV Position Feedback 1 GG IGV Position Feedback 2 GG Lube Oil Control Valve Feedback GG NH Speed 1 GG NH Speed 2 GG NL Speed 1 GG NL Speed 2 GG Starter Speed PT Speed 1 PT Speed 2 GG NL Act Speed AV #002 - NL Setpoint GG NH Act Speed AV #004 - NH Setpoint PT Act Speed AV #006 - PT Setpoint AV #007 - Nu Setpoint T455 Act Temp AV #009 - T455 Setpoint AV #010 - P30 Actual AV #100 - High dP SD Datum AV #101 - Temp. Compensated GG Bearing dP AV #102 - GG L.O. Scheduled Flow AV #103 - LOC Cntrl Valve dP High Alm Setpt AV #104 - LOC Cntrl Valve dP High SD Setpt AV #105 - LOC Cntrl Valve dP AV #106 - GG L.O. Reservoir Level High Alm Setpt AV #107 - GG L.O. Reservoir Level Low Alm Setpt AV #108 - GG L.O. Reservoir Level Low SD Setpt AV #209 - SIS Shutdown Reset Lockout Preset Timer AV #011 - P30 Setpoint AV #110 - H1 High Alm Datum AV #111 - H1 Press Low Alm Datum AV #112 - H1 Press Low Trip Datum AV #113 - Scavenge Blockage Alm Set AV #114 - Scavenge Blck SD Setpt AV #115 - L1 Temp. LSS AV #116 - L1 Temp. High Alm Datum AV #117 - L1 Temp. High SD Datum AV #118 - T455 T/C 1 Spread AV #119 - T455 T/C 2 Spread AV #012 - Gas Start Fuel Setpoint AV #120 - T455 T/C 3 Spread AV #121 - T455 T/C 4 Spread


9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 0:00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 -7.95 -7.644 -7.162 -10.356 -5.763 -7.731 4845 4850 4843.125 4843.125 4843.75 4847.5 274.875 275.375 274.625 274.5 274.5 275.5 74.738 74.4 74.55 74.175 74.925 74.587 0 0 0 0 0 0 0 0 0 0 0 0 13.3 57.399 50.4 37.1 22.45 7.45 301.683 302.674 302.636 302.674 301.492 301.416 20.389 20.389 20.386 20.389 20.386 20.379 20.431 20.431 20.431 20.431 20.431 20.431 12.145 12.142 12.137 12.143 12.147 12.14 6683.333 6680 6676.667 6680 6676.667 6676.667 6683.333 6680 6676.667 6680 6676.667 6676.667 3251.111 3248.889 3248.889 3251.111 3251.111 3248.889 3251.111 3248.889 3248.889 3251.111 3251.111 3248.889 0 0 0 0 0 0 1367.619 1367.619 1367.619 1367.619 1367.619 1367.619 1367.619 1367.619 1367.619 1367.619 1367.619 1367.619 3251.111 3248.889 3248.889 3251.111 3251.111 3248.889 3250 3250 3250 3250 3250 3250 6683.333 6680 6676.667 6680 6676.667 6676.667 9514.64 9514.64 9514.64 9514.64 9514.64 9514.64 1367.619 1367.619 1367.619 1367.619 1367.619 1367.619 3346 3346 3346 3346 3346 3346 3200 3200 3200 3200 3200 3200 375.686 376.144 376.023 375.786 375.657 375.031 761 761 761 761 761 761 278.457 277.73 277.276 278.184 278.093 277.276 184.019 183.807 183.807 184.019 184.019 183.807 77.357 77.493 77.285 77.312 77.544 77.253 11.383 11.369 11.369 11.383 11.383 11.369 70 70 70 70 70 70 100 100 100 100 100 100 21.003 20.717 20.592 20.503 20.503 20.842 325.882 325.882 325.882 325.882 325.882 325.882 250.952 250.952 250.952 250.952 250.952 250.952 225.806 225.806 225.806 225.806 225.806 225.806 120 120 120 120 120 120 2309 2309 2309 2309 2309 2309 6895 6895 6895 6895 6895 6895 3792 3792 3792 3792 3792 3792 3450 3450 3450 3450 3450 3450 0 0 0 0 0 0 -20 -20 -20 -20 -20 -20 55.2 55.6 55.7 55.8 55.2 55.3 70 70 70 70 70 70 80 80 80 80 80 80 10.135 10.818 10.724 10.529 10.394 10.447 19.935 19.518 19.724 20.329 19.394 19.747 99000 99000 99000 99000 99000 99000 -1.265 -0.882 -1.276 -0.771 -1.206 -0.853 -0.265 -0.482 -0.077 -0.471 -0.506 -0.453


RR TAGS ACT122 ACT123 ACT124 ACT125 ACT126 ACT127 ACT128 ACT129 ACT13 ACT130 ACT131 ACT132 ACT133 ACT134 ACT135 ACT136 ACT137 ACT138 ACT139 ACT14 ACT140 ACT141 ACT142 ACT143 ACT144 ACT145 ACT146 ACT147 ACT148 ACT149 ACT15 ACT150 ACT151 ACT152 ACT153 ACT154 ACT155 ACT156 ACT157 ACT158 ACT159 ACT16 ACT160 ACT161 ACT162 ACT163 ACT164 ACT165 ACT166 ACT167 ACT168 ACT169

DESCRIPTION AV #122 - T455 T/C 5 Spread AV #123 - T455 T/C 6 Spread AV #124 - T455 T/C 7 Spread AV #125 - T455 T/C 8 Spread AV #126 - T455 T/C 9 Spread AV #127 - T455 T/C 10 Spread AV #128 - T455 T/C 11 Spread AV #129 - T455 T/C 12 Spread AV #013 - Total Fuel Demand AV #130 - T455 T/C 13 Spread AV #131 - T455 T/C 14 Spread AV #132 - T455 T/C 15 Spread AV #133 - T455 T/C 16 Spread AV #134 - T455 T/C 17 Spread AV #135 - T455 Min Spread AV #136 - T455 Max Spread AV #137 - T455 Spread Alm Limit AV #138 - T455 Over Temp. Alm Setpt AV #139 - T455 Over Temp. Coolstop Setpt AV #014 - Accel Fuel Setpoint AV #140 - TC455 Average Input SD Setpt AV #141 - VIGV A RVDT Input Corrected AV #142 - VIGV B RVDT Input Corrected AV #143 - VIGV A RVDT Position AV #144 - VIGV B RVDT Position AV #145 - VIGV A RVDT Gain AV #146 - VIGV A RVDT Input AV #147 - VIGV A RVDT Zero AV #148 - VIGV B RVDT Gain AV #149 - VIGV B RVDT Input AV #015 - Decel Fuel Setpoint AV #150 - VIGV B RVDT Zero AV #151 - VIGV Maximum Indicator Position AV #152 - VIGV Minimum Indicator Position AV #153 - GG Rolldown Timer Preset AV #154 - GG Rolldown Timer AV #155 - Starter Overspeed S/D Setpt AV #156 - NL Overspeed S/D Setpt AV #157 - NL Underspeed S/D Setpt AV #158 - N3 Overspeed S/D Setpt AV #159 - N3 Underspeed S/D Setpt AV #016 - Liq 1 Start Fuel Setpoint AV #160 - BOV's Close NLQRT20 Setpt AV #161 - BOV's Open NLQRT20 Setpt AV #162 - LOC Flow Control Valve Drive Output AV #163 -LOC Flow Control Valve Position Feedback AV #164 - Gas - Methane AV #165 - Gas - Ethane AV #166 - Gas - Propane AV #167 - Gas - Butane AV #168 - Gas - Pentane AV #169 - Gas - Hexane


9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 0:00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 -1.565 -1.682 -1.676 -2.671 -1.706 -1.853 -10.365 -9.082 -9.577 -8.671 -9.406 -9.253 4.535 6.218 4.824 6.029 5.094 5.447 -12.665 -14.082 -13.477 -14.471 -13.006 -13.253 17.335 16.818 16.724 16.029 16.994 17.347 -13.253 -12.824 -12.577 -12.471 -12.606 -12.553 24.447 25.376 24.423 24.529 24.694 23.947 -37.053 -37.924 -37.577 -37.971 -37.406 -37.753 8781.433 8834.432 8819.429 8757.428 8754.052 8824.68 -4.853 -5.424 -4.577 -4.771 -4.306 -5.153 8.047 8.376 7.124 7.529 7.594 7.947 1.547 1.076 2.724 1.829 0.094 0.547 -18.253 -18.724 -18.776 -18.471 -18.806 -18.953 13.447 13.076 13.324 13.929 14.694 14.647 13.447 13.076 13.324 13.929 14.694 14.647 24.447 25.376 24.423 24.529 24.694 23.947 110 110 110 110 110 110 771 771 771 771 771 771 781 781 781 781 781 781 13500 13500 13500 13500 13500 13500 800 800 800 800 800 800 1.637 1.642 1.631 1.631 1.631 1.637 1.634 1.634 1.64 1.64 1.64 1.634 37.501 37.499 37.504 37.504 37.504 37.501 37.502 37.502 37.5 37.5 37.5 37.502 1.606 1.606 1.606 1.606 1.606 1.606 20.386 20.392 20.383 20.386 20.386 20.389 19.37 19.37 19.37 19.37 19.37 19.37 1.605 1.605 1.605 1.605 1.605 1.605 20.434 20.428 20.428 20.431 20.431 20.428 4754.074 4750 4750 4754.074 4754.074 4750 19.41 19.41 19.41 19.41 19.41 19.41 -7.5 -7.5 -7.5 -7.5 -7.5 -7.5 38.25 38.25 38.25 38.25 38.25 38.25 480 480 480 480 480 480 480 480 480 480 480 480 4970 4970 4970 4970 4970 4970 7000 7000 7000 7000 7000 7000 2800 2800 2800 2800 2800 2800 5292 5292 5292 5292 5292 5292 3178.7 3178.7 3178.7 3178.7 3178.7 3178.7 99000 99000 99000 99000 99000 99000 345 345 345 345 345 345 337 337 337 337 337 337 12.216 12.209 12.209 12.216 12.216 12.209 12.142 12.138 12.14 12.145 12.148 12.14 88.69 88.69 88.69 88.69 88.69 88.69 4.06 4.06 4.06 4.06 4.06 4.06 2.28 2.28 2.28 2.28 2.28 2.28 0.6 0.6 0.6 0.6 0.6 0.6 0.12 0.12 0.12 0.12 0.12 0.12 0.3 0.3 0.3 0.3 0.3 0.3


RR TAGS ACT17 ACT170 ACT171 ACT172 ACT173 ACT174 ACT175 ACT176 ACT177 ACT178 ACT179 ACT18 ACT180 ACT181 ACT182 ACT183 ACT184 ACT185 ACT186 ACT187 ACT188 ACT189 ACT190 ACT191 ACT192 ACT193 ACT194 ACT195 ACT196 ACT197 ACT198 ACT199 ACT20 ACT21 ACT22 ACT23 ACT24 ACT25 ACT26 ACT28 ACT29 ACT32 ACT34 ACT35 ACT36 ACT37 ACT38 ACT39 ACT46 ACT48 ACT49 ACT50 ACT51 ACT65

DESCRIPTION T1 Act Temp AV #170 - Gas - Heptane AV #171 - Gas - Octane AV #172 - Gas - Nonane AV #173 - Gas - Carbon Dioxide AV #174 - Gas - Carbon Monoxide AV #175 - Gas - Ethene AV #176 - Gas - Propene AV #177 - Gas - Butene AV #178 - Gas - Pentene AV #179 - Gas - Water Vapor AV #018 - N1 SQRT T20 AV #180 - Gas - Hydrogen Sulfide AV #181 - Gas - Hydrogen AV #182 - Gas - Iso Butane AV #183 - Gas - Iso Pentane AV #184 - Gas - Nitrogen AV #185 - Gas - Oxygen AV #186 - Gas - Sulfur Dioxide AV #187 - Gas - Low Heat Value AV #188 - Gas Molecular Weight AV #189 - Gas Metric Constant AV #190 - GGNL=1;GGNH2;PT=3;T4=4;P3=5;St=6;Ac=7;D AV #191 - Fuel Gas Temperature Alarm Setpoint AV #192 - Fuel Gas Temperature Coolstop Setpoint AV #193 - Fuel Gas Temperature Shutdown Setpoint AV #194 - IP Compr. Operating Life Cycles AV #195 - IP Turbine Operating Life Cycles AV #196 - HP Compr. Operating Life Cycles AV #197 - HP Turbine Operating Life Cycles AV #198 - IP Turbine SHAFT Operating Life Cycles AV #199 - HP Compressor 4-5 Assmbly Operating Lif P1 Act Press AV #021 - Gas Valve Actual Position AV #022 - Gas Valve Setpoint AV #023 - Gas Fuel Flow Setpoint AV #024 - Liq 1 Fuel Flow Setpoint AV #025 - Gas/Liq 1 Fuel Blend Setpoint AV #026 - Fuel Gas Temperature AV #028 - Gas Valve Upstream Pressure AV #029 - Gas Valve Downstream Pressure AV #032 - Ignition Time AV #034 - VIGV Actual Position AV #035 - VIGV Setpoint Position AV #036 - VIGV Servo Drive AV #037 - VIGV A Actual Position AV #038 - VIGV B Actual Position AV #039 - VIGV C Actual Position AV #046 - Ns Actual AV #048 - Liq 2 Valve Setpoint AV #049 - Liq 2 Fuel Flow Setpoint AV #050 - Gas/Liq 2 Fuel Blend Setpoint AV #51 - Spare AV #65 - High dP SD Curve X1


9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 0:00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 28.3 28.3 28.3 28.2 28.141 28.153 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1.84 1.84 1.84 1.84 1.84 1.84 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 187.248 187.12 187.12 187.279 187.297 187.166 0 0 0 0 0 0 0 0 0 0 0 0 1.35 1.35 1.35 1.35 1.35 1.35 0.2 0.2 0.2 0.2 0.2 0.2 0.5 0.5 0.5 0.5 0.5 0.5 0 0 0 0 0 0 0 0 0 0 0 0 46701.367 46701.367 46701.367 46701.37 46701.367 46701.367 19.039 19.039 19.039 19.039 19.039 19.039 436.711 436.711 436.711 436.711 436.711 436.711 1 1 1 1 1 1 69 69 69 69 69 69 64 64 64 64 64 64 59 59 59 59 59 59 86.545 86.545 86.545 86.545 86.545 86.545 78.204 78.204 78.204 78.204 78.204 78.204 113.308 113.308 113.308 113.308 113.308 113.308 76.6 76.6 76.6 76.6 76.6 76.6 1679.601 1679.601 1679.601 1679.601 1679.601 1679.601 68.89 68.89 68.89 68.89 68.89 68.89 0 0 0 0 0 0 10.775 10.815 10.785 10.763 10.758 10.777 10.769 10.811 10.804 10.761 10.75 10.797 8781.433 8834.432 8819.429 8757.428 8754.052 8824.68 0 0 0 0 0 0 100 100 100 100 100 100 67.626 68.5 68.6 68.348 67.581 67.448 3883.837 3884.7 3883.837 3883.837 3886.856 3882.112 306.188 304.462 304.462 305.325 304.894 304.462 1.475 1.475 1.475 1.475 1.475 1.475 37.5 37.5 37.5 37.5 37.5 37.5 37.5 37.5 37.5 37.5 37.5 37.5 12.092 11.886 12.116 12.198 12.25 11.952 37.501 37.501 37.504 37.501 37.504 37.508 37.5 37.5 37.5 37.5 37.5 37.5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 100 100 100 100 100 100 0 0 0 0 0 0 0 0 0 0 0 0


RR TAGS ACT66 ACT67 ACT68 ACT69 ACT70 ACT71 ACT72 ACT73 ACT74 ACT75 ACT76 ACT77 ACT78 ACT79 ACT80 ACT81 ACT82 ACT83 ACT84 ACT85 ACT86 ACT87 ACT88 ACT89 ACT90 ACT91 ACT92 ACT93 ACT94 ACT95 ACT96 ACT97 ACT98 ACT99 BOV1MANUALSTROKE_HMI BOV2MANUALSTROKE_HMI BOVMANUALSTROKE_HMI C75FGMC C75GGIGVC C75QGCVC C75SRPC C99FCGGNH C99FCGGNL C99FCPT

DESCRIPTION AV #66 - High dP SD Curve X2 AV #67 - High dP SD Curve X3 AV #68 - High dP SD Curve X4 AV #69 - High dP SD Curve X5 AV #70 - High dP SD Curve Y1 AV #71 - High dP SD Curve Y2 AV #72 - High dP SD Curve Y3 AV #73 - High dP SD Curve Y4 AV #74 - High dP SD Curve Y5 AV #75 - High dP Alm Curve X1 AV #76 - High dP Alm Curve X2 AV #77 - High dP Alm Curve X3 AV #78 - High dP Alm Curve X4 AV #79 - High dP Alm Curve X5 AV #80 - High dP Alm Curve Y1 AV #81 - High dP Alm Curve Y2 AV #82 - High dP Alm Curve Y3 AV #83 - High dP Alm Curve Y4 AV #84 - High dP Alm Curve Y5 AV #85 - Low dP SD Curve X1 AV #86 - Low dP SD Curve X2 AV #87 - Low dP SD Curve X3 AV #88 - Low dP SD Curve Y1 AV #89 - Low dP SD Curve Y2 AV #90 - Low dP SD Curve Y3 AV #91 - Low dP Alm Curve X1 AV #92 - Low dP Alm Curve X2 AV #93 - Low dP Alm Curve X3 AV #94 - Low dP Alm Curve Y1 AV #95 - Low dP Alm Curve Y2 AV #96 - Low dP Alm Curve Y3 AV #97 - Low dP Alm Datum AV #98 - Low dP SD Datum AV #99 - High dP Alm Datum HP3 BOV1 Tune from HMI to ECS HP3 BOV2 Tune from HMI to ECS BOV Tune from HMI to ECS Fuel Gas Metering Valve Position Control GG Inlet Guide Vane Position Control GG Lube Oil Control Valve Position Control Hydraulic Starter Pressure Control GG NH Speed from Fuel Controller GG NL Speed from Fuel Controller PT Speed From Fuel Controller


9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 9/14/2011 0:00:00 1:00:00 2:00:00 3:00:00 4:00:00 5:00:00 2200 2200 2200 2200 2200 2200 3000 3000 3000 3000 3000 3000 5300 5300 5300 5300 5300 5300 7500 7500 7500 7500 7500 7500 35 35 35 35 35 35 35 35 35 35 35 35 160 160 160 160 160 160 380 380 380 380 380 380 380 380 380 380 380 380 0 0 0 0 0 0 2200 2200 2200 2200 2200 2200 3000 3000 3000 3000 3000 3000 5300 5300 5300 5300 5300 5300 7500 7500 7500 7500 7500 7500 30 30 30 30 30 30 30 30 30 30 30 30 120 120 120 120 120 120 345 345 345 345 345 345 345 345 345 345 345 345 3000 3000 3000 3000 3000 3000 5300 5300 5300 5300 5300 5300 7500 7500 7500 7500 7500 7500 10 10 10 10 10 10 150 150 150 150 150 150 150 150 150 150 150 150 3000 3000 3000 3000 3000 3000 5300 5300 5300 5300 5300 5300 7500 7500 7500 7500 7500 7500 20 20 20 20 20 20 170 170 170 170 170 170 170 170 170 170 170 170 36.377 36.232 36.232 36.377 36.377 36.232 25.285 25.15 25.15 25.285 25.285 25.15 144.565 144.348 144.348 144.565 144.565 144.348 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 10.769 10.811 10.804 10.761 10.75 10.797 12.092 11.886 12.114 12.198 12.25 11.957 12.216 12.209 12.209 12.216 12.216 12.209 0 0 0 0 0 0 6683.333 6680 6676.667 6680 6676.667 6676.667 3251.111 3248.889 3248.889 3251.111 3251.111 3248.889 1367.619 1367.619 1367.619 1367.619 1368.571 1366.667



14.0 APPENDIX VII: SAMPLE TABLE OF CONTENT (TOC) FOR OVERALL DETAILED TESTING, PRECOMMISSIONING AND COMMISSIONING PROCEDURE.


End of Document


CSP20 Testing Precommissioning and Commissioning Guideline - Full Compilation

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