MC Handbook

MC Handbook – Section A 1

INTRODUCTION & OV E R V I E W

1. 1I 1. 2

n t r o du c t i on

4

CoM ncCept

1. 3

ComputeriseMdSCystem

1. 4

AbbreviationsT, erms&Definitions

2

4

4 6 6

STARTIP NAR GOJECT

2. 1

9

WhE taost tablisEharly

2. 2

9

PM hiClosophy

2. 3

9

LevelofMCforSuppliersandContractors

9

2. 4

SyM stC em

11

2. 5

MaM nC u al

12

2. 6

PreservatioMnanual

2. 7

PMr o Ccedur es

2. 8

DefineCommissioningPackages

3

12 13 13

ENGINEERINDGATA

14

3. 1

HandlingoE f ngineeringRegisters

14

3. 2

ImportingRoutines&DiscrepancyReporting

16

3. 3

SupplieEr ngineering & MC Da t a

17

4 DCEPFINITION 4. 1

DevelopmentofCommissioningPackages

4. 2

CommissioningSchedule&PlanningLevels

4. 3

ControoB lf oundarD y ra w in g s

5

18 18 19 20

MCPACKAGEDEFINIT ION&CONTENT

5. 1

Developmenot M f CPackages(MCPs)

5. 2

TiSec-Ionpe

5. 3

P ip in g

5.3.1 5.3.2 5.3.3 5.3.4

Levels Tracking of Release Piping of TestingofPipeworkatContractorInterfaces Critical Areas to Maintain Control

23 23 26 27

27 30 31 32

Page 1 of 84 (Oct 2000 Edition)

MC Handbook – Section A 5. 4

E q u ip m C e& natbles

5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 5.4.8

Static Vessels Equipment Motors, – Heaters etc Testing electrical equipment Lighting Small & Power Electric Heat Tracing Instrument Field Cables Underground Cableworks Control Cabinets (in CCR & LCRs)

5. 5

S te e l w o r k

5. 6 5. 7

LiftiE nq guipment C iv il s

5.7.1 5.7.2 5.7.3 5.7.4

General Concrete Structures Foundations U/G Pipework (No line numbers) :

35

35

36 38 39 40 41 42 43

44 46 46 46 46 46 48

5. 8

F i r e p r oo f i n g

5. 9

AC reoampletion

49

5.10

SteBalm o wi ng

50

6 PMUCNCH-OUT 6. 1

Punch-oSutat ge s

6. 2

PunIctheEmxamples

7

CARRYOVEW R OR(KCOW)

8

PRESERVATION

8. 1

PreservatioR n e sp o n s i b i l i t y

8. 2

PreservatioSnystem

8. 3

PreservationExperienceFeedback

8.3.1V 8.3.2 8.3.3

9 10

alves Stainless Steel Surfaces Boxed Items for Long Term Storage

48

51 51 52

54 55 55 55 57 60

LIVENING-UNPOTICE

61

LOTOEPSTING

1 0 .1

Loops D ia g r a m & Loop R e g is t e r

1 0 .2

G u i de l i n e s foM r CP D e f i ni t i o n

1 0 .3

Releaso eLfoopfsoTresting

1 0 .4

LooTpestinO g r ga n i s a t i o n

57

59

63 63 65 65 65


MC Handbook – Section A 11

INTRINSICALLYSAF EEQUIPMENT

12

CHANG CE ONTROL

66 72

1 2 .1

SiteInstructionsorSimilarChangeInstruction

72

1 2 .2

A s -B u Sitlat tus

73

13

STATURSEPORTING

1 3 .1

Graphicaal ndTabulaR r e po r t i n g

1 3 .2

P la n n i n Ingterface

13.3B

14 1 4 .1 1 4 .2

74 74 81

e n c h m a r ki n g

81

DO SS I ER S HandovDeor ssiers DMoC ss ie rs

82 82 82


MC Handbook – Section A 1 Introduction& Overview 1.1

Introduction The purpose of this handbook is to provide a concise set of guidelines to establish and maintain a mechanical completion system on land-based or offshore construction projects. It is compiled in three distinct sections :Section A

- MC Handbook

Section B

- Sample MC Manual

Se ct io n C

- Sa mple Pr es er va ti on Ma nua l

Although the manuals in Section B & C are from the Statoil KUP land-based project, they can equally be adapted to suit offshore projects with the addition of some specific offshore-related check-sheets. The main objective of this handbook is to provide a comprehensive understanding of Statoil’s MC strategy. All references to MC in this document implies bringing to a state of ‘Ready for Commissioning’, however, where a project has planned for a distinct pre-commissioning phase then the MC System, handover routines and manuals would be modified accordingly. The objective of MC is to bring equipment/systems up to a state where they are ready for dynamic testing. This comprises of verification that all the required tests and inspections are performed and deemed to be mechanically complete, all equipment/systems will work for their intended use and that the maintainability/operability requirements are fulfilled.

1.2

MC Concept The aim is to establish a common project-wide MC strategy which will enable progressive verification of the physical progress in-line with the installation and therefore help to achieve a smooth and timely handover of the scope to the Commissioning Group, in pre-defined commissioning packages. In addition, a progressive compilation of a consolidated MC Dossier for each CP from the various contractors MC Packages will spread the workload over the length of the project thus avoiding back-end loaded documentation verification activities. This approach will secure speedy preparation of the Handover Dossier for each commissioning package and subsequent issue.


MC Handbook – Section A

HANDOVER

Engineering Construction MC

Commissioning

Start-Up

T he C omplet ions Flag

Contractor No.01

Contractor No.02

Contractor No.03

Others

MC Dept.

MC Dept.

MC Dept.

MC Dept.

Progressive submission by MC Package

MC Core Group • • • • • • • • • • •

Handle Engineering Data Scope Comm.Packages Process MC Packages MC Reporting (Project wide) Interim Milestone reporting Liaise with Contractors MC Status meetings MDP administration Verification of CP status Prepare handovers Prepare MC Dossiers

Project MC Core Group

Compile & Issue Handover Dossier per CP Compile & Issue MC Dossier per CP


MC Handbook – Section A 1.3

ComputerisedMC System The advantages of having a corporate MC system are well proven and with today’s technology, the benefits of setting up an on-line system are realistic, practical and desirable. This would enable the server to be strategically placed to optimise system support to all user groups. In addition, a corporate approach would establish a consistent standard across all projects and eventually develop into an instantly recognisable Client system, which would benefit both Statoil and Contractors, i.e. ‘ MC - The Statoil Way ’. The MC system’s main functionality should include : • • • • • • •

•

1.4

Routines for importing engineering data Link tags/cables to relevant commissioning packages Link to appropriate Inspection & Test Records Link tags/cables to specific event (e.g. for cables : pulled, term1, term2, tested etc) Allow for allocation of MC Packages to Tags/Cables/Isometrics by contractors Comprehensive punchlist administration facility (including COW) Comprehensive status reporting (incl. High level graphical to show trends plus detailed tabular format ) Preservation system, which will track all items in the preservation programme, produce weekly work lists and negative observation reporting.

Abbreviations,Terms & Definitions This section is not intended to be an exhaustive listing of all abbreviation, acronyms, terms and definitions applicable to all aspects across a typical project, but instead an extract of the important ones deemed to be essential in the understanding of this document and mechanical completion in general. Terms, Acronym s & Abbreviations

Definitions & Addition

Carry Over Work (COW)

This is work outstanding from the various suppliers’, which is to be finalised by others (in most cases) at the next/final location. Category "A" items are defined as incomplete work preventing further testing, commissioning performance or continuous operation and maintaining of the plant systems. For piping test packs with A-items, which shall be cleared prior to release of pressure test, then these shall be flagged on the punchlist in the appropriate column. All A-items shall be cleared prior to handover of the Commissioning Package to COMM.

Category ‘A’ Punch Item

al Notes

Category ‘B’ Punch Item

Category "B" items have no significance on safe operation and maintenance of the systems and can be accepted as not completed at handover provided that the number of such items is limited and subject to COMM acceptance.

Commissioning (COMM)

Means the testing and adjustment of an assembly or plant sections and will comprise of Operational testing under real or simulated conditions to ensure that it meets all applicable Rules, Regulations, Codes and Standards and that it fulfils it’s intended duty and ready for start-up.

Commissioning Package (CP)

Is a discrete part of the plant, which enables Commissioning to be performed in a sequential manner. These would be defined on marked-up boundary drawings e.g. P&IDs, Single Line Drawings, Block Diagrams etc.


MC Handbook – Section A Terms, Acronym s & Abbreviations


al Notes

Discipline Punchlist (DPL)

A DPL is the result of a joint punch-out of the scope of a specific MCP. The items are detailed, reference to item/cable/tag/isometric/drawing and categorised as A or B.

EPCS

Engineering, Procurement & Construction Supervision contractor.

Handover (HO)

The presentation of Commissioning Packages in the form of a Handover Dossier, which comprises of a Handover Certificate, MC documentation summary report, multi-discipline punchlist, copies of relevant MACs’, boundary drawings and as-built drawings. Upon acceptance of the Handover Certificate is signed and the operational responsibility for the CP is formally transferred from Contraction Group to the Commissioning Group.

Handover Dossier

A dossier which summaries the CP status and comprises: Handover Certificate, Multi-Discipline Punchlist, MC Status Summary Report, Copies of all relevant MACs’, boundary drawings which define the limits of the CP, relevant as-built drawings and copies of other documentation required by the Commissioning Group e.g. copies of PSV/TSV calibration certificate, vessel final closure certificates, instrument loop test records & as-built loop diagrams. The srcinal MC Dossier which contains all test and inspection records would be made available for verification purposes but not formally delivered to the project until all disciplines fully completed (i.e. surface protection, heat tracing and insulation). .

IOM

Installation and Operation Manual (from Vendors)

KUP

Kårstø Utbyggings Prosjekt (Kårstø Development Project)

MC Dossier

A specific dossier for each CP that comprises all MC Package filed by discipline. Such MC Packages would include MAC, Discipline Punchlist, All Inspection & Test Records, Additional Charts, Test Reports and marked-up drawings appertaining to the specific scope. In addition, a total listing of all tags, cables and isometrics should be included together with an overall index.

Mechanical Completion (MC)

Means all checking, verification and testing of fabrication, construction and installation work performed by the respective contractors & sub-contractors in order to confirm that the applicable Rules, Regulations, Codes & Standards are being met and that the Project requirements as shown on the design drawings and outlined in the specifications are fulfilled. The system (i.e. CP) shall be preserved and ready for Commissioning when Mechanical Completion is completed.

Mechanical Completion Package (MCP)

A meaningful single discipline group of items belonging to one specific CP which will ultimately be completed and offered as a discrete scope for discipline punch-out and acceptance. Typical


MC Handbook – Section A Terms, Acronym s & Abbreviations


al Notes

examples can be found later in this document. MET

Methanol Project, Tjeldbergodden

MRB

Manufacturer Record Book

Multi-Discipline

This is the term used for the "Final Inspection" of a full Commissioning Package prior to handover to COMM. It shall cover all disciplines and the primary aim is to verify the overall MC status of the package and document all outstanding items on a consolidated punchlist i.e. MultiDiscipline Punchlist..

Punchlist (MDPL)

This punch-out shall be carried out relatively close to the planned handover date, however sufficient time should be allowed to clear any additional A-items that may be identified and to reduced the number of B-items to an acceptable level for handover. PIMS-MC

The on-line computerised mechanical completion system used by Statoil.

Responsibility Matrix

This matrix details the various levels of inspection, testing and verification to be carried out by the Contractors, Client/EPCS Construction Group, Commissioning Group, Third Party and Vendor/Supplier across all disciplines. The matrix important of the project MC Manual andforms wouldantherefore bepart customised to suitspecific the project organisation. The matrix clearly specifies who witnesses or verifies specific activities.

Start-Up

Start-up means bringing the plant sections and the complete plant to operating conditions of all systems, in a defined sequence to meet the product qualities and production rates outlined in design documents and specifications.



2 Starting a Project 2.1

What to Establish Early The primary MC tasks at the outset of a new project are as follows : • • • • • • •

2.2

Agree on MC philosophy Agree on level of MC for suppliers and contractors Agree on a computerised MC system Establish a project specific MC Manual Establish a project specific Preservation Manual Establish project specific MC Procedures Define Commissioning Packages and Issue Boundary Drawings

MC Philosophy The MC philosophy is based on the identification of discrete parts of the plant, which can be commissioned independently. These are subsequently broken down into smaller single discipline packages and on completion, each package is offered for punch-out and acceptance. As mentioned in paragraph 1.3, a corporate approach would maintain consistency across projects. This progressive approach ensures that punch items are circulated back into construction, thus minimising the number of items outstanding at handover of a complete CP. There are various options for the completion and compilation of the MC documentation :a)

Prepare, complete and compile in an MC dossier per CP by each contractor.

b)

Prepare, complete and deliver to Client or EPCS Contractor on a progressive basis by MC Package, thereafter the Client/EPCS MC Group prepares Handover Dossiers and MC Dossiers.

The preferred option is b), which has been implemented very successfully on both the MET and KUP projects. The main disadvantage on option a) is that it is back-end loaded for both the contractors and client with respect to compiling MC Dossiers for their scope and subsequent verification/approval by Client/EPCS. In addition, it produces a fragmented set of MC Dossiers for the site scope i.e. one MC Dossier from each relevant contractor per each CP.

2.3

Level of MC for Suppliers and Contractors In general, the module yard and site contractors would implement the full MC requirements as specified in the project specific MC Manual, however, a simplified MC level is normally applicable to most suppliers and a project specification would be issued to clearly specify these requirements. (e.g. on KUP E060-SB-A-SS-0014 – ‘Mechanical Completion Specification for Equipment/Fabricated Items’) This is an extremely important aspect of MC and historically has proved to be a potential area of concern due to late or missing information, which may have impact on the project at a later phase.


MC Handbook – Section A Example : Supplier’s MC Dossier Typical Structure • •

•

• • •

Supplier’s Certificate of Compliance Supplier’s Final Acceptance Check Lists for a) Equipment b) Piping c) Electrical d) Instrumentation Punchlist List of Outstanding Work List of Shipped Loose Items Relevant Drawings

The above final acceptance check lists tend to be based on main tag numbers (e.g. Compressor Tag No.) and therefore it is important that all related tag/cable numbers on this package are included in order to assist with MC punch out and verification of final acceptance. This could be achieved by the inclusion of a dual purpose ‘Engineering Register and MC Matrix’ which would effectively supply all the required key engineering data plus satisfy the MC Status reporting requirements. In addition, this could be set-up as an on-line facility through the Internet.

Engineering Register and MC Status (P.O. No. C-309999) Equipment :

Instrumentation

Final Acceptance Piping Final Check Acceptance List FinalCheck List Equipment Acceptance Xxxxx FinalCheck List Xxxxx xxxxx Acceptance Xxxxx Xxxxx CheckXxxxx List xxxxx Certificate of Xxxxx Xxxxx xxxxx Compliance Electrical

+

Xxxxx Xxxxxxxxxxxxxx Xxxxxxxx Xxxxx xxx

MC Punchlist

+

Item. Descr. 01 Xxxxxxxxx 02 Xxxxxxxx 03 Xxxxx 04 xxx

+

Descr. Xxxxxxxxx Xxxxxxxx Xxxxx

Cables No. Type Size From CL-62-xxxx bbb 3x2.5 PL-62-vvvv mm 3x

Actual Date MC Status 10/05/99 OK 09/10/99 OK 15/10/99 PL To

Test Result MC Status OK PL

Proposed New Engineering/MC Matrix would comprise a comprehensive listing of all Tag Nos and Cables for each Main Item (e.g. skid)

Outstanding Work List

Item 01 02 03

Tag No. Description 62-HA-101 xxxxx 62-VD-106 zzzzzz 62-PA-109A cccccc Cables :

Shipped Loose Items

+

Item 01 02 03 04 05

Descr. Location Xxxxxxxxx Case 1 Xxxxxxxx Case 2 Xxxxx On Skid Xxxxxxx Xxxx

+

Drawings

Other key data would be included in M.R.B, I.O.M. and ‘Revisjonsbok’ (Code Book) :Data Sheets, Power Cable Calculations, IS Loop Calculations, Ex Certification, CE Certification, Third Party Approval, Nameplate details etc.



MC System This should be established as early as possible in order that this can be specified in the relevant contracts/purchase orders. It is strongly recommended that an on-line system be utilised to allow the latest data and status to be available to all applicable users plus accurate and up to date reporting.

On-Line MC System SITE LOCATION E&I Contractor Site

Mechanical

Mechanical

Contractor No.2 - Site

Contractor No.1 - Site

SQL SERVER (Location to Suit)

Project Team Site

EPCS Contractor

Civil Contractor Site

Module Yard No.1

Module Yard No.2



MC Manual A project specific MC Manual should be produced and distributed as early as possible in a project in order that it can be included in the relevant contracts / purchase orders (Refer to sample manual). A thorough MC strategy and corresponding manual will eliminate the need for significant revision after contract award. In addition to the full sized controlled issues, it is also advisable to print reduced B5 sized uncontrolled issues for general distribution. The aim isthat to get personnellevel involved in MC to activities tothe be well versed requirements to ensure theall verification is adhered and that quality of thewith MCthe documentation is maintained. To achieve this end a comprehensive training programme on MC principals combined with the use of the MC System should be established. To optimise the benefit of such training sessions, it is preferably to limit them to small groups sharing a common interest in specific aspects of MC e.g.

2.6

q

Management Group – Focus on status reporting

q

Planning Group – Focus on interfaces with MC & planning system – how to best use data

q

Disciplines Groups – Focus on responsibility matrix, MC Certificates and punchlist standard and routines.

PreservationManual A project specific Preservation Manual should be produced and distributed as early as possible in a project in order that it can be included in the relevant contracts/purchase orders (Refer to sample manual). A thorough preservation strategy and corresponding manual will eliminate the need for significant revision after contract award. In addition to the full sized controlled issues, it is also advisable to print reduced B5 sized uncontrolled issues for general distribution. The aim is to get all personnel involved in preservation activities to be well versed with the requirements and establish good and speedy reporting routine where discrepancies are found to ensure minimum impact to the integrity of the permanent plant. A training programme should be set-up for the direct users of the preservation system but in addition, it is beneficial to details the objectives of preservation to a broader construction group. This can be achieved by having presentation to each contractor construction group in order to initiate ‘front-line’ preventative measures. This should be followed-up on a regular basis at contractor toolbox meetings. Emphasis should be made to the Quality aspects Commercial aspects • •


MC Handbook – Section A Examples of preventative measures that will avoid costly rework and/or additional extensive cleaning :•

•

•

•

•

2.7

Prevent ingress of debris and water during the construction phase by using end caps, plugs etc Protect all stainless steel surfaces from carbon steel contamination caused by adjacent grinding or welding operations. Protect fully painted surfaces from contamination or damage. Although there will always be a need for minor touch-up and repair work, much can be done to prevent major rework to completed paint system. Protect valve stems and machined surfaces. This can be a significant source of problem during the commissioning phase and possibly have long term impact of the reliability of the plant. Prevent contamination and damage to cable trays from grinding, welding, sandblasting, painting activities.

MC Procedures Project specific MC related procedures should be issued as early as possible in order that personnel involved in MC activities are fully conversant with the requirements. Some suggested procedures to establish :•

Commissioning Package Handover Procedure

•

Punchlisting Procedure (Discipline & Multi-Discipline Stages)

•

Site Receiving Inspection of Vendor Packages

•

•

•

•

2.8

PSV handling procedure Engineering Data Importing Routines & Discrepancy Reporting Construction Blinding Procedure Construction Temporary Links & Jumpers Procedure

Define CommissioningPackages This is dealt with in Chapter 4.



3 EngineeringData 3.1

Handling of EngineeringRegisters This fundamental step provides the foundation for the identification of the MC scope and therefore it is essential to establish regular import routines from the Engineering Contractor(s) as their various registers are developed and updated. Some register are included for information only while the majority are for inclusion in the main MC Database for subsequent linking to applicable Contractor and MC Package. There is of course the option for the Engineering Contractor(s) to utilise the MC System engineering registers as the ‘live’ master registers. Typical Engineering Register are :•

Piping Line List

•

Isometric Register

•

Equipment Register

•

Instrument Index

•

Cable Schedule (Electrical, Instrumentation & Telecom)

•

Electrical Heat Tracing Schedule

•

Electrical Equipment Register

•

Junction Box Schedule

•

•

•

•

PSV Register (may be incorporated into other registers) Piping Special Items Register Tie-In Register(s) Loop Register (it is important that if such an Engineering Register is not established by the Engineering Contractor, then it should be built up in MC System by the Project Team)


MC Handbook – Section A Useful Notes and Tips !

Isometric Register : Expand the isometric register in order to cover other key information that is extremely useful to the contractors in scoping the MC for piping. Engineering Data

Isometric No.

Line No.

P&ID

Suggested Control Fields s s n g s a a lu l e h n l g P m n s C o C i u i d te l l n l s c s F a e o n a y i l c r t tS T la i i O e N lW T m t t a u t e l a in s e o o h e a S H In C B H P

E060-AD-LL-…..

Y

16

Y

N

Y

E060-AD-LL-…..

N

0

N

N

N

Y

E060-AD-LL-…..

Electric Heat Tracing Schedule : This scope tends to be an independent design (e.g. Raychem) and as it is dependent on the piping design can be difficult to establish as early as the other engineering registers. Establish a link to piping isometrics and/or tag nos. to enable an easy allocation of scope to the correct CP No. If a schedule does not exist for heat tracing tapes, then consideration should be given to producing one, from the load lists for each distribution board. PSV Schedule : Establish a PSV/TSV schedule or if the data is incorporated in other registers (e.g. instrument index or special piping items), then as a minimum, establish a specific PSV/TSV Report which gives the key engineering information plus the calibration status. A close interface with the Planning and Commissioning Groups is required to agree on the optimum timing for re-calibration and reinstatement. Piping special Items : It is not required to perform individual MC on each item as many of such items are included on the piping isometrics and would therefore be punched as part of the relevant piping test pack. (e.g. various in-line manual valves, hose connections, flame arrestors, etc). It is however advisable to perform specific MC on some items and these should be flagged in some way to allow an easy download to the MC database (e.g. sample connections, strainers, orifice plates, interlocks etc). Tie-In Registers : Tie-in registers will be related to piping, electrical, instrumentation and telecom tie-in scope to existing plant to enable integration with new plant. These registers are important to clearly identify what scope was completed during pre-project shutdowns and that which needs to be executed during the project proper.



ImportingRoutines & DiscrepancyReporting The raw engineering data forms the basis for the MC scope and therefore good handling/importing procedures are essential. Importing Philosophy : EPC No.1 Raw Data

EPC No.2 Raw Data

Convert to Access Format

Convert to Access Format

Note : Raw Engineering Data from all Engi neering Sourc es EPC No.01, 02, 03 etc (var ious file formats)

Produce Report on any duplicate Tag Nos/Cable Nos

EXTERNAL MC SYSTEM MC Engineering Registers Each register is overwritten with new downloads

Note : Engineering data held in specific Registers plus an additional field ’Source’ to indic ate the rele vant EPC Company Vendor.

/or

MC Main Table

Discrepancy Report

Tag Nos/Cable Nos. plus key engineering data downloaded

Compares data from new downloads with ’Key Data’ already in system

The MC System master engineering registers would provide a convenient ‘read-only’ version of each distinct imported file for the front-end user. These would be dated to clearly show the last download date. Typical Engineering Registers are shown in Section 1 of this chapter.


MC Handbook – Section A Handling Discrepancies :

During the import routines, all new Tag Nos./Cable Nos. would be added to the MC system, while discrepancies would be subsequently actioned based on discrepancy category.

Dis c rep an c y Categ o ry

A c tio n

Removed Objects

Flag objects as ‘DELETED’ in MC System (records retained for reference)

i.e. were in previous download but not in latest

Objects added in advance.

Change source field from ‘MC’ to relevant Engineering Contractor Code.

i.e. added by MC Dept. prior to formal download – Source Field marked ‘MC’

Deleted objects.

Flag objects as ‘DELETED’ in MC System

i.e. where registers retain records but indicate a deleted date

(records retained for reference)

Duplicates

These would be addressed direct with Engineering.

separate report prior to import

e.g. Possible duplication between Engineering Contractors/Supplier – Block allocation of Tag Nos./Cable Nos.)

Changes to key fields

Discrepancy Report would show old and new data and these would be review prior to updating. Discrepancy Reports filed for historical reference.

3.3

Supplier Engineering& MC Data It is beneficial to include all vendor tags and cables in the overall MC system and therefore good routines must be established at the early phase of the project to ensure that all Vendor engineering data is available electronically through the Engineering Contractor. Historically, this has proved to be a potential problem area with respect to obtaining timely downloads of vendor engineering data (tag nos. & cables nos.) on a progressive basis. Engineering should perform regular verification on vendor data and in addition, that MC Status is being reported. On large projects it is worth considering an on-line option for all suppliers data and status as previously mentioned in paragraph 2.3..



4 CP Definition 4.1

Developmentof CommissioningPackages The commissioning package definition is normally performed by the Commissioning Group in conjunction with Operations and comprises discrete multi-discipline parts of the permanent plant, which allows progressive initial commissioning activities to proceed in-line with the startup sequence. This will then allow a Commissioning Schedule to be produced, which will reflect the pre-requisite systems required for the commissioning of process systems.

Development of Commissioning Packages Engineering

Company

Operations

Detailed Start-Up planning

Agree Start-Up sequence

Agree Start-Up sequence

Establish Commissioning Packages

Establish Commissioning Packages

Input comments by discipline

Review

Mark up drawings, P&ID’s,Block diagrams etc. to show Commissioning package boundaries

Distribute to all Involved parties

Receive/Review colour Marked-Up boundary drawings

Receive/Review colour Marked-Up boundary drawings

Issue & maintain controlled sets of colour marked boundary drawings to contractors



4.2

Commissioning Schedule & Planning Levels A detailed commissioning schedule is developed from the start-up sequence and the block diagram below shows the interface with planning levels.

LEVEL 2 PLAN Cost/Contract Based

Discipline /Area Based

Work Breakdown Structure (WBS) Key Activities

LEVEL 3 PLAN Discipline/Area activities

Start-Up Sequence

System Level (CP compatible)

Commissioning Schedule Detailed to CP No. level

LEVEL 4 PLAN System level activities (i.e. CP related)

Project Overall Level 4 prepared from Specific L4 Plans from the various Contractors. This allows switch from Area based to System based reporting.

Level 5 and below developed by Contractors to level of detail required. Detailed Level (CP, Area & Discipline compatible)

LEVEL 5 PLAN Job Card Level activities



Control of Boundary Drawings The issue and subsequent control of commissioning package boundary drawings is of prime importance and the following recommendations should be taken into consideration :a)

Establish a method of identifying the drawings used, distinct from the project drawing revision. This can be achieved by using a stamp, which states the independent CP revision of the mark-up drawing.

Commissioning Boundary Drawing

Example Drawing Title Block

Issue Date : Drawing title CPB Rev No : Approved by :

Drawing Number & Revision

Use Drawing No. with CPB Rev No to control Boundary Drwgs.

Cross out on drawing title block and use the Commissioning Boundary Drawing revision (in the stamp block) as the CBD Rev No. This is important in order that all parties including the client and contractors DCC Department can track these as distinct drawing issues. The added benefit of implementing such a system is that individual drawings can be revised and re-issued without the need to issue new full sets. With each new issue there should be a simply Revision Matrix which lists all boundary drawings and latest CBD revision numbers. b)

Only re-issue drawings where there is significant new scope added e.g. •

Do not issue for new instruments, which are clearly within the specified CP limits.

•

Re-issue where CP limits are moved.

•

Re-issue for new lines, which affect CP definition.

•

Re-issue if new P&ID generated.



CP Limits added on CAD Drwg.

Example of a manually marked-up P&ID showing CP limits. As can be noted, the Engineering contractor can also add the CP limits in the CAD system. This is the primary vehicle to allow the allocation of scope to the relevant commissioning package in the MC system and subsequently produce a comprehensive definition of each CP at tag/cable/isometric level.



CP splits to suit the planned energisation sequence.

Example of a manually marked-up Single Line Diagram showing CP limits. This CP definition will be compatible with the energisation s equence.



5 MC Package Definition& Content 5.1

Developmentof MC Packages (MCPs) The MC Package definitions are the single-discipline parts of a CP and are defined by the relevant contractors. This is shown on the following graphical representatio ns.

E n g in e e r in g /C o m p a n y

Contractor

Establish Commissioning Packages & Issue Boundary Drawings

Link all Tags and Cables in the MC System to the appropriate Commissioning Package No. Note : Done on a progressive basis

Establish MC Packages & Produce MC Test & Inspection Records together with supporting drawings.

Issue MC Packages to Construction for progressive completion inline with installation.



MC BREAKDOWN 24

2401

2402

Plant System

2403

2404

Commissioning Packages MultiDiscipline

MC Discipline Packages Single Discipline MC MC Packs Packs MC Packs Civil

MC MCPacks Packs MC Packs Pi pi ng

MC MCPacks Packs MC Packs M ec h

MMCCPP aa cc kk ss MC Packs S tr u c t

MMCCPPaa cc kk ss M CP a c k s E l ec tro

MMCCPPaa cc kk ss M C P ac ks I n s tr

MMCC PPaacckkss M CP a c k s Tel ec om

MC Acceptance Certificate


Punch List

Punch List

MC Inspection & Test Records


Test Pack Iso’s

Marked Up Drawings

Documents included in MC Discipline Packages(examples)

Marked Up P&ID’s

Sub-contractors to define MC Packages within their scope of work to allow progressive punch-listing and subsequent release to follow-ondisciplines e.g. Piping Test Packs.



Completion Sequences Discipline

Mechanical Acceptance

MultiDiscipline

HANDOVER

Punch Out

Certificate

Punch Out

CERTIFICATE

MDP

MAC

PL-

Start-Up Notice SUN

HOC

01

CONSTRUCTION

MC

CONSTRUCTION

MC

CONSTRUCTION

MC

CONSTRUCTION

MC

CONSTRUCTION CONSTRUCTION

CLEAR PUNCH ITEMS. NO A-ITEMS FOR HANDOVER

CONSTRUCTION CONSTRUCTION CONSTRUCTION

PROGRESSIVE PUNCH OUT AND CLEARANCE BY MCPACKAGE

MC

CONSTRUCTION

MC

CONSTRUCTION

Clear Punch Items

MC

CONSTRUCTION

COMMISSIONING

START-UP

MC

CONSTRUCTION

MC

CONSTRUCTION

MC


Construction Responsibility

MC

Commissioning Responsibility

Operations

Commissioning Involvement



Tie-In Scope Most tie-ins will have been performed prior to the project proper and documentation submitted to client. Where there are post-shutdown tie-ins, then these should be flagged in the overall Tie-in Register to ensure that they are brought into the overall MC for the main project scope. In addition, any carryover work from the shutdown phase should be brought into the project scope and handled as detailed in Chapter 7. Some examples of tie-ins as follows :•

•

New piping connections on existing lines for new plant. Extensions to switchgear and distribution boards to cater for new loads.

•

Upgrading of existing control systems.

•

Additional instrumentation on existing plant (new transmitters etc).

•

Modification to existing telecom cabinets to cater for new racks and sub-racks.

It is recommended to create one MCP per discipline for each tie-in.

Typical Piping Tie-In :

LIVE SIDE !

Project Test Limit

Double isolation with closed valve and spectacle blind in closed position.

Permission required from Operations/Comm. before joint can be split to complete project pressure test o flange limit.

New Line

Field Weld Interface

Pre-project Tie-In (double isolation)

Pro ect Limit



5.3 5.3 .1

Piping Levels of Tracking The preferred level for tracking piping is by design isometric or part isometric where split. The main reason for this is that the reconciliation should be against design isometrics to ensure that all scope is covered. If a project has site-run lines, were no isometric are issued, then either the line number or a project sketch number can be used for MC purposes. The contractor(s) would prepare test packs (i.e. Piping MC Package) made up of a group of isometric within a specific CP, which has the same test pressure as stipulated in the Line List and which suits the pre-fabrication/erection sequence. This activity should be closely followedup to ensure that the contractors have sufficient resources on test pack definition. The contractors Testing Engineer would maintain a ‘master’ set of P&IDs marked-up with all test pack limits to enable verification that all scope has been covered. The use of contractor isometrics (shop drawings) is not recommended as these do not tend to be formally reviewed/approved by the Client/EPCS and therefore discrepancies could exist between shop and design drawings. The general rule for MC is to always use design drawing to punch against. As piping is one of the most substantial and critical activities to track due to it’s impact on follow-on discipline (painting, instrumentation, heat tracing, insulation) it is desirable to have a detailed tracking system that interfaces well with the planning group. A well-proven system to monitor the fabrication status is to track the pipe spools. This could be incorporated as an additional reporting function in the MC System as these spools are defined on the contractors shop isometrics, thus giving both area and system based reporting.

TrackMC

TrackFabrication

DesignIsometrics

ShopIsometrics

Use for Test Pack Definition and MC Punchout

Track/ Report Status (Spool Level) Pre-Fab On-Site Erected Welded

Reconcile that all scope is tested.


MC Handbook – Section A It is of great benefit to have Test Composite Isometrics produced (normally by contractors) :•

Better overview for Test Crews and Punch Teams.

•

Ideal for verifying that all required vents & drains are in place.

•

Use as inspection isometrics (Commissioning and Operations).

•

Identification of plug, which require seal welding.

Typical Example :

Simplified overall isometric view for each est has advantages : •

•

•

Helps the Test Crews to prepare and execute test. Helps in the punch-out of the test scope. Easier to inspect system during test.


MC Handbook – Section A Notes and Tips :

- Instrument Air Manifolds

Include manifolds with Instrument Air Header CP as hey may serve many users in different CPs. Treat as extention of air header.

With Instrument Air Header CP

With Instrument CP


MC Handbook – Section A 5.3.2

Release of Piping It is extremely important to release pipework to the follow-on disciplines in order that the actual workfronts are identified and actioned as soon as possible. To achieve this, a routing card or stage release card may be used which is effectively signed confirmation that a specific discipline has completed their scope and is formally released to the next discipline. This not only releases the work as soon as possible, but also avoids the risk of contractors proceeding with other disciplines prematurely, resulting in abortive work.

Example o f Stage Relea se Form (rele ased by Test Pack) :-

Sign for each Stage Release to next discipline. This would ensure workfront is clearly identified and avoid abortive work due o premature release of Test Pack.



Testing of Pipework at Contractor Interfaces There are not always convenient mechanical joints at contractor piping interfaces, therefore it is important to clearly identify where the responsibility lies for the various MC activities. This can be achieved by preparing a simple project specific procedure to suit the situation and organisation. The schematic below is an example of how this could be approached, bearing in mind that there may be more than two contractors involved. The main objective is to avoid double testing and to make it clear which contractor takes ownership of the combined pressure test.

Field Weld Interface. Not practical or economical to use hydro-plugs, welded caps or install break flanges. Solution : Combine to 1 x Interface Test

ContractorNo.01

ContractorNo.02

FIRST CROSS-BOUNDARY TEST

SECOND CROSS-BOUNDARY TEST

1) 2) 3) 4) 5) 6) 7) 8) 9)

1) 2) 3) 4) 5) 6) 7)

Complete constructio n. QC release. Discipline pre-test punch. Flush/Test (or vice versa). Dry/blow out excess water. Reinstate. Seal off interface end. Reinstatement punch. Copy test pack to Contractor No.02 10) Complete surface protection to approx. 1m from tie-in. 11) Complete heat tracing to 1m from tie-in and coil/protect cable. 12) Complete insulation to 1m from tie-in and seal end.

Complete constructio n. QC release. Discipline pre-test punch. Flush/Test (or vice versa). Dry/blow out excess water. Reinstate. Reinstat ement punch.

COMPLETION OF TIE-IN 1) 2) 3) 4) 5) 6) 7)

Complete tie-in weld or spool. QC Release. Dry FULL interface test. Reinstate after drying. Complete surface protection . Complete heat tracing. Complete insulatio n.


MC Handbook – Section A 5.3 .4

Critical Areas to Maintain Control Experience from previous projects clearly identifies key piping related areas which have to be addressed at the outset of the project, carefully maintained and followed-up. • • • • • •

Flushing standard Drying Bolt tensioning Seal welding of plugs Construction blinds status Verification of special items e.g. strainers.

If the MC philosophy is to be maintained i.e. MC means ‘Ready for Commissioning’, (includes pre-commissioning activities), then the above areas must be dealt with satisfactorily.

5.3.4.1

Flushing/Drying : It is strongly recommended that high cleanliness standards is set at the various vendors and module yards to ensure that equipment and piping are delivered to site in clean condition.

Some Recommendations : • • •

•

Use hydro-jetting on pipework Use optical instruments to inspect equipment (e.g. heat exchangers) Sweep blast fitting which have internal coating that could be problematic at a later stage (e.g. on pipework which is to be chemically cleaned) Use vapour corrosion inhibitors (VCI)

The various contractors complete their piping scope by test pack and this is ideal for reinstatement, punch-out and release to other discipline, however there is a need to flush and dry on a system or part system basis to ensure that correct standard of cleanliness and dryness are achieved. It is recommended that a specialist group or contractor perform these activities. Where there is a mandatory dry-out of major piping systems to low dew points prior to introducing feed stock, it may be worth giving consideration during the design phase to install vacuum piping (permanent or temporary). This would achieve a much quicker and effective dryout and where permanent vacuum piping was installed, then this could be utilised during future shutdowns.

5.3.4.2

Bolt Tensioning : A master set of isometric should be prepared where joint numbers are allocated to all mechanical joints, which require bolt tensioning. These would then be tracked in the MC system and a formal notification system set-up if completed joints were broken for any reason. This would build up to a historical record on all joints based on direct reporting from the operatives performing the actual work via double label system.


MC Handbook – Section A Notes & Tips :

Careful consideration should be given to specifying that all labels and bolt caps to be used are suitable for the service temperature of the lines. Experience has shown that during the commissioning & start-up phases, the plastic caps melt and cause problems for later maintenance and also labelling is destroyed.

Bolt Tensioning Control Flowchart :

Bolt Tensioning Mark-Up Drwg :

BOLT TENSIONING STATUS REPORT

Drwg No. BT Date Press A Press B Split Date Reason Iso No.1 01 Iso No.1 02 Iso No.2 01 Iso No.2 02 Iso No.2 03 Iso No.2 04 Iso No.3 01

Joint No. Iso No. XXXX

Contractor performs bolt tensioning on joint

Update Master Drwg.

Update MC System

Contractor labels joint and caps all bolts MC Dept. affixes label to Master Drwg. Contractor sends duplicate label to MC

And updates MC System

Dept.


MC Handbook – Section A 5.3.4.3

Seal Welding Control : This would be controlled in a similar way to the bolt tensioning, with a master set of marked-up drawings and corresponding status report. In addition, plugs, which are required to be left unwelded until the commissioning phase, should be flagged as such, otherwise they would normally be welded at the test pack reinstatement stage.

The various contractor would then forward a welding completion slip which contains :•

Drawing No.

•

Weld/Joint No.

•

•

5.3.4.4

Client welding authorisation signature. WPS/Welder/Date Welded.

ConstructionBlinds Status : Construction blinds are used through the construction period for various reason e.g. pressure tests, preservation, temporary isolation etc.

It is crucial to maintain a comprehensive overall ‘Blind List’ and be able to extract blinds applicable to any particular commissioning package. This is a mandatory section for the Handover Dossier and also a safety requirement. On the KUP project, it was agreed to let the contractors control their own temporary blinds and commence formal identification and tracking from the multi-discipline punch-out stage. All temporary blinds, dust blinds, spectacle blinds in reverse position to that shown on the design P&IDs, temporary strainers etc. should be listed as punch items on the MDPL and subsequently allocated a unique blind number. A blind list can then be produced from the MC System, followed-up and closeout as each item is cleared and verified. 5.3.4.5

Verificationof Strainers : This would be a witness point in the MC Manual responsibility matrix and therefore signed verification (Client Construction and/or Commissioning Group) that strainer is clean and correctly installed. Either a certificate for miscellaneous equipment or a Strainer log could be completed and MC system updated accordingly. Should be labelled (dated & initialled) and a notification system set-up if strainers need to be removed for any reason.


MC Handbook – Section A 5.4 5.4.1

Equipment & Cables Static Vessels The sketch below shows a typical static vessel (column) and how the MCP split should be approached. The attached pipework should not be included with the vessel, but instead be included in piping test packs for the relevant CP. Remember the rule – ‘MC is discipline driven’.

Mechanical MC Package : Covers placement, verticality, holding down bolts, torquing, grout release, internal inspection, survey of internals, final closure of manhole(s). Dimensional survey report(s) to be included.

Piping MC Package : All piping to vessel nozzles would be covered by a specific test pack.

Surface Protection MC Package : Covers painting of vessel.

Insulation MC Package : Cover insulation of vessel

Final Closure Certificate :itness Point for Comm. New gaskets to be installed.

Fireproofing MC Package : Covers fireproofing of vessel skirt.



Equipment – Motors, Heaters etc In general, the rule of thumb is to allocate electrical cables to the same CP as the user. Example : •

Motor

:22-PA-200C(M)

•

RCU

:22-PA-200C-RCU

•

Power Cable

: PN-22-4012

•

Control Cable

: CD-22-4012

•

Outgoing Unit

: 82-EN-641.04P

The above items would be scoped with the same CP as pump 22-PA-200C which is shown on the colour marked-up P&ID Boundary Drawings.

Mechanical MC Package would include :-

Electrical MC Package would include :-

Pump including all alignment activities relating o positioning of pump skid, connecting piping

Motor, power cable, control cable, RCU and Outgoing Unit in Switchboard (see below).

and to driver.

Mechanical/Electrical Split


MC Handbook – Section A Example of Switchboard :

Example :Outgoing Unit for Pump 22-PA-200C. 82-EN-641.04P



5.4.3

Testing electrical equipment This can be a complex operation due to the interfaces with differe nt systems as shown on the schematic below and the possibility of separate contractors for the switchgear scope and field equipment scope. Careful planning is required for the completion of the Electrical Management System, Process Control System and ESD System in order to avoid multiple testing.

Required Testing :• • • • •

Signals between PLC and starter. Signals between PCDA and starter. Signals between ESD and starter. Full loop test from PCDA to starter including signals from ESD and RCU. Signals between Electrical Management System operator station and PLCs.

Where there is more than one contractor, careful consideration should be given to allocating the testing of field equipment to the switchgear contractor, as specialised knowledge is required for the electrical management system and to programme the protection settings. Another option would be to set up a dedicated testing team which comprises of technicians from both switchgear and field equipment contractors.

ESD System

Electrical Management System Operator Station

Interface Relay Cabinet

Electrical Management System

PCDA

PLCs

Process Control

Motor Starter Motor Runs

Motor Data required or starter settings U C Motor R

Start From Preference : 1) PCDA 2) Operator Station 3) Starter If not fully tested from PCDA hen some retesting would be required.



5.4.4

Lighting & Small Power In general, there would be specific Commissioning Packages for L&SP scope and these should be defined to suit the site layout and needs. A good example is the need for lighting to be energised in order to improve the lighting for construction enabling temporary lighting arrangements to be removed. Energis ing as much lighting as possible at an early phase is also a desirable safety consideration.

Typical MC Packages :L&SP Distribution Board, feeder cables Outgoing L&SP circuit or groups of circuits

MC Package Split at DB/Feeders and Outgoing circuits (each or groups)

DB CCT No.01

Lighting Circuit

Outgoing circuits may be for different structures, areas etc. Create MC Packages to suit project livening-up philosophy.



Electric Heat Tracing Electric Trace heating tapes are allocated to the same CP as the piping isometric, mechanical equipment or instrument it protects. There are options relating to the power supply cables to the first on-line junction box. -

They can be allocated to the same CP as the applicable distribution board (i.e. 82… CP). This is the preferred split (see diagram below) but does need co-ordination to ensure that the necessary power supply cables are installed and handed over in order that system heat tracing can be energised. Consideration should be given to schedule the full circuit power supply side for the first earliest CP rather than planning for partcircuits. This will allow for more straightforward control and disconnection at JBs can be added as punch items.

-

Cable from first JB to on-line JB can be allocated to the same CP as the piping, mechanical equipment or instrument, while the first cable from distribution board to first JB can be allocated to same CP as board.

See attached circuit diagram showing alternative CP splits.

Process/Utility CP Nos. may have different planned handover dates. Ensure power supply cables are planned in-line with these dates in order to allow circuits to be energised.

Heat Trace Tapes TL-??-… CP No. 1 Dist Board 82-EN-???

Power Cables PL-82-… CP No. 2

CCT 12

CP No. 3 Power Supply with L&SP CP

CP Split at on-line Junction boxes (Go with Process/Utility Systems)

Plan to install full circuit power supply cables and punchlist any disconnection at JB required to energise a specific Process /Utility CP.



Instrument Field Cables These would be allocated to the same CP as the field instrument as shown on the colour marked-up P&ID CP Boundary Drawings, while the multi-core and relevant JB would be allocated to the earliest CP which they serve (see diagrams below).

Instrument (Field)

Part of M ul ti - Cor e

Field Cable

System Cabinet

Marshalling Cabinet

Multi-Core Junction Box

S y s t e mC a b l e

Multi-Core & JB allocated to earliest scheduled CP which hey serve. Field instrument and field cable to relevant CP as per coloured marked-up CP Boundary Drwgs.

Cabinets & System Cables with relevant CP for PCDA, ESD or F&G within a specific substation or control room.

Instrument Field Cables (Relevant CP No.) CP No. 1 (Date 01.05.XX) CP No. 2 (Date 01.08.XX) CP No. 3 (Date 01.03.XX) CP No. 1 (Date 01.05.XX)

Multi-Core Junction Box

CP No. 2 (Date (01.08.XX) CP No. 4 (Date 01.10.XX)

This multi-core & JB serves instruments(CP in 4Nos.) different systems If CP No. 3 is the earliest scheduled, then the multi-core & JB would be allocated to that specific CP No.

Mutli-Core Cable



Underground Cableworks During the early cable pulling phase it is important to have a control system for the inspection and release of each layer of underground cables prior to sand filling and ultimate back filling or placement of covers. This control should be handled as Civil MC Packages for the culverts and trenches. Although this involves checking that all cables are correctly positioned, segregated and free of debris which could cause damage, the specific cables will be allocated to the relevant active commissioning packages of which they form part. One method of controlling this is to utilise the unique segment number as detailed on the nodal layout drawings and use this as the MC Tag No. for sections of trenches or culverts.

Nodal Layout Example :

Nodal Point

Unique Segment Identification (Use as MC Tag No.) Example : CA411-2-006 Cable Culvert from Node 0582-0584

CA 4 1 1 - 2 - 0 0 6

CA 4 1 1 - 2 - 0 0 8

0581

CA411-2-007

0583

CA411- 2- 006 0584

0582

CA 4 1 1 - 2 - 0 0 5

0585

Culvert/Trench sections controlled from nodal point to nodal point. Inspect & Release each layer for sand fill.



Control Cabinets (in CCR & LCRs) Normal practice is to define specific CPs for these systems in order that they can be inspected, punched and subsequently handed over to allow them to be powered up. Although other work may require entry to such control panels, it is limited to specific group of authorised technicians. Examples of such systems :PCDA ESD Fire & Gas Metering The exception would be UCPs that are dedicated to specific machines e.g. compressors. These would be allocated to the same CP as the machine. • • • •

Therefore it is recommended to create at least one MC Package per discipline per LCR/CCR for any specific CP.

LCR XXX ESD System Cabinet No.1

ESD System Cabinet No.2

ESD Marshalling Cabinet No.1

Interface Relay Cabinet No.1

ESD System Cabinet No.3

ESD Marshalling Cabinet No.2

Interface Relay Cabinet No.2

PB s

Fire Area XXX Field ESD Pushbuttons (i.e. CP for each Fire Area including connecting cables to Marshalling Cabinets)

Normal CP Split between LCR Scope and Field Scope.

This CP could be split in a minimum of 3 x MCPs : All ESD cabinets, all IE, PE & IS earthing cables, all inter-connecting system cables and relevant connecting ESD cables to other LCRs and/or CCR. Instrumentation 1 :

Instrumentati

on 2 :

All loop testing related to LCR Internal Pushbuttons and intertrips etc.

Interface Relay Cabinets, UPS power supply cables to ESD & IR cabinets and control cables. Electrical :



Steelwork It is important that steelwork MCPs are created such that they are compatible with the erection schedule. It is possible to use Model Reference Nos, Design Drawings or even Dummy Tag Nos. for MC purposes, however, whichever system is adopted, it should be consistent across the project. The recommendatio n is to use a reference to a Tag No. or Model Ref. where possible and list the relevant drawings on the MAC. Also note that it is worth considering creating separate MCPs forsequence the Primary Secondary Structural Steelwork Scope. Again, this is linked to the erection andand schedule, where handrails, ladders, etc are installed at a later date. This allows the primary structure to be fully inspected, punched and accepted. Typical MC Package Definition for Steel Structure :-

1 x MC Package or Steelwork Create extra MCPs for secondary steelwork as required.

1 x MC Package for Surface Protection Create extra MCPs for secondary steelwork protection as required.surface

1 x MC Package for Passive Fire Protection (if applicable) Grade Level

Example :

The following example is from Kårstø where suitable Structural Key Plans were produced to allow easy identification of structure and rack, tracks. It is advisable to prepare one MC Package per ‘stand-alone’ structure, and group pre-fabricated sections of racks/tracks into full or practical portions. The primary aim is to allow progressive punch-out of the structures and hence re-cycling punch items back into construction.



Example : Pre-Assemble Rack (PAR) Use PAR No as MC Tag No.

Typical Example :-

a)

At Module Yard : Create an MC Package for PAR and punch out to applicable design General Arrangement & Detail Drawings.

b)

At Site : Create an MC Package for the placement, positioning, bolt-down or weld-out. Such at package would include a dimensional survey report. The site MC package may include more than one structure e.g. all PARs’ which form the full rack or discrete section of a rack.



Lifting Equipment Powered lifting equipment such as cranes would normally have dedicated commissioning packages defined for this scope. Where lifting equipment is incorporated as part of other CPs, then separate mechanical MC Packages should be created for this scope to allow easy traceability for future re-certification purposes. Examples :- Monorails, Davits, Lifting Frames and Lifting Lugs.

5.7 5.7.1

Civils General The focus for this section is on concrete structures, foundation, roads and underground piping which is not allocated lines numbers (e.g. oily water drains)

5.7.2

Concrete Structures MC Packages should be created for each large concrete structure e.g. bridges, jetties, buildings, sea-water intake pits, basins, weir boxes and these would contain all MC Records for pour release, piling, traceability to concrete test results, dimensional survey reports and as-built data/drawings.

5.7.3

Foundations It is important to track all foundation in the MC system and these can be grouped into practical MC Packages for specific construction areas. All relevant MC and survey records would be included in these packages as for the concrete structures noted above and in addition, there would be foundation release records. As the various items of equipment, skids, modules, PARs, PAUs, VAUs etc., are delivered to site, there will be a need to progressively accept and release the applicable foundations. The priority will be set by the Planning Group and be synchronised to heavy lift and installation sequences. The MC System should be used to track this acceptance and release to ensure a smooth interface between the Civil and Mechanical Contractors. Either Model Ref.Nos, Co-ordinate References or Dummy Nos. should be used to identify foundations. Examples :

FD:22-HA-203A

: Foundation for 22-HA-203A

FD:1E-PS-06

: Backflow Area : M iscellaneous Foundations

Prefix ‘FD :’ for foundation with Equipment Tag No. or Block Ref./Support No.


MC Handbook – Section A Example of Foundation Layout Drawing :

Foundations for vessels

Group of Foundations for PAU

Foundations for pumps



U/G Pipework (No line numbers) : Where design isometrics are generate for underground piping, then this scope would be handled in exactly the same way as above ground piping i.e. create test packs of specific isometrics and mark-up test limits on suitable P&ID or U/G Layouts. Where U/G piping is not allocated line nos., then meaningful dummy references should be created in the MC system to identify the scope and these subsequently used to define test packs. Example :

MH-39 This test between two manholes and including one gully, could be identified as : MH40-MH41(incl.Gully)

MH-41

5.8

MH-40

Fireproofing MC Packages should be created for the passive fire protection scope for equipment, structures, cables and junction boxes. Some examples and recommendations are listed below :•

Vessel Skirts – Create 1 x MCP per Tag No.

•

Structures – Create 1 x MCP per specific structure or pre-fabricated unit.

•

Cables & JBs – Two options proposed :

•

•

•

Where a CP has been created for Area Completions, then one fireproofing MCP could be created for each specific sub-area. Create one fireproofing MCP for all mechanical equipment in each CP, plus one for all E&I scope in each CP. Valves – Create one fireproofing MCP for all valves in each specific CP if not included in b).



5.9

Area Completion The preparation of MCPs for area completion is an important aspect of mechanical completion and allows specific focus on Safety and Electrical compliance to Rules and Regulations. It also establishes a convenient punch-out for specific areas required by Commissioning prior to ‘GasIn’. MC Packages should be generated for each specific area, group of areas or building that can conveniently be identified on site plot plans, safety layouts, schematic layouts or other suitable drawings. The typical focus on these punch outs include :-

Safety equipment in place (fire fighting equipment, first aid equipment etc.)

-

Mechanical protection of electrical/instrument cables (covers, bumpers etc.)

-

Removal of construction debris, temporary equipment, containers, grading etc.

Asgard Reception / Feed & Rundown Pipetrack

MCP Example :- CA 461

2A - De-Ethaniser Overhead Compressors 2B - Sales Gas Compression 2C - Asgard Fractionation 2D - NGL Extraction Tr. 1 2E - NGL Extraction Tr. 2 3C - Existing Utilities 3D - Europipe II North/ South Pipetrack

CA62 CA401 CA492

Propane Cavern / Propane Subs. / Cavern Subs.

Backflow 3 46 A C

CA16

3B

Statpipe Booster Compressor & EP II Pig Launcher 1E

CA15

Control Room CA462

CA467

CA13

Gradetrack 79 / Sleipner / Ethane Treatment Gasoline Storage

CA461

Ethane Storage & Jetty 3& Pipetracks

CA21

4A Butane Storage & Jetty 1 & Jetty 2

CA14

8 44 CA

3A Statpipe Train 100/200 & Effluent Treatment CA19

2 4 A C

CA44

CA10

CA18

3 CA45

2C

41 CA4

CA411

CA43

1C CA309

9 44 CA

CA445

1F

CA412

6 44 CA

CA452

Ethane Storage & Jetty 3 & Pipetracks

CA451

2F

3C 3D

CA481

CA471

2E

CA444

2B

CA47

9 A C

2D

Sea Water Intake

CA22

1A

CA421

2A

CA4

CA3

CA423

CA443

CA17 CA466

1D 2 44 CA

CA24

CA5

CA1

4 45 CA

CA45

CA34

Statpipe Booster Compressor & EP II Pig Launcher CA46

CA491

3B

CA2

1B 1A

CA323 CA8

Example for Site - Area Completion Breakdown (MC Package per Construction Area or Group of Areas)


MC Handbook – Section A 5.10 Steam Blowing Steam blowing is regarded as a construction activity as it is performed to achieve the standard of cleanliness of steam piping systems. It is also required by machine vendors (e.g. steam turbines) to comply with their guarantee conditions. There tends to be a significant involvement of the Commissioning Group and they may infact co-ordinate the whole steam blowing operation as systems have to be brought into service in order to produce the medium for this activity (e.g. open tie-ins or start-up boilers). It isfollowing recommended to create MC Package each steam blow pre-blow, circuit which the items and would one be punched out inforthe normal manner afterwould blow include sequence completed and reinstated :•

•

•

Mechanical Acceptance Certificate (MAC) Punchlist Marked-up P&IDs

•

List of in-line items removed (control valves, orifice plate, thermowells, etc.)

•

Steam Blowing MC Certificate (signed by all parties including Vendor (if applicable))

•

Final Target Plates or reference to location stored.

•

•

Bolt Tensioning records Temporary piping, dummy spools, silencers, quench-pots etc

Pre-Blow Punch-Out Ensure readiness for blow adequate supporting adequate restraints temporary pipework in place sensistive in-line equipment removed dummy spools installed etc.

Perform Sequence of Blows •

Perform initial blows

• •

•

•

Perfom blow(s) to target plate

•

•

•

Sign for acceptance when acceptable results achieved

•

Post-Blow Punch-Out Ensure system is fully reinstated Temporary piping removed In-line items reinstated Bolt-tensioning completed Insulation reinstated • • • •



6 MC Punch-out 6.1

Punch-outStages The punch-out activities are one of the most important aspects of all the MC activities as it identifies the outstanding scope and deficiencies, which need to be completed and/or rectified. Although many of the punch items which are identified by the contractors are rectified very quickly by the personnel directly involved in the day-to-day construction work, there are equally many punch items that will be followed-up at a later date and in some cases, by other groups or contractors. In order to avoid the expenditure of unnecessary man-hours in locating such items at a later stage, it is of the utmost importance that a high standard of punch item identification/description is maintained.

Pu n c h -o u tG u i d eli n es

A d d i t i o n alR em ar k s

Make items specific.

Do not generalise to groups of items

Reference Tag No./ Cable No. / Isometric No.

Helpful to quote Layout Drawing for E&I tags.

State precise location e.g. module, construction area, elevation etc.

Significant help on towers and multi-level structures e.g. a)

State Module No. + El.xxxxxx

b)

State Northing/Easting co-ordinates

Ensure category of item is specified ( A or B).

Mandatory to agree this at time of punch.

Ensure items required to be cleared pretest are flagged.

Dedicated column on punchlist sheet for this purpose. These items must be cleared and verified prior to a piping test pack being released for pressure test.

If necessary, attach a marked-up drawing to assist with identification.

Useful for items relating to untagged equipment e.g. a)

Marked-up isometrics for piping items – supporting, shims, etc.

b)

Marked-up layout for civil items.



Punch Item Examples The following are a selection of punch items which highlight the variation in standard of punchlisting :• •

Good Standard (blue text) Poor Standard (red text)

Electrica l Examp le :

PN Lo .

8239-FU-E2041

It em

005

O b jecID t

Des c rip tio n

EAB-842-24-L1-02

Cat

Drwg : E060-AD-82-EA0087.001

Disc

A

Loc

E

DRV204

Re-instate luminaire and traywork (3m tray, 6m cable and re-terminate). 8239-FU-E2041

005

Re-instateluminaireEAB-842-24-L1-02

Category missing Discipline code missing Location missing Drwg No would help

Details all information to easily locate item including Drwg. No. plus additional information on material requirements.

Instrumentation Example : PN Lo .

2002-FU-J2101

It em

001

O b jecID t

20-PDT-4152

Des c rip tio n

Cat

Drwg : E060-AD-21-JP0019.001

Disc

A

Loc

J

DRV210

Install capillaries and terminate cable. (11m) 2002-FU-J2101

001

Description not specific. Category missing Location missing Drwg No would help

Complete 20-PDT-4152.

A

J

Details all information to easily locate item including Drwg. No. plus specific information of remaining scope.



Mechanical Example : PN Lo .

It em

O b jecID t

Des c rip tio n

Cat

2106-FI-M0450

089

21-VE-421

1blackboltonmanwaysM1&M3ofDRV202

2106-FI-M0450

089

21-VE-421

Replaceboltson21-VE-421manways

OK, but a little more detail would assist with locating and establish material requirements.

A A

Disc

Loc

M

DRV202 M

DRV202

Additional information on specific Manhole No. and number of bolts to be changed-out is of great benefit.

Piping Example : PN Lo .

It em

O b jecID t

Des c rip tio n

Cat

2102-UM-L0023

008

E060-AD-LL-492A21-PL-4550.001

Pipe support 1104-137/G Bolts to be shotened 2 off. New 85mm length required

2102-UM-L0023

008

492A-21-PL-4550

Supportbolttoolong.

Does not specify which Iso Sheet No. and which support.

Disc

B

B

Loc

L

CA 492

L

Information identify actual support number plus materials required.

Impotant Note for Piping : It is good policy to mark up items on a set of isometrics or test isometrics. Significant benefit to punchlist crews.



7 Carryover Work (COW) The outstanding scope, which is identified at the various suppliers’ and fabrication yards, is termed carryover work and of primary importance for the following reasons: •

•

To establish a definitive remaining scope, which is formally identified, documented and agreed between the contracting parties. This will facilitate the closeout of the relevant purchase orders and/or contracts from both an MC and commercial perspective. To establish a concise scope which is transferred to other parties at the following location (module yard or site). This scope needs to be formally issued in order that the responsible contractor initiates the necessary work preparation, inclusion in their construction plan, execution of scope, subsequent punch-out and close-out.

Suppliers COW 7.1.1.1

Module Yards COW Action Supplier COW as directed by Client Site Project Team Review and formally issue COW to relevant contractors

• • • • • •

Site Contractors

Suppliers

Work Prep Include in plan Execute

Complete specific vendor site scope after installation of

Punch Closeout Progress Report

package/skid.


MC Handbook – Section A 8 Preservation 8.1

PreservationResponsibility It is important to establish clear demarcation lines for preservation responsibility to ensure continuity and follow-up of preservation activities. The preservation is initiated at the various suppliers and maintained through the various construction phases.

INITIAL

PRESERVATION

PRESERVATION

PRESERVATION

MAINTENANCE

MAINTENANCE

Module Yard 1

Client Preservation Su ervisor

Preservation Supv.

Preservation Teams

Piping & Mech.

Piping & Mechanical

Module Yard 2 Preservation Supervisor E &I

Preservation Teams

Other Contractor

SUPPLIERS

E&I and Telecom

Other Contractor

Other Contractor

S u p pl ie r s

8.2

ModulY e ards

Site

PreservationSystem This is commonly incorporated as part of the MC System and therefore can utilise the engineering data and more importantly be easily integrated to the overall handover status. The example below from the KUP MC System (PIMS) shows the link between :•

•

Flagging Tag Nos. to be included in preservation programme. Linking to Preservation checklist.

•

Producing Preservation Weekly Work Lists (‘To-Do’ Lists).

•

Recording negative comments/observations and implementing appropriate action.


MC Handbook – Section A Example of Preservation Control System (PIMS):

Engineering info. are transferred into the

Preservation Active = efore the tag is included in the ToDo-List

1) 2) 3) 4) 5) 6)

Flag all Tag Nos which are to be included in PreservationProgramme i.e. PRflag Link to applicable standard or special checklist. Activate when arrives on site (or location) i.e. PA flag. Generate weekly work list ’ToDo-List’. Action preservation activities. Report status plus any Negative comments.

The ToDo list is generated on a weekly basis. When you click the Generate ToDo-list button in the ToDo-list , PIMS MC copies all records from the Preservationscope-form wherePA is “ticked”

Standard project preservation equirements

Specific preservation equirements from

In addition it selects only preservation events ased on the StartPreservfrom Preservation Scope oined with the period code in preservation Check Lists

New To-Do list printed out and used for Site

“Negative” comments are



PreservationExperienceFeedback In order to improve the long-term reliability of the plant and to avoid costly corrective action during the construction phase, it is of great importance to establish a thorough preservation programme. Such a programme should focus on preventive measures as well as the routine preservation as specified in the preservation checklists and suppliers’ requirements. Three key examples have been selected to highlight areas where close follow-up will have substantial quality and commercial benefit (based on practical feedback from KUP).

8.3.1

Valves Ensure that temporary protection tape on valve stems is applied during blasting and painting at the various pre-fabrication locations and that it is removed, stem cleaned, greased and retaped. If not done, blast grit which has penetrated the tape is a source of corrosion and contamination which may caused damage to the stem and/or valve packing. Close follow-up will avoid costly rework to valves at a later stage when access also becomes a major factor in the commercial implications. Potential rework : •

Need to remove paint from valve stems

•

Clean and/or repair valve stems/packing

•

Replace or repair sticking or damaged valves

Examples of valve spindles being painted during the pre-fabrication stage. This causes significant problems for construction and commissioing.

THIS HAS QUALITY & COMMERCIAL IMPACT


MC Handbook – Section A Poor or no preservation to valve stems. Possible sticking valve, repair or replacement would be required.

Preserved but corrosion underneath denso-tape. Ensure machined surfaces are coated with a suitable oil or grease prior to applying protective tape.

Protection tape applied for blasting/painting operations at preab stage and left on. Ingress of shot/grit blast has caused corrosion. Remove, clean, grease and re-tape prior to shipment.

ALL HAVE QUALITY & COMMERCIAL IMPACT



Stainless Steel Surfaces Ensure the stainless steel surfaces, fully painted surfaces, cables trays etc., are protected during grinding, welding or blasting operations in adjacent areas. Again, if this is not properly controlled becomes a source of major rework and hence needs to be addressed at the frontline i.e. to the foremen and workforce via toolbox meetings etc. Potential rework : •

•

Chemical cleaning of external stainless steel surfaces which are contaminated with carbon steel High pressure cleaning or sweep-blasting of fully painted surfaces in order to remove contaminated top coat and subsequent re-coating.

Example of carbon steel contamination of statinless steel material. Protect adjacent materials and equipment when performing grinding, welding and blasting activities.


Example of carbon steel contamination of fully painted structural steelwork. Protection covers andmats will minimise damage.




Boxed Items for Long Term Storage Ensure that all items, which are received, boxed and will be stored for considerable periods, are open and inspected to ensure that initial preservation is intact e.g. spare parts, commissioning spares. Potential rework : • • •

Parts require specialised cleaning/repair. Parts not fit for purpose and need to re-order. Potential delays in repair and maintenance of plant.

These examples show the need to open and inspect all items to ensure intial preservation is intact. Assuming that items are preserved or long term storage can lead to cases like these. hen spares are required – make sure they are fit for purpose by implementing good preservation routines.

ALL HAVE QUALITY & COMMERCIAL IMPACT


MC Handbook – Section A Livening-Up Notice

9 Livening-UpNotice There is a need during construction to ‘liven-up’ electrical systems or part systems in order to perform the various MC activities or it is required by the project. Examples :a)

Liven-up motors to perform rotation checks and 4-hour uncoupled runs.

b)

Liven-up lighting circuits to provide better overall lighting for construction.

c)

Liven-up heat tracing for frost protection.

The control of this should be handled by the MC system and this could easily be extended to cover the livening-up during the commissioning period (i.e. E-LUN and C-LUN).

LUN Table in MC System LUN No: Scope Description 0001 xxxxxxx 0002 zzzzzzzz 0003 0004

Objects Table in MC System ObjectID: Description CL-62-NNNN vvvvvvv PL-62-NNNN xxxxxxx PL-62-NNNN zzzzzzzz PL-64-NNNN ccccccc

LUN 0100 0210 0250 0500

Additional fields can be added for C-LUN and E-LUN to easily control livening-up during the commissioning period

Print Livening-Up Notice Notice details specific listing of cables to be livened-up and the reason required. Formal approval required.


MC Handbook – Section A Example of LUN : Description of scope and where it is fed from i.e. Switchboard cubicle.

List of cables to be livened-up.



10 Loop Testing 10.1 Loops Diagram & Loop Register It is not very common for the EPCS Contractors to produce a definitive Loop Register and if this should be the case, then it is strongly advisable to create one for MC purposes. This will greatly simplify the accurate reporting of :-

Loop testing status

-

Identification of I.S. Loops

-

Linking software tags.

-

Release of Loops

Loop Register Suggested Structure :-

L o o p No .

D ra w in g N o .

Type

24-F-2016

XXXXXXXXX

IN

N

Nnnnmmmm

25-P-2624

YYYYYYYYY

IN

Y

kkkk

25-X-2906

ZZZZZZZZZZ

IN

Y

74-GD-4021

FFFFFFFFFF

FG

Y

Loop Reference No. Used in the MC system to :Linking field tags & cables Linking to relevant multicores Linking to software tags Loop Release Loop Status Reporting •

I . S . F l a g R e m a r ks

Facilates reporting of I.S. Calculation scope and status. (Tabular & S-Curves)

• • • •


MC Handbook – Section A Loop Diagram Example :-

Loop Number All relevant Tag Nos and Field Cables linked with this number.

Instrinsically Safe Loop


MC Handbook – Section A 10.2 Guidelinesfor MCP Definition The simple recommendation is to create one MC Package for the loop testing scope for each CP. It is important that the as-built loop diagrams are prepared as the loops are tested i.e. as attachment to the MC Loop Test Certificate and that a master set are maintained at a central location which is normal the CCR. These MC Packages should be discipline punched in he normal manner and in order that all temporary links and jumpers are controlled, these should be include as individual punch items. These can then be allocated a unique link number and a link register can be produced from the MC System for inclusion in the Handover Dossier.

10.3 Release of Loops for Testing As this activity is dependent on completion by other disciplines and commences at an advanced stage on construction, it tends to on the critical-path for most projects. It is therefore of paramount importance that the available loops are identified and released to the Test Teams without delay in order to maximise the work front. To achieve this in an effective manner, the field components and cables of the loop have to be tracked in the MC system. In addition, the related multi-core junction box(es), multi-core cable(S), barrier (if applicable) and system cable(s) also need to be taken into consideration to allow verification that a full loop from field to control room can be released. With careful planning during the detailed engineering phase, the majority of this data can be made available through the Instrument Index., however any additional time/effort expended to provide such a loop release facility, would be a wise investment.

Import Tag Nos.

Import Cable Nos.

From Mater Instrument Index, including Loop Reference

From Mater Cable Schedule and create Loop Reference for field cables in MC system.

MC SYSTEM

MC SYSTEM TABLE

Tag No. & Loop No. Cable No. & Loop No. Barrier No. & Loop No. Multi-core & Loop No. System Cable & Loop No.

Multiple System Items e.g. Multi-core JBs Multi-core cables System cables

LOOP RELEASE Release of Loops based on MC on all components

10.4 Loop Testing Organisation This organisation is usual made up of Field Teams, Personnel in CCR, Client Construction personnel and also Commissioning personnel. Due to the interfaces with both the PCDA and ESD systems, it is strongly recommended that vendor representatives for both systems should be engaged on a full-time basis during the loop-testing phase.



11 Intrinsically Safe Equipment It is a mandatory requirement that I.S. Calculations are prepared and verified for all equipment that is required to be intrinsically safe due to operation in a potentially explosive environment. This is determined by the location of equipment in respect to the Area Classification drawings. It is important to collate the required certification on a progressive basis during the course of a project and extract the data required to perform such calculations. •

Field instrument Ex data (Veq, leq, Ceq & Leq) from Ex Certification for instrument.

•

Zener Barrier Ex data (Voc, Isc, Ca & La) from Ex Certification for barrier.

•

Cable data (R/m, C/m & Z/m) from manufacturer’s cable datasheets plus as-built length.

Where field equipment is classified a ‘simple apparatus’ in accordance with EN 50020 Sect 5.4, then it is equally important that the project obtains the required ‘Letter of Conformity’ for each equipment type. Example (elements in a loop) :-

Loop

: 46-P-2202

Instrument

: 46-PT-2202

FieldCable

: J ZS-46-PT2202

Multicore Cable System Cable

: J ZS-46-238 : J ZS-85-L34-3022

Instrument Certification

: BAS No Ex 89C2360

Barrier Certification

: PTB No. Ex-95.D.2165 X

Certification Examples :-

The following example shows one format for I.S. calculation sheet plus extracts from Excertification with essential data highlighted.



I.S. Calculation Sheet raceabilty to certification references.



Unique Certification Reference

Equipment Type Code



Key Data for I.S.Calculation



Unique Ex Certificate Reference No.

Protection Type



Key Data for I.S.Calculation



12 Change Control 12.1 Site Instructionsor Similar Change Instruction In order to maintain the latest design status it is essential for a project to establish a ‘FastTrack’ method for both issuing changes as well as maintaining control of design drawings. Projects may employ differing terminology for such change notifications, however, for the purposes of this document, they shall be referred to as Site Instructions (S.I.s) and a detailed project specific procedure should be prepared accordingly. Such a procedure should include a flowchart, which details the responsible groups/department and would deal with the main elements shown in the simplified flowchart below. Typical SI Flowchart (simplified) :

Issue Site Instruction For change or additional work scope.

Update SI Registration System (could be part of MC System) a) Record CP Nos. affected. b) Record Drawings affected.

Perform Work

Issue As-Built Details

Notify Client that complete

To relevant Groups/Department (including mark-ups)

SI Verified by Client

Update ’Master’ Design Drawings (if applicable).

a) Signed-off as completed. b) Issue punchlist as required.

Cloud change and reference SI No.


MC Handbook – Section A Site Instruction Format :

The design of a Site Instruction Form or any other change notification form, would in most cases already exist as either a corporate or project specific form, however, it may well be worth creating a new or revised version if it does not cater for the following main elements : -

Section or additional sheet where affected design drawings are listed.

-

Section where affected commissioning packages are listed.

-

Verification Sectioninwhere Client/EPCS canas-built signed drawings off to confirm that change has been implemented the field and relevant marked-up.

This will allow a total overview of changes which impact specific commissioning packages and there state of completion, thus providing accurate design status for punch out basis.

12.2 As-Built Status An as-built procedure should be issued early in the project to ensure that all parties are fully aware of the responsibility to maintain ‘red-line’ marked-up drawings. Such a procedure should clearly identify which type of drawings are to be marked-up by the various contractors and which are to be marked-up by Project Team (Engineering Dept.). By establishing a thorough procedure and ensuring that it is fully implemented via periodic verification, the project can be confident that the latest design status is available at all times. Key objectives : •

Create central location(s) for availability of master mark-ups.

•

Create a steady stream of as-built data to allow progressive mark-up of design drawings.

•

Maintain traceability to reason for changes via reference to SI No.

•

Master red-line mark-ups are available for both discipline and multi-discipline punch-out.

•

Field verification that all changes issued via S.I.s are completed and signed-off.



13 Status Reporting 13.1 Graphical and Tabular Reporting If is essential that concise consistent reporting is adopted on any project and avoid or minimise any ‘ad-hoc’ reports. The overall suite of reports should be comprehensive enough to provide :a)

High level reports for management & construction, which show trends e.g. s-curves •

CP Handover Status S-Curve

•

Piping S-Curve – By Test Pack

•

Piping S-Curve – By Isometric

•

Cables S-Curves (Electrical & Instrumentation)

•

•

b)

Loop Test S-Curve Punchlist S-Curve (showing A & B totals against cleared)

Detailed tabular report for analysis, follow-up. •

Test Pack Status Report

•

Loop Test Report

•

Outstanding Punchlist Items

•

MC Status Report per CP

•

CP Comments (Action list for MC Meetings)

•

Object Status Report (status of all Tags/Cables per CP)

The overall suite of reports should be made available for various level of monitoring :•

Overall Project

•

Specific Contractors

•

Interim Milestone (i.e. group of CP Nos.)


MC Handbook – Section A Example : CP Handover S-Curve (Also available for Groups of CPs forming Project Interim Milestones)

Track Planned/Actual Handovers Other Options :a) Run for Interim Milestones b) Add Commissioning Curves


MC Handbook – Section A Example : Piping Test Pack S-Curve (Also available for Individual Contractors) Key Activities Monitored Delta between QC Released and Tested shows workfront. Monitoring reinstatement is critical for release to other disciplines.


MC Handbook – Section A Example : Loop Test S-Curve (Also shows the release of loops for testing i.e. workfront)

Delta between Loop Released (red) and Tested (blue) shows Loop Testing Workfront ! CRITICAL ACTIVITY TO CONTROL !


MC Handbook – Section A Example : Punch Item S-Curve (Also available for Individual Contractors)

Track growth of both A-Items(red) and B-Items(blue) plus clearance rends. Delta shows outstanding scope. Tabulation gives weekly figures.


MC Handbook – Section A Example : Punch Item Summary Report (By CP No) (Selection by CP, Contractor, Discipline, Category etc)

Monitor and Prioritise outstanding punch items. Review valid action codes and highlight & track where there is a material requirement. (CP review/status meeting)


MC Handbook – Section A Example : Test Pack Status Report (Tabular) (Also available for Individual Contractors or CP)

Track Key Stages Follow-up against Piping Test Plan


MC Handbook – Section A 13.2 PlanningInterface It is important to track and report against Project Interim Milestones and therefore a close interface to the Planning Dept. is essential for consistent meaningful reporting that will assist both Contractors and Client Management. It is strongly recommended that completion meetings be held on a regular basis to evaluate status of interim milestone and implement the necessary action to secure target dates. MC status data can also be utilised to enhance ‘Visual Planning’ posters and notices, which will increase the awareness of all personnel regarding Project key targets and achievements.

13.3 Benchmarking The project may require reporting (s-curves) against agreed benchmarks and this can be a valuable tool to monitor both quality and commercial aspects. Examples :a)

Set a specific target for the number of Carryover Items (COW) for each Purchase Order. This would effectively monitor the ‘quality’ of skids/packages delivered to site.

b)

Set a specific target figure of outstanding punchlist B-items at the handover stage. This would effectively monitor the ‘quality’ or ‘state of completeness’ of each commissioning package.

Example : This shows start to be worse than the target, however is recovered by some corrective measures, then again a peak mid-project before brought back to better initial targets.

Delta : Below Red Curve – Better than Target Above Red Curve – Worse than Target

Y IT T N A U Q / R E B M U N

Benchmark Curve

Actual Curve

TIME



14 Dossiers 14.1 Handover Dossiers The intention of a handover dossier is to provide a comprehensive summary of the specific commissioning package in a format that the Commissioning Group can easily verify without the need to send through a complete MC Dossier. Ideally, the submission of a completed MC Dossier could be possible, however from experience there tends to be back-end discipline scope, which is incomplete and which does not hinder the start of commissioning. In order to avoid submitting incomplete MC dossiers and updating these at a later date, it has been found to be a much more practical approach to submit a Handover Dossier and have the compiled MC dossier made available for detailed verification. The primary objective is to avoid unnecessary delays, which would have direct impact on the Commissioning Schedule.

14.2 MC Dossiers These dossiers are normally compiled on a CP basis and contain all the MC documentation from the relevant contractors in the form of MC Packages. These are divided by discipline together with an index of MC Packages contained in each section. In addition, each dossier should contain a summary report of all tags/cables with traceabilty to the respective MC Package No.

Section X Section 6

Section 5 Section 4 Section 3 Section 1

MC Dossier Index MC Dossier CP No. XXXX

1) 2) 3) 4) 5) 6) 7) 8) 9)

Status Report Electrical HVAC Instruments Piping Mechanical Structural Civils/archt. Etc….

Doc No……… MC Dossier Document No: Formal Project Document Number o be registered in DCC system.

Status Report : Comprehensive listing of all Tag Nos, Cables, Isometrics forming CP scope.

Discipline Sections : Contain all MC Package from all relevant contractors. Include index of MCPs in each section.



Handover Philosophy and MC Responsibility Single Discipline

MC Record

PUNCHLIST

MAC

HANDOVER

Multi-Discipline

MDP

MC Dossier

H/O Dossier

H/O Dossier

+

Complete MC Records in-line with Construction

Co nt ra c t o r s KUP Field MC KUP QS Progressively f ollowup scope and verif y MC Records (as required) *See Responsibility Matrix in MC Manual KUP QS sign f or QC Release on Pipe Testing Certif icate

Punch List by MCPackag e

Co n t ra c t o r s KUP Field MC

Review/Sign. Mechanical Acceptance Certif icate (Only “B” items)

Contractors KUP Field MC

Multi Discipline Pun chLi st wh en AL L MAC’s comple ted f or a Comm.Package

Contractors KUP Field MC

Finalise MC Dossier + Hand Over Dossier

KUP MC Dept.

Issue HO Dossier to Commissioning f ollowed by f inalised MC Dossier

KUP MC Dept.

Commissioning PunchListMC Packages when of f ered up by contractor. NOTE: Contractors must punch out f irst. (Joint discipline punch out where mutually agreed)

MAC to be signed when all ‘A’ items cleared and a reasonable amount of ‘B’ items are outstanding

Participate as required. MDP may take place with some outstanding scope upon agreement with Comm. e.g. Insulation / Heat Tracing All outstanding discipline punch items transf erred to MDP. KUP MC issue Notif ication !

CompileHandoverDossier and MC Dossier f or each Commissioning Package

IssueHandover Dossier to f ormally handovereach CP to Commissioning Group. MC Dossier to be made available, but not issued until totally f inalised.


MC Handbook – Section A Sample MC Dossier Index :


MC Handbook – Section B Sample Mechanical Completion Manual

This is a sample MC Manual from the KUP project, which has been revised at the end of the project to incorporate some experience feedback. Such a MC Manual should be prepared to suit the specific project organisation with particular emphasis on the development of the Responsibility Matrix.

HANDOVER

Engineering Construction MC

Commissioning

Start-Up

Oct2000 Edition

Sheet No. 1 of 18

KÅRSTØ UTBYGGINGSPROSJEKT (KUP) M.W. Kellogg Limited Job No. 5622

CONTRACT/P.O.

ReviewStatusCodeStamp

C-217091

TAG No.: N/A

C

04.10.00

B

12.04.99

Post Project Revision for MC

N /A

A.Dynowski

A.Dynowski

N.Carlsen

A.Dynowski

J. Austerheim

P. McLeod

G. Hystad

J. Austerheim

A. Traa

N/A

N/A

Handbook

A 0 Rev.No.

General Revision due to Integration

30.04.98

Revised as recorded

09.03.99

Issued for Implementation

Date

ForOriginatorUse:

J. Austerheim

DESCRIPTION

Prepared Checked ORIGINATOR KUP MC MainContract PurchaseOrder DOCUMENT TITLE

P.O.Skytterholm

Approved KUP CONSTR. N/A

G.Hystad

Approved KUP CONSTR.

KARTSØ UTBYGGINGSPROSJEKT (KUP) MECHANICAL COMPLETION MANUAL System Supplier’sDocument

Area Code:

DOCUMENTNUMBER:

Rev.

EY0M –SA 6--B00001

B

Filing Keyword: Distribution: Security: Comments:

WBS

G.Velde

Approved KUP COMM

Document Title : KARTSØ UTBYGGINGSPROSJEKT (KUP) MECHANICAL COMPLETION MANUAL

Doc. No.: MWKLJobNo.5622

Rev.No.:C

E060 - SB - M - YA 0001 Rev.Date:04.10.00

Page 2 of 18 _______________________________________________________________________________ 1

PURPOSE........ ........................................................................................................................................ 4

2

SCOPE......... ............................................................................................................................................ 4

3

REFERENCES ....................................................................................................................................... 5

4

5

6

7

8

DEFINITIONS ........................................................................................................................................ 5

4.1.1

Mechanical Completion (MC) ...................................................................................................... 5

4.1.2

Handover (HO)........... .................................................................................................................. 5

4.1.3

Commissioning ............................................................................................................................. 6

4.1.4

Start-up ......................................................................................................................................... 6

4.1.5

Contractor..................................................................................................................................... 6

4.1.6

KUP CONSTR............................................................................................................................... 6

4.1.7

KUP COMM ................................................................................................................................. 6

4.1.8

PA ................................................................................................................................................. 6

4.1.9

Commissioning Package (CP) ...................................................................................................... 6

4.1.10

Mechanical Completion Dossier................................................................................................... 6

4.1.11

MC Package.................................................................................................................................. 7

4.1.12

Responsibility Matrix......... ........................................................................................................... 7

4.1.13

Punch Item............ ........................................................................................................................ 8

4.1.14

Discipline Punch-Out ................................................................................................................... 8

4.1.15

Multi-Discipline Punch-Out.......................................................................................................... 8

4.1.16

Notification ................................................................................................................................... 8

4.1.17

PIMS-MC ...................................................................................................................................... 8

COMMISSIONING PACKAGES & MC PACKAGES.. .................................................................... 9 5.1.1

Commissioning Package Definition.............................................................................................. 9

5.1.2

MC Package Definition ................................................................................................................ 9

5.1.3

Relation Between Plant Systems, Commissioing Packages and MC Packages .......................... 10

5.1.4

KUP Completion Sequence Flowchart ....................................................................................... 11

MECHANICAL COMPLETION ACTIVITIES ............................................................................... 12 6.1.1

General ....................................................................................................................................... 12

6.1.2

MC General Responsibilities ...................................................................................................... 12

6.1.3

Mechanical Completion Flowchart - Fabrication Yards/Kårstø Site ......................................... 13

CARRYOVER WORK (COW).... ....................................................................................................... 14 7.1.1

COW/MSR Preparation .............................................................................................................. 14

7.1.2

Supporting Technical Documentation (with COW List) ............................................................. 14

7.1.3

Marking of COW Materials ........................................................................................................ 14

PIMS-MC SYSTEM...... ....................................................................................................................... 15

2



Rev.No.:C

E060 - SB - M - YA 0001 Rev.Date:04.10.00

Page 3 of 18 _______________________________________________________________________________ 9

RESPONSIBILTY FOR MC ACTIV ITIES....................................................................................... 15

10

MECHANICAL COMPLETION INSPECTION & TEST RECORDS..... ..................................... 16

11

REVISION CHANGE RECORD....... ................................................................................................. 17

12

APPENDIX NO.01 – CONTRACTOR CODES ................................................................................ 18

3



Rev.No.:C

E060 - SB - M - YA 0001 Rev.Date:04.10.00

Page 4 of 18 _______________________________________________________________________________

1

PURPOSE This Mechanical Completion Manual forms the basis for Mechanical Completion (MC), for the Kårstø Utbyggingsprosjekt (KUP). It also details the MC activities, level of verification and MC documentation requirements. Other primary aims and objectives include the following: • • • • • • • • • •

2

Achieve a consistent and adequate standard for MC documentation. Stipulate the level of verification by KUP CONSTR/KUP COMM. Use MC as a verification tool for status of project. Progressive completion of MC Certificates/Records. Progressive punch-out of the scope of work. Achieve a consistent standard of punch-listing activities. Progressive submission of MC Package to KUP MC Dept. Progressive compilation of MC dossiers. Achieve good traceability to MC documentation. Smooth handover of Commissioning Packages to KUP COMM.

SCOPE The use of this manual is limited to the following: a) Site Contractors b) Module Yards Contractors c) DRV Yard Contractor d) Multi-Discipline Package Suppliers (as defined in Appendix No.01) The MC requirements for equipment suppliers are specified in document E060SB-A-SS0014. This manual does not cover the full scope of work for each individual Contractor/Supplier and therefore reference shall be made to the relevant contract documents.

4



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3

REFERENCES

DocumentNo.

Title

E060-AD-A-KB0001 E060-AD-A-KC0002

Storage, Handling and Preservation Maintenance Guidelines for Mechanical completion of PressureManual Tests which Cross from Inner Area to ISBL/OSBL Commissioning Package Handover Procedure (KUP MC to KUP Commissioning) Pressure Safety Valve Handling Procedure Construction Blinding and Temporary Strainers Procedure Guidelines for Inspection and Punchlisting Activities Documentation for Operation-Purchase Order Requirements Structure and Contents of Manuals Instructions for Preparation Fabrication Record Books Instruction to Sub-Contractors for pr eparation of “As -Built” Drawings and Documents Initial Preservation Specification for Suppliers Mechanical Completion Specification for Equipment/ Fabrication Items Engineering Numbering System (ENS) PIMS - User Manual

E060-AD-A-KC0004 E060-AD-A-KK0011 E060-AD-A-KK0012 E060-AD-A-KV-0002 E060-AD-A-SS0001 E060-AD-A-SS0003 E060-AD-A-SS0004 E060-AD-A-SS0010 E060-SB-A-SS0013 E060-SB-A-SS0014 E002-XX-A-YA-5001 N/A

4

DEFINITIONS

4.1.1 Mechanical Completion (MC) Means all checking, verification and testing of the fabrication, construction and installation work performed by the individual Subcontractors to confirm that applicable Rules, Regulations, Codes and Standards are being met, and that the Project requirements as shown on drawings and outlined in specifications are fulfilled. The system shall be preserved/depreserved as per KUP Commissioning requirements and ready for handover. All inspection and testing shall be in accordance with the MC Manual and relevant specifications. No deviations shall be accepted unless prior written approval from the Company has been obtained.

4.1.2 Handover (HO) Handover is defined as the stage when all tests and checks are completed and MC has been obtained for a specified Commissioning Package. A Mechanical Completion Handover Dossier for the Commissioning Package will then be prepared which is detailed in Section 6. 5



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When the Handover Certificate is signed/accepted by KUP COMM the operational responsibility for the CP is transferred to KUP COMM.

4.1.3 Commissioning Commissioning means the testing and adjustment of an assembly, system or partsystem, and will comprise operational testing under real hydrocarbons or simulated conditions to ensure that it meets all applicable Rules, Regulations, Codes and Standards, fulfils its intended duty and is ready for start-up and operation. Legal responsibility for the Commissioning Package during this phase shall fall with KUP COMM. It should be noted that Contractor support may be required during this phase and KUP shall identify this in the scope of work relevant to the Contractors concerned. 4.1.4 Start-up Start-up means the start-up of plant sections and the complete plant to operating conditions of all systems, in a defined sequence to meet the product qualities and production rates outlined in design documents and specifications. Legal responsibilities for KUP during this phase shall fall with the Company (PA). It should be noted that Contractor support may be required during this phase, and PA shall identify this in the scope of work relevant to the Contractors concerned.

4.1.5 Contractor Means a person or company performing any item of work for the Project. 4.1.6 KUP CONSTR Means the integrated Statoil/M.W. Kellogg Ltd. construction group. 4.1.7 KUP COMM Means the Commissioning Group on behalf of the partners in the Åsgard Unit and Statpipe and Europipe II Joint Venture. 4.1.8 PA The operator of Kårstø Gas Treatment Plant. 4.1.9 Commissioning Package (CP) Means the logical of an assembly, system or part-system enabling initial commissioning to forming be performed.

4.1.10 Mechanical Completion Dossier The file of documents for a specific CP containing Mechanical Completion Acceptance Certificates, Punch Lists, Test Records, etc. compiled by discipline (see 6.1 for content overview).

6



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4.1.11 MC Package This is the term used to identify and define a single discipline related group of items forming an assembly within the boundaries of a specific Commissioning Package. The basis for the allocation of items into MC Packages is to enable the scope of work within each Commissioning Package to be progressively inspected, punched out and tested, in an effective manner as it is completed. The following examples of MC Package definitions are for guidance only: • • • • •

•

• •

•

•

Civil - for each area or structure etc. Structural - for each specific structure, building, rack etc. Mechanical/HVAC - for each item of equipment (or group of items) etc. Piping - for each piping test pack. Surface Protection - on pipework by piping test pack; for structural steelwork as per structural package. Insulation - on pipework by testpack, for mechanical as per mechanical package. Fireproofing - for steelwork as per structural package. Electrical - for each main item or equipment (or group) including feed cables, control cables, outgoing unit etc.; for each circuit or group of circuits etc. Instrumentation - by loop components (or group of loop components); group of stand-alone items etc. Telecom - by loop components (or group of loop components); group of standalone items etc.

4.1.12 Responsibility Matrix This matrix details the various levels of inspection, testing and verifications to be carried out by Contractor, KUP Construction, KUP Commissioning and/or Vendor/Supplier across all disciplines. All personnel involved in MC activities shall familiarise themselves with the relevant sections of this document (Ref. Section 2 of the manual).

7



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4.1.13 Punch Item This is the term used to identify and document incomplete work at time of discipline punch-out and multi-discipline punch-out. Each Punch Item identified shall be noted on a punch list, described in sufficient detail and marked on sketches or drawings as required for the item to be easily traced. Punch Items shall be categorised as follows:Category "A" items are defined as incomplete work preventing further testing, commissioning performance or continuous operation and maintaining of the plant systems. For pipng test packs, the ”A” item which shall be cleared prior to release of pressure test shall be flagged on the punchlist. All "A" items shall be cleared prior to handover of the Commissioning Package to KUP COMM. Category "B" items have no significance on safe operation and maintenance of the systems and can be accepted as not completed at handover provided that the number of such items are limited and subject to KUP COMM acceptance. •

•

4.1.14 Discipline Punch-Out This is the term used for a discipline related inspection of a MC Package scope which is presented by the relevant contractor as substantially completed (i.e. limited punch items). 4.1.15 Multi-Discipline Punch-Out This is the term used for the "Final Inspection" of a full Commissioning Package prior to handover to KUP COMM. It shall cover all disciplines and the primary aim is to verify the overall MC status of the package and document all outstanding items on a consolidated punchlist i.e. Multi-Discipline Punchlist.. This punch-out shall be carried out relatively close to the planned handover date, however sufficient time should be allowed to clear any additional "A-items" that may be identified and to reduced the number of "B-items" to an acceptable level for handover. 4.1.16 Notification A Notification system shall be implemented to ensure timely notice to the relevant personnel via the use of a "Notification" form, of the various MC activities which require verification as detailed in the Responsibility Matrix. Contractors may propose other methods for notification of MC activities (e.g. establishment of MC field/test centre with "Notification" board or similar). This shall be subject to KUP acceptance.

4.1.17 PIMS-MC The Statoil on-line computerised Mechanical Completion System.

8



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5

COMMISSIONING PACKAGES & MC PACKAGES

5.1.1 Commissioning Package Definition The commissioning package (CP) are defined by KUP into logical discrete parts of the permanent plant which can be commissioned/energised independently from the remaininig ongoing construction scope. These CPs are allocated a four digit number with the first two digits indicting the plant system number. The identification of commissioning packages are shown on colour marked-up boundary drawings e.g. P&IDs Single Line Drawings Block Diagrams • • •

A full listing of the currently defined CP Nos. are listed in Section 4 of the manual.

5.1.2 MC Package Definition MC Package numbering shall be in accordance with the following convention.

NNNN - AA - DNNNN CP No. (4 digit number) Refer to Section 4 For complete listing

Sequence Number 4 digits

Two character Contractor Code Refer to Appendix No.01

One character Discipline Code

9


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5.1.3 Relation Between Plant Systems, Commissioing Packages and MC Packages

24

24 01

MC MC MC Packs Civil Packs Packs

Plant System

2 40 2

MC MC MC Packs P ip in g Packs Packs

MC MC MC Packs Me ch Packs Packs

2403

MC MC MC Packs S t r uc t Packs Packs

MC MC MC Packs E le c t r o Packs Packs


2 40 4

MC MC MC Packs I ns t r Packs Packs

MC MC MC Packs T e le c o m Packs Packs

Commissioning Packages MultiDiscipline

MC Discipline Packages Single Discipline


Punch List

Punch List



Test Pack Iso’s

Marked Up Drawings

Marked Up P&ID’s

10

Documents included in MC Discipline Packages(examples)


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5.1.4 KUP Completion Sequence Flowchart Discipline Punch Out

PL01

HANDOVER CERTIFICATE

MultiDiscipline Punch Out

Mechanical Acceptance Certificate

MDP

MAC

Start-Up Notice

SUN

HOC

MC MC


MC

CONSTRUCTION

MC

CONSTRUCTION

PROGRESSIVE PUNCH OUT AND CLEARANCE BY MCPACKAGE

MC

CLEAR PUNCH ITEMS. NO A-ITEMS FOR HANDOVER

CONSTRUCTION CLEAR ITEMS

CONSTRUCTION

C O M M IS S I O N IN G

S TA R T- UP

MC

KUP Construction

KUP Commissioning

11

PA



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6

MECHANICAL COMPLETION ACTIVITIES

6.1.1 General Contractors shall complete all inspection and test records, prepare a discipline punchlist and a Mechanical Acceptance Certificate for each of their MC Packages. The following status codes shall be used on all inspection & test records checklist boxes :-

N/A Not applicable shall be written in all check windows or sections on the individual records when the checks or sections are not applicable for the corresponding item or equipment. OK Shall be written in all check windows when the checks/tests have been performed and accepted. The check window shall be left blank if the checks/tests are not done. The reason for not completing the inspection, shall be given in the remark column. If the check item can not be completed the item shall normally be punch listed, the punch item be categorised to "A" or "B" and noted on the MC punch list for the relevant MC Discipline Package with cross reference to check record and item. When all records reach status "OK" or "NA" with "B" punch items only the MC Package will be accepted i.e. signing of MAC01.

6.1.2 MC General Responsibilities General responsibilities are detailed in tabulation below, while specific responsibilty for MC activities and level of verification are detailed in the Responsibility Matrix included in Section 2 of the manual with the corresponding flowchart in Section 3.

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GeneralResponsibilities

Suppl.

EnsuremobilisationofMCpersonnelasrequired. Y Prepare detailed plan/schedules for of all inspection and Y testing activities. Ensure that subcontractors comply with the same MC Y requirements. Ensure piping test packs are defined within the Y package/module/commissiong package (as applicable) Organise, co-ordinate and notify all MC activities with Y Package Eng(PRE), KUP CONSTR and/or KUP COMM (as applicable). Ensure PIMS is updated progressively in line with progress of construction work and MC activities. Verification of MC activities in accordance with the Responsibility Matrix in Section 2 of this manual. Inspection and punch listing shall be carried out in Y accordance with relevant specifications, regulations and approved drawings. Prepare a Carryover Workhas List covering all outstanding work, which to (COW) be carried out at Kårstø (or for Supplier COW possibly at Module Yard). Compile an MC Dossier for each package/module including COW and copies of relevant as-built information, filed by discipline and submitted to KUP for formal acceptance. Complete outstanding work from suppliers and/or module yards (COW) as required. Prepare and progressively submit MC documentation by MC Package to KUP MC Dept. for inclusion in the master MC Dossier per Commissioning Package. Including punchlist and as-built information.

Fab Site Yard Y Y Y Y Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

-

Y

Y

-

-

Y

Y

-

-

Y

6.1.3 Mechanical Completion Flowchart - Fabrication Yards/Kårstø Site See Section 3 of the manual

13


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7

CARRYOVER WORK (COW)

7.1.1 COW/MSR Preparation The Carryover Work List shall be a comprehensive listing prepared by the supplier/module fabricator and verified by KUP, which details all outstanding work for the module, package, equipment, etc. The item numbers on the COW List shall be the same as for the corresponding discipline Punch List items, with additional final inspection items allocated the COW No. and a sequential item numbers. Each Carryover Work List shall have attached a corresponding Material Status Report MSR (if applicable) which shall give the correct status of material for each specific item on the COW List.

7.1.2 Supporting Technical Documentation (with COW List) The Technical Documentation to support COW scope shall be sufficiently detailed to enable other Contractors to identify and execute the work at site, e.g. marked-up drawing, technical queries, material certificates, welding and test procedures, etc. It is fabrication contractor's/supplier's responsibility to compile necessary documentation for each specific Carryover Work List item.

7.1.3 Marking of COW Materials This section applies only for equipment/items related to Contractor's scope of work, which is not installed at the time of transportation to Kårstø and is identified on the Carryover Work Lists and associated Material Status Report. All equipment, KUP provided or Contractor provided and/or fabricated items which are not installed, shall follow the module at transportation to Kårstø or be shipped immediately after to site. Each item shall be clearly marked with non-perishing marks:

Module No./P.O. No. Discipline Code Tag No. COW List No. All items shipped separately shall be securely wrapped, packed and preserved in accordance with approved procedures.

14



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8

PIMS-MC SYSTEM The Statoil MC system will be networked and on-line to KUP and main Contractors and site and at Module Yards. The system is centred around the downloaded engineering data from the design office(s), which will be performed by KUP MC Dept., together with the allocation of the CP No. to all items. It is the responsibility of the Contractor to define and allocate MC Packages to all Tags Nos/Cable Nos/Isometrics within their scope of work. Contractors shall print out the relevant MC Inspection & Test Records and progressively complete these in line with MC/construction activities. PIMS shall also be used for the administration of all punch list items generated at the suppliers and fabrication sites i.e. Carryover Work (COW), together with all the site raised punch items.

9

RESPONSIBILTY FOR MC ACTIVITIES The responsibilty for MC activities are detailed in the Responsibility Matrix included in Section 2 of the manual with the corresponding flowchart in Section 3. It must be recognised that MC work at Kårstø will proceed in close proximity to plant under commissioning and/or fully operational. It is therefore of outmost importance that the KUP Safety Regulations are closely observed and adhered to by all parties involved.

15



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10 MECHANICAL COMPLETION INSPECTION & TEST RECORDS MC certificates, inspection and records are divided into one general group and specific discipline sections. Blank formats are included in Sections 5 to 17 of the manual and these may bewith completed or where PIMS-MC application is available, can be printed the all manually available data included (recommended option). Section 5 : General MC Forms Section 6 : Electrical MC Forms Section 7 : HVAC MC Forms Section 8 : Instrumentation MC Forms Section 9 : Piping MC Forms Section 10 : Mechanical MC Forms Section 11 : Structural MC Forms Section 12 : Civil MC Forms Section 13 : Surface Protection MC Forms Section 14 : Safety MC Forms • • • • • • • • • • • • •

Section 15 : Telecommunication MC Forms Section 16 : Insulation/Refractory MC Forms Section 17 : Architectural

16



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11 REVISION CHANGE RECORD Rev N o. Rev C

Details o f R evision Experience feedback - certificates revised

Rev B

General revisonindue Statoil/MWKLtoIntegration the primary aim toofbuild in more flexibilty thetodocumentation, streamlineand andwith to reduce the volume certificates. General revision to simplify the opening narrative section. Revised MC flowchart at Kårstø in line with integration and participation of KUP Comm. Revised and streamlined Responsibilty Matrix. General change on all signature boxes i.e. references to Subcontractor, EPCS, Company now changed to Contractor, KUP Contruction, KUP Commissioning respectively. PL01(B) revised to include a new column to flag A-item required before pressure test. Introduction of new E&I, T MC Certifcates by MC Package to reduce volume of documentation. New MC Cert. E41, 42, 43 & 44. Revised Telecom Certs. T01 to T13 – now by MC Package not individual tag. New MC Cert. T14 – Miscellaneous Telecom Equipment. Consolidation of Electric Motor MC Certs to reduce number of certificates required, resulting in the following :E24 & E25 deleted. E03, E23 & E29 revised. Revised MC Cert J06 – Instrument Junction Boxes. Revised MC Cert J11 – Fire & Gas Loop. Revised MC Cert J12 – Orifice Plate (now cover verification of reinstatement). New MC Cert. L08 – Bolt Tensioning. New MC Cert. L09 – Steam Blowing. MC Cert M26 – Gas Turbines (now re-introduced). New MC Cert. M27 – Machinery Pre-Alignment. New MC Cert. M31 – Pump/Driver Release. New MC Cert. N02 – Structural Steelwork (By Tag No.). Deletion of Intrinsically Safe Calc Certs J14 & 15 due to separate application developed to cover this scope. Deletion of Q11 Cert. – L06 to be used. New MC Cert. Q12, 13, 14 & 15 for Tunnels, Caverns and Site Preparation. New MC Cert. Z01 – Architectural – Area. Added document references under Section 2 General revision to content Subcontractor codes added Added Check Form J 09-Instrument Pre-Installation Test/Inspection Added Check Form Q 11-Civils Flushing and TV Inspection Revised Check Form E 18-Lighting and Small Power Circuits-Lighting Fixtures Revised Check Form E 19-Lighting and Small Power Circuits SocketOutlets/Isolators Revised Check Form E 32-Ex Certification & Data Sheet Deleted Check Form E33-Ex Certification & Data Sheet Verification

Rev A

17



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12 Appendix No.01 – Contractor Codes Civils Contractors : Contractor

Contactor/Supplier Na me

Code AF SE VD VS

AFSpesialprosjekter Selmer Veidekke Vassbakk&Stol

Scope CivilsI Jetty03andTugBoatJetty CivilsII CivilssitePrep.Camp

Site Contractors : AB FO

ABB Offshore Technology Norske Fabricom

FI

Fabricom

UM

Umoe

E&I,T Hook-up/Installation, Kårstø Site OSBL : Mechanical Hook-up/Installation, Kårstø Site ISBL:MechanicalHook-up/Installation, Kårstø Site InnerArea:MechanicalHook-up/Installation, Kårstø Site

Module Yard Contractors : FB FU GR

FabricomS.A. Fabricom Contracting Ltd. GrootintB.V.

PAT&PAUFabrication DRV PARFabrication

Multi-Discipline Package Suppliers : AA DE DI DR FR HA IS

Aalborg Demag DanielIndustries DresserRand Framatome WilliamHare ISG

KE

KværnerEureka

KL KO KV MT NI PP

MaskinK.Lund Kongsberg Offshore Kvaerner MafiTrench Nikkioso Panaqua Process

WH

Whessoe

HeatRecoverySteamGenerator Propane&EthaneBoilOffCompressors n-ButaneMetering SalesGasCompressors&Drivers PropaneRefrigerationCompressors SteelBuildings PropaneCavernCoolDown,VapourBoil-off Treatment Facility SeawaterCoolingPumps Instrument AirPackage Fiscal Metering Packages (Gas & Liquid) NitrogenGenerationPackage TurboExpanderPackages Submerged Cryogenic Pumps Water Demineralisation Plant/Condensate Polisher Plant EthaneStorageTank

18

MC Responsibilty Matrix Kårstø Utbyggingsprosjekt (KUP) At t ac hm en t t o : E060-

SB - M- YA0001 R ev C

Responsibility Codes : The responsibility codes used in this matrix are as follows :Code A

Function

Description

Approval required.

Agreement by signature that specified work is completed to an acceptable standard in accordance andmandatory procedures. The letter A with doesdrawings not require presence of the approving party during the activity.

B

Advise to be provided.

Provide information, notification on the timing and availability of referenced activity.

I

Inspection required.

Carry out examination/overview of responsible party's work, and verify by signature as required on the relevant MC forms. The party's duty is to inspect the item or area in question during and/or after completion of the activity. Where a party only performs a monitoring role e.g. where KUP Comm perform inspection at their discretion, then they would sign the specific MC forms relating to scope inspected.

R

Responsibility to carry out the work.

Liable/accountable for ensuring the work is carried out.

W

Witness activitiy. (HOLD POINT)

Verify by physical observation and confirm by signature that test/activity are carried out in accordance with the requirements specified. The party has an obligation to witness the activity, and the activity shall not proceed without the witnessing party`s presence. The letter W does not involve approval authority. Signature does not constitute approval of completed work.

Parties Involved : The four parties involved are as follows :Symbol:

Description

X C

Contractors (including fabrication, installation and hook-up) KUP Construction, including Third Party (as required)

O

KUP Commissioning

S

Supplier/Vendor

Resp.Codes : X - Contractors; C - KUP Construction (T/P as required); O - KUP Commissioning; S - Supplier/Vendor #Error

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Item No:

01

SB - M- YA0001 R ev B

Description

Ref.Docum.

XCOS

Statutory Inspections

01.01

Plan for any special inspections of the facilities as may be required by local or governmental authorities or insurance companies, and obtain required approvals.

-

R

B

-

01.02

Maintain all QA related coordination and interfaces with authorities, e.g. DBE until Mechanical Completion.

-

R

B

-

01.03

Initiate application for the procurement of all permits issued in Company's name and required for plant installation, use, occupancy and operation.

-

B

R

-

02

General

02.01

Ensure facilities for disposal of hydrotest fluid are available.

-

R

A

-

02.02

Provide list of additives minimum 4 months ahead and provide permits from authority as required.

-

R

A

-

02.03

Establish and maintain blind lists up until Mechanical Completion handover and include in Handover Dossier.

-

R

I

-

02.04

Check and verify nameplates on all items of equipment and rectify any deficiencies. Check Authority requirements for marking are complied with (CE marking, etc.)

R

A

I

-

02.05

Perform inspection of scope to approved drawings and relevant specifications. Prepare and agree discipline punch lists.

R

I

I

-

02.06

Clearandverifyconstructionpunchlistitems.

R

I

I

-

02.07

Issue/verify completed MC Packages (I.e. no 'A' punch items).

MAC01

R

I

I

-

02.08

CompileconsolidatedMulti-DisciplinePunchlist.

MDPL

-

R

I

-

02.09 02.10

Issue notification for Multi-Discipline Punch Out (MDP) Perform Multi-Discipline Punch Out and agree/sign Multi-Discipline Punchlist (MDPL).

R

R I

I

-

02.11

ClearandverifyMDPLitems.

02.12

Issue Mechanical Completion Handover Certificate, Handover Dossier and MC Dossier for each Commissioing Package to KUP Commissioning.

03

PL01 PL01

NOT01 MDPL Master MDPLMaster HOC01

R

I

I

-

-

R

A

-

R

I

I

-

R

I

I

-

Steel Structures

03.01

Inspect structure is in accordance with drawings and specifications.

03.02

Inspect cladding and accessories comply with local and governmental regulations

04

Blind List

N01 N01

Pipework

04.01

Inspect lines internally during construction to ensure that all debris, welding rods, weld splatter, etc., are removed.

R

I

I

-

04.02

Perform punch out of own work and clear punch items with the priority on A- PL01

R

-

-

-

04.03

items. QC release MC Packages (Test Packs) - By KUP QS Group.

R

A

-

-

04.04

Release MC Packages (Test Packs) for pressure testing.

A

-

-

-

04.05

Perform cleaning flushing in accordance with project requirements (post test upon agreement).

L01

R

-

W

-

04.06

Perform pressure tests as required by the project specifications; ensure water is drained on completion of testing. Third Party approval as required.

L01

R

W

-

-

04.07

Perform drying in accordance with project requirements.

R

-

W

-

04.08

Reinstate piping test packs after completion and acceptance of flushing/pressure testing/drying and perform reinstatement punch out. Add new punch items to new page of punchlist agree/sign.

R

I

I

-

L01 L01

L01 L01,PL01


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Item No:

Description

04.09

Bolt tension all relevant flange joints in accordance with specifications and fit plastic caps plus affix signed tag/label to joints.

04.10

CarryoutvideoinspectionasinstructedbyKUP.

04.11

Performchemicalcleaningonspecifiedlines.

04.12

Perform hot-oil flushing on specified piping system e.g. lube oil.

04.13

Perform steam blowing on specified lines to target plate.

04.14

Install flow coding to lines in accordance with specification 0000-XX-LSF9002

04.15

Install orifice plates after line flushing/testing or as directed by KUP Comm. Also coordinate with E&I contractor.

04.16

Complete interlock installation.

05

Ref.Docum.

L08

L06 L04 L05 L09

J12

XCOS

R

I

I

-

-

R

W

-

R

-

W

I

R

-

W

I

R

-

W

A

R

I

I

-

R

I

I

-

R

I

W

I

R

I

I

-

R

I

I

-

R

W

I

-

R

W

I

-

-

-

R

I

R

-

W

-

R

I

I

-

Mechanical Equipment

05.01

Remove all temporary supports, bracing or other foreign objects that were installed in vessels, transformers, rotating machinery, expansion bellows, spring supports, instruments or other equipment and piping to prevent damage during shipping, storage, erection and pressure testing.

05.02

Install equipment in accordance to drawings and specifications.

05.03

Performvacuumboxtestontankbases.

05.04

Hydrostatic leak test atmospheric tanks as per code and specification requirements.

05.05

Check internals of vessels/equipment are in acoordance with drawings and specifications with respect to dimensional clearances and alignment.

05.06

Check internal cleanliness and completion of equipment prior to 'Final

05.07

Closure'. Perform cold alignment to project tolerances, prior to attachment of pipework, tighten holding down bolt and dowel where specified.

05.08

Perform final alignment (some equipment will require supplier witness).

R

W

I

(W)

05.09

Conduct refractory dry out and boil out operations as per Supplier recommended procedure.

R

I

W

A

05.10

Inspect and repair refractory as required.

R

I

W

A

06

M01-M25 M02 M02

M30

M28

Safety Equipment

06.01

Check that personnel protection insulation, protective guards, all ladders, ladder cages, platforms, safety bars, handrailing, etc. are correctly installed

S20

R

I

I

-

06.02

Check that utility stations are correctly marked (special warning signs for Nitrogen)

S20

R

I

I

-

06.03

Installofallsafetyequipment.

S01-S11

R

I

I

-

06.04

Install safety notices, as required by local and governmental regulations

S20

R

I

I

-

R1,R2 or R3

R

I

I

-

R

W

-

-

R

I

A

-

R

I

I

-

07

Painting, Insulation and Fireproofing

07.01

Complete painting, insulation and/or fireproofing is in accordance with specifications and to the extent specified on drawings.

07.02

Performadhesiontestsasrequired.

08

TestReport

E le c t r ic a l In s t a lla t io n s

08.01

Perform continuity check, insulation resistance check, pressure test, insulating oil tests, injection tests according to specifications

08.02

Dry out electrical equipment, if necessary to achieve required insulation resistance level

E01 to E44


06-okt-2000 14:29 Page: 3



Item No:

Description

08.03

Carry out tests on all switchgear with bus-bars de-energized to ensure correctness of operating and panel wiring

08.04 08.05

08.06

Ref.Docum.

XCOS

R

I

Provide relay tabulations for all protective and time delay relays

B

Fill distribution transformers with oil using oil filtration and circulation unit and circulate oil until the di-electric strength of oil is satisfactory. Check Buchholz and High Oil Temperature devices for correct operation

R

Energize transformer and leave on no load for 24 hours, then phase out transformers with parallel systems NB! Approval of local authority is required before equipment is energized! Check for correct operating substation DC power systems and UPS systems

08.08

I

-

R

I

-

I

A

-

R

I

W

-

R

I

W

-

Check Emergency Generator engine operation and rotation. Check governor operation. Check output of Generator overspeed test generator, check synchronism with main, load test generator and check AVR operation. Check trips and alarm functions and check auto transfer systems.

R

I

W

-

08.09

Fill Unit Transformers with oil and circulate until the die electric strength of oil is satisfactory. Check Buchholz and High Oil Temperature protection for current operation. Energize transformers, check phase rotation and leave on soak for 24 hours. Deenergize transformer and check motor rotation. Check motor insulation monitoring systems.

R

I

W

-

08.10

Set protective relays and time delays on all switchgear in accordance with tabulated data. Test relay characteristics at points on the relay calibration curves as indicated in the tabulated area.

R

I

I

-

08.11

Energize systems up to main instrument power distribution board, assuming responsibility for operation and maintenance.

B

B

R

-

08.12

Energize substations and assume responsibility

B

B

R

-

08.13

Issue work permitsare to carry out checks on electrical equipment after electrical facilities energized.

-

-

R

-

08.14

Function test Variable Speed Drives

R

I

W

-

08.15

Check motor nameplate speed, horsepower and voltage against specification

-

R

A

-

08.16

Carryoutearthingtestandcontinuitytest

R

I

W

-

08.17

Bump start motors to check direction of rotation

R

I

A

-

08.18

Run-in motors uncoupled for 4 hours and check bearings (motors > 100kW) E03

R

I

A

-

08.19

Check that plant lighting is adequate and meets specification

-

R

I

-

08.20

Carry out functional tests on thyristor controlled heaters

R

I

W

-

08.21

Visually inspect all cables for correct sizing, spacing and freedom from kinks and damage

-

R

A

-

08.22

Certify clearance for backfilling underground cables

08.23

Check that all electrical tracing is complete and has been tested for both continuity and insulation integrity. NB! Tracing must be tested before and after the insulation is installed!

08.24 08.25

08.07

09

E04

E03,E29 E14

E05,13,18,

-

A

A

-

R

I

A

-

Check operation of all communication systems

R

I

W

B

Energize trace heating circuits and check for correct operation.

R

I

A

-

R

I

B

-

R

I

I

-

R

I

I

-

R

I

I

-

E16 E27,E28

Instrumentation

09.01

Clean and degrease all instruments and remove shipping stops, preservation materials, etc.

09.02

Visually check that all instruments, tubing, wiring, and piping are installed and connected in accordance with project specifications.

09.03

Check the accessibility of all instruments and components for field adjustments, routine maintenance and removal for overhaul.

09.04

Clean all transmission tubing and control tubing by blowing with dry, filtered air prior to connection of instrument components.

J01 to J16

J02


06-okt-2000 14:29 Page: 4



Item No:

Description

09.05

Leak test pneumatic transmission and control tubing using an approved method.

09.06

Leak test process impulse tubing using an approved method.

09.07

Remove in-line components as necessary for line flushing operations and reinstall when completed and dry

09.08

Checktheorificeplatesagainstspecification

09.09

Test all wiring including thermocouples for correct source of power, polarity,

Ref.Docum.

J02 J02

J12

XCOS

R

I

I

-

R

I

I

-

R

I

I

-

-

R

I

-

R

I

A

-

joining conductors, continuity, Bottomof thermocouples in wells. insulation and earthing as appropriate. 09.10

Check wiring connections to marshalling, equipment and interface panels in control room, equipment rooms and substations

R

I

I

-

09.11

Check wiring connections to local panels on or adjacent to skids and mechanical packages

R

I

I

-

09.12

Check fuses and perform voltage checks on the ESD systems, the PCDA system, and all electrically powered instruments.

R

I

A

B

09.13

Assist with the PCDA system acceptance test (OSAT)

R

W

A

B

09.14

Check thermocouples and resistance thermometer circuit from element to measuring instrument by simulation

R

I

W

-

09.15

Carry out loop tests in accordance with the loop test procedure

R

A

W

-

09.16

Maintain log book of installation/removal of orifice plates up to Mechanical Completion Handover

R

I

I

-

09.17

Set direct-connected process switches (e.g. alarms, cut-outs) and controls

R

I

W

-

09.18

Fully pressurize the pneumatic transmitting and control signal systems and set air pressure regulators to manufacturer's recommendations

R

I

W

-

09.19

Energize instruments, alarms and shutdown systems

-

I

R

B

09.20 09.21

Energize the ESD systems Energize the PCDA system

-

I I

R R

B B

09.22

Maintain instrument power supply

-

-

R

-

09.23

Check and adjust calibration of all other field and panel mounted instruments

R

I

W

-

09.24

Loop test complete control loops, PCDA, HIPPS, PSD, ESD, PA, CCTV, UHF/VHF, F&G systems to verify capability to measure and operate and to verify the correct action of the control elements.

R

I

W

B

09.25

Fill instrument process lines with seals and condensate, etc. test purges and heat tracing, and then isolate all process connections, steam supplies and purges, etc.

R

I

W

-

09.26

Undertake routine maintenance and checking of instrumentation from Mechanical Completion Handover.

-

I

R

-

09.27

Check and set hardware range and span of transmitters against those shown on software

R

I

W

B

09.28

Input calculated tuning parameters on control loops

-

I

A

R

09.29

Check fire and gas detection and measurement systems

R

I

W

B

10

J10,J11

J10

HVACSystems

10.01

Installed HVAC equipment in accordance with drawings and specifications.

G01-G07

R

I

I

-

10.02

Inspect and test ducting is in accordance with drawings and specifications.

G08

R

W

I

-

11

Preservation

11.01

Review Suppliers preservation requirements and if required prepare new specific checklists.

-

R/A

I

B

11.02

Perform preservation in accordance with default or specific checklists.

R

I

I

-

11.03

Maintain lubrication charts on equipment until handover.

R

I

I

-


06-okt-2000 14:29 Page: 5



Item No:

Description

11.04

De-preserve as instructed by KUP Comm. with special attention to removing descicant bags placed inside equipment.

11.05

Prepare and Preservation Verification Certificate & Preservation Dossier.

12

Ref.Docum.

PVC01

XCOS

R

I

I

-

-

R

A

-

CivilWorks

12.01

Inspect all driven piles including sheet piles (incl survey results).

R

I

-

-

12.02 12.03

Inspectformworkandreleaseforconcretepour. Q01 Inspect foundations post pour that they are in accordance with drawings Q01 and specifications (incl. survey results).

R R

A I

-

-

12.04

Release foundation for placement of equipment and/or structures.

R

A

-

-

12.05

Prepareandreleaseforgrouting.

R

A

-

-

12.06

Inspect all buildings including services and finishing.

R

I

I

-

12.07

Verify that concrete cube test results are acceptable to specifications (alternative test reports to Q09 may be used upon agreement with KUP).

R

A

-

-

12.08

Clean/flushundergroundpipingsystems.

R

-

W

-

12.09

Carry out leak tests and/or pressure testing of underground piping systems.

R

W

I

I

12.10

Inspect and release underground piping for backfilling.

R

A

-

-

12.11

Inspect/test sumps, manholes, catchbasins and pits to project drawings and specifications.

Q03

R

I

I

-

12.12

Perform video inspection as directed by KUP on underground piping systems.

L06

-

R

W

-

Q04

Q08 Q02 Q07 Q09 Q05 Q05 Q10


06-okt-2000 14:29 Page: 6

Attachm ent to : E060- SB-M-Y A0001 Rev C

FLOWCHART SHOWING SEQUENCE OF MECHANICAL COMPLETION AT FABRICATION YARD CONTRACTOR

KUPCONSTRUCTION

ConstructionComplete Punch own work and clear punch items. Priority on A-Items

Pre-TestPunch

PerformPunchOut (by MC Package) Agree a discipline punchlist and indicate the category i.e. A or B

ClearPunchItems Clear Punch Items priority on A PerformMCActivities

KUPCOMMISSIONING

Participate in pre-test punch out

PerformPunchOut Agree formal punchlist by signing PL01 (incl. CATEGORY)

VerifyClearedPunchItems Sign off on original PL01 Verify/Approve

Verify/Approve

In accordance with specified requirements

In accordance with MC Responsibilty Matrix with Third Part attendance as required.

ReinstatementPunchOut Agree additional items andsignPL01newpage

ReinstatementPunchOut Update Discipline Punchlist Agree&signPL01newpage

ReinstatementPunchOut Agree additional items andsignPL01newpage

Continue ToClear Items Toagreedpriorities

Verify ClearedPunchItems SignoffonoriginalPL01

Verify Cleared Punch Items SignoffonoriginalPL01

In accordance with MC Responsibilty Matrix

At KUP Comm.discretion Compile MC Dossier Compile MC Packages into MC Dossier per CP No.

PreparC eOW List Agree new items and sign'Master'MDPL

AgreC eOW Perform final punch out and agreeCOWList&MSR

PrepareCOW/MSR Prepare/SignCOW&MSR

VerifyClearedMDPLItems SignoffonMasterMDPL

CompleteMCDossier Finalise MC Dossier per Module

ApproveMCDossier Review and approved

incluing required number ofcopies

MC dossier for each module includingCOW/MSR

Transporatation to Kårstø Send MC Dossier to Site DCC

AgreC eOW Perform final punch out and agreeCOWList&MSR

VerifyClearedMDPLItems SignoffonMasterMDPL

Attachm ent to : E060- SB-M-Y A0001 Rev C

FLOWCHART SHOWING SEQUENCE OF MECHANICAL COMPLETION AT KÅRSTØ CONTRACTOR

KUPCONSTRUCTION

KUPCOMMISSIONING

Construction Complete Punch own work and clear punch items. Priority on A-Items Issue Notification via Notice or Notice Board PerformPunchOut (by MC Package) *For Piping : Flag A-Items that must be cleared prior to test ClearPunchItems Flagged A-Items first priority QC Release QC release piping test packs and sign L01 certificate

PerformPunchOut Agree formal punchlist by signing PL01 (incl. CATEGORY)

PerformPunchOut Agree formal punchlist by signing PL01 if attended

VerifyClearedPunchItems Sign off on original PL01 QC Release KUP QS to QC release piping test packs and sign L01 certificate

Release for Test (Piping) Test Engineer verifies all Flagged AItems Cleared PerformMCActivities In accordance with specified requirements

Verify/Approve In accordance with MC Responsibilty Matrix

ReinstatementPunchOut

ReinstatementPunchOut

Agree additional items andsignPL01newpage

Update Discipline Punchlist Agree&signPL01newpage

Continue ToClear Items Toagreedpriorities

Verify ClearedPunchItems SignoffonoriginalPL01

Verify/Approve In accordance with MC Responsibilty Matrix ReinstatementPunchOut Agree additional items andsignPL01newpage Verify Cleared Punch Items SignoffonoriginalPL01 At KUP Comm.discretion

Compile MC Dossier Compile MC Packages into MC Dossier per CP No. Produce Multi-Discipline Punchlist (MDPL) Consolidate all outstanding punch items to one MDPL Issue MDP Notification To CP Responsible Perform MDP Agree new items and sign'Master'MDPL ContinuetoClearItems A-Items first priority Notes :1)Skipstepsspecificto piping which do not apply to other disciplines. 2) Reject loops omitted for clarity.

Perform MDP Prepare 'Master' MDPL Agree&sign'Master'MDPL

Perform MDP Agree new items and sign'Master'MDPL

VerifyClearedMDPLItems Sign off on Master MDPL

VerifyClearedMDPLItems Sign off on Master MDPL

Complete MC Dossier AllTest&InspectionRecords Prepare MC Dossier & Handover Dossier for HandovertoKUPComm.incl. Handover Cert. (No A-Items)

Review Handover Dossier If acceptable SignHandoverCertificate and return a copy to KUP MC

MC Manual CP Listing Kårstø Utbyggingsprosjekt (KUP) At t ac hm en t t o E060- SB - M- YA0001 R ev C

CPNo:

Title:

0001

Area Completion : EPII/Backflow Area (Electrical, Safety)

0002

Area Completion : Propane Cavern Area (Electrical, Safety)

0003

Area Completion : Åsgard Reception Area (Electrical, Safety)

0004

Area Completion : Unit 46 - CA 461 Area

0005

Area Completion : Ethane Tank - CA 466 Area

0006

Area Completion : Metering Stations - CA 2 & 14 Areas

0007 0008

Area Completion : Jetty III - CA 471 Area Area Completion : Ethane Treatment - CA 481 Area

0009

Area Completion : Boiler/Sales Gas & Condensate Treatment Area

0010

Area Completion : Basin, Free Area, Seawater Intake, Weir Box Area

0011

Area Completion : T-410, T-420, Fractionation, Future, Process Subst., DEOH Areas

0012

Area Completion : All Exisiting Substations (with KUP Scope)

1501

Feed Gas - Reception & Let Down

1502

FeedGasFilters

1503

Backflow Piping & Let-Down (early SG to EPII)

1504

Analyser House - Unit 15 (15-ZG-201)

2001

MercuryRemoval

2002

GasDrying-Train410

2003

Drier Regeneration - Train 410

2004

GasDrying-Train420

2005

Drier Regeneration - Train 420

2006

Analyser Shelter - Tr. 410 Driers (20-JA-411)

2007

Analyser Shelter - Tr. 420 Driers (20-JA-421)

2101

NGL Extraction - Train 410, Wash Column

2102

NGL Extraction - Train 410, De-ethaniser

2103

Turboexpander - Train 410 (warm)

2104

Turboexpander - Train 410 (cold)

2105

NGL Extraction - Train 420, Wash Column

2106

NGL Extraction - Train 420, Deethaniser

2107

Turboexpander - Train 420 (warm)

2108

Turboexpander - Train 420 (cold)

2109

Analyser House - Extract. Train 410 (21-ZG-410)

2110

Analyser House - Extract. Train 420 (21-ZG-420)

2113

Building - TEX Tr.410(21-ZH-411)

2114

Building - TEX Tr. 420(21-ZH-421)

2115

O/HCrane-21-MA-411

2116

O/HCrane-21-MA-421

2201

Dethaniser Overhead Compressor "A"

2202

Dethaniser Overhead Compressor "B"

2203

Sales Gas Compressor "A"

2204

Sales Gas Compressor "A", Gas Turbine

2205

Sales Gas Compressor "B"

2206

Sales Gas Compressor "B", Gas Turbine

2207

O/HCrane-22-MA-201A

2208

O/HCrane-22-MA-201B

2209

Building - Deeth. O/H Compr. Tr.410(22-ZH-201A)

2210

Building - Deeth. O/H Compr. Tr.420(22-ZH-201B)

2211

Building - S.G. Compr. Tr.410(22-ZH-203A)

PIMS 97 (Concept by Omega AS)

04-okt-2000 16:47Page: 1


CPNo:

Title:

2212

Building - S.G. Compr. Tr. 420(22-ZH-203B)

2213

O/HCrane-22-MA-202A

2214

O/HCrane-22-MA-202B

2216

FuelGasTreatment

2301

Sales Gas Metering - Asgard

2302

Sales Gas Metering - Statpipe

2303 2401

Analyser House - Sales gas (23-ZG-201) Depropaniser

2402

Debutaniser

2403

ButaneSplitter

2404

Analyser House - Fractionation (24-ZG-401)

2501

PropaneR efrigerationCompressor

2502

Propane Refrigeration System

2503

O/HCrane-25-MA-400

2504

Building - Prop. Refrig. Comp.(25-ZH-001)

2901

EthaneTreatment

2902

Analyser House - Ethane (29-ZG-101)

3101

Åsgard Pipeline & Pig Receiver Kårstø

3104

HPU - Åsgard Pipeline-Kårstø

3401

Europipe II - Pipeline & Pig Launcher

3402

HPU-EPIIPipeline

3403

Pipeline Instrumentation at Bokn

4201

PropaneCavern"A"

4202

Propane Cavern "A" - Water Pumps

4203

Propane Cavern "A" - Loading Pumps

4204

PropaneCavern"B"

4205

Propane Cavern "B" - Water Pumps

4206

Propane Cavern "B" - Loading Pumps

4207

i-ButaneStorage

4208

n-ButaneStorage

4209

EthaneStorage

4601

Propane Compressor"A"

4602

Propane Compressor"B"

4603

Propane Chilling & Vapour Recovery

4604

Ethane Refrigeration Compressor

4605

Ethane Chilling & Vapour Recovery

4606

Temp. Equipment for Cavern Cooldown

4607

Building-P rop./EthaneCompr.(46-ZH-201)

4608

O/HCrane-46-MA-200

4701

Propane Loading & Cavern Boil-off to Exist.

4702

i-ButaneLoading

4703

n-ButaneLoading

4704

EthaneLoading -Jetty3

4705

Gasoline Loading - Jetty 3

4706

O/HCrane47-MB-210

4707

O/HCrane47-MB-211

5201

BFWDistribution

5202

HPSteam&Condensate


04-okt-2000 16:47Page: 2


CPNo:

Title:

5203

MPSteam&Condensate

5204

LPSteamDistribution

5205

LPSteam-Train410

5206

LPSteam-Train420

5207

LP Condensate Recovery

5208

LP Condensate -Train 410

5209 5210

LP Condensate -Train 420 Condensate Treatment

5211

WasteHeatBoiler'A'

5212

WasteHeatBoiler'B'

5213

LP Steam/Condensate - EP II & Metering

5214

LP Steam/Condensate - NGL Chilling & Offsites

5215

Analyser Shelter- Unit 52 (52-JA-501)

5301

Methanol Storage & Inj. - Prop. Caverns (Temp)

5401

ColdFlare Header

5402

Cold Flare - EP II & Metering

5403

ColdFlare-Reception

5404

ColdFlare-Train410

5405

ColdFlare-Train420

5406

Cold Flare - Fractionation

5407

Cold Flare - Ethane Treatm. & O ffsites

5408

WarmFlare-Åsgard

5409

LPFlare-Caverns

5410

LP Flare -Ethane Storage

5411

46Flare-Åsgard

5412

46Flare-Caverns

5501

Seawater Intake & Screens

5502

SeawaterPumps

5503

Seawater Distribution and Return

5504

Sea Water Tunnels - AF Scope

5601

Tempered WaterSystem

5602

Tempered Water System - Unit 46

5701

FuelGasSystem

5702

DieselOilSystem

5703

L.P.FuelGasSystem

5704

Analyser House - Fuel Gas (57-ZG-401)

6001

Air Compressor/Drier Package

6002

Instrument Air - Train 410

6003

Instrument Air - Train 420

6004

Instrument Air - Compression Area

6005

Instrument Air - Fractionation

6006

Instrument Air - Reception

6007

Instrument Air - Ethane Treatm./Tank & Jetty 3

6008

Instrument Air - NGL Chilling/Vapour Rec. & Caverns

6009

Instrument Air - Liquid Metering

6010

Instrument Air - Utilities

6011

Instrument Air - EP II & Metering

6013

PlantAir-Train410


04-okt-2000 16:47Page: 3


CPNo:

Title:

6014

PlantAir-Train420

6015

Plant Air - Compression Area

6016

Plant Air - Fractionation

6017

PlantAir-Reception

6018

Plant Air - Ethane Treatment & Jetty 3

6019

Plant Air - NGL Chilling/Vapour Rec. & Caverns

6020 6021

Plant Air - Ethane Storage & Liquid Metering PlantAir-Utilities

6022

Plant Air - EP II & Metering

6023

Building - Air Compr.(60-ZH-401)

6101

Nitrogen Generation Package

6102

Nitrogen-Train410

6103

Nitrogen-Train420

6104

Nitrogen - Compression Area

6105

Nitrogen - Fractionation

6106

Nitrogen-Reception

6107

Nitrogen - Ethane Treatment & Jetty 3

6108

Nitrogen - NGL Chill./Vapour Rec. & Caverns

6109

Nitrogen - Liquid Metering

6110

Nitrogen-Utilities

6111

Nitrogen - Ethane Storage

6112

Nitrogen - EP II & Metering

6114

Nitrogen for Caverns Cool Down (Temp.)

6201

Fresh Water Distribution (incl. New Pumps)

6202

Fresh Water - Fractionation

6203

FreshWater-Train410

6204

FreshWater-Train420

6205

Water Treatment & Distribution

6206

Fresh Water - EP II & Metering

6207

Fresh Water - Propane Caverns

6301

Potable Water Distribution

6302

Potable Water to EP2 from T-63K-284

6401

Oily Water Drains - Holding Basin

6402

Oily Water Drains - Gasoline Metering

6408

Oily Water Drains - Reception

6409

Oily Water Drains - Ethane Treatment

6411

Oily Water Drains - Propane Caverns

6412

Oily Water Drains - Utilities

6413

Oily Water Drains - Europipe II Pig Launcher

6414

Oily Water Drains - Jetty 3

7001

Fire Water D istribution

7002

Fire Water - EP II Pig Launcher

7003

Fire Water - NGL Chilling & Caverns

7101

Firewater Sprinkler & Deluge - Train 410

7102

Firewater Sprinkler & Deluge - Train 420

7103

Firewater Sprinkler & Deluge - Fractionation

7104

Firewater Sprinkler & Deluge - Compression Area

7106

Firewater Sprinkler & Deluge - Ethane Storage


04-okt-2000 16:47Page: 4


CPNo:

Title:

7108

Firewater Sprinkler & Deluge - Flare Drums

7202

Fire Fighting Equipment - Train 410

7203

Fire Fighting Equipment - Train 420

7204

Fire Fighting Equipment - Fractionation

7205

Fire Fighting Equipment - Compressors

7206

Fire Fighting Equipment - Ethane Recovery

7207 7208

Fire Fighting Equipment - Ethane Storage Fire Fighting Equipment - NGL Chilling & Caverns

7209

Fire Fighting Equipment - Flare Drums

7210

Fire Fighting Equipment - EP II Pig Launcher

7211

Fire Fighting Equipment - Offsites

7401

Fire & Gas Monitoring - Feed Reception

7402

Fire & Gas Monitoring - Train 410

7403

Fire & Gas Monitoring - Train 420

7404

Fire & Gas Monitoring - Fractionation

7405

Fire & Gas Monitoring - Sales Gas Compr.

7407

Fire & Gas Monitoring - EP II Pig Launcher Area

7408

Fire & Gas Monitoring - Ethane Recovery

7409

Fire & Gas Monitoring - Ethane Storage

7410

Fire & Gas Monitoring - Caverns

7411

Fire & Gas Monitoring - Bokn LVS

7412

Fire & Gas Monitoring - Grid Substation

7413

Fire & Gas Monitoring - Åsgard Intake Subst.

7414

Fire & Gas Monitoring - Refrig./Caverns Subst.

7415

Fire & Gas Monitoring - Process Trains Substation

7416

Fire & Gas Monitoring - Sales Gas Substation

7417

Fire & Gas Monitoring - Jetty LCR

7418

Fire & Gas Monitoring - Centr. Control Room

7419

Fire & Gas Monitoring - EP II Substation

7420

Fire & Gas Monitoring - Receiving Area LER

7424

Fire & Gas Monitoring - Deeth. O/H Compr.

7425

Fire & Gas Monitoring - Gasoline Metering

7426

Fire & Gas Monitoring - Jetty 3

7427

Fire & Gas Monitoring - Sea Water Intake Area

7428

Fire & Gas Monitoring - Sales Gas Metering

7434

F & G Monitoring - 46 Compr. & Chilling Area

7435

Fire & Gas Monitoring - N ew CER & Effluent Treatment UPS/Battery Rooms

7436

Fire & Gas Monitoring - Analyser House 23-ZG-201

7437

Fire & Gas Monitoring Backflow Area

7438

Fire & Gas Monitoring Propane Fiscal Metering Area

7440

Fire&GasCabinetsCCR

7441

Fire & Gas Cabinets Receiving LCR

7442

Fire & Gas Cabinets EPII LCR

7443

Fire & Gas Cabinet Cavern LCR

7444

Fire & Gas Cabinet Åsgard LCR

7445

Fire & Gas Cabinet Sales Gas LCR

7446

Fire & Gas Cabinets Ethane Recv./Jetty LCR

7448

Air Compressor & Water Treatment (FA 24/1)


04-okt-2000 16:47Page: 5


CPNo:

Title:

7449

Fire & Gas Monitoring - Road Tunnel

7501

ESD System - Feed Reception (Field PBs)

7502

ESD System - Train 410 (Field PBs)

7503

ESD System - Train 420 (Field PBs)

7504

ESD System - Compression (Field PBs)

7505

ESD System - Gas E xport (Field PBs)

7506 7507

ESD System - Fractionation (Field PBs) ESD System - Ethane Recovery & Jetty 3 (Field PBs)

7508

ESD System - Ethane Storage (Field PBs)

7509

ESD System - Caverns (Field PBs)

7510

ESD System - Butane Storage/Butane LCR

7520

ESD System CCR (incl. Cabinets/Matrix and PBs in CCR)

7521

ESD Cabinets Receiving LCR (incl. PBs in LCR)

7522

ESD Cabinets EPII LCR (incl. PBs in LCR) and Field PBs

7523

ESD Cabinets Cavern LCR (incl. PBs in LCR)

7524

ESD Cabinets Åsgard LCR (incl. PBs in LCR)

7525

ESD Cabinets Sales Gas LCR (incl. PBs in LCR)

7526

ESD Cabinets Ethane Recv./Jetty LCR (incl. PBs in LCR)

7530

ESDIntertrips

7531

ESD - Socket Outlet and Welding Outlet Trips

8001

Electrical Power to G rid Substation

8201

Electric Power to Åsgard Intake Subst.(22kv)

8202

Electric Power to Refrig./Cavern Subst.(6,6kV)

8203

Electric Power to Process Trains Subst.(690V)

8205

Electric Power to Sales Gas Subst. (6,6kv)

8206

Electric Power to Sales Gas Subst. (690v)

8207

Electric Power to EP II Subst. (690V,Temp.)

8208

Electric Power to EP II Subst. (690V,Perm.)

8209

Electric Power to EP II Subst. (400V)

8210

Electric Power to Bokn LVS Subst.

8212

Electric Power Distribution - Train 410 (690V)

8213


8214


8215


8216

Electric Power Distribution - General Process (400V)

8217

Electric Power Distribution - Sales Gas Subst. (400V)

8218

Electric Power Distribution S.G. Compr.A (690V)

8219

Electric Power Distribution S.G. Comp. B (690V)

8220

Electric Power Distribution S.G. Comp. A (400V)

8221

Electric Power Distribution S.G. Compr. B (400V)

8222

Electric Power to Cavern Subst. (690V)

8223

Electric Power to Cavern Subst. (400V)

8224

Electric Power to Åsgard Intake Subst. (690V)

8225

Electric Power to Åsgard Intake Subst. (400V)

8226

Lighting & Heat Tracing Distribution from Effluent Treatment Subst. (82-ZE-103)

8227

Lighting & Heat Tracing Distribution from Refrig/Cavern Subst. (82-ZE-106)

8228

Lighting & H eat Tracing Distribution from Butane Subst. (82-ZE-108)

8229

Lighting & Heat Tracing Distribution from Sea Water Subst. (82-ZE-105)


04-okt-2000 16:47Page: 6


CPNo:

Title:

8231

Existing Effl. Treatment Subst.

8234

Booster Compr. Upgrade - Electrical

8235

Electric Power - P ropane Liquid Export Metering Package 47-XT-211

8236

Electric Power Distribution - Bokn LVS

8237

Lighting & Heat Tracing Distribution from EP II Subst. (82-ZE-118)

8238

Lighting & Heat Tracing Distribution from Åsgard Sales Gas Subst. (82-ZE-116)

8239 8240

Lighting & Heat Tracing Distribution from Åsgard Process Subst. (82-ZE-114) Electrical-AFScope

8241

Lighting & Heat Tracing Distribution from Åsgard Main Intake Subst. (82-ZE-117)

8242

Lighting & Heat Tracing Distribution from Utility Subst. (82-ZE-104)

8243

Lighting & Heat Tracing Distribution from Existing Propane Subst. (82-ZE-107)

8251

Main Intake Subst. - Exist. 82-EM-200

8252

Main Intake Subst. - Exist. 82-EN-700

8253

Effl. Treatm. Subst. - Exist. 82-EN-530

8254

Effl. Treatm. Subst. - Exist. 82-EN-730

8255

Utility Subst. - Exist. 82-EN-541

8256

Utility Subst. - Exist. 82-EN-740

8257

Seaw. Intake Subst. - Exist. 82-EN-550

8258

Seaw.Intake subst. - Exist. 82-EN-750

8259

Butane Subst. - Exist. 82-EN-581

8270

CECSSystem(Level3)

8271

CECS System (L1 & 2) - Effluent Treatment Subst.(CCR)

8272

CECS System (L1 & 2) - Main Intake Subst.

8273

CECS System (L1 & 2) - Propane Cavern Subst.

8274

CECS System (L1 & 2) - EPII Subst.

8275

CECS System (L1 & 2) - Åsgard Process Subst.

8276

CECS System (L1 & 2) - Åsgard Sales Gas Subst.

8277

CECS System (L1 & 2) - Exisiting Sea Water Subst.

8278

CECS System (L1 & 2) - Existing Utilities Subst.

8279

CECS System (L1 & 2) - Existing Butane Subst.

8281

Existing Effluent Treatment Subst. (82-ZE-103) - IR Cabinet

8282

Existing Utilities Subst.(82-ZE-104) - IR Cabinet

8283

Existing Seawater Subst. (82-ZE-105) - IR Cabinet

8284

Existing Butane Subst. (82-ZE-108) - IR Cabinet

8285

Process Subst. (82-ZE-114) - IR Cabinets

8286

Sales Gas Subst. (82-ZE-116) - IR Cabinet

8287

Main Intake Subst. (82-ZE-117) - IR Cabinet

8301

Emergency Generator (Process Trains Subst.)

8302

Emergency/Essential Power Distr.(Åsg. Intake Subst.)

8303

Emergency Power - Process Train Subst.

8304

Emergency Power - Sales Gas Subst.

8305

UPS - Grid Subst. (incl.Tie-in work)

8306

UPS - Åsgard Intake Subst.

8307

UPS - Refrig./Cavern Subst.

8308

UPS-ProcessSubst.

8309

UPS - Sales Gas Substation

8310

UPS-EPIISubst.

8311

UPS-BoknLVS


04-okt-2000 16:47Page: 7


CPNo:

Title:

8312

UPS - Effl.Treatment Subst./Distr.Panels in Åsgard Recv.LCR

8313

UPS in Ethane Recovery/Jetty LCR

8314

Emergency Power from Butane Subst. to 82-EN-560

8351

Butane Subst. - Exist. 83-EE-180

8352

Main Intake Subst. - Exist. 82-ED-502

8401

Earthing-RingMain

8402 8403

Earthing - Grid Substation (80-ZE-100) Earthing - Åsgard Intake Substation (82-ZE-117)

8404

Earthing - Refrig./Cavern Substation (82-ZE-106)

8405

Earthing - Process Substation (82-ZE-114)

8406

Earthing - Sales Gas Substation (82-ZE-116)

8407

Earthing - Jetty LCR (93-ZC-107)

8408

Earthing - EP II Substation (82-ZE-118)

8409

Earthing - Receiving Area LER (93-ZC-106)

8411

Earthing - Central Control Room (93-ZC-100)

8412

Earthing - Propane Cavern Top Area

8413

Earthing - EPII/Backflow Areas

8414

Earthing - Remaining Construction Areas

8415

Earthing-BoknLVS

85

Existing Seawater Subst.- Exist. 82-EM-350 (De-Comm)

8501

PCDA/ESD - Central Control Room (CCR)

8502

PCDA/ESD - Prop. Caverns/Propane Loading LCR

8503

PCDA/ESD-EPIILCR

8505

PCDA/ESD - Åsgard LCR (82-ZE-114)

8507

PCDA/ESD - Ethane Recovery/Jetty LCR

8509

Fiscal Metering - Statpipe Gas

8510

Fiscal Metering - Gasoline

8511

Fiscal Metering - Propane

8513

AllocationMeters

8519

Booster Compr. Upgrade - Instrumentation

8520

Machinery Monitoring System

8522

Pipeline Protection System (PPS)

8523

HIPPS - Sales Gas & Booster Compressors, EPII

8525

PCDA/ESD - Åsgard Recv. LCR (93-ZC-106)

8526

PCDA/ESD - Sales Gas LCR (82-ZE-116)

8529

PCDA/ESD - Aux Cabinet 15-ZC-100-XC02

8530

PCDA/ESD - Existing Butane/Refrigeration LCR

8601

PASystem(A&B)fromCER

8603

Communication -Bokn LVS

8604

Communication - Kalstø

8607

Telephone/Data Netw. - Tie-in to Exist.

8611

PA System (A&B) from Propane Cavern Subst.

8612

PA System (A&B) from EP II Subst.

8613

PA System (A&B) from Åsgard Process Subst.

8614

Data/Telephone Network in CER

8615

Data/Telephone Network in Åsgard Recv.LCR

8616

Data/Telephone Network in Propane Cavern Subst.

8617

Data/Telephone Network in Åsgard Main Intake Subst.


04-okt-2000 16:47Page: 8


CPNo:

Title:

8618

Data/Telephone Network in Åsgard Process Subst.

8619

Data/Telephone Network in Ethane Recv./Jetty III LCR

8620

Data/Telephone Network in Åsgard Sales Gas Subst.

8621

Data/Telephone Network in EPII Subst.

8622

Wind/Noise MeasuringS ystem

8888

Dummy System - Lighting Distr. (Module Yards)

8889 8900

Dummy System - Heat Tracing Distr. (Module Yards) Dummy System - Instr. JB's / Multicores (Module Yards)

9001

Site Preparation and Restoration

9002

Civils Foundations - O.S.B.L.

9003

Civils Foundations - Inner Area

9004

Civils Foundations - I.S.B.L.

9005

Civils Trenches/Culverts - O.S.B.L.

9006

Civils Trenches/Culverts - Inner Area

9007

Civils Trenches/Culverts - I.S.B.L.

9101

Roads, Walkways, Paving and Site Restoration

9202

TugBoatJetty

9203

Jetty3

9204

Crane 92-MA-101 on Tug Boat Jetty

9301

Building - Grid Substation(80-ZE-100)

9302

Building - Åsgard Intake Subst.(82-ZE-117)

9303

Building - Refrigeration/Caverns Subst.(82-ZE-106)

9304

Building - Process Trains Substation(82-ZE-114)

9305

Building - Sales Gas Substation(82-ZE-116)

9306

Building - Jetty LCR(93-ZC-107)

9307

Building - CCR Extension(93-ZC-100)

9308

Building - Europipe II Substation(82-ZE-118)

9309

Building - Receiving Area LER(93-ZC-106)

9310

Storavatn Pumphouse Extention

9311

Building - Effl. Treatment Subst.(82-ZE-103)

9312

O/HCrane-93-MA-212

9313

Building - Existing CCR Modification

9402

CCTV System from CCR Central Rack

9403

CCTV System from Propane Cavern Subst. Sub-Rack

9404

CCTV System from Åsgard Sales Gas Subst. Sub-Rack

9405

CCTV System from Bokn LVS.

9701

HVAC - Grid Substation (80-ZE-100)

9702

HVAC - Åsgard Intake Substation (82-ZE-117)

9703

HVAC - Refrigeration/Caverns Substation (82-ZE-106)

9704

HVAC - Process Trains Substation (82-ZE-114)

9705

HVAC - Sales Gas Substation (82-ZE-116)

9706

HVAC - Jetty LCR (93-ZC-107)

9707

HVAC - Central Control Room (93-ZC-100)

9708

HVAC - Europipe II Substation (82-ZE-118)

9709

HVAC - Receiving Area LER (93-ZC-106)

9710

HVAC - Effluent Treatment Substation

9713

HVAC - Booster Compressor Substation (82-ZE-113)

9714

Future HVAC - Electrical Supply


04-okt-2000 16:47Page: 9


CPNo:

Title:

9901

Miscellaneous Steel Structures

N/A

Not applicable to CP Nos (e.g. Preservation Dummy Tags)

T/IN

Tie-In Packages (Shutdown and Post-Shutdown)

NOTE : THIS LISTING IS FOR INFORMATION ONLY - REFER TO PIMS FOR COMPLETE CONTROLLED LISTING OF COMMISSIONING PACKAGES.

PIMS 97 -(Concept by Omega AS)

04-okt-2000 16:47Page: 10

Inspection & Test Record Index Kårstø Utbyggingsprosjekt

GENERAL MC FORMS

COW01

CarryOver Work List

HO C01

Handover Certificate

L UN01

Livening Up Notice

MAC01

Mechanical Acceptance Certificate

MSR01

Material Status Report (MSR)

P L01

Discipline Punch List

P L01B

Discipline Punch List ( Blank )

06-Oct-2000 14:58 Page: 1

MC Inspection & Test Record COW01 CarryOver Work List Rev : 0

COW List No :

Sheet

of

CP No:

Description : Equipment : :

Site

Item

Location/Area :

:

Date Drawing and Document ref. No

Description

MSR

Comments:

COW List Agreed:

Contractor

KUPConstruction

Other:-

KUPCommissioning

Name : Sign : Date : Printed: 6-Oct-00 13:38

Handover Certificate ( HOC01 ) Rev : A

Comm Pack: Description: Statement:

It is hereby certified that the system referenced, has been mechanical completed in accordance with drawings, specifications, inspection and test records, with the exception of outstanding work according to attached Multi-Discipline Punch List. The referenced system is ready for Commissioning. System Description:

Part System Description:

Comments / Qualifications:

KUPConstruction Prepared by :

Approved by :

KUPCommissioning Accepted by :

Accepted by :

Name : Sign : Date : PIMS arpt 97 -(Concept by Omega AS)

09-Oct-2000 12:15

MC Inspection & Test Record MAC01 - Mechanical Acceptance Certificate

Comm Pack

MC Discipline Pckg No : Description :

Discipline

: Site

Location/Area

: Date

Statement :

It is hereby certified that the equipment referenced, has been inspected, tested and mechanically completed in accordance with the attached inspection and test records, but with the exception of outstanding work according to attached Punch List. ( If applicable ) Punchlist Attached: Yes Description of plant / equipment :

No

Comments :

Prepared/A cce ptedby:

A cceptedby:

C o n t r ac t o r

A ccept edby:

K U PC on struct i on

A ccepte dby:

O th er :-

K U PC omm i ssi on i n g

Name :

Name :

Name :

Name :

Sign :

Sign :

Sign :

Sign :

Date :

Date :

Date :

Date :

Rev : A

Date/Time: 9-Oct-00 13:50

Muliti Discipline Punch List Master MDPL Multi Discipline PunchList ( Blank ) MDPL No : MDIt em Or ig ina l PL No

Item

Ob ject ID

Pr ep a r ed

Disc Des cr i p t i o n

Cat

Ch eckeBdy

A g r e ebdy

Lo c a t i o n

Resp

Ac t i o n

C lea red

C he c k e d

Ag r e ebdy

Name : Sign : Date : Rev : 0

Date/Time: 9-Oct-00 13:13

Page: 1

MC Inspection & Test Record MSR01 Material Status Report (MSR) Rev : 0

Site:

Module Equipment: /

Item

Contractor

Ref. MSR / COW List No:

Date:

M a t e r i a lD es c r i p t i o n

P .O .N o .

KUP Construction

Other:-

Order Date

Responsible for ordering Delivery Shipped Equipment Loose Marking Sub Cont ractor Cont ractor Date

KUP Commissioning

Name : Sign : Date : Report: arpt_Completion_Cert-MSR

Date/Time: 9-Oct-00 13:47Page: 1

MC Inspection & Test Record PL01 Discipline Punch List

Punch List No :

Commissioning Package :

Discipline :

Responsible SubContractor :

Description : Item

Description

Object ID:

Punchlist Agreed:

Contractor

Cat Req'd A/B PreTst

KUPConstruction

Other:-

Cleared S i gn & D at e

Checked S i gn & D a t e

KUPCommissioning

Name : Sign : Date : Cert Rev.No: 0

Printed: 9-Oct-00 14:11

MC Inspection & Test Record PL01B Discipline Punch List ( Blank )

Punch List No :

CP No :

(Same as MC Pack )

Responsible SubContractor :

Sheet

Discipline :

of

Description : Item

Description

Cat Req'd A/B PreTst

SubContractor Cleared

Contractor Cleared

Sign Date

Sign Date

Comments:

Punchlist Agreed:

Contractor

KUPConstruction

Other:-

KUPCommissioning

Name : Sign : Date : Rev : A



ELECTRICAL MC FORMS

E01

Generator

E02

Transformer

E03

Electric Motor

E04

Outgoing Unit - Switchgear

E05

Switchgear

E06

Low Voltage Distribution Board

E07

Charger/Inverter

E08

Reactor/Resistor

E09

Heater

E10

Bus-Duct

E11

Control Panel

E12

Batteries

E14A

Electrical Junction Boxes - By MC Package

E14B

Junction Boxes by Circuit

E14C

Electrical Junction Boxes - By Tag

E15A

Lighting Fixtures - By MC Package

E15B

Lighting Fixtures - By Circuit

E15C

Lighting Fixtures

E16A

Socket Outlets/Isolators - By MC Package

E16B

Socket Outlets / Isolators - By Circuit

E17

High Voltage Cable

E18A

LV Electrical Cable - By Cable No.

E18B

LV Electrical Cables - By MC Package

E18C

LV Electrical Cables - By Circuit

E19

Earth Loop Resistance

E20

Underground Cableworks Release

E21

Heat Tracing Installation & A-Test

E22

Heat Tracing Cable B-Test

E23

Heat Tracing Circuit (C-Test)

E30

Electrical - Area Acceptance

06-Oct-2000 14:58 Page: 2

Document Title: MC Manual Instruction - Testing of Electrical Equipment Doc.N o.: E060-SB-M-YA0001 MWKLJobNo.5622 Rev.No.:A Rev.Date:05.10.00 Page 1 o9 _____________________________________________________________________________ 1

INTRODUCTION

The testing of electrical items, as required by the specifications, shall be performed by the responsible contractor. The requirements in the Check Lists and Test Records for electrical discipline in this manual are theover minimum requirements to be completed, prior to electrical equipment being handed to Company for performance of Commissioning and Start-up. 2

GENERAL

The Contractor shall be responsible for performing all tests and checks as required to provide a safe, reliable and functionally sound electrical installation. Where applicable, the test requirement specified herein shall be conducted in accordance with the manufacturer’s instructions or under the supervision of a manufacturer’s representative when equipment warranties could otherwise be voided. Details of procedures for testing including additional tables and forms for recording results, shall be submitted to Company for approval. Company reserves the right to witness all tests and functions. Contractor shall inform Company when the various tests are going to take place. All test equipment shall be provided by Contractor, as defined in their respective contracts and be subject to approval by Company. All testing and equipment operation shall be executed in a safe manner in accordance with procedures stated in ‘Prosedyresamling Elektro/Automasjon’. Periodic clean-up of indoor equipment areas, especially electrical rooms, shall be performed during construction. As part of the final hand over, Contractor shall thoroughly clean the areas, including dusting and vacuuming of equipment enclosures on both outside and inside, to ensure that the equipment is completely free of dust and other contaminants which could affect performance and reliability of live equipment. 3

3.1

TESTING

HV Cables All the 6,6kV and 22kV cabling shall be high voltage tested using DC on completion of glanding and with braiding earthed, but before connection to equipment is made at either end.

The positive pole of the test equipment shall be earthed and the negative pole of the test equipment shall be connected to the conductor under test. The remaining conductors of a 3 x Core cable shall be earthed. The test procedure and test voltage for high voltage cables shall be in accordance with IEC 502, Section 14.4 and 18.

Document Title: MC Manual Instruction - Testing of Electrical Equipment Doc.N o.: E060-SB-M-YA0001 MWKLJobNo.5622 Rev.No.:A Rev.Date:05.10.00 Page 2 o9 _____________________________________________________________________________

The test voltage shall be increased slowly until the test value is obtained and then maintained at this value for 5 minutes (after leakage current have stabilised). On equipment where no disconnection of cable cores is possible, an approval shall be obtained from the supplier of the equipment to allow the test voltage to be applied to the equipment terminals for the time specified. 3.2

Electrical Equipment

High-voltage pressure testing of electrical equipment, except cables, shall be carried out at the manufacturer’s works with AC at voltage levles in accordance with the relevant IEC publications. As repeated exposure to excessively high voltages may introduce weak points in the insulation of windings, such tests shall not be applied at site to generators, motors, or transformers. If however, for special reasons these tests are considered necessary, written approval from the manufacturer shall be obtained prior to the tests being performed. All equipment containing insulation oil, such as transformers, circuit breakers etc., shall have the oil dialectically tested. The test shall be according to IEC 295. Insulation necessary.oil with too low breakdown voltage shall be properly filtered or replaced where 3.3

HV Switchgear

Site tests and inspections shall be carried out in accordance with suppliers’ instructions. HV testing shall be carried out in accordance with IEC 298 and IEC 60. The voltage transformers shall be isolated and all incoming and outgoing cables shall be disconnected. Padlocking of circuit breakers / contactors shall be used. All necessary precautions shall be taken to prevent the circuit breakers / contactors from being operated without authorisation from the Electrical Manager (‘Driftsleder’). The high voltage tests of the main power circuit shall be carried out on each phase with the remaining two phases connected to earth. For the test, one pole of the testing supply is connected to earth and to the frame of the equipment under test. 3.4

Insulation Resistance Tests (IR)

The connections used for insulation resistance tests shall be similar to the ones used on high voltage testing. A 5000V Megger shall be used for testing the 6,6kV switchgear, and a 1000V Megger shall be used on the majority of the other applications. The minimum applicable insulation values shall be as follows :

Document Title: MC Manual Instruction - Testing of Electrical Equipment Doc.N o.: E060-SB-M-YA0001 MWKLJobNo.5622 Rev.No.:A Rev.Date:05.10.00 Page 3 o9 _____________________________________________________________________________ Description of Equipment 6,6kVequipment 600V and 440V equipment ControlCircuits Lowvoltageequipment

Minimum Insulation Value 20Megaohms 10 Megaohms 10Megaohms 1Megaohm

The measured voltage level. insulation resistance will increase if the test is carried out at a lower For the correct comparative interpretation of test data, consequent tests on electrical equipment shall be carried out at the same voltage level. The measured resistance value is also dependent on the temperature of the insulation. See Appendix 1 – ‘Nomogram for temperature correction’. Insulation resistance testing of electric motors shall, for motors with system voltage greater than or equal to 1000V, include the determination of polarization index. This index is the ratio between the insulation resistance measured after 1 minute and the ratio measured after 10 minutes of continuous testing at the appropriate voltage. See Appendix 2 – ‘Typical curves for variation of insulation resistances’. 3.5

Polarisation Index

If the insulation resistance test for the motor / generator / power transformer windings are below the minimum acceptable value, the Polarisation Index shall also be measured. The polarisation index is obtained by use of Megger. Use the Megger for reading of IR between U, V, W to E with neutral disconnected, i.e. all three phases linked together. Log the readings after 1 minute and after 10 minutes. The ratio of the 10 minutes value and the 1 minute value is the Polarisation Index. Insulation Condition Excellent Good Fair Questionable Poor

10:1 min. ratio 4> 3 2 1,5 to 2 1,5 <

4 to 3 to

The listed values are for guidance. Large rotating machinery with a high number of surface leakages may have a P.I. 25% lower that the above values.

3.6

Equipment General

Tests shall be performed to prove the proper function of all generators, emergency generators, transformers, circuit breakers, relays, motor control equipment, motors, motor-operated valves, distribution systems, heating and ventilation systems, lighting systems, all control circuits, interlocks and alarms.


Checks shall be performed to measure resistance of grounding systems and ground continuity where applicable. Checks for correct phase rotation and marking of buses and cables. Checks for correct installation of earthing, cable termination, glands, cable transits, cleating of cables, sealing of local panels and junction boxes, proper greased flanges, nuts, bolts and washers, anti-corrosion treatment etc. Check illumination level and area lighting requirements to ensure installations conform to requirements. Check that all equipment nameplates, instruction signs and circuit directories are installed. Also tagging for identification purposes of all cables and conductors routed through cable transits and ending in junction boxes of equipment shall be in accordance with applicable installation drawings and specification. 3.7

Motors All motors shall be checked for proper lubrication of the motor bearings.

Motor insulation resistance shall be measured using a megaohmmeter prior to motor being connected to it’s supply conductors. Each motor shall be checked for correct direction of rotation. Before coupling, motors rated 100kW or higher shall be given a four hour no-load run. During the running period the motor shall be checked periodically for excessive noise, vibration and overheating of the bearing housing and motor frame. Anti-condensation heaters shall be checked for proper function. 3.8

Swithgear and Motor Controllers

The insulation resistance of switchgear and motor control equipment shall be tested in accordance with manufacturer’s recommendations before completing the associated wiring and cable terminations. Tests will normally consists of insulation test between each phase and ground and between phases. Before livening up the system, a final insulation test for the entire system shall be obtained. Bolted bus joints, terminals and other connections for each separate equipment installation shall be checked for tightness on a selected basis. All control circuits shall be 100% function-tested. Protection relays shall be set and tested in accordance with the relay studies. Relays having an operating characteristic, which varies with time, shall be tested to verify conformity with manufacturer’s data. Thermal overload relays used for motor protection shall be individually checked to ensure correct setting according to motor nameplate full-load current.


Other devices having variable timing characterisitics, such as time delay relays, shall be set and tested in accordance with intended control function.

3.9

Relay Testing

Relay testing can be carried out by using primary injection or secondary injection current. During initial testing, primary injection testing should be used, as this test includes the whole circuit. However, since the primary current availability is limited, relays cannot be checked at high current. Secondary injection testing is therefore recommended as well. This will in addition provide reference data for future routine testing, in which secondary injection testing will suffice. A test at the selected relay setting should also be included where the relay should be allowed to trip the circuit breaker or contactor. Relay contacts should not be interfered with unless they are obviously corroded. After each test it shall be verified that the actual relay setting is in accordance with the setting laid down in the overall protection scheme of the power system. It is recommended that the relay shall be provided with an adhesive label, indicatiing the selected setting and the latest test date. Insulation tests shall be carried out on the relay wiring using a 500V tester. Care shall be taken to disconnect any electronic circuits before testing. 3.10 System Phasing Testing Phase testing of circuits shall be carried out by using appropriate phasing sticks. 3.11 Generator Synchroscope Testing A generator synchronising system can be tested by using phasing sticks or voltage transformers.

Preference is given to the method of energising both the ‘running’ and ‘incoming’ system from the same source. The alternator is open-circuited either at the main terminals or at the neutral poit. See Appendix 3 - ‘Generator Synchronising System Testing’ The test proved the synchroscope, the secondary wiring connections and the voltage transformers complete. It the synchroscope / V leads are subsequently removed for any purpose, the synchronising system shall be tested again. 3.12 Conductivity Testing

Conductivity tests shall be carried out with low resistance test set, e.g. a ducter with at


least 20DC. The measured voltage drops shall be interpreted on a comparative basis. For identical connections / circuits the measured values shall not differ by more than 20% from each other. 3.13 Earth Resistance Testing

The resistance to earth of an earthing system or earth mat shall be tested with the external cabling disconnected. The resistance of separate system shall be lower than : -

1 Ohm for electrical system and equipment earthing. 1 Mohm for static discharge earthing.

3.14 Insulation Oil Testing

Electrical withstand test shall be carried out using a standard oil testing apparatus with 25mm diameter mushroom-shape electrodes at a distant of 2,5mm apart. The minimum withstand voltage for one minute without breakdown shall be 40kV, i.e. 160kV/cm. In contradiction to IEC 422 – ‘Maintenance and supervising guide for insulating oils in service’, this value shall apply to all equipment, including switchgear, up to a system voltage level of 36kV for new as well as used/filtered oil.

4

ATTACHMENTS

4.1

Appendix 1 – Nomogram for temperature correction.

4.2

Appendix 2 – Typical curves for variation of insulation resistance.

4.3

Appendix 3 – General synchronising system testing.

5

REVISI ON CHA NGE RECORD

Rewritten post project for MC Handbook. Only minor changes implemented.

Document Title: MC Manual Instruction - Testing of Electrical Equipment Doc.N o.: E060-SB-M-YA0001 MWKLJobNo.5622 Rev.No.:A Rev.Date:05.10.00 Page 7 o9 _____________________________________________________________________________ Appendix 1 – Nomogram for temperature correction.

Document Title: MC Manual Instruction - Testing of Electrical Equipment Doc.N o.: E060-SB-M-YA0001 MWKLJobNo.5622 Rev.No.:A Rev.Date:05.10.00 Page 8 o9 _____________________________________________________________________________ Appendix 2 – Typical curves for variation of insulation resistance.

Document Title: MC Manual Instruction - Testing of Electrical Equipment Doc.N o.: E060-SB-M-YA0001 MWKLJobNo.5622 Rev.No.:A Rev.Date:05.10.00 Page 9 o9 _____________________________________________________________________________ Appendix 3 – General synchronising system testing.

MC Inspection & Test Record E01 Generator Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

Rating (kW)

P.O. Package

Drwg.Ref.

Supplier

Duty

DataSheet

Remarks

Item:

OK N/A PL Result/Data:

1

Warni n g ! : E nsure E quipment in De -E n ergised S tate.

1.01 2

Check for no voltage and proper earthing applied. Te s t i n g by M a n u f a c t u r e r :

2.01 2.02 2.03 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09

Confirm tested in accordance with Manufacturer's instructions and under their supervision. Confirm Manufacturer's Testform Reference No. Attach copy of Manufacturer's Testform. I n s pe ct i on Ch ec k l i st : Check against data sheet including nameplate/rating plate details. No mechanical damage. Nofluidleaks. Nutsandboltstight. Paintworkgood. Glanding correct and tightened. Protection of 'Live' parts correct. Earthing correct and securely tightened. Instruments correctly installed and tagged.

3.10 3.11

Heatersc orrectlyi nstalled. All labelling and warning marks correctly installed and visible.

3.12 3.13 3.14 3.15 3.16

All cabling and auxilliary wiring neat, undamaged and in accordance with drawings/documentation. Terminal blocks correctly marked and segregated. Tag No. visible and correct. Safety devices correctly installed and accessible (e.g. Emergency Stop) CEMarkinplace.

3.17 4 4.01 4.02

A ddi t i on al C h ec k l i s t f o r C o n t ai n er i se d Un i t s :

Unit lighting correctly installed. Cable transits correctly i nstalled and tightened.

Comments:

Note : 'Tick all Check Item columns under OK - Satisfactory; N/A - Not Applicable; PL - Punch Item(s) against check point. Also record Test Results or Data'

Contractor Name : Sign : Date :

KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E02 Transformer Rev : C

Tag No:

CP No:

Descr:

MC No:

Location

Drwg.Ref

P.O.Package

Duty

Supplier

Remarks

Datasheet

Item:


1

Warn i ng! : E n sure Equipmen t i n De-E n ergised State.

1.01 2


2.01 2.02 2.03 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09

Confirm tested in accordance with Manufacturer's instructions and under their supervision. Confirm Manufacturer's Testform Reference No. Attach copy of Manufacturer's Testform. I n s pe ct i on Ch ec k l i st : Check against data sheet including nameplate/rating plate details. No mechanical damage. Nofluidleaks. Nutsandboltstight. Paintworkgood. Glanding correct and tightened. Protection of 'Live' parts correct. Earthing correct and securely tightened. All labelling and warning marks correctly installed and visible.

3.10 3.11

All cabling and auxilliary wiring neat and undamaged. Terminal blocks correctly marked and segregated.

3.12 3.13 3.14 3.15 3.16

Cooling fans correctly installed. Oillevelcorrect. Silica gel breather checked. Drainage system checked. Tapsetcorrect.

3.17 3.18 3.19 3.20

Tag No. visible and correct. CEmarkinplace.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E03 Electric Motor Rev : D

Tag No.

CP No:

Description.

MC No

Location Supplier

Item:


01

Warn in g! : E n sure E qui pm en t i n D e-E nergi sed S tate.

01.01 02

Check for no voltage and proper earthing applied. M o to rD at a:

02.01 02.02 02.03 02.04

Record Motor Serial Number Datamotor. Manufacturer. kW.

02.05 02.06 02.07 02.08 02.09 02.10 02.11

Voltage. Current. Powerfactor. Revolution. la/lnfactor. G1/T1 : Record TE value. G2/T2 : Record TE value.

02.12 02.13 02.14 02.15

G3/T3 : Record TE value. G4/T4 : Record TE value. Record Ex-Certificate No. Confirm Ex label affixed.

02.16 02.17 03

Record type of Ex protection. Check equipment against data sheet including nameplate/rating plate details. I n sp ec t i o n Ch e ck l i s t :

03.01

No mechanical damage.

03.02 03.03 03.04 03.05 03.06 03.07 03.08 03.09 03.10

Nofluidleaks. Nuts and bolts tight. Paintworkgood. Terminal boxes correct. Cable termination and glanding correct. Earthing correct and securely tightened All labelling and warning marks correctly installed and visible. Tag No. visible and correct. Motor free to turn by hand.

03.11 03.12 04 04.01

All unused cable entries correctly plugged. CEmarking in place. N o t es: Tests marked (A) for motors with system voltage over 1000 V.

04.02 06 06.01 06.02 06.03 06.04

Tests marked (B) may be waived for motors below 30kW rating driving centrifugal pumps. In sulati on Re si stance Tests (Be fore Cabl e Con nected) :

07 07.01 07.02 08

In sulati on Resi stance Tests (Aft er Cabl e Co nnected) : Check c ableconnection c orrect. Insulation resistance motor + cable (phase to earth) (Mohm) E ar th i n g:

08.01 09 09.01

Check the condition of earthing connection at motor and control unit. S p e c i al I t e m s :

09.02

Test voltage (V DC). Insulation resistance of motor (phase to earth) :- After 1 m in (Mohm) (A) Insulation resistance of motor (phase to earth) :- After 10 min (Mohm). See Test Instructions. (A) Insulation resistance of motor (phase to earth) :- Polarisation index. See Test Instructions.

Check anti-condensation heater. Test and record results of insulation resistance of heater at 500 V - (Mohm)


Contractor

KUPConstruction

Other:-

KUPCommissioning

Name : Sign : Date : Sheet 1 of 2


MC Inspection & Test Record E03 Electric Motor Rev : D

Tag No.

CP No:

Description. 09.03 09.04 10 10.01 10.02 10.03 10.04 10.05

MC No

Test and record results of insulation resistance of temp.detector at 500 V - (Mohm) Confirm basic inspection sheet completed. U n co up l e dR un Record rotation from NDE. (B) Measure vibration and reference sheet no. (B) Record maximum vibration reading (DE/NDE). Record starting time (if over 1 sec.). Record starting current (Amps).

10.06 10.07

Record no-load current (Amps). Record bearing temperature (motors below 30kW : 30min, over 30kW : 210min).

Comments:

Table 1: Min.

Time (min)

0

30

60

90

120

150

180

210

Temperature DE (deg Celcius) Temperature NDE (deg Celcius) Ambient Tempe rature (deg C elcius)

Table 2: Test Record

I N x3

I N x5

I

N

x factor

Measured motor current

Setpoint thermal relay

Date

Sign

I N / 1N Trip Time Trip Time Trip Time Trip Time Trip Time Trip Time Trip Time Trip Time Trip Time Note : 'Tick all Check Item columns under OK - Satisfactory; N/A - Not Applicable; PL - Punch Item(s) against check point. Also record Test Results or Data'

Contractor

KUPConstruction

Other:-

KUPCommissioning

Name : Sign : Date : Sheet 2 of 2


MC Inspection & Test Record E04 Outgoing Unit - Switchgear Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

Distr. Board

P.O. Package

Circuit No

Data Sheet

Arrgm. Drwg.

Supplier

Remarks

Item: 1

OK N/A PL Result/Data: C h eck l i s t & Tes t R es ul ts :

1.01 1.02

Check circuit labelling. Check for mechanical damage.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 2 2.01 2.02 3 3.01 3.02

Check door interlock. Check mechanical position indication. Check electrical closing local/remote. Check electrical trippel local/remote. Check alarm i ndicatorslocal/remote. Check secondary auxilliary wiring. Tag No. visible and correct. E art h i n g: Check the condition of earthing bar and connections. Test the earthing bar contiuity (Mohm). In sulati on R esi stan ce Test o f S wi tch in g D evice at 1 000 V TestPhaseR (MOhm) TestPhaseS (MOhm)

3.03 4

TestPhaseT( MOhm) Pr o t e c t i o n R e l a y I n s p e c t i o n / Te s t

4.01 4.02 4.03 4.04 4.05

Confirm/Record manufacturer. Confirm/RecordT ype. Contactorrating. Trip setting range (A). Primary i njection test at selected trip setting (A).

4.06 4.07 4.08 4.09

Earth-fault relay setting (A). Measured pick-up current (A). Setting After Test : Earth-fault relay setting (A). Setting After Test : Setting sealed (A).

4.10 5 5.01 5.02 5.03

Auto reset. C onfirm YES/NO Fu se s Confirm/Record fuse class. Confirm/Record fuse rating. Confirm/Recordf usecondition.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E05 Switchgear Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

Fed From

P.O. Package

Single Line Drwg.

Data Sheet

Arrgm. Drwg.

Supplier

Remarks

Item:


1


1.01 2


2.01 2.02 2.03 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09

Confirm tested in accordance with manufacturer's instructions and under their supervision. Confirm Manufacturer's Testform Reference No. Attach copy of Manufacturer's Testform. I n s pe ct i on Ch ec k l i st : Check installed equipment against data sheet. No mechanical damage. Paintworkgood. Nutsandboltstight. All busbar connections correctly tightened. Earthingcorrect Earthing securely tight. Phase identification correct. Protection of 'Live' parts correct.

3.10 3.11

Instruments correctly installed. Voltage and Current transformers correctly installed.

3.12 3.13 3.14 3.15 3.16

All labelling and warning marks correctly installed and visible. Contactors, relays, protection relays etc correctly installled and in accordance with drawings. All cabling and auxilliary wiring neat and undamaged. Terminal blocks correctly mounted and segregated. Tag No. visible and correct.

3.17 3.18

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E06 Low Voltage Distribution Board Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

DistBoardTag

P.O. Package

CircuitNo

Data Sheet

Arrgm. Drwg

Supplier

Remarks

Item:


1


1.01 2

Check for no voltage and proper earthing applied. D at:a

2.01 2.02 2.03 2.04 2.05 3

Record Serial Number of Distribution Board if there is an EX requirement. Confirm Ex label affixed. Record Ex-Certificate No. (if applicable). Record Type of Ex protection. Complies with Area Classification. I n s pe ct i on Ch ec k l i st :

3.01 3.02 3.03 3.04 3.05 3.06 3.07

Check installed equipment against data sheet. No mechanical damage. Paintworkgood. Nutsandboltstight. Earthingcorrect. Earthing securely tight. Earthing barcorrect.

3.08 3.09

Terminals correctly mouted and segregated. Phase identification correct.

3.10 3.11 3.12 3.13 3.14

Busbars and connecting links tight. All labelling and warning marks correctly installed and visible. All cables and wiring neat and undamaged. Protection of 'Live' busbars and spouts correct. Megger Test performed.

3.15 3.16 3.17 3.18

Protection equipment correct. Tag No. visible and correct. Check panels, doors, locks and that keys available. Auxilliary contactors and relays correctly installed.

3.19 3.20 4

All cabling and auxilliary wiring neat and undamaged. Terminal blocks correct. Pr o t e c t i o n R e l a y I n s p e c t i o n / Te s t

4.01 4.02 4.03 4.04 4.05 4.06 4.07 4.08 4.09 5 5.01 5.02

Confirm/Record manufacturer. Confirm/RecordT ype. Contactorrating. Trip setting range (A). Primary i njection test at selected trip setting (A). Earth-fault relay setting (A). Measured pick-up current (A). Setting After Test : Earth-fault relay setting (A). Setting After Test : Setting sealed (A). Fu se s Confirm/Record fuse class. Confirm/Record fuse rating.



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E07 Charger/Inverter Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

Fed From

P.O. Package

Drwg Ref

Data Sheet

Drwg Ref

Supplier

Remarks

Item:


1


1.01 2


2.01 2.02 2.03 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09

Confirm tested in accordance with manufacturer's instructions and under their supervision. Confirm Manufacturer's Testform Reference No. Attach copy of Manufactuer's Testform. I n s pe ct i on Ch ec k l i st : Check i nstalled equipment against data on single line diagram. No mechanical damage. Paintworkgood. Nutsandboltstight. All busbar connections correctly tightened. Earthingcorrect. Earthing securely tight. Phase identification correct. Protection of 'Live' parts correct.

3.10 3.11

Instruments correctly onstalled. Contactors, r elays a nd f uses c orrectly i nstalled.

3.12 3.13 3.14 3.15 3.16

All labelling and warning marks correctly installed and visible. All cables and auxiliiary wiring neat and undamaged. Terminal blocks correctly mouted and segregated. Glanding correct and tighted Tag No. visible and correct.

3.17 3.18 3.19

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E08 Reactor/Resistor Rev : 0

Tag No:

CP No:

Descr:

MC No:

Location

Duty

P.O. Package

Single Line Drwg

Datasheet

Dwg Ref

Supplier

Remarks

Item:


1


1.01 2


2.01 2.02 2.03 3 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09

Record Serial Number of Reactor/Resistor if there is an Ex requirement. Record Reactor/Resistor Ex-Certificate No. applicable. Record Type of Ex-certifcation for Reactor/Resistor. I n s pe ct i on Ch ec k l i st : Check i nstalled equipment against data on single line diagram. No mechanical damage. Paintworkgood. Earthingcorrect. Earthing securely tight. Nutsandboltstight. Nofluidleaks. Complies with Area Classification. Tag No. visible and correct.

3.10 3.11

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E09 Heater Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

Duty

P.O. Package

P & ID

Datasheet

Dwg

Supplier

Distr. Board

Item:


1


1.01 2

Check for no voltage and proper earthing applied. D at a-H eater:

2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 3 3.01 3.02 3.03

Record Serial Number of Heater if there is an Ex requirement. Confirm Ex label affixed. Record Heater Ex-Certificate No. applicable. Record Type of Ex protection for Heater. Record Serial Number of Safety Thermostat. Record Safety Thermostat Ex-Certificate No. applicable. Record Serial Number of Operational Thermostat. Record O perational Th ermostat Ex -Certificate No . ap plicable. Complies with Area Classification. I n s p e c t i o n C h e c k l i s t - H e at e r : Check i nstalled equipment against data on single line diagram. No mechanical damage. Paintworkgood.

3.04 3.05

Earthingcorrect. Earthing securely tight.

3.06 3.07 3.08 3.09 3.10

Nutsandboltstight. Nofluidleaks. Tag No. visible and correct. Safety devices connected and correctly set Cable terminations and glanding correct.

3.11 4 4.01 4.02 5 5.01 5.02 6 6.01 6.02 6.03 6.04 6.05 7

Unused cable entries correctly plugged. Te s t i n g ( H e a t e r ) :

7.01 7.02 8

Test for proper operation of safety thermostat. Test f or proper o peration of o perational t hermostat. R e c o r d S e t t i n gs ( Th e r m o s t a t s ) :

8.01 8.02

Meggertestresult. Continuity test through elements result. D a t a - Th e r m o s t at : Record Serial Number of thermostat. Record Ex-Certificate No. Applicable. I n s p e c t i o n C h e c k l i s t - T h e r m o s t at : Check correct thermostat installed according to drawing and area classification. Labelling / numbering / ferruling correct. Thermostat mechanically sound, solidy and correctly mounted. Capillary installed correctly and mechanically sound. Tag No. Visible and correct. Te s t i n g ( T h e r m o s t a t s ) :

Record set point of safety thermostat. Record set point of o perational thermostat.



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E10 Bus-Duct Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

Duty

P.O. Package

Single Line Drwg

Datasheet

Dwg

Supplier

Distr. Board

Item: 1

OK N/A PL Result/Data: I n s pe ct i on Ch ec k l i st :

1.01 1.02 1.03 1.04 1.05 1.06 1.07 2

Check Tag No., Voltage and Current rating. Check for any apparent damage / missing parts. Check bus insulator suports for cracks or dirty condition. Check shipping blocks and supports removed. Check that bus-duct is clean and free of debris. Check bus enclosure for correctness of mechanical assembly, support and alignment. Check gaskets, wall seals installed correctly. TestC h eck s:

2.01 2.02 2.03 2.04 2.05

Check torque bus-bar bolts according to specification. Check for proper phasing after installation. Megger busandrecord. Test earthing bar continuity.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E11 Control Panel Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

Duty

P.O. Package

Single Line Drwg

Datasheet

Dwg

Supplier

Distr. Board

Item:


1


1.01 2


2.01 2.02 2.03 2.04 2.05 3

Record Serial Number of Control Panel if there is an Ex requirement. Confirm Ex label affixed. Record Ex-Certificate No. (if applicable). Record Type of Ex protection. Complies with Area Classification. I n s pe ct i on Ch ec k l i st :

3.01 3.02 3.03 3.04 3.05 3.06 3.07

Check installed equipment against data sheet. No mechanical damage. Paintworkgood. Nutsandboltstight. Earthingcorrect. Earthing securely tight. Protection of 'Live' parts correct.

3.08 3.09

All labelling and warning marks correctly installed and visible. All cables and wiring neat and undamaged.

3.10 3.11 3.12 3.13 3.14

Terminal blocks and segregation plates correct. Segregation of different voltage correct. Anti-condensation heater correctly installed. Protection equipment correct. Tag No. visible and correct.

3.15 3.16

Check panels, doors, locks and that keys available.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E12 Batteries Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

:

Duty

:

P.O. Package

:

Single Line Drwg

:

Datasheet

:

Dwg

:

Supplier

:

Distr. Board

:

Item:


1 1.01 1.02

I n s pe ct i on Ch e ck l i st : Check installed equipment against data sheet. Nomechanical damage.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12

Check that all connections are tight and anti-corrosive coating (acid free vaseline) is provided. All cells correctly installed. Cables correctly installed. Protection of 'Live' parts correct. All labelling and warning marks correctly installed and visible. Alli ntercellc onnectionsi nstalled. Check liquid level of each cell. Check the cells for leakage. Test the insulation resistance to earth. For lead acid batteries :- Test and record the specific gravity of the electrolyte in each cell (results below). For alkaline batteries :- Test the open circuit voltage of e ach cell with di gital voltmeter (results below). Tag No. visible and correct. D i s c h ar g e T e s t ( C ) ( M ) : Record discharge start (h). Record discharge finish (h).

1.13 1.14 2 2.01 2.02 2.03 2.04 2.05

Recordtotal(h). Record discharge current (A). Record capacity (Ah).

Comments:

Time Terminal Voltage Discharge (A) Room Temperature (deg Celcius) Specific Gravity / mV per C ell :

Cell No.1 Cell No.2 Cell No.3 Cell No.4 Cell No.5 Cell No.6 Note : 'Tick all Check Item columns under OK - Satisfactory; N/A - Not Applicable; PL - Punch Item(s) against check point. Also record Test Results or Data'

Contractor Name : Sign : Date : #Error

KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E14A Electrical Junction Boxes - By MC Package

Rev : A

MC Package :

CP No:

Description : Item:

1.02 1.03 1.04

Labelling / numbering / ferruling correct. Junction box mechanically sound, solidly and correctly mounted. Correct type of cable glands and glands tightened.

1.11 1.12 1.13 1.14 1.15

Cablesc orrectlyc leated. Terminal blocks are correct type, mechanically sound, mounted and segrated correctly. Junction box located correctly to allow easy access for maintenance. Mounting rail f or PE-Terminals is made of copper (Cu). Drainp lugi nserted.

1.05 1.06

Earthing / bonding / shrouding correct. Terminationcorrect.

1.16 1.17

Confirm Ex lables affixed (where applicable) Tag No. Visible and correct.

1.07 1.08

Spare holes plugged (i.e. unused cable entries). All nuts, bolts and washers in place and secure.

1.18 1.19

Check correct thermostat installed according to drawing and area classification. Thermostat mechanically sound, solidy and correctly mounted.

1.09 1.10

All wiring neat and tidy. Gaskets in place and correct.

1.20 1.21

Capillary in stalled correctly a nd mechanically so und. CEmarkinplace.

1 1.01

I n s p e c t i o nC h e c k l i s t: Check correct junction box installed according to drawing and area classification.

Cable No

Ch ec ked

Junction Box

De sc ri pt io n

Serial No

Ex-Cert

Thermostat ( if applicable ) SerialNo

Ex-Cert

TestSafety Thermostat

ACCEPTANCE

Contractor

KUP Construction

Other:-

Test

Set Point

Set Point

Operational

Safety Therm

Operational

KUP Commissioning

Name : Sign : Date : 05-Oct-2000 09:02

Page: 1

MC Inspection & Test Record E14B Junction Boxes by Circuit Rev : 0

CP No:

MC Package : Description : Distribution Board :

CircuitNo:

SystemVoltage:

Item: 1

I n sp ec t i o n Ch e ck l i s t :

1.01 1.02 1.03

Check correct junction box installed according to drawing and area classification. Labelling / numbering / ferruling correct. Junction box mechanically sound, solidly and correctly mounted.

1.04 1.05

Correct type of cable glands and glands tightened. Earthing / bonding / shrouding correct.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Termination correct. Spare holes plugged (i.e. unused cable entries). All nuts, bolts and washers in place and secure. All wiring neat and tidy. Gaskets in place and correct. Cables correctly cleated. Terminal blocks are correct type, mechanically sound, mounted and segrated correctly.

1.13 1.14 1.15

Junction box located correctly to allow easy access for maintenance. Mounting rail for PE-Terminals is made of copper (Cu). Drain plug inserted.

1.16 1.17 1.18 1.19 1.20 1.21

Confirm Ex lables affixed (where applicable) Tag No. Visible and correct. Check correct thermostat installed according to drawing and area classification. Thermostat mechanically sound, solidy and correctly mounted. Capillary installed correctly and mechanically sound. CEmarkinplace.

Comments: Object ID

Checked

Record S eri al No

Record E x. Ce rti fi cate No

Protection Type

Remarks

Note : As-Built Block Diagram sketch ( as required ) or red-line marked up drawings to be attached. Contractor

KUPConstruction

Other:-

KUPCommissioning


MC Inspection & Test Record E14C Electrical Junction Boxes - By Tag Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

Layout Drwg

P.O. Package

Distr. Board

Data Sheet

Circuit No

Supplier

Remarks

Item: 1

OK N/A PL Result/Data: D at:a

1.01 1.02 1.03 2 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11

Record Serial Number of junction box. Confirm Ex label affixed. Record Ex-Certificate No. (if applicable) I n s pe ct i on Ch ec k l i st : Check correct junction box installed according to drawing and area classification. Labelling / numbering / ferruling correct. Junction box mechanically sound, solidly and correctly mounted. Correct type of cable glands and glands tightened. Earthing / bonding / shrouding correct. Termination correct. Spare holes plugged (i.e. unused cable entries). All nuts, bolts and washers in place and secure. All wiring neat and tidy. Gaskets in place and correct. Cables correctly cleated.

2.12 2.13

Terminal blocks are correct type, mechanically sound, mounted and segrated correctly. Junction box located correctly to allow easy access for maintenance.

2.14 2.15

Mounting rail for PE-Terminals is made of copper (Cu). Drain plug inserted.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E15A Lighting Fixtures - By MC Package Rev : 0

CP No:

MC Package : Description : Item: 1.02 2 2.01 2.02 2.03

OK N/A PL Result/Data: Confirm Ex label affixed. I n sp ec t i o n Ch e ck l i s t :

2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18

Check correct lighting fixtures installed according to drawing and area classification. Labelling / numbering / ferruling correct. Proper identification of emergency lighting. Fixtures mechanically sound, solidly and correctly mounted. Earthing / bonding /shrouding correct. Termination correct. Spare holes plugged (i.e. unused cable entries). All nuts, bolts and washers in place. All wiring neat and tidy. Gaskets in place and correct. Enclosure / Glasses correctly sealed, clean an d undamaged. Cables correctly cleated. TestChecks: Check earth continuity to plant earth. Check i nsulation resistance to earth. Check battery light for correct function. Verify that fi xture with battery back-up are terminated as p er manufacturers instructions and link is removed. CEmarking in place.

Comments:

O bj e c t I D

Checked

R e c o r dS e r i al N o

R e c o r dE x . C e r t i f i c at eN o

E x . c e r t i f i c at i o n t y p e

R e m ar k s

Note : As-Built Block Diagram sketch to be attached. Contractor

KUPConstruction

Other:-

KUPCommissioning

Name : Sign : Date : Rev : 0


MC Inspection & Test Record E15B Lighting Fixtures - By Circuit Rev : A

CP No:


CircuitNo:

SystemVoltage:

Item: 1

D at a

1.01 1.02 1.03 2 2.01

Record Serial Number of light fixtures in tabulation below. Confirm Ex label affixed. Record Ex-Certificate N os ( if applicable) in tabulation b elow. I n sp ec t i o n Ch e ck l i s t : Check correct lighting fixtures installed according to drawing and area classification.

2.02 2.03 2.04 2.05 2.06 2.07 2.08

Labelling / numbering / ferruling correct. Proper identification of emergency lighting. Fixtures mechanically sound, solidly and correctly mounted. Earthing / bonding /shrouding correct. Termination correct. Spare holes plugged (i.e. unused cable entries). All nuts, bolts and washers in place.

2.09 2.10 2.11

All wiring neat and tidy. Gaskets in place and correct. Enclosure / Glasses correctly sealed, clean an d undamaged.

2.12 2.13 2.14 2.15 2.16 2.17

Cables correctly cleated. TestChecks: Check earth continuity to plant earth. Check i nsulation resistance to earth. Check battery light for correct function. CEmarking in place.

Comments: Object ID

Checked

Record S eri al No

Record E x. Ce rti fi cate No

Protection Type

Remarks


KUPConstruction

Other:-

KUPCommissioning


MC Inspection & Test Record E15C Lighting Fixtures Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

Arr. Drwg.

PO Package

Distr. Board

Data Sheet

Circuit No.

Supplier

Remarks

Item: 1

OK N/A PL Result/Data: D at a

1.01 1.02

Record Serial Number of light fixture. Confirm Ex label affixed.

1.03 1.04 2

Record Ex-Certificate No. (if applicable). Confirm Ex protection type. I n s pe ct i on Ch ec k l i st :

2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10

Check correct lighting fixtures installed according to drawing and area classification. Labelling / numbering / ferruling correct. Proper identification of emergency lighting. Fixtures mechanically sound, solidly and correctly mounted. Earthing / bonding /shrouding correct. Termination correct. Spare holes plugged (i.e. unused cable entries). All nuts, bolts and washers in place. All wiring neat and tidy. Gaskets in place and correct.

2.11 2.12

Enclosure / Glasses correctly sealed, clean an d undamaged. Cables correctly cleated.

2.13 2.14 2.15 2.16 2.17

TestChecks: Check earth continuity to plant earth. Check i nsulation resistance to earth. Check battery light for correct function. Verify that fixture with battery back-up are terminated as p er manufacturers instructions and li nk is removed. CEmarking inplace.

2.18

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E16A Socket Outlets/Isolators - By MC Package Rev : A

CP No:

MC Package : Description : Item: 1

I n s pe ct i on Ch ec k l i st :

1.01 1.02 1.03 1.04 1.05

Check correct socket oulets/isolators installed according to drawing and area classification. Labelling / numbering / ferruling correct. Sockets outlets/Isolators mechanically sound, solidly and correctly mounted. Earthing / bonding /shrouding correct. Termination correct.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Spare holes plugged (i.e. unused cable entries). All nuts, bolts and washers in place. All wiring neat and tidy. Gaskets in place and correct. Cables correctly cleated. Terminal blocks correct type and mechanically sound. Test phase sequence correct.

1.13 1.14 1.15

CEMarkingin place.

Comments: Obj ectI D

Checked

R ec ordS eri alN o

R ecor dE x.C ert i f i cat eN o

Prot ect i onType

R e m ar k s


KUPConstruction

Other:-

KUPCommissioning


MC Inspection & Test Record E16B Socket Outlets / Isolators - By Circuit Rev : A

CP No:


CircuitNo:

SystemVoltage:

Item: 1


1.01 1.02 1.03 1.04

Check correct socket oulets/isolators installed according to drawing and area classification. Labelling / numbering / ferruling correct. Sockets outlets/Isolators mechanically sound, solidly and correctly mounted. Earthing / bonding /shrouding correct.

1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Termination correct. Spare holes plugged (i.e. unused cable entries). All nuts, bolts and washers in place. All wiring neat and tidy. Gaskets in place and correct. Cables correctly cleated. Terminal blocks correct type and mechanically sound. Test phase sequence correct. CEMarkingin place.

Comments: Obj ectI D

Checked

R ecor dS eri alN o

R ecor dE x .C e rt i f i cateN o

Pro tec ti onType

R e m ar k s


KUPConstruction

Other:-

KUPCommissioning


MC Inspection & Test Record E17 High Voltage Cable Rev : B

Cable No:

CP No:

Description:

MC No:

From

Switchboard

To

Panel No.

CableType

Feeding Equip.

CableSize

System Voltage

Item:

1


I n sp ec ti o n C h e ck l i s t :

1.01 1.02

Check installed cable against data above and cable schedule. Glanding, lockouts and shrouding correct.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10

Phase sequence belled out. Stress c ones c orrectly i nstalled, stress relieved and earthed. Earth conductor / cable armouring continuity. Glands comply with Area Classification. Beddingcorrect. Radius of bends within specification. Labellingcorrect.

Comments:

Note : 'Data, Resu lts or Check' column v alid entries are :- a) OK , b) NA, c) Blank, to be comp leted later on clear ance of punchlist it ems d) Enter data or resul ts.

Megger Test : L1 to Earth :

L1 to L2 :

L2 to Earth :

L2 to L3 :

L3 to Earth :

L3 to L1 :

High Voltage Pressure Test :

(to be performed according to manufacturer's instructions) Kilovolts applied

Time in minutes

Leak in current in mA

L1 to L2 with L3 to Earth L2 to L3 with L1 to Earth L3 to L1 with L2 to Earth


KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E18A LV Electrical Cable - By Cable No. Rev : B

Tag No:

CP No:

Descr:

MC No:

From

Distr. Board

To

Panel No

Cable Type

Feeding Equipm.

Size/Core

System Voltage

Item: 1


1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 2 2.01 2.02 2.03 2.04

Check installed cable against data above and cable schedule. Glanding, l ockoutsand shrouding correct. Phase sequence belled out. Check that all cable f astening i s correct and secure. Earth conductor / cable armouring continuity. Glands comply with Area Classification. Beddingcorrect. Radius of bends within specification. Labelling / numbering / ferruling correct. Spare cores earthed, tightened and identification correct. M egge rTes t: Record voltage applied (V) ResultsL1toL2 ResultsL2toL3 ResultsL3toL1

2.05 2.06

Results L1, L2, L3 to Earth ResultsL1toN.

2.07 2.08 2.09

ResultsL2toN. ResultsL3toN.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record E18B LV Electrical Cables - By MC Package Rev : A

MC Package :

CP No:

Description : Item: 1 1.01

I n s p e c t i o nC h e c k l i s t: Check installed cable against data above and cable schedule.

1.02 1.03 1.04

Glanding,lockoutsand shroudingcorrect. Phases equencebelledout. Check that all cable fastening is correct and secure.

1.05 1.06

Earth conductor / cable armouring continuity. Glands comply with Area Classification.

1.07 1.08

Beddingcorrect. Radius of bends within specification.

1.09 1.10

Labelling / numbering / ferruling correct. Record megger test results below for full circuit.

N oC a b l e

C h ec ked

F r o mT a g

T oT ag

S i z e/ C o r e s

C a b l eT y p e:

L 1t oL 2

Note : As-Built Block Diagram sketch ( as required ) or red-line marked up drawings to be attached. ACCEPTANCE Contractor KUP Construction Other:-

L 2t oL 3

L 3t E oL 1

Lt o 1 , L2 , L3

L 1t oN

L 2t oN

L 3t oN

KUP Commissioning


Page: 1

MC Inspection & Test Record E18C LV Electrical Cables - By Circuit Rev : A

MC Package :

CP No:

Description : Distribution Board :

Circuit No :

System Voltage :

Item: 1

I n s p e c t i o nC h e c k l i s t:

1.01 1.02 1.03 1.04 1.05 1.06

Check installed cable against data above and cable schedule. Glanding,lockoutsand shroudingcorrect. Phases equencebelledout. Check that all cable fastening is correct and secure. Earth conductor / cable armouring continuity. Glands comply with Area Classification.

1.07 1.08

Beddingcorrect. Radius of bends within specification.

1.09 1.10

Labelling / numbering / ferruling correct. Record megger test results below for full circuit.

N oC a b l e

ACCEPTANCE

C h ec ked

S i z e / C or es

F ro mT a g

Contractor

T oT ag

C a b l eT y p e:

KUP Construction

L 1t oL 2

Other:-

L 2t oL 3

L 3t E oL 1

Lt o 1, L2 , L 3

L 1t oN

L 2t oN

L 3t oN

KUP Commissioning


Page: 1

MC Inspection & Test Record E19 Earth Loop Resistance Rev : 0

CP No:

MC Package No: Description: Reference Drawings :

Components : Rods :

Check :

Installation Checks :

Check :

Check : 4 : Rods to correct position.

1 : Components noted have been installed.

Wire :

2 : Lock nuts installed.

5 : Cable joints visually inspected.

Insulated Cable :

3 : Cable / Wire bends within radius.

6 : Labelling correct.

:I t em C/abl e

CableType: F rom :

To :

Resistance

Co mm en t s :

m Ohms m Ohms

Contractor

KUPConstruction

Other:-

KUPCommissioning


Page: 1

MC Inspection & Test Record E20 Underground Cableworks Release

Rev : B

CP No:

Scope:

Contractor

Ref No (Segment No)

Location

Segregation No

Culvert Ref Coordinates

1. Inspection of Installation of Geotextile Membrane Inspection to take place : Date :

Time : Contractor

Issued : by KUPConstruction

Date :

Other:-

KUPCommissioning

Name : Sign : Date :

2. Inspection for Sandfilling Clearance Inspection to take place : Date :

Time : Contractor


Date :

Other:-

KUPCommissioning

Name : Sign : Date : Sandfilled :

Date :

Sign:

3. Tiling / Cover Completed ( Required before power-up of cables ) Inspection to take place : Date :

Time : Contractor


Date :

Other:-

KUPCommissioning

Name : Sign : Date :

Date :

Sign:

4. Inspection for Backfilling Clearance. Inspection to take place : Date :

Time : Contractor


Other:-

Date : KUPCommissioning

Name : Sign : Date : Sandfilled :

Date :

Sign: Printed: 5-Oct-00 08:52

MC Inspection & Test Record E21 Heat Tracing Installation & A-Test Rev : C

MC Package:

CP No:

Description. Item: 1


1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 2 2.01

Check cable indent correct. Check cable installation correct, secure and in correct position. Check junction boxes correct. Check glands and locknuts correct and secure. Checkt hermostatc orrect. Checkm echanicalp rotection. Termination correct. End seals correctly installed. Check for correct fixing materials used (SS for MIC) Check for correct bending radius. A -Tes:t Pre-insulation testing carried out (record results in table below).

Comments: Note : 'Tick all Check Item columns under OK - Satisfactory; N/A - Not Applicable; PL - Punch Item(s) against check point. Also record Test Results or Data' CicuitNo.

Ohms EarthLoopImpedance L1 to Earth L2 to Earth

Continuity Ohms

Heat Tracing Scope : (Isometrics/Lines/Instruments/Tape) O bj e c t I D Checked C i r cu i t N o Tracer Type


M Ohms

Isolation Core to Screen

Screen to Earth

N o. of El em en ts

To t al Le n gt h ( m )

KUPConstruction

Other:-

Comments

C o n n e c t i o n s S o ak e d E l e m e n t Pr e s s u r e Te s t e d

KUPCommissioning

MC Inspection & Test Record E22 Heat Tracing Cable B-Test Rev : A

CP No:

MC Package No: Description: Item: 1


1.01 1.02

Check glanding correct. Checkm echanicalp rotection.

1.03 1.04 1.05

Check all cores terminated in field. Check all cores terminated in distribution panel. Confirm items checked. (enter Name in block capital letters).

1.06 1.07 2 2.01

Confirm items checked. (enter Date checked). Confirm i temschecked. (Signature). Te s t C h e c k A f t e r I n s u l a t i o n . Record test results in table below.

3

Megger Test : ( At 500V m in im um, but n ot m ore th an 2500V DC )

3.01

Minimum isolation resistance between each core and earth shall be 10 MOhms (Regardless of length). Record test results in table below. Th e rm o st at:

4

4.01

Verify thermostat settings (us e comments section if more space needed).

Comments:

O bj ectI D

Checked

E ar thLo op

Co n ti n u i ty

Impedance (Ohms )


KUPConstruction

C oretoS creen

(O hm s)

(MO hm s)

Other:-

ScreentoE arth ( MOhms)

E achC oretoE arth ( Min. 10 M Ohms)

KUPCommissioning

MC Inspection & Test Record E30 Electrical - Area Acceptance Rev : B

CP No:

MC Package No: Description: Scope : (Detail Project Drawings)

DataN/A / Results Check: OK PL Re/ mar ks:

Item: 1 1.01 1.02 1.03

Inspection Checklist : Check cable trays and ladders conform to specification and drawings. Check location, orientation, cable tray/ladder routing to and from destination, elevations and layout as per drawings. Check all braces and supports are adequate for load.

1.04 1.05 1.06 1.07 1.08 1.09 1.10

Check minimum distance between power and i nstrumentation cable trays is a s per s pecification. Check no sharp edges to cut cables. Check no obstruction to pulling cable. Check covers, fire stops and partitions installed. Check sealing of ducts/pipes. Check all bonding of equipment, cable ladders and trays. Check that there are no clashes with piping etc.

1.11 1.12 1.13 1.14

Check routing checked for interface with above ground piping. Check cable identification, cable fastening, routing and grouping etc. Check main earthing. Main l ighting i dentification.

1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23

Check main a nd emergency lighting fi xtures are l abelled correctly. Check socket outlets are labelled correctly. Check that all cable transits are correctly installed and tightened. Junction boxes and identification as per layout drawing(s). Check & Record illumination intensity according to project requirements (LUX). Mechanical protection of horizontal/vertical ladders and trays (as required). Independent mechanical protection where risk of damage from vehicles. Check that all required fireproofing is completed.

Comments:



KUPConstruction

Other:-

KUPCommissioning


HVAC MC FORMS

G01

Fans

G02

Dampers

G03

Filter Coalescers

G04

Sound Attenuators

G05

Steam Humidifiers

G06

Heating/Cooling Coils

G07

Air Terminal Units

G08

HVACDucting

06-Oct-2000 14:58 Page: 3

MC Inspection & Test Record G01 Fans Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg

Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Confirm type of fan :- Axial or Centrifugal Confirm drive type :- Belt or Direct

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Installed according to specifications and drawings. Check nameplate data against data sheet. Protectivec oatingc omplete. Internally cleaned. Couplingfitted. Belt fitted (if apllicable). Guard of non-sparking material fitted. Guard enclosed, prevents access to rotating parts. Maintainance hatch fitted. Speed sensor and activator correctly installed. Fan rotates freely & direction of rotation clearly marked. Tag No. visible and correct.

1.16 1.17 1.18 1.19 1.20

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record G02 Dampers Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg

Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Confirm type of damper :- Shut-Off/Fire/PressureControl/Others to be specified. Installed according to specifications and drawings.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Check nameplate data against data sheet. Adequately supported. Internally cleaned. No mechanical damage. Indication 'Open/Closed' fitted. Function check with compressed Air/Nitrogen after installation. Inspection panel fitted. Tag No. visible and correct

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record G03 Filter Coalescers Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg

Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Confirm type of filter/coalescer. Installed according to specifications and drawings.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Check nameplate data against data sheet. Maintenance hatch fitted. Adequately supported. Protectivec oatingc omplete. Drain including water-trap installed. Heat tracing installed. Internally cleaned. Filter medium installed and clean. Pressure difference monitor installed. Tag No. visible and correct

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record G04 Sound Attenuators Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg

Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Installed according to specifications and drawings. Check nameplate data against data sheet.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Protectivec oatingc omplete. Internally cleaned. Baffles properly fixed. Adequately supported. External condition. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record G05 Steam Humidifiers Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg

Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Confirm/Record type of humidifier. Installed according to specifications and drawings.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Check nameplate data against data sheet. Protectivec oatingc omplete. Automatic drain down installed. Manual drain fitted. Inspect pipes/nozzles. Checkwatersupply. Adequately supported. Internally cleaned. Maintenancep anelf itted. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record G06 Heating/Cooling Coils Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg

Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Confirmtypeof Coil. ConfirmMedium.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Installed according to specifications and drawings. Check nameplate data against data sheet. Protectivec oatingc omplete. Internally cleaned. Inspect pipes/nozzles. Adequately supported. Maintenance hatch fitted. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record G07 Air Terminal Units Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg

Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Protectivec oatingc omplete. Adequately supported. Mixing box with actuator installed. Heating battery installed. Insulation complete. Internally cleaned. Constant air volume regulator installed. Maintenance hatch fitted. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record G08 HVAC Ducting Rev : 0

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg

Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Confirm position :- From: Installed according to specifications and drawings.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.12 1.13 2 2.01 2.02

Protectivec oatingc omplete. Fireproofingc omplete. Thermal insulation complete. Internally cleaned. Adequately supported. Balancingd ampersc orrectlyset. Supply / Extract grills fitted.

To:

Te st i n g:

Air leak test after installation. Air leakage test certificate attached.

Comments:



KUPConstruction

Other:-

KUPCommissioning


INSTRUMENT MC FORMS

J01

Instrument Cables

J02

Instruments (incl piping/tubing)

J03

Control Valves

J04

Safety Relief Valves

J05

Control Panels

J06

Instrument Junction Boxes

J07

Instrument Calibration

J08

Valve Calibration

J09

Instrument Pre-installation Test Inspection

J10

Loop Test Record

J11

Fire&GasLoop

J12

Orifice Plate Calibration/Installation

J13

Optical Fibre Cable

J16

BurstingDisc

06-Oct-2000 14:58 Page: 4

MC Inspection & Test Record J01 Instrument Cables Rev : 0

CP No:

MC Package No: Description: Reference Drawings :

Components : Rods :

Check :

Installation Checks :

Check :

Check : 4 : Rods to correct position.

1 : Components noted have been installed.

Wire :

2 : Lock nuts installed.

5 : Cable joints visually inspected.

Insulated Cable :

3 : Cable / Wire bends within radius.

6 : Labelling correct.

:I t em C/abl e

CableType: F rom :

To :

Resistance

Co mm en t s :

m Ohms m Ohms

Contractor

KUPConstruction

Other:-

KUPCommissioning


Page: 1

MC Inspection & Test Record J02 Instruments (incl piping/tubing) Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

LineNo

P.O Package

P & ID

Data Sheet

Loop Dwg No

Supplier

Remarks

Item: 1


1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 2 2.01

Check instrument against data sheet and manufacturer's data plate. Record Serial No. of instrument. Instrument installed according to specifications. Location in accordance with drawings and requirements. Instruments upportedp roperly. Instrument has good service ability. Instrument Tag.No. affixed and traffolyte label visible. Flow direction correct. Functional Test completed. Refer to calibration certifcate J07 or J08 (as applicable). Instrument enclosure mounted correctly. Instrument enclosure weather t ight. Electrical h eater i n e nclosure o perational. Instrument earthing complete. I n s t r u m e n t P i p i n g / Tu b i n g: Confirm type of hook-up :- Process/Pneumatic/Hydraulic.

2.02 2.03

Correct piping/tubingu sed. Piping/Tubing supported properly.

2.04 2.05 2.06 2.07 2.08

Piping/Tubing heat tracing checked. Instrument tubing f ittings correctly i nstalled. Are slopes on piping/tubing as specified. Leak-Pressure Test : Has piping/tubing been tested to specification. Confirm test pressure.

2.09 2.10 2.11 2.12

Piping/Tubing cleaned with dry air. All dirt and cutting debris removed from Piping/Tubing . Piping/Tubing chemically cleaned. Piping/Tubing 'Hot-Oil' flushed.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record J03 Control Valves Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

LineNo

P.O Package

P & ID

Data Sheet

Loop Dwg No

Supplier

Remarks

Item: 1


1.01 1.02

Valve according to data sheet. Position and orientation correct.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12

Direction of flow correct. Labelling correct. Position/Booster correctly installed. Flangeboltstight. Correctgasket. Airsupply to actuatori nstalled. Check if valve can be removed for service. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record J04 Safety Relief Valves Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

Set Pressure

P.O Package

Line No

Data Sheet

P & ID

Supplier

DwgNo

Item: 1


1.01 1.02

Check valve in accordance with data sheet. Record serial number.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 2 2.01 2.02 2.03

Record design Set Pressure (barg). Check/Record c alibration procedure u sed. Recordmediumused. Record seat lift pressure. (Barg) Record seat reseat pressure. (Barg) Bubble leak test. (per min)

R e - i n s t a l l at i o n C h e c k l i s t :

Recordr e-installationd ate. Reinstallation check :- Gaskets, Flanges, bolts etc. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record J05 Control Panels Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

P & ID

P.O Package

DwgNo

Data Sheet Supplier

Item: 1


1.01 1.02

Correct control panel according to data sheet and manufacturer's data plate. Installation according to specifications.

1.03 1.04 1.05

Location i n a ccordance with layout drawing. No mechanical damage. Equipment Tag No., labeling and warning marks visible, easily readable and installed in accordance with specifications. Nutsandboltstight. Paintworkgood. Earthingcorrect. Earthing and termination securely tight. Protection of 'Live' parts correct. All cables and auxilliary wiring neat and undamaged. Terminal blocks and segregation plates correct. Anti-condensation heater correctly installed. Pneumatic installation in panel correct. Tag No. visible and correct. All fuses/MCBs are correct rating.

1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20

Check panel interior is free from dust and debris.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record J06 Instrument Junction Boxes Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

Type

P.O Package

Dwg No

Data Sheet

Cable No

Supplier

Hook up dwg

Item: 1


1.01 1.02

NOTE : REFER TO RELEVANT CABLE TEST RECORDS FOR TERMINATION CHECKLIST ITEMS Check correct junction box installed according to drawing and area classification.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Labellinga ndn umberingc orrect. Junction box mechanically sound, solidly and correctly mounted. Correct type of cable glands and glands tightened. Earthing / bonding / shrouding correct. Spare holes plugged (i.e. unused cable entries). All nuts, bolts and washers in place and secure. Gaskets in place and correct. Terminal blocks correct type and mechanically sound. Junction box located correctly to allow easy access for maintenance. Tag No. visible and correct. Drain plug installed.

1.16 1.17

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record J07 Instrument Calibration Rev : A

Tag No:

CP No: MC No:

:LDR No

PCDA : Ref. No

Location

Hookup Dwg

Data Sheet

P & ID

Supplier

Layout Dwg

Loop Dwg

Remarks

Input using :

Output Rising / Switching:Unit:

Unit:

Switches:

Input Falling:

Unit:

Unit:

Output Falling / Switching:Unit:

Inputfalling/rising:

Contacts open at Contacts close at

Item:


1

I n s t r u m e n t ( D at a ) :

1.01 1.02 2 2.01 3 3.01 3.02

Record Serial Number: Record instrument calibration results in table above. S w i t c h e s( D at a ) Record switches calibration results i n table above. A dd i t i o n a l C h e c k l i s t I t e m s : Overrange checked to (no calibration change observed): Note : 'CALIBRATED' - label affixed:

3.03 3.04

Record Test instruments used. Record Test instrument serial numbers.

Comments:

Note : 'Data, Results or Check' column valid entries are :- a) OK, b) NA, c) Blank, to be completed later on clearance of punchlist items d) Enter data or results.

SubContractor: Name : Sign : Date :

EPCS:

Company:

MC Inspection & Test Record J08 Valve Calibration J08 Tag No.

CP No: MC No:

LDR No.

PCDA Ref.No.

:

:

Location

Hookup Dwg

Data Sheet

P & ID

Supplier

Layout Dwg

Loop Dwg

Remarks

Item:

1 1.01 2 2.01 3 3.01

Valve(Data): Record Serial Number: Calibration Results: Record calibration results in the table below. InspectionA Opening time (0 - 100%)

3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09 3.10 3.11 3.12 4

Fail Safe function tested Is valve moving smoothly and continuously Backupa ccumulatorf illed Valve o perated w ith a ccumulator Limit switches function checked Test instrument 'CALIBRATED' label affixed Valve position transmitter 0 - 100% closed - open 4 - 20 mA output

4.01 4.02 4.03 4.04 4.05

Closing time (100 - 0%) Fail Safe function tested Valve checked for leakage Nitrogen precharged to ( BARG ) Number of strokes, starting from the 'Non-Fail Safe' position.

InspectionB

4.06 4.07 4.08

Comments:

Valve Input Signal (primary) to Positioner / Pilot :

Unit:

Actuator (secondary) Input Signal

Unit:

Valve Opening 100 %

Open

75 % 50 % 25 % 0%

Close

Note : 'Data, Resu lts or Check' column v alid entries are :- a) OK , b) NA, c) Blank, to be comp leted later on clear ance of punchlist it ems d) Enter data or resul ts.

Contractor

KUPConstruction

Other:-

KUPCommissioning


MC Inspection & Test Record J09 Instrument Pre-installation Test Inspection Rev : 0

Tag No:

CP No:

Descr:

MC No:

Supplier

Model

P & ID

SerialNo

Manufacturer DataSheet

Item: 1

OK N/A PL Result/Data: I n s pe ct i on Ch ec k l i s t

1.01 1.02

Check that instrument & data plate is correct according to data sheet Check that a Valid Ex Certification is supplied with Instrument

1.03 1.04 2

Check that a Valid Calibration Certificate is supplied with Instrument. See note 1. Check for mechanical damage. Te s t i n g C e c k l i s t - S t an da r d I n s t r u m e n t s

2.01 2.02 2.03 2.04 2.05 3 3.01 3.02 3.03 3.04

Remove all shipping stops Connect test equipment and power up instrument Simulate process input and verify that instrument functions correctly according to data sheet Check calibration according to calibration certificate Replace all shipping stops and ensure preservation Te s t i n g C h e c k l i s t - V a l v e s Remove all shipping stops Connect test equipment & air supply Check that valve moves smoothly and continuously Check air failure mode according to data sheet

3.05 3.06

Check calibration according to calibration certificate Check & record failure to opening time

3.07 3.08 3.09 3.10 4

Check & record failure to closing time Carry-out SOV energise/failure check Check Limit Switches Replace all shipping stops & ensure preservation Te s t i n g C h e c k l i s t - D i s p l ac e r s ( f l o at t y p e )

4.01 4.02 4.03 4.04 5 5.01 5.02 5.03 5.04 6

Remove all shipping stops Connect test equipement & power up instrument Apply simulated weight to displacer to verify presence of output signal Replace all shipping stops & ensure preservation Te s t C e c k l i s t - I n l i n e I n s t r u m e n t s Remove all shipping stops Connect test equipment & power up instrument Apply simulated process action to verify presence of output signal Replace all shipping stops & ensure preservation Note: Sub- Con tractor shall prov ide a val id cal ibrati on Cer tif icate when man ufacturer Cer tif icate is not supplied with equipment.

6.01

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record J10 Loop Test Record Rev : A

Loop No:

P&ID Ref:

Field Tags:

PCDA Tags:

LDR No:

PCDA Ref.No:

Item:

OK N/ A PL Result/Data:

1

I n sp ec ti on C h ec k l i st ( B e f o re L oo p Tes t) :

1.01 1.02 1.03 1.04 2 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10

Check that all loop components are listed above are correct. Processisolated. All field items in the loop calibrated. PCDA system included in the loop check. (NOTE: IF LOCAL FIELD LOOP, ENTER 'NO'). In puts (S im ul at e process in put then ch eck 1, 2, an d 6 ) Check that transmitter at 0, 25, 50, 75, 100% is within tolerance. Check switchpoint and that reset point is within tolerance. Check valve(s) p osition transmitter/limit switches with re gard t o valve position, an d in dication on PCDA. Simulate 0, 25, 50, 75, 100% of range of thermo-couples and RTDs' to PCDA. Check T/Cs' and RTDs' fi eld temperature on P CDA. If not possible, check wiring/polarities and type of sensors. Check that indicators at 0, 25, 50, 75, 100% correspond with transmitter output. Check PCDA software alarms(analog). Check that analog range and engineering units on PCDA correspond with field device. Check digital alarms. Check status indications and interlock signals from MCCs', vendor packages, PSD, ESD etc.

2.11 2.12 3

Check raw signals. These cannot be found on nominal graphic or status screen. Check signal appears on correct graphic display. Tr eatm en t:

3.01 3.02 3.03 4

Check pneumatic controllers operation and balance of output. Check standard software controller. (Direct/Reverse action etc.) Check sp ecial tr eatment (C ascade-controller, s elector, g ap-controller et c.) O ut pu ts:

4.01 4.02 4.03 4.04 4.05 4.06 5

Check that manual output 0, 25, 50, 75, 100% from controller correspond with valve position. Check solenoid and/or switch output function. Record travel time for valve : to open / to close (sec) Check PSD trip according to Cause & Effect diagram. Check visual, audible and printout message of alarms. Operate complete loop at 50% and Auto. Observe direction of valve movement with respect to P&ID. Wor k Af t er L oo p Ch e ck :

5.01

CP No:

Filling fluids completed.


SubContractor

EPCS

Company


MC Inspection & Test Record J11 Fire & Gas Loop Rev : A Drwg.Ref:

Loop No: Field Tags:

PCDA Tags:

LDR No:

PCDA Ref.No:

Item:


1

G asD et ec t or

1.01 1.02 1.03 1.04a 1.04b 1.04c 1.04d 1.04e 1.05 1.06 1.07 2 2.01

Isolate power to gas detector and install gas head collection cone and scrubber, ensure tag is affixed For gas detectors not in aspirators, calibrate according to item 4 below Calibrate detector & r ecord results (enable in hibits are on during alarm settings & ca libration) ensure PCDA override Gas detector Serial No: Test Gas Certificate No: Resitance referance element ( in Ohms ): Resitance measuring element ( in Ohms ): Alarm setting low ( in % LEL ): Alarm setting high ( in % LEL ): Module zero ( in free air ): Test Gas ( in % Propane in air ): Reading ( % LEL ): Check alarms, accept and resets: Check fault indication by O/C & S/C: Restore gas modules & system to normal, remove overrides: PC D A A l ar m O u t p u t s Simulate output alarm by coincidence gas, smoke or heat (ensuring all other output trips are isolated)

2.02 2.03 2.04 3

Check correct contact function at associated PCDA input termination rack Reset alarm & ensure trip contact reset to normal Remove isolation from switchboard and inform electrical supervisor O p e n Pa t h I R G as D e t e c t o r s

3.01 3.02a 3.02b 3.02c 3.02d 3.02e 3.03 4 4.01 4.02

Check for stability, physical protection and obstructions. Check calibration - adjust as necessary Alarm setting low ( in % LEL ): Alarm setting high ( in % LEL ): Module zero ( in free air ): Test Gas/Filter ( in % Propane in air ): Reading ( % LEL ): Check alarms, accept and resets: Restore gas modules & system to normal, remove overrides: S m ok e, H eat , F l ame D et ec t or s & M an u al C al l B ut to n s Check end of line resistor fitted in last device in loop Check F&G panel has no fault indicators for loop under test

4.03 4.04 4.05 4.06 4.07a 4.07b 4.08 4.09 4.10 5 5.01

CP No:

Ensure any necessary output isolations are on Check each detector operates correctly by simulating alarm condition, smoke, heat etc For each smoke detector in loop, simulate smoke using approved test medium and check alarm on F&G panel Check flame lens isclean Check detector is covering intended area by using the IR/uV test gun and aiming at detector to find limits of alarm. Check alarms are on correct graphic display. Check alarm printout message. Check each manual alarm push button in the loop alarms Check alarms, accept & reset Check fault indication by O/C & S/C Lam ps/B eaco n s Ensure r elevant la mp i n each l oop op erates upon si mulating p ower a t ou tput t erminals



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record J12 Orifice Plate Calibration/Installation Tag No. Comm. Pack No: Location

Line No P & ID

Data Sheet

Component

Supplier

Remarks

Item: 1 1.01 1.02

OK N/A PL Result/Data: I n s pe ct i on Ch ec k l i st : Confirm Orifice Tag No. stamped correctly. Record specified I.D.

1.03 1.04

Record Actual I.D. (at position A) Record Actual I.D. (at position B)

1.05 1.06 1.07 1.08 1.09 1.10 1.11

Record specified O.D. RecordactualO.D. Record specified plate thickness. Record actual plate thickness. Confirm flatness acceptable. Confirm material correct. Confirm weep h ole position Top/Bottom

1.12 1.13 1.14 2 2.01 2.02

Sign/Date f or Calibration Verification - Contractor Sign/Date fo r Calibration Verification - KUP Construction Sign/Date fo r Calibration Verification - K UP Commisiioning R e - i n s t a l l at i o n C h e c k l i s t : Recordr e-installationd ate. Reinstallation check :- Gaskets, Flanges, bolts etc.

2.03

Tag No. visible and correct.

2.04

Sign in boxes at foot of certificate for installation correctly completed.

Comments:

Note : 'Data, Results or Check' column valid entries are :- a) OK, b) NA, c) Blank, to be completed later on clearance of punchlist items d) Enter data or results.

SubContractor

EPCS

Company


MC Inspection & Test Record J13 Optical Fibre Cable Rev : 0

Tag No:

CP No:

Descr:

MC No:

From

Location

To

Service

Cable Type

Remarks

Size/Core

Item: 1


1.01 1.02

Check cable against specification and drawings. Check cable against Data Cable Schedule.

1.03 1.04 1.05 1.06 1.07 1.08 1.10 1.11 1.12 1.13 1.14 1.15 1.16 2 2.01

Check l abelling, n umbering and f erruling correct. Check clamping and cleating correct. Check glanding, locknuts and shrouding correct. Check cable grouping correct. Check cable mechanically protected. Check cable terminated correctly. Check cable bending radius correct. Check bending radius for each fibre when terminated. Check armouring is earthed.

C h e ck A t te n uati on (dB / k m )

Pair Number 01 :

Fibre 1 :-

Fibre 2 :-

2.02 2.03 2.04 2.05 2.06

Pair Number 02 : Pair Number 03 : Pair Number 04 : Pair Number 05 : Pair Number 06 :

Fibre 1 :Fibre 1 :Fibre 1 :Fibre 1 :Fibre 1 :-

Fibre 2 :Fibre 2 :Fibre 2 :Fibre 2 :Fibre 2 :-

2.07 2.08 2.09 2.10

Pair Number 07 : Pair Number 08 : Pair Number 09 : Pair Number 10 :

Fibre 1 :Fibre 1 :Fibre 1 :Fibre 1 :-

Fibre 2 :Fibre 2 :Fibre 2 :Fibre 2 :-

2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20

Pair Number 11 : Pair Number 12 : Pair Number 13 : Pair Number 14 : Pair Number 15 : Pair Number 16 :

Fibre 1 :Fibre 1 :Fibre 1 :Fibre 1 :Fibre 1 :Fibre 1 :-

Fibre 2 :Fibre 2 :Fibre 2 :Fibre 2 :Fibre 2 :Fibre 2 :-

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record J16 Bursting Disc Rev : 0

Tag No:

CP No:

Descr:

MC No:

Location

Line No

P.O Package

P & ID

Data Sheet

DwgNo

Supplier

Item: 1

OK N/A PL Result/Data: Pr e - I n s t a l l a t i o n I n s p e c t i o n C h e c k l i s t :

1.01 1.02 1.03 2 2.01 2.02 2.03 2.04 2.05

Check against data sheet and manufacturer's data plate/markings. Record Serial No. of bursting disc. Check that there i sn o physical damage. Po s t - i n s t al l at i o n I n s p e c t i o n C h e c k l i s t : Location in accordance with drawings and requirements. Installed in correct orientation. Tag.No. affixed and traffolyte label visible. Check bolt, nuts and gaskets correct, with bolts correctly tightened. Check cabling correctly terminated, glanded.

Comments:



KUPConstruction

Other:-

KUPCommissioning


PIPING MC FORMS

L01

Piping :- Flushing/Testing/Drying.

L02

Reinstatement Check List

L03

Piping :- Chemical Cleaning

L04

Piping: Hot Oil Flushing

L05

Piping : Video Inspection

L06

Orifice Flanges

L07

BoltTensioning

L08

Steam Blowing

11-Oct-2000 11:14 Page: 5

MC Inspection & Test Record L01 Piping :- Flushing/Testing/Drying. Rev : B

CP No:

Test Pack No :

Flushing : Pressure Testing :

FlushDate:

Flush Medium:

Test Date :

TestMedium:

Test P ressure:

Test Type :

FlushTemperature:

Ambient Temperature:

WaterChlorideContent(%):

TestStartPressure:

DesignPressure:

Test Finish Pressure :

Hydrostatic :

Static Head :

Service Test :

Pneumatic :

Visual Only :

Alternative :

Leak Test :

NDE Only :

Test Duration : Reference Concessions Request Nos :

Specify .............................. Test Equipment Serial Nos or Reference Nos:

Drying Started (Date/Time) :

Drying Completed (Date/Time) :

List Combined Test Nos:

Final Dew Point Inlet :

Final Dew Point Outlet :

Drying : Duration of Drying :

IsometrN ic:o

Rev: LinNe:o

Orig.P&I:D

QC Released:

Contr.:

KUP:

Release for Testing :

Contr:

KUP:

ACCEPTANCE

Flushed Name/Date/Sign.

Tested Name/Date/Sign.

Dried Name/Date/Sign.

Remark:s

Reinstated Name/Date/Sign.

Contractor KUP Construction Other:KUP Commissioning Printed: 5-Oct-00 12:25

MC Inspection & Test Record L02 Reinstatement Check List MC Package No :

CP No:

Description : Item: 1

OK N/A PL Result/Data: I n s pe ct i on Ch e ck L i s t :

1.01 1.02 1.03 1.04 1.05

Flushing and hydrostatic testing have been satisfactory completed All items used for testing / flushing removed Correct bolts and gaskets are installed at all mechanical joints All nuts are pulled to required tihtness All flange faces are parallel and no visible damage to gaskets

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Sealant on screwed connections is as pre specification All vents and drains are correctly installed All temporary vents and drains comply with specification All process blinds and spades have been installed as indicated on PID Spectacle blinds are in the correct flow position All pipe cleaning and pickling has been satisfactory completed Control valves have been installed i n the correct f low position

1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22

Specified block valves have locking devices correctly installed All valves are functioning properly and that spindle has been lubricated All spindles and chain wheels have been correctly installed All relief valves have been correctly installed All gauges have been correcty installed Restriction and orifice plates have been correctly installed All pump suction strainers have been correctly installed Correct flow through filters and strainers, traps, check and globe valves All gags have been removed from spring supports and expansion bellows All pipe seals have been correctly fitted

Comments:

Contractor

KUPConstruction

Other:-

KUPCommissioning


MC Inspection & Test Record L03 Piping :- Chemical Cleaning

CP No:

MC Package No: Description: Chemical Cleaning :

Drying :

Pickling Number :

Actual Pickl ing Date :

Drying Started (Date/Time) :

Pickling Specification :

Pickling Temperature :

Drying Completed (Date/Time) :

Pickling Procedure :

Pickling Duration :

Final Dew Point Inlet :

Pickling Medium :

Final Dew Point Outlet : Duration of Drying :

Design IsTo / ag No

IsoLRev ine No :

Orig.P&ID:

Remark:s

Client Release forChemical Cleaning : Name:

Sign:

Chem. Cleaned Name/Date/Sign.

Dried Name/Date/Sign.

Date:



MC Inspection & Test Record L04 Piping: Hot Oil Flushing Rev : 0

CP No:

MC Package No: Description: Item: 1

OK N/A PL Result/Data: I n sp ec ti o n C h e ck Li s t:

1.01 1.02 1.03 1.04

Bearings bypassed and blinded/plugged. Piping/Equipment chemically cleaned. Reservoir clean and accepted prior to oil filling. Type of flushing oil correct.

1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Sample points correct. Microscopic evaluation of test samples. Marked up PID's attached. Hot oil flushing log attached Laboratory analyses completed. Reservoir clean after flushing. New filter of correct type installed. Initial fill of operational oil. System/Equipmentt agged/labelled. Associated systems accepted. System/Equipment reinstated.

DesignIsT o/ agNo

Iso Rev LineNo:


KUPConstruction

Orig.P&ID

Other:-

Remarks

KUPCommissioning

MC Inspection & Test Record L05 Piping : Video Inspection

MC Package No:

CP No:

Description: Video Inspection Scope :

Ref. Cassette No : Entry point :

IsometricNo/TagNo

Iso Rev

LineNo

Video Inspected Name/Date/Sign.

Orig.P&ID

Extent(Spools)/Remarks

Test Ref



MC Inspection & Test Record L06 Orifice Flanges Rev : 0

Tag No:

CP No:

Description:

MC No:

Location

P&ID

P.O. Package

Design Isometric

Module

Shop Isometric

Supplier

Shop Isometric

Item: 1

OK N/A PL Result/Data: I n s p e c t i o n : ( U P S TR E A M F L A N G E )

1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 2

2.01 2.02 2.03

Verify upstream flange orientation correct (tappings) Verify weld root ground flush RecordDesign IsometricNo.a bove Record Shop Isometric No. above RecordSpoolNo. RecordWeldNo. Name: ………. .………… ………… …………… ………… Sign: ………. .………… ………… …………… ………… Date: ………. .………… ………… …………… ………… Location where verification performed (Supplier, Module Yard, Site or specify other location) I n s p e c t i o n : ( D O W N S TR E A M F L A N G E ) Verify downstream flange orientation correct (tappings) Verify weld root ground flush RecordDesign IsometricNo.a bove

2.04 2.05 2.06 2.07 2.08 2.09 2.10

Record Shop Isometric No. above RecordSpoolNo. RecordWeldNo. Name: ………. .………… ………… …………… ………… Sign: ………. .………… ………… …………… ………… Date: ………. .………… ………… …………… ………… Location where verification performed (Supplier, Module Yard, Site or specify other location)

……………

……

……………

……

……………

……

……………

……

……………

……

……………

……

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record L07 Bolt Tensioning Rev : 0

Tag No:

CP No:

Description:

MC No:

Location

P&ID

P.O. Package

Design Isometric

Module

Shop Isometric

Supplier

Shop Isometric

Item: 1

OK N/A PL Result/Data: Fi e l dC h ec k l i s t

1.01 1.02 1.03 1.04 2

Alljointslabelled. All boltsh ave plastic capsi nstalled.

D o c um e n tat i on

2.01 2.02

Contractor marked-up and stamped drawings complete and enclosed.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record L08 Steam Blowing Rev : 0

Tag No:

CP No:

Description:

MC No:

Location

P&ID

Scope

Main Line No.

Item: 1

OK N/A PL Result/Data: D at:a

1.01 1.02

Steam source (e.g. Boiler Tag No.) Target Plate No.01 material

1.03 1.04 1.05 1.06 1.07 1.08 2 2.01

Target Plate No.01 size Target Plate No.02 material Target Plate No.02 size Extent of blowing marked-up on P&IDs and attached.

Pr e - B l o w C h e c k l i s t :

2.02 2.03 2.04 2.05 2.06 2.07

Check silencer location with respect to underground cableworks and pipework (to avoid potential damage). All re lated pi ping i s fu lly mechanical c ompleted (including MC documentation). Re-check that all sliding supports are free to move. Re-check that all support anchors are installed as per design drawings. Recheck that supports do not allow excess lateral movement. Re-check that all test vent/drain plugs are installed. Steam start-up v entsa vailable a nd c omplete.

2.08 2.09 2.10 2.11 2.12

All temporary blow-off piping connected and secure. Quick-Release sacrifical valve installed and correct. Check that all combustible materials (e.g. wood or plastics) are removed (potential fire hazard). Barriers and safety signs erected around area. Extent of temporary insulation or personnel protection is adequate (may only require barriers).

2.13 2.14 3 3.01 3.02 3.03 3.04 4 4.01 4.02 4.03 4.04 4.05

N o i s eC o n t r o l:

Silencer connected and secure Water injection system connected and functional

S t e am B l o w i n g A c t i v i t i e s / R e s u l t s :

Record Date and Time steam blowing activities commenced. Duration of initial header heating. Number of blows prior to use of target plate(s). Record number of blow to target to achieve acceptable result. Record Date and Time steam blowing activities accepted.

Comments:



KUPConstruction

Other:-

KUPCommissioning


MECHANICAL MC FORMS

M01

Heat Exchangers

M02

Vessels & Tanks

M03

Diesel Engines

M04

Centifugal Pumps

M05

Reciprocating Machinery

M06

Submerged Pumps

M07

Manual Hoists, Monorails and Jibs.

M08

Powered Hoists and Cranes

M09

Belt Driven Machinery Alignment

M10

Compressors

M11

Steam Turbines

M12

GearUnits

M13

Refrigeration Compressor Packages

M14

Mixers

M15

Blowers

M16

Sanitary, Sewage & Treatment Plant

M17

Water Treatment Systems

M18

Water Softeners

M19

FlareTips

M20

Flare Stack and Guys

M21

Centrifuge/Shakers

M22

Air Cooled Heat Exchangers

M23

Miscellaneous Equipment

M24

FiredHeaters

M25

Field Assembled Boilers

M26

GasTurbines

M27

Machinery Pre-Alignment

M28

Machinery Final Alignment

M30

Final Closing of Vessels and Towers

M31

Pump/Driver Release

MDPL

Multi Discipline Punch List

06-Oct-2000 14:58 Page: 6

MC Inspection & Test Record M01 Heat Exchangers Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

Shell Design Press.

P.O. Package

Tube Design Press.

Data Sheet

Shell Design Temp.

Supplier

Tube Design Temp.

Item: 1


1.01 1.02

Check namplate data against data sheet. Position and orientation correct.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Support and footings correct with sliding supports free to move. Holding down bolts fitted. Inspect internal lining. Internalclean. Jack screwsretracted. Check anodesare fitted. Inspect floating head. Inspection nozzles. External condition. Inspectiondate. Dateopened. Dateclosed. Plate e xchangers. C orrect n umber o f plates.

1.16 1.17

Plate exchangers. Ring gaskets correct and in good condition. Tag No. visible and correct.

1.18 1.19 1.20

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M02 Vessels & Tanks Rev : A

Tag No:

CP No:

Descr:

MC No:

P.O. Package

Design Press. 1

LxWxH

Design Temp 1.

Data Sheet

Duty

Supplier

Design Capasity

Item: 1


1.01 1.02

Check nameplate data against data sheet. Position and orientation correct.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Supports and footings correct. Holding down bolts fitted. Heating coils installed. Nozzles (internal & external). Internal fittings checked against Vendor drawings. Internalcoating. Internal cleanliness. Externalcoating. Inspectiondate. Dateopened. Dateclosed. Manwayfreetomove. Lubrication for davit.

1.16 1.17

API 650 - Standard Certificate (Tanks) Tag No. visible and correct.

1.18 1.19 2 2.01 2.02 2.03 2.04 2.05 2.06 3 3.01 3.02 3.03 3.04

Te st i n g:

Record bottom plate vacuum pressure. Record period of vacuum test. Record leak test pressure. Record period of leak test.

F l oat i n gR oo f s

Sealstested. Pontoonstested.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M03 Diesel Engines Rev : A

Tag No:

CP No:

Descr:

MC No:

Description

AreaCode

Rev

PIDNo

SystemNo

DwgNo

Supplier

SuperTagNo

Item: 1


1.01 1.02

Check nanplate data against data sheet. Position and orientation correct.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Mountingcorrect. Holding down bolts fitted. Shimscorrect. Dowelsfitted. Aligment checked. (Ref. form M28) Couplingchecked. Direction of rotation correct. Lubricant type correct. Lubrication level correct. Grease pointsclear. Lubricant oil filters fitted and correct. Fuel oil lines checked. Fuel stop valve checked.

1.16 1.17

Sight glasseschecked. Fuel oil filters checked.

1.18 1.19 1.20 1.21 1.22

Engine coolant system checked. Radiatorchecked. Belt tension checked. Airintakeclear. Battery and starting circuit checked.

1.23 1.24 1.25 1.26

Exhaustchecked. DayTankchecked. Barring gear checked. Crankcase vent clear.

1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35

Inlet airstopvalve. External condition. Lube oil system cleaned. Fuel systemcleaned. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M04 Centifugal Pumps Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

P & ID

P.O. Package

Arrgm. Drwg

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Position and orientation correct. Mountingcorrect. Holding down bolts fitted. Dowelsfitted. Alignment checked. ( Ref. form M28) Spacer type coupling installed. Coupling g uard of n on sparking marterial i nstalled. Coupling enclosed to prevent access to rotating parts. Coupling component match markings performed. All coupling bolts fitted. Jack screw and driver fitted. Lubricantcorrect Constant oiler fitted.

1.16 1.17

Oilthrowersfree. Grease pointsclear.

1.18 1.19 1.20 1.21 1.22

Glandcooling fitted. Sealfitted. Packingfitted. Balancelineclean. Pump case drain valved.

1.23 1.24 1.25 1.26

Pump case drain clear. Base plate drain pan line installed. Pumpventvalved. Pumpventclear.

1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35 1.36

Shims pack for driver i nstalled (min. 3mm - max. 6mm). Suction valveaccess. Inlet strainer access. Pumpturnsbyhand. Seal flushing and quench. Permanents traineri nstalled Direction of rotation arrow correct. Tag No. visible and correct.

1.37 1.38

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M05 Reciprocating Machinery Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Position and orientation correct. Resillient mountings correct. Shimscorrect. Holding down bolts fitted. Dowelsfitted. Alignment checked. ( Ref. form M28) Couplingfitted. All coupling bolts fitted. Coupling guard fitted. Crankcase cover secure. Crankcase vent clear. Crankcase drain clear. Stroke controller correct.

1.16 1.17

Lubeoil systemclean. Lubricanttype.

1.18 1.19 1.20 1.21 1.22

Lubeoilcorrect. Lubricating lines clear/ Lube oil system cleaned Oil filterscoorect. Oil level gaugesfitted. Constant oiler fitted.

1.23 1.24 1.25 1.26

Coolingmedia. Cooling linesclear. Exchanger anodes fitted. Air intake filter clean.

1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35 1.36

Relief valve correct and adjusted. Discharge valve access. Diaphragm leak detection correct. Permanent strainer installed. Vibration monitoring fitted. Barring gear checked. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M06 Submerged Pumps Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrng. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Installed according to specification and drawings. Check nameplate data against data sheet.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Direction of rotation correct. Position and orientation correct. Mountingcorrect. Holding down bolts correct. Dowelsfitted. Caisson installed. Couplingchecked. Lubricant type correct. Lubricant level correct. Gas tight mounting plate. Sealsfitted. Coupling guard fitted. Lubricant lines fitted.

1.16 1.17

Rotorclearance. Suctionstrainer.

1.18 1.19 1.20 1.21 1.22

Discharge valve access. Tag No. visible and correct. Pump riser/ delivery line fitted.

1.23 1.24 1.25

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M07 Manual Hoists, Monorails and Jibs. Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 2 2.01 2.02 2.03 2.04

Installed according to specifications and drawings. Check nameplate data against data sheet. Tag No. visible and correct. Monorail installation. Endstopsinstalled. Yellow / zebra stripes painted. Marking 'Safe Working Load' (SWL). Lifting radius coverage. WedlingNDT accepted/documented. Confirm Monorail Number. I n s p e c t i o n o f Tr o l l e y : Confirm Trolley Tag No. Trolley in correct location. ConfirmTrolleySWL Record Trolley Serial No.

2.05 2.06

Trolleyc orrectlyi nstalled. Trolley spark proof.

2.07 3 3.01 3.02 3.03

Trolleywheelsposition correct. I n s pe c t i o n of H o i s t :

3.04 3.05 3.06 4

Record Hoist Serial No. Hoistsparkproof. CEc ertification/ documentation Te st i n g:

4.01 4.02 4.03 4.04 5 5.01 5.02 6 6.01 6.02

Record Trolley test date. Record Hoist test date. Record Trolley Certificate No. Record Hoist Certificate No. F u n c t i o n a l Te s t : Functional test of Trolley. Functional test of Hoist. I n s t al l a t i o n Te s t : Record i nstallation test :- Test Load. Deflectionst estr esults.

ConfirmHoistTag No. Hoist in correct position. ConfirmHoistSWL.

6.03 6.04 6.05

Record Installation Test Certificate No. issued. Record Installation Test C ertificate date of issue. Permanent deflection.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M08 Powered Hoists and Cranes Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1. 03 1.01

Tag No. visible and correct. Installed according to specification and drawings.

1.02 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Check nameplate data against data sheet. Correctorientation. Radiusof coverage. Railinstallation. Bridge installation. Hoist stops installed. NDT complete on rail installation. Welding/NDT accepted and documented. Rail(s) identification. Inspectb ridgec ondition. Inspect trolley condition. Inspect hoist condition. Inspect enclosed gears (including lubrication & lubricant type).

1.16 1.17

Inspect open g ears (including lubrication & l ubricant type). Inspect wire guides.

1.18 1.19 1.20 1.21 1.22

Inspectwire clamps. Inspect drum(s) ans sheaves. Inspect grease points. Inspect if wire correct and lubricated. Record Wire Certificate No.

1.23 1.24 1.25 2

Record Load Hook Certificate No. CEc ertification/ documentation Anti-condensation h eater i nstalled Fu n c t i o n alTes t

2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 3 3.01

RecordTestLoad Runtest-Bridge. Runtest-Trolley. Runtest-Hoist. Record date performed. Limit switches- Bridge. Limit switches - Trolley. Record Issued Certificate No. I n s t al l at i on Tes t TestLoad.

3.02 3.03 3.04

Deflectiontest. Overload protection set point. Inspection forvisible defects.

3.05 3.06

Record date performed. Permanent deflection.



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M09 Belt Driven Machinery Alignment Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Confirm i nstalled according to specifications and drawings. Check n ameplate and data against datasheet.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 2 2.01 2.02

Recordb eltm anufacturer. Recordbeltnumber. Record type and size of belt. Number of belts fitted. Antistatic. Confirm belt guard fitted. Confirm belt tensioning fiited. Tag No. visible and correct.

A l i gn m en t:

2.03 2.04

Drive and pulley checked for being in plane. Confirm method alignment method used (detail in comments below, if required). Direction of rotation arrow fitted. Rotatesfreely.

2.05 2.06 2.07

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M10 Compressors Rev : B

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Installed according to specification and drawings. Check n ameplate and data against datasheet.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Alignment checked per Suppliers procedure Nozzle loads within tolerances. Check for freedom of movement and direction of rotation. Bearing housing flushed and relubricated. Record date lubricated. Noexternaldamper. Paintworkintact. Handvalvesoperable. Coupling and bolts checked. Drain valves and blinds fitted. All pipework correctly fitted. All controls, protective devices and auxilliary systems correct. Barring gear interlock correct. Pipe supports fitted and adjusted.

1.16 1.17

Maintenance access adequate Lubeoil systemclean.

1.18 1.19 1.20 1.21 1.22

Holding down bolts checked. Grouting complete and accepted. Cooling system clean. Seal Gas/Oil system clean. Dust blinds installed / removed.

1.23 1.24 1.25 1.26


1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M11 Steam Turbines Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Baseplate level and properly grouted, jacksrews removed, foundations tightened. Excessp ipingstraina lleviated. Final cold alignment to manufacturer's tolerance. Check for freedom of movement and direction of rotation. Bearing housing flushed and relubricated. Record date lubricated. Check carbon packing. Governor mechanism f ree a nd operable. Handvalvesoperable. Check sentinel valve (if supplied). Over speed mechanism free and operable. Record Setting of Tripout (RPM) Turbine doweled (when specified). Casingsdrained. Condenser operable.

1.16 1.17

All controls, protective devices and auxilliary systems correct. Barring gear interlock correct.

1.18 1.19 1.20 1.21 1.22

Pipe supports fitted and adjusted. Lubeoil systemclean. Tag No. visible and correct.

1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M12 Gear Units Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

P & ID

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Installed according to specifications and drawings. Check n ameplate and data against datasheet.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Baseplate level and properly grouted, jacksrews removed, foundations tightened. Final cold alignment of driver to gear unit to manufacturer's tolerance. Record nominal coupling gap :Check for freedom of movement and direction of rotation. Inspect internally for cleanliness. Flush and refill. Record lubricant type :Coupling lubricated and closed. Record lubricant type :Coupling guard in place and secured. Dowelling c omplete( when specified). All controls, protective devices and auxilliary systems correct. Teeth mesh pattern complete.

1.16 1.17 1.18

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M13 Refrigeration Compressor Packages Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Baseplate level and properly grouted with jackscrews removed and foundations tightened. Excessp ipingstraina lleviated. Final cold alignment to manufacturer's tolerance. Rec ord nominal gap : Check compressor and driver for freedom of movement. Driver check for correct rotation (uncoupled). Check level of lubricant. Record lubricant type : Check motor bearing lubrication. Record lubricant type : Add refrigerant as required. Record refrigerant type : Belts installed or coupling lubricated and closed. Record lubricant type : Belt or coupling guard in place and secure. Compressor and driver dowelled (when specified). Vents and drains correct. Non-return valve fitted correctly.

1.16 1.17

Pressure safety valve setting correct. All controls, protection devices and auxilliary systems correct.

1.18 1.19 1.20 1.21 1.22

Pipe supports fitted and adjusted. Suction piping chemically cleaned. Lubeoil systemclean. Tag No. visible and correct.

1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M14 Mixers Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Final cold alignment of driver to gear unit to manufacturer's tolerance. Record nominal coupling gap : Check for freedom of movement and direction of rotation. Inspect in ternally f or cleanliness. Flush and refill. Record lubricant type : Coupling lubricated and closed. Record lubricant type : Coupling guard in place and secured. Dowelling c omplete( when specified). All controls, protective devices and auxilliary systems correct. Compare record with nameplate. Remove preservatives as necessary. Holding down bolts secure, without any distortion. Lube oil crankcase, or bearing housing is vented. Ancilliary pipework installed correctly and connections tight. Check position of impeller from bottom of vessel (via Vendor's drawings)

1.16 1.17

Check for transport damage. Check that construction mods have been completed.

1.18 1.19 1.20 1.21 1.22


1.23 1.24 1.25

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M15 Blowers Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Baseplate level and properly grouted. Jackscrews removed and foundations tightened. Remove shipping preservatives from bearing and relubricate. Record lubricant type (when required) : Excessive piping strain alleviated. Final cold alignment to manufacturer's t olerance. Record nominal coupling gap : Check blowers and drivers for freedom of movement. Driver checked for correct rotation (uncoupled). Gear unit checked per gear unit checklist (when applicable). Bearing lube system chemically cleaned, flushed and operable. Record lubricant type : Check motor bearing lubrication. Record lubricant type : Belts installed or coupling lubricated and closed. Record lubricant type : Belt or coupling guard in place and secured. Blower a nd d river d owelled ( when specified). Casingdrained.

1.16 1.17

Vents and drains correct. Inlet guide vanes set correctly and operable.

1.18 1.19 1.20 1.21 1.22

Air filtration system correct. All controls, protective devices and auxilliary systems correct. Pipe supports fitted and adjusted. Louvres set and operable. Tag No. visible and correct.

1.23 1.24 1.25 1.26 1.27

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M16 Sanitary, Sewage & Treatment Plant Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

System checked for surface damage. Skid No.1 (Aeration Basin, clarifier) anchored to foundation. Catwalks, stairways and handrails installed. Skid No.2 (Surface Basin) anchored to f oundation. Blowers installed on Aeration Basin. Communitor installed on Surge Basin. Transfer pumps installed in Surge Basin. Check i nterconnecting piping : T ransfer pump discharge line. Check interconnecting piping : Pump discharge line from surge to aeration basin. Check interconnecting piping : Overflow line. Check interconnecting piping : Waste sludge line. Check interconnecting piping : Air header connection. Water supply line connected to chlorine mater control house.

1.16 1.17

Water supply connected to froth control system. Electrical check : P umps, communitor connected to junction box on Skid No.2.

1.18 1.19 1.20 1.21 1.22

Electrical check : Blower connected to local plant. Electrical check : Junction box on Skid connected to local panel on Skid No.1. Electrical check : Power supply connected to local panel. MC check sheets completed for all tagged equipment. Tag Nos. visble and correct.

1.23 1.24 1.25 1.26 1.27

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M17 Water Treatment Systems Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Skid mounted day tanks. Injectionpumps. Controlsystems. Bulkstoragetanks. Chlorinator. Mixers. Equipment anchored to foundation. Structural supports anchored to foundations. Pumps and drivers checked for freedom of movement. Static mixers installed. Chlorine gas line connected to chlorinator. Water supply connected to chlorinator. Solution lines connected.

1.16 1.17

Chlorinator vent connected. Acidlineconnected.

1.18 1.19 1.20 1.21 1.22

Solenoid blow down valve installed. Power supply connected. MC check sheets completed for all tagged equipment. Tag Nos. visible and correct

1.23 1.24 1.25 1.26 1.27

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M18 Water Softeners Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Check for surface damage :- a) Vessels. b)Multiport valves. c)Watermeters. d) Dilution water rate of flow indicator. e)Brinemeter. Skid anchored to foundations. Water metersinstalled. Prefabricated items i nstalled :- a) Inlet. b)Outlet. c) Wash and rinse outlet header. d)Watermeter. Dilution water line connected. Brine meter and brine rate set valve connected to regeneration brine line.

1.16 1.17

Connections complete :-

1.18 1.19 1.20 1.21 1.22

a) Water inlet. b)Soft water outlet. c) Raw brine to regeneration brine line. d) Wash and rinse to drain.

Water softener resin filled. Electrical :- Power supply connected. Tag No. visible and correct.

1.23 1.24 1.25

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M19 Flare Tips Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item:


1


1.01 1.02 2 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 3

Installed according to specifications and drawings. Check n ameplate and data against datasheet. Fl areTi p: Check external surface for damages to flare tip pilot, assemblies and nozzles. Check nozzle orientation and elevation. Flare tip level and plumb. Mounting bolts tightened. Pilot burners correctly installed. Correct number of thermocouples in place. Identify and pipe all connections. Ladderinstalled. Visual inspection of welds. Inspect and/or apply paint. Thermocouples wired to the flame front generator. F l am e F r o n t G e n e r at o r Pa n e l :

3.01 3.02

Flame Front Generator Panel : Check nameplate data against data sheet. Visuali nspection of g augeg lass.

3.03 3.04 3.05 3.06 3.07

Handvalvesoperable. Anchor bolts tightened. Identify and pipe connections. Check air flow through each flame generator pipe. Alarm switch wired to main control panel.

3.08 3.09 3.10

Power connected to control panel. Wind deflectors fitted.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M20 Flare Stack and Guys Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02 1.03 2 2.01 2.02 2.03 2.04 3 3.01 3.02 3.03 3.04 3.05 3.06

Check that all required permits are in files. Ensure all start-up procedures are available (vendor instructions). Ensure all temporary bracing etc. are removed. Tes ts: Panel and valve box tests complete. Check tightness and field installed lines. Check for continuity for instruments and electrical cables. Check records and tests etc. I n s pe c ti o n: Check equipment connected as per flow diagram. Verify all instrument as per scope (P&ID) are installed. Test/Calibration Certificate for valves/thermocouples are available. Checklist for operative pressures are available. Check backup battery in flare. Check sparking device.

3.07 3.08

Check purge lines / connections. Check guy wire tension device and check that tensioning device is available for adjustments.

3.09 3.10 3.11 3.12 3.13

Check that air horn or other alarm devices are connected for indicative flare operation. Warning signs for flare sterile area are installed. Check Test (functional) Certificate for flare panel is available. Check winch and cable system. Check that all flare front lines between panel and flare are sloped and no dead legs are present.

3.14 3.15 3.16 3.17

Check nameplate against data sheet.

3.18 4 4.01 4.02

S par es:

Check that spare pilot and thermocouples are available. Check replacement procedures (pilot and thermocouples) are available.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M21 Centrifuge/Shakers Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Confirm equipment type :- Centrifuge / Shaker Installed according to specifications and drawings.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Check nameplate data against data sheet. Position and orientation correct. Mountingcorrect. Holding down bolts correct. Check hydraulic piping. Check hydraulic hoses. Grease points checked. Alignmentchecked. Coupling and guards installed. Beltschecked. Tag No. visible and correct

1.16 1.17 1.18 1.19 1.20

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M22 Air Cooled Heat Exchangers Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Installed according to specifications and drawings. Check structure for correctness, line and level, correct bolting etc.

1.03 1.04

1.07

Check plenum chambers, fanrings sliding pads, bundle packers, bundle bolting, seal plates etc. Check that tube bundle header fixing required for transportation only are removed to permit free expansion of tubes. Check as per item 04, to permit (when required), free transverse movement of headers to accomodate piping expansion. Check bundle n ameplate, bundle orientation, clearances, header linkages (i f required), bundle header welding etc. Check platforms and ladders (where applicable).

1.08 1.09 1.10 1.11

Fan shaft centered and plumb. Belt sheave alignment. Alignments of gear unit of fan, coupling gap. Checkgearunit.

1.12 1.13 1.14 1.15

Installation of fan blades and set to proper angle. Record degree of pitch :Fixed Type : Check blade tip clearance. Check fan and drive for freedom of movement.

1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24

Driver checked for correct rotation (uncoupled). Check fan and motor lubricant. Record lubricant type : Belts installed or coupling lubricated and closed. Record lubricant type : Belts, coupling and fan guards in place and secure. Bearing housings and drive dowelled (when specified). Louvresand actuatorsi nstalled c orrectly. Directiono fr otation marked. Fins/tubesundamaged. Tag No. visible and correct.

1.05 1.06

/ Variable Type : Min. -

Max. -

1.25 1.26 1.27 1.28 1.29 1.30

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M23 Miscellaneous Equipment Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02

Check nameplate data against data sheet. Installed according to drawings and specifications.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Confirm type of equipment. Tag No. visible and correct External condition.

1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M24 Fired Heaters Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item:


1.01 1.02 1.03

Installed according to specifications and drawings. Check nameplate data against data sheet. Heater shell is level, plumb and properly grouted with foundation bolts tightened.

1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17

Welding or bolting of shell i nspected. Tube supports installed per drawings. Refractory anchors installed as per drawings. Epoxy coating per specification (when applicable). Refractory sound and correct thickness. Expansion joints as per drawing. Corbels installed per drawing. Tube clearances at walls, roof and heater boxes as per drawing. Welding tubes per approved welding procedure of rolling of tubes per specification. All Non-Destructive Testing (NDT), Post-Weld h eat treatment (PWHT) and Brinell Hardness testing compete as per specification. Skin thermocouples installed as per drawings. Hydrotest or Air Test complete as per specifications. Stack checked for plumb and bolts tightened. Damper, cable and indicator checked as per drawing. Burner alignment and orientation checked.

1.18 1.19 1.20 1.21 1.22

Burner piping checked. Sootblower alignment, cleaned and lubricated. Ladder, platforms and stairways checked as per drawings. Clearances for thermal expansion checked. Ductingchecked.

1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35

All debris and foreign material removed and expansion joints are clean. Painter's trolley lines in place. Tag No. visible and correct

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M25 Field Assembled Boilers Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

CCTNo

Item: 1

OK N/A PL Result/Data: I n i t i a lc h e c k s

1.01 1.02

Check nameplate data against datasheet. Check tag no. visible and correct.

1.03 1.04 1.05 1.06 1.07 2

Checkframelevel. Checkalignment. Checkgrouting. Check tightness of anchor bolts. Check ladders, platforms and stairways to manufactors drawings. S t e am a n d M u dD r u m s

2.02 2.03 2.04 3 3.01 3.02 3.03 4 4.01

Check manufactors identification certification and code symbol. Dimensional check of position/oriantation. Inspection of tube holes (cleanliness and preparation for tube rolling or welding). E c o n o m i s e r , s u p e r h e at e r , d e s u p e r h e at e r , e t c . Check manufactors identification certification and code symbol. Dimensional check of position/oriantation. Insp. of flanges (correct size, type & rating). B oi l erTubes Check material certification and verify correctness of s ize, bending and general dimensions against

4.02 4.03 5 6

manufactors drawing. Tubewelding. Visual examination of welding. Preliminary hydrotest (when applicable). D r umi n t er n al s

6.01 6.02 6.03 7 7.01 8 8.01 8.02 9 9.01

Check internals for conformance to approved drawings. Check internals for correct installation. Check for completeness of tube rolling. Pr ess ur epi pi n g Visual examination of welding. A t tach m e n t s t o p re ssu re part s. Check for conformance to approved drawings and specifications. All attachments to pressure patrs are complete. Ce n t r i f ugal p um p ( s) Check per Centrifugal Pump Checklist.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M26 Gas Turbines Rev : A

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Baseplate level a nd properly grouted, foundations t ightened. Excessp ipingstraina lleviated. Alignment to manufacturer's tolerance, jack screws retracted. Check for freedom of movement and direction of rotation. Bearing housing flushed and relubricated. Record date lubricated. Skidgibkeyschecked Transmission checked. Handvalvesoperable. Coupling guard / closer checked. Air inlet assembly correctly installed and clean. Enclosure sealing checked. Enclosure ventilation checked. Exhaust duct system correctly i nstalled and clean.

1.16 1.17

All controls, protective devices and auxilliary systems correct. Gas generator & P.T. checked

1.18 1.19 1.20 1.21 1.22

Pipe supports fitted and adjusted. Lube oil system flushed. Fuel gas system chemically cleaned. Dust blinds installed / Removed.

1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M27 Machinery Pre-Alignment Rev : 0

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg.

P.O. Package

Arrgm. Drwg.

Data Sheet

Remarks

Supplier

Item: 1

OK N/A PL Result/Data: Pr e p ar at i o n

1.01 1.02

Foundation surveyed and datum/reference points marked. Bolt pocket sleeves cut flush with top of foundation.

1.03 1.04 2

Sleeve pocket cleaned out. Shims set each side of foundation bolts (clear of pockets) to obtain correct elevation. I n st al l at i o n

2.01 2.02 2.03 2.04 2.05

Bolts, washers and nuts correct. Correct b olt p rojection t hrough baseplate. Pump lifted and bolts located correctly in pockets. Pump positioned, levelled and aligned to datum marks and blocked to avoid accidental movement. Grout release certificate (Q02) issued and approved for gouting of " Bolts Only" - to a pprox.50mm below top of foundation. Tighten bolts and set final level after grout set. Check coupling alignment and adjust shims accordingly to achieve best results (record and attach figures). F i n alG r ou t i n g On completion/acceptance of above issue second Q02 for baseplate grouting. Confirm if final grouting is witnessed by KUP (Sign and Date) Confirm if cube test taken for grout. R e l e as e f o r U n - c o u p l e d M o t o r R u n Release certificate M31 issued to E&I Contractor

2.06 2.07 3

3.01 3.02 3.03 4 4.01

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M28 - Machinery Final Alignment

Tag No:

CP No: MC No:

Location :

P & ID :

P.O. Package :

Arrgm. Drwg. :

Data Sheet :

Revision :

Supplier :

Remarks :

Remarks:

SubContractor (Sign/Date) Flanges Loose : Flanges Tight : Hot Alignment : Cert Rev.No: 0

EPCS(Sign/Date)

Company(Sign/Date)

MC Inspection & Test Record M30 Final Closing of Vessels and Towers Rev : 0

Tag No:

CP No: MC No:

Location

Dwg

P.O. Package

P & ID

Data Sheet

Revision

Supplier

Remarks

It is hereby verified that the equipment specified has been internally inspected in accordance with drawings and specifications obtained from Project. The equipment is accepted and ready for operation. Item:


1.01

Depreservation completed

1.02 1.03 1.04 1.05

Equipment blindedoff Equipment valve isolated Internallycleaned Internals correctly installed

1.06 1.07 1.08 1.09 1.10

Coatingundamaged Manways installed with new gaskets and correct bolts installed.

Comments:

Final closure has been effected ............................. Date..........................

Sign.......................

Remarks:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record M31 Pump/Driver Release Rev : 0

Tag No:

CP No:

Descr:

MC No:

Location

P & ID

P.O. Package

Arrgm. Drwg.

Data Sheet

Revision

Supplier

Remarks

Item: 1

OK N/A PL Result/Data: R E L E A S E F RO M M E C H A N I CA L C O N TR A C TOR

1.01 1.02

Confirmthatcoupling is removed. Coupling guard replaced.

1.03 1.04 1.05 1.06

Confirm that driver is secure. Confirm that all alignment equipment, tools and aids have been removed. Confirm the motor free to turn by hand. RELEASED TO E&I CONTRACTOR FOR RUN-TEST :Name:…… …… …… …… …… …… …… …… …… …… . Sign : … … … … … … ..… … … … … … … … … … … … … Date : … … …… …… …… …… .…… … …… … …… … .. Note : No further work to be performed on pump until release form return by E&I Contractor. ACCEPTED BY KUP CONSTRUCTION :-

1.07

Name:…… …… …… …… …… …… …… …… …… …… . Sign : … … … … … … ..… … … … … … … … … … … … … Date :… … …… …… …… …… .…… … …… … …… … . 2 2.01

M O TO R U N - C O U PL E D R U N TE S T Test completed and MC Certificate (E03) c ompleted.

2.02

E&I CONTRACTOR RELEASE BACK TO MECHANICAL CONTRACTOR :Name:…… …… …… …… …… …… …… …… …… …… . Sign : … … … … … … ..… … … … … … … … … … … … …

2.03

Date :… … …… …… …… …… .…… … …… … …… … . ACCEPTED BY KUP CONSTRUCTION :Name:…… …… …… …… …… …… …… …… …… …… . Sign : … … … … … … ..… … … … … … … … … … … … … Date :… … …… …… …… …… .…… … …… … …… … .

Comments:



KUPConstruction

Other:-

KUPCommissioning


STRUCTURAL MC FORMS

N01

Structural Steelwork

N02

Structural Steelwork (By Tag No.)

06-Oct-2000 14:58 Page: 7

MC Inspection & Test Record N01 Structural Steelwork MC Package No:

CP No:

Item: 1


1.01 1.02 1.03 1.04 1.05

Pre-erection checks completed. Main columns, beams of roof members are plumb, level and aligned. Secondary columns of beams are plumb, level and aligned. Bracingsa rep roperlyi nstalled. Structural bolts and washers are in place.

1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19

Bolts are according to specification and correctly tightened. Sliding connections are properly made. Sheeting rails are properly installed. Purlins are properly installed. Roof cladding is properly installed. Side cladding is properly secured. Cladding is colour matched. Penetrations have closure pieces. Windows and doors operate correctly. Flashingsarefitted. Gratings, floor plated, stairway, handrails etc., are completed and safe.

Note : 'Data, Results or Check' column valid entries are :- a) OK, b) NA, c) Blank, to be completed later on clearance of punchlist items d) Enter data or results. Drawing No :

Re v:

Contractor

Red L. Date: D r aw i nTgi t l:e

KUPConstruction

Co mme n ts

Other:-

KUPCommissioning

Name : Sign : Date : Rev : B


MC Inspection & Test Record N02 Structural Steelwork (By Tag No.) Rev : A

Tag No:

CP No:

Descr:

MC No:

Drawings

Item: 1


1.01 1.02

Pre-erection checks completed. Main columns, beams of roof members are plumb, level and aligned.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Secondary columns of beams are plumb, level and aligned. Bracingsa rep roperlyi nstalled. Structural bolts and washers are in place. Bolts are according to specification and correctly tightened. Sliding connections are properly made. Sheeting rails are properly installed. Purlins are properly installed. Roof cladding is properly installed. Side cladding is properly secured. Cladding is colour matched. Penetrations have closure pieces. Windows and doors operate correctly. Flashingsarefitted.

1.16 1.17

Gratings, floor plated, stairway, handrails etc., are completed and safe.

1.18 1.19 1.20 1.21 1.22

Comments:



KUPConstruction

Other:-

KUPCommissioning


CIVIL MC FORMS

Q01

Civils Concrete Pour Release / Støpevarsel

Q02

Civils Grout Release / Understøp

Q03

Drainage Civils Sump, Manholes, Catchbasins and Pits

Q04

Driven Piles (Pre-cast / steel) including Sheet Piling

Q05

UG Piping :- Flushing & Testing

Q07

Buildings - Structure & Finish

Q08

Foundation Release Form / Godkjenningsskjema Fundamenter

Q09

Concrete Test Result

Q10

Underground Piping Civils Release Form

Q12

Civils Concrete Checklist / Sjekkliste for Betong

Q13

Civils Tunnel Checklist

Q14

Civils Cavern Checklist

Q15

Civils Site Preparation/Roads Checklist

06-Oct-2000 14:58 Page: 8

MC Inspection & Test Record Q01 Civils Concrete Pour Release / Støpevarsel Rev : C

Tag No:

CP No:

Descr:

MC No:

SubContractor

Area

Site

Location

Drwg/Rev

Drwg/Rev

Drwg/Rev

Drwg/Rev

Item: 1

1.1 1.2 1.3 1.4 1.5 2

2.1 3

3.1 4

4.1

OK N/A PL Result/Data: I n s p e c t i o n - P r e Po u r / F ø r S t ø p . Prior to pouring of concrete blinding layer Før støping av m agerbetong lag Formwork and reinforcement (prior to locking) Forskaling og armering (før lukking) Sub-Contractor's Checklist completed and attached. Sub-Contractor's Sjekkliste utfylt og vedlagt. Surveyreportattached Kontroll rapport vedlagt KUPsurvey report attached KUP kontroll rapport vedlagt Re ady for I n specti on ( S ubC ontractor) / K lart for K on trol l . Sign: Date: T ime: . Pour S ch edule (S ubContractor) / Pl an lagt Støpestart . Sign: Date: T ime: . A p pr ov al t o P o ur ( K U P ) / G o dk j e n t f o r S t øpi n g ( K UP ) . Sign: Date: T ime: .

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record Q02 Civils Grout Release / Understøp Rev : A

Tag No:

CP No:

Descr:

MC No:

SubContractor

Drwg Ref.

P & ID No Location Area

Item: 1

OK N/A PL Result/Data: M i x D e s i g n / M i x D e s i gn

1.1 1.2

Cement; Sand / Sement; Sand Non-Shrink / Tilsettingsmiddel for Ekspansjon

1.3 1.4 2

DryPack/Tørrmørtel Epoxy/Epoxy E q u i p m e n t R e l e a s e / F r i g i v e l s e av U t s t y r

2.1 2.2 2.3 2.4 2.5 2.6 2.7 3 3.1 3.2

Equipment released for grouting / Utstyr frigjort for understøp MECH(SubContractor) Sign: Date: T ime: EPCSContractor Sign: Date: T ime: Company(ifrequired) Sign: Date: T ime: I n s pe ct i on / I n s pe k s j o n Surface are prepared for grout / Overflate klargjort for understøp Bolt sleeves & block-outs cl eared and clean / Utsparinger klare / rengjort

3.3 3.4 3.5 4 4.1 5 5.1

Displaced air can be vented / Luftlommer kan fjernes Formwork is properly fitted / Forskaling montert & tilpassert Facilities f or curing are available / Utstyr for herding er tilgjengelig Re ady for Gr out / Kl ar for Un derstøp (S ubCo n tractor) Sign: Date: T ime: Ap proval t o G rout / G odk je n t t i l U n derstøp ( E PCS Co n tr actor) Sign:

Date:

T ime:

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record Q03 Drainage Civils Sump, Manholes, Catchbasins and Pits Rev : 0

Tag No:

CP No:

Descr:

MC No:

SubContractor

Area

P & ID No

Flush Date

Site

Flush Temp

Location

Flush Medium

Item: 1

OK N/A PL Result/Data: E qu i p m e n t R e l e as e

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2. 1 2.10 2.2 2.3 2.4

Excavation to correct dimensions Bottom undisturbed or compacted Binding Bottom Slab (Pour Release Audited) Walls ( Pour Release Audited) Roof ( Pour Release Audited) Shuttering dismantleda nd removed Precast concrete manhole section Tanking - waterproofing Internallycleaned W a t e r f i l l t e s t ( i f a p p l i c a bl e ) Embedments and intergal foundations Backfill and compact (if applicable) Proprietary GRPseperation

2.5 2.6 2.7 2.8 2.9

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record Q04 Driven Piles (Pre-cast / steel) including Sheet Piling Rev : 0

Tag No:

CP No:

Descr:

MC No:

SubContractor

Drwg.No.

Location

Drwg.No

Item No

Drwg.No

Description

Item: 1

OK N/A PL Result/Data: I n s p ec t i on

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2. 1 2.10 2.2 2.3 2.4

PileReferanceNo Location Length of pre-formedpile Timeofdriving Ground level prior to driving Workinglevel Drivenlengthofpile Cutofflevel Toeelevation Typeofpacking I n t er medi at e s et Intermediateset Final set (mm. per 10 blows) Final set (No.blows p er 25 mm)

2.5 2.6 2.7 2.8 2.9

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record Q05 UG Piping :- Flushing & Testing Ref: L06 - for video inspection verification Comm. Pack No:

Test Pack:

Flushing :

Pressure Testing :

Flush Date :

Test Date :

Flush Medium :

Test Medium :

Flush Temperature:

Ambient Temperature :

Design Pressure :

Test Start Pressure :

Test Finish Pressure :

Test Duration :

Design Isometric No :

LinNe:o

Orig P.&I:D

Comments:

QCReleased(Name Date / Sign.) / :

Contr.:

Release Testing for :

Name:

Company: Sign:

Flushed Name/Date/Sign.

Date:

Tested Name/Date/Sign.

SubContractor: EPCS: 3. Party: Company: Printed: 5-Oct-00 10:37

MC Inspection & Test Record Q07 Buildings - Structure & Finish Rev : A

Tag No:

CP No:

Descr:

MC No:

SubContractor

Drwg. Ref.

Location

Remarks

Item No Description

Item: 1

OK N/A PL Result/Data: Str uctur e

1.01 1.02

Excavation complete. / Ut graving ferdig. Sub-grade compaction. / Grunn komprimert.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 2 2.01 2.02

Foundation complete. / Fundamenter ferdig. Drainage tested. / D renering ferdig. Columns & bearings installed. / Søyler & bærere ferdig. Floor slab; slabs. / Pl ater; dekker ferdig. Roof complete. / Tak ferdig. Walls erected. / V egger ferdig. Interior partitions complete. / Invendige konstrukstrosjoner ferdig.

In stal l at i on s In stal l ed & Tested. / I nstal le rt og Testet .

Plumbing. / Rørleggerarbeide. Electrical power & lighting. / Elektrisk opplegg & lys.

2.03 2.04 2.05 3 3.01 3.02 3.03

Air conditioner. / HVAC.

Fin ish in g

3.04 3.05 3.06 3.07

Exterior walls & woodwork. / Ytre vegger & treverk. Interior & woodwork. / I nnvendige arbeider. Ceilings. / Undertak. Floors. / Gulv.

3.08 3.09 3.10

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record Q08 Foundation Release Form / Godkjenningsskjema Funda Rev : A

Tag No:

CP No:

Descr:

MC No:

SubContractor

Drwg. Ref.

Location

Remarks

Item No Description

Item:


1

I n s pe ct i on / I n s pe k s j o n

1.1

Foundations complete and prepared for grout. Fundamenter ferdig og klar for gysemasse. Centre lines and elevation marked and checked by Mech SubContractor. Sentrering / Høyde, merket & sjekket. Anchor bolts size and spacing correct. Ankerbolt er, større lse / mellomr om sjekket. Anchor bolts straight, threads clean, sleeves clear. Ankerbolter, r ette / skrugjeng er rene, utspari nger klar. Backfill completed and compacted as per specification. Tilbakefylling ferdig & komprimert I.h.t. spesifikasjon. All QC documantation complete. Alle QC dokument asjon ferdig. Ac ceptan ce of Foun dati on / Go dkj en ni ng av Fundame n t CivilSubContractor Sign: Date:

1.2 1.3 1.4 1.5 1.6 2

2.1 2.2 2.3 2.4

Mechanical SubContractor Sign:

Date:

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record Q09 Concrete Test Result Rev : A

Tag No:

CP No:

Descr:

MC No:

SubContractor

Pour Location 1

Layout Drwg

Pour Location 2

Site

Pour Location 3

Area

Test Report Ref

Item: 1

OK N/A PL Result/Data: I n s p e c t i o n / D at a

1.1 1.2

ConcreteCubeNumber ConcreteGrade

1.3 1.4 1.5 1.6 1.7 2

Datecast Weightofcube DensityFresh Slump V/CRatio Fi r st Tes t (7 D ays )

2.1 2.2 2.3 2.4 2.5 2.6 2.7 3 3.1

TestNo.1Date TestNo.1Age DensityatTestNo.1age Appliedload Strengthrequired Strengthattained Passoffail S e c o n d Te s t ( 2 8 D ay s ) TestNo.2Date

3.2 3.3 3.4 3.5 3.6

TestNo.2Age DensityatTestNo.2age Appliedload Strengthrequired Strengthattained

3.7

Passoffail

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record Q10 Underground Piping

MC Pack No:

CP No:

SubContractor

Area

P & ID No

Layout Drwg

Site

Layout Drwg

Location

Layout Drwg

Item:

1

1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 2.1 3 3.1 4 4.1 5 5.1 6 6.1

Inspection Inspeksjon Prior to backfilling Før Tilbakefyllin g Stretching of GRE piping performed (attach documentation) Strekking av GRE Rør utført Flushing / TV-inspection (Note separate form to be attached) Flushing/TV Inspeksjon Leak testing, pressureless pipes (Note separate form to be attached) Lekkasjetest, ikke Trykkrør. Pressure testing, pressure pipes (Note separate form to be attached) Trykktest, Trykkrør Coating and wrapping of u/g metallic pipe and components Overflatebehandling og Wrapping av Metall Rør U.Ground Other, as specified Annet, som beskre vet Ready for inspection (SubContractor) Klar for Inspeksjon Sign: Date: . Backfilling Schedule (SubContrator) Tilbakefyllin g Plan Sign: . Prepared by (SubContrator) Klargjort Av Sign: . Approved by (EPCS Contrator) Godkjent Av Sign: . Backfilled Tilbakefyllt Sign: .

Date:

Date:

Date:

Date:

Comments:

Note : 'Data, Resul ts or Check' column v alid entries are :- a) OK , b) NA, c) Blank, to be comp leted later on clea rance of punchlis t items d) Enter data or resu lts.


EPCS:

Company:

MC Inspection & Test Record Q12 Civils Concrete Checklist / Sjekkliste for Betong Rev : 0

MC Package :

Comm. Pack No:

Description :

Item: 1

OK N/A PL Result/Data: I n s pe ct i on / I n s pe k s j on

1.01

Installed according to specifications and drawings. Installert i henhold til spesifikasjo ner og tegninger.

1.02

Concrete finish acceptable. Betongoverflate godkjent. Survey report attached. Kontroll rapport vedlagt. Survey conclusion satisfactory. Resultat av kontroll tilfredstillende . Embedded item clean and protected. Innstøpninggods rengjord.

1.03 1.04 1.05

Comments:

Foundation ID :

Area:

Description :

Remarks:

Note : 'Tick all Check Item columns under OK - Satisfactory; N/A - Not Applicable; PL - Punch Item(s) against check point. Also record Test Result s or Data'


KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record Q13 Civils Tunnel Checklist Rev : 0

Tag No:

CP No:

Descr:

MC No:

Description Area Remarks

Item: 1

1.1 1.2 2

2.1 3

3.1 4

4.1 5

OK N/A PL Result/Data: I n s p e c t i o n o f Pe r m an e n t R o c k S u p p o r t Inspeksjon av Permanentsikring Rockbolts Rockbolter Shotcretea pplicationa cceptable Sprøytebetong Sur ve y Målinger Confirm profile survey completed (attach or reference documentation) Tverrsmittsm ålinger ferdig Cl ean l i n e ss Ryddig General clean-up and removal of temporary equipment Nedrigging og rydding O th er Annet Roadcondition Vei standard K U P F I N A L R E L E A S E F O R C L O S U R E / W A TE R F I L L : -

5.1a

Name: .

5.1b

Sign . : Date: .

5.1c

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record Q14 Civils Cavern Checklist Rev : 0

Tag No:

CP No:

Descr:

MC No:

Description Area Remarks

Item: 1

1.1 1.2 2

2.1 3

OK N/A PL Result/Data: I n s p e c t i o n o f Pe r m an e n t R o c k S u p p o r t Inspeksjon av Permanentsikring Rockbolts Rockbolter Shotcretea pplicationa cceptable Sprøytebetong Sur ve y Målinger Confirm profile survey completed (attach or reference documentation) Tverrsmittsm ålinger ferdig C on cre teW ork s

3.1 3.2 3.3 4 4.1 5

5.1 5.2 5.3 6 6.1 7

7.1a 7.1b 7.1c

Floor Floorslopecorrect Concrete around fill lines Cl ean l i n e ss Ryddig General clean-up and removal of temporary equipment Nedrigging og rydding O th er Annet Pipesupportbolts Holes for temperature elements Hull for temperaturmålere Penetration caissonsi nstalled correctly C aver nC l o sur e Kaverne Stenging Cavern plugsinstalled Kaverne plugg installert K U P F I N A L R E L E A S E F O R C L O S U R E / W A TE R F I L L : Name: . Sign: . Date: .

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record Q15 Civils Site Preparation/Roads Checklist Rev : 0

Tag No:

CP No:

Descr:

MC No:

Contractor

Drwg No

Location

Drwg No

Area

Drwg No Remarks

Item: 1

1.01 1.02 1.03 1.04 1.05 1.06 2

2.1a 2.1b 2.1c 3

3.1 3.2 3.3 3.4 3.5

OK N/A PL Result/Data: I n s p ec t i on Inspeksjon Installed according to specifications and drawings. Installert i henhold til spesifikasjo ner og tegninger. Crushedr ockl ayer(s)c ompleted. Betongoverflate godkjent. Backfillingc ompleted. Tilbakefylling ferdig. Compaction completed. Sammenpressing ferdig. Survey report attached. Kontroll rapport vedlagt. Survey conclusion satisfactory. Resultat av kontroll tilfredstillende . K U P R e l e a s e f o r A s p h a l t S u r f ac i n g ( i f a p p l i c ab l e ) KUP Godkjent for Asfalt Vei Dekking. Name: . Sign: . Date: . R o a d S u r ac e I n s p e c t i o n Vei Dekke Inspeksjon Installed to specificationsand drawings. Installert i henhold til spesifikasjo ner og tegninger. Asphalt surfacing thickness correct. Asfalt tykkelse korrekt. Asphalts urfaceq uality/structure. Asfalt overflate kvali tet/stuktur. Transition to drains and manholes etc. Overgang til avløp og manhull etc. Slopescorrect. Tverrfall korrekt.

Comments:



KUPConstruction

Other:-

KUPCommissioning


SURFACE PROTECTION MC FORMS

R01

Surface Protection (Equipment)

R02

Surface Protection (Piping)

R03

Surface Protection (Structural)

06-Oct-2000 14:58 Page: 9

MC Inspection & Test Record R01 Surface Protection (Equipment) Rev : 0

Tag No:

CP No:

Descr:

MC No:

P.O. Package

Arrng. Drwg.

Location

Remarks

Data Sheet Supplier

Item: 1

OK N/A PL Result/Data: S u r f ac e Pr e p ar at i o n

1.01 1.02

1. 2.

1.03 1.04 1.05 1.06 2 2.01 2.02 2.03 3 3.01 3.02 3.03 3.04

3. Humidity%RH DBTemperatureDegC C o at i n gS p ec i f i c at i on

1. 2. 3. A c t u al C o at i n g A p p l i e d 1. 2. 3. 4.

3.05 3.06

Humidity%RH DBTemperatureDegC

3.07 3.08 3.09

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record R02 Surface Protection (Piping) MC Package No: CP No: Scope/Refs :

Surface Preparation :

Location / Area :

1:

Coating Specification : 1:

Actual Coating Applied : 1:

Service Descr :

2:

2:

2:

Coating System No.:

3:

3:

3:

Humidity %RH :

Humidity %RH :

DB Temperature Deg C :


Design Isometric No :

e :o Shop Iso L i nN Rev:

Contractor

KUPConstruction

O r i g . P& I D :

Other:-

R emark:s

KUP Commissioning


MC Inspection & Test Record R03 Surface Protection (Structural) MC Package No: CP No: Scope/Refs :

Surface Preparation :

Location / Area :

1:

Coating Specification : 1:

Actual Coating Applied : 1:

Service Descr :

2:

2:

2:

Coating System No.:

3:

3:

3:

Humidity %RH :

Humidity %RH :



D es i gnI so m e t ri cN o:

Rev: R edLD . at e:

Contractor

D r aw i n gTi t l e:

KUPConstruction

R emark s:

Other:-

KUPCommissioning



SAFETY MC FORMS

S01

Dual Agent Hose Reels

S02

Firewater Hydrants

S03

Firewater Monitors

S04

Oscillating Firewater Monitors

S05

Firewater M onitor/Hydrant A ssemblies

S06

FoamSystems

S07

Hosereels

S08

Portable Extinguishers

S09

FM200 Clean Agent Systems

S10

Deluge & Sprinkler Systems

S11

Firemans Cabinets

S20

Safety Equipment - Area Acceptance

06-Oct-2000 14:58 Page: 10

MC Inspection & Test Record S01 Dual Agent Hose Reels Rev : A

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02

Inspection Checklist : Installed according to specification and drawings. Check nameplate data against data sheet.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Skid correctly installed and bolted to deck. Firewater/Foam connections to skid correct. Electrical connection to skid. Check water supply line is insulated up to and including the stop valve. Check water supply line is trace-heated up to and including the stop valve. Tag No. visible and correct. External condition.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S02 Firewater Hydrants Rev : B

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Hydrant correctly i nstalled. Hydrant braced against jet reaction force. Check elevation and traverse for unrestricted movement. Check hydrant h as clear "f ield of application". Check water supply line is insulated up to and including the stop valve. Check water supply line is heat-traced up to and including the stop valve. Tag No. visible and correct. Check coupling caps and chains installed.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S03 Firewater Monitors Rev : B

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11

Monitor correctly installed. Monitor braced against jet reaction force. Check elevation and traverse for unrestricted movement. Check monitor has clear "field of application". Check water supply line is insulated up to and including the stop valve. Check water supply line is heat-traced up to and including the stop valve. Tag No. visible and correct. External condition.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S04 Oscillating Firewater Monitors Rev : B

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Oscillating moitor correctly installed. Oscillating moitort braced against jet reaction force. Check elevation and traverse for unrestricted movement. Check oscillating moitor has clear "field of application". Check water supply line is insulated up to and including the stop valve. Check water supply line is heat-traced up to and including the stop valve. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S05 Firewater Monitor/Hydrant Assemblies Rev : B

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Monitor/Hydrant correctly installed. Monitor/Hydrant braced against jet reaction force. Check elevation and traverse for unrestricted movement. Check monitor/hydrant has clear "field of application". Check water supply line is insulated up to and including the stop valve. Check water supply line is heat-traced up to and including the stop valve. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S06 Foam Systems Rev : B

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Foam u nits c orrectly i nstalled a nd f ixed t o fo undation/supports. Monitors and towers correctly installed and fixed to foundation/supports. Monitor panels correctly installed and fixed to foundation/supports. Systems piping installed to design drawings. System piping hydrotest completed. Foam Pouren's correctly installed. System pipe supports checked. Instrument air supply connected. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S07 Hosereels Rev : B

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10

Hose reel correctly installed. Cabinetd oorsf unctional. Tag No. visible and correct.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S08 Portable Extinguishers Rev : B

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02

Inspection Checklist : Installed according to specification and drawings. Check namplate data against data sheet.

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12

Record type of extinguisher : A) Dry Chemical - 12kg, B) CO2 - 6kg, C) Specify if other. Record colour o f e xtinguisher. Location correct. Bracket fixing secure. Instruction label in place. Extinguisher visible. Extinguisher charged. Record Serial No.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S09 FM200 Clean Agent Systems Rev : 0

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08

FM200 skid correctly installed and fixed/welded to foundation supports. FM200 piping installed to drawings.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S10 Deluge & Sprinkler Systems Rev : 0

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12

Deluge/sprinkler ski d correctly installed and fi xed/welded to fo undation/supports. System piping installed to design drawings. System piping hydrotest complete. System discharge sprayers correctly installed. System pipe supports checked. Pneumatic heat detector system/pneumatic test complete and approved. Pneumatic heat detector system correctly installed. Instrument air supply connected. Heat tracing and insulation installed and checked.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S11 Firemans Cabinets Rev : 0

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02


1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10

Cabinet correctly installed and fixed/welded to foundation/supports. Cabinetu ndamaged. Check cabinet contents against specifications. Check door fastenings easily open. Check c abinet c learly l abelled. Check instructions for Breathing Apparatus (B.A.) sets included.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record S20 Safety Equipment - Area Acceptance Rev : 0

Tag No:

CP No:

Descr:

MC No:

Area Code Drwg No. Drwg No. Drwg No.

Item:

Data/Results/Check:

1.01 1.02 1.03

Central Fire Points. LifeBuoys. Emergency Wire Ladders.

1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15 1.16

Stretchers. Collapsible Stretchers. EyeBaths. Safety Showers. First Aid Kits. Bosun's Chair. BreathingA pparatus. Safety Signs. Escape Routes. Penetrations. Fire Proofing. Fire Extinguishers. Fireman's Cabinets.

1.17 1.18

Piping and HVAC ducts correctly marked.

1.19

Comments:



KUPConstruction

Other:-

KUPCommissioning


TELECOM MC FORMS

T01

Harbour Radar Systems

T02

Wind Measuring Instruments

T03

Sub-Sea Current Meters

T04

Docking Aid Systems

T05

PASystems

T06

Automatic Telephones Systems

T07

UHF Radio Equipment

T08

Intercom Equipment

T09

Telex, Telefax and Teletex Equipment

T10

Close Circuit Television Equipment

T11

Radio Paging Equipment

T12

Security Access Systems

T13

TelecommCable

T14

Miscellaneous Telecom Equipment

06-Oct-2000 14:58 Page: 11

MC Inspection & Test Record T01 Harbour Radar Systems MC Package :

Comm. Pack No:

Description : Item: 1 1.01 1.02 1.03 1.04 1.05

Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. No fluid leaks. Nuts and bolts tight. Paintwork good.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Glanding correct. Protection of 'Live' parts correct. Earthing correct. Earthing securely tight. Unit displays correctly installed. Sensors correctly installed. Heaters correctly installed.

1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20

All labelling and warning marks correctly in stalled and vi sible. All cabling and auxilliary wiring neat and undamaged. Terminal blocks correct. Power supplies correctly installed. Air supply correctly installed and sensors checked for air tightness. Radar scanner correct installed. Equipment r acks c orrectly i nstalled.

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

DataSheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning

Name : Sign : Date : #Error


MC Inspection & Test Record T02 Wind Measuring Instruments Rev : A

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02

Inspection Checklist : Checked to installation drawing. Anemometer location and mounting correct.

1.03 1.04 1.05 1.06 1.07 1.08 2 2.01 2.02

Junction box location and mounting correct. Cabinet and fittings installed and secured correctly. No physical damage to installed items. All cable entries and terminations correct. Display unit, heater, PSU and control unit check. Functional Test : FunctionalTest: Control unit working correctly. Amemometer calibrated.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record T03 Sub-Sea Current Meters Rev : A

Tag No:

CP No:

Descr:

MC No:

P.O. Package

System Drwg.

Location

Arrgm. Drwg.

Data Sheet

Ref.

Supplier

Remarks

Item:

Data/Results/Check:

1 1.01 1.02

Inspection Checklist : Checked to installation drawings. Checked to installation drawing.Sensor location and mounting correct - De pth in sea-water.

1.03 1.04 1.05 1.06 1.07 1.08 2 2.01 2.02 2.03

Junction box location and mounting correct. Sensors installed and secured correctly. No physical damage to installed items. All cable entries and terminations correct. Processor, display and PSU check. Functional Test : FunctionalTest: Sensors working correctly. Sensors calibrated. Display and processor calibrated.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record T04 Docking Aid Systems MC Package :

Comm. Pack No:


Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. No fluid leaks. Nuts and bolts tight. Paintwork good.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Glanding correct. Protection of 'Live' parts correct. Earthing correct. Earthing securely tight. Unit displays correctly installed. Sensors correctly installed. Heaters correctly installed.

1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24

All labelling and warning marks correctly in stalled and vi sible. All cabling and auxilliary wiring neat and undamaged. Terminal blocks correct. Power supplies correctly installed. Air supply correctly installed and sensors checked for air tightness. Computer c orrectly i nstalled. Equipment r acks c orrectly i nstalled. Traffic lights correctly installed. Ex. Certificate status verified on sensors. Civils works inspected.

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

Data Sheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning



MC Inspection & Test Record T05 PA Systems MC Package :

Comm. Pack No:


Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. All loudspeakers and supports correctly installed. Nut and bolts tight. Paintwork good.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Glanding correct ( all un its an d ju nction boxes). Protection of 'Live' parts correct. Earthing correct. Earthing securely tight. Unit d isplays an d co ntrols c orrectly i nstalled. All labelling and warning marks correctly in stalled and vi sible. All cabling and auxilliary wiring neat and undamaged.

1.13 1.14 1.15 1.16 1.17 1.18

Terminal blocks correct. Power supplies correctly installed. Cooling fans correctly installed. Racks mounted equipment correctly i nstalled.

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

Data Sheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning



MC Inspection & Test Record T06 Automatic Telephones Systems MC Package :

Comm. Pack No:


Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. Paintwork good. Nut and bolts tight. All MDF connections correct and tightened.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Earthing correct. Earthing securely tight. Phase i dentification c orrect. Protection of 'Live' parts correct. Telephone extension correctly installed. Power supplies correctly installed. Ex. t elephones correctly i nstalled.

1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20

All labelling and warning marks correctly in stalled and vi sible. Auxilliary flashing beacons, bells, hooters etc., correctly installed. All cabling and auxilliary wiring neat and undamaged. Terminal blocks correct. Glanding correct. Cable routing in buildings. Extension cable routes.

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

Data Sheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning



MC Inspection & Test Record T07 UHF Radio Equipment MC Package :

Comm. Pack No:


Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. Paintwork good. Nut and bolts tight (Tower and Racks). Earthing correct.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Earthing securely tight. Power supply correct. Radio feeder correct. Antenna and tower correct and tight. Control units. Transmitters/R eceivers. All labelling and warning marks correctly in stalled and vi sible.

1.13 1.14 1.15 1.16 1.17 1.18

All cabling and auxilliary wiring neat and undamaged. Associated hand-portable units. Auxilliarye quipment. Battery charger (including carrying equipment, spare batteries etc.).

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

Data Sheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning



MC Inspection & Test Record T08 Intercom Equipment MC Package :

Comm. Pack No:


Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. Paintwork good. Nut and bolts tight. Earthing correct.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Earthing securely tight. Location correct. Cablingc orrect. All labelling and warning marks correctly in stalled and vi sible. All wiring neat and undamaged. Protection of 'Live' parts correct. Handsets correct.

1.13 1.14 1.15 1.16

Central control units correct. Expansion capability provided.

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

Data Sheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning



MC Inspection & Test Record T09 Telex, Telefax and Teletex Equipment MC Package :

Comm. Pack No:


Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. Paintwork good. Nut and bolts tight. Visual inspections.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Earthing correct. Earthing securely tight. Terminal identifications correct. Protection of metal surface correct. Terminals correctly. Powerc onnections. All labelling and warning marks correctly in stalled and vi sible.

1.13 1.14 1.15

All cabling and auxilliary wiring neat and undamaged.

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

Data Sheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning



MC Inspection & Test Record T10 Close Circuit Television Equipment MC Package :

Comm. Pack No:


Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. Paintwork good. Earthing correct. Earthing securely tight.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Nut and bolts tight. Camera installed correctly. Monitorsi nstalled c orrectly. Correctl ocations. Cables and glands. Video optical equipment installed correctly. Camera cotrol equipment installed correctly.

1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20

Video matrix/switching equipment correct. Ex.camera housing. Pan an d ti lt d rive equipment correctly in stalled. Power supplies. Window, washer and wipers installed and correct.

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

Data Sheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning



MC Inspection & Test Record T11 Radio Paging Equipment MC Package :

Comm. Pack No:


Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. Paintwork good. Nut and bolts tight. Earthing correct.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Earthing securely tight. Protection of 'Live' parts correct. All labelling and warning marks correctly in stalled and vi sible. All cabling and auxilliary wiring neat and undamaged. Base station equipment. Power supplies. Paging unit.

1.13 1.14 1.15

Batteryc harger.

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

Data Sheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning



MC Inspection & Test Record T12 Security Access Systems CP No:

MC Package : Description : Item: 1 1.01 1.02 1.03 1.04 1.05

Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. Paintwork good. Nut and bolts tight. Terminal boxes correct.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Termination correct. Glanding correct. Earthing correct. Earthing securely tight. All labelling and warning marks correctly in stalled and vi sible. Correct instructions o n card r eaders. Correct marking on central computer and display unit.

1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20

Turnstiles correctly installed. Sliding gates correctly installed. Power supplies. Cable runs and entries. Civilworks.

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

Data Sheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning

Name : Sign : Date : Rev : A


MC Inspection & Test Record T13 Telecomm Cables ( By MC Package )

Rev : A

MC Package :

CP No:

Description : Item: 1 1.01

I n s p e c t i o nC h e c k l i s t: Check cable against specification and drawings.

1.02 1.03 1.04

Check cable against Data Cable Schedule. Check labelling, numbering and ferruling correct. Checkc lampinga ndc leatingc orrect.

1.05 1.06

Check glanding, locknuts and shrouding correct. Checkcablegroupingcorrect.

1.07 1.08

Checkc ablem echanicallyp rotected. Checkcableterminatedcorrectly.

1.09 1.10

Checks parec orese arthed. Checkbendingradiuscorrect.

O bj e cI D t

C h ec ke d

C a blTey p e

F ro m

To

S iC z/eo res

M e g g e r T es t

C o n t i n u i t y T es t

R em a r k s

Note : As-Built Diagram sketch as required or red-line marked up drawings to be attached. ACCEPTANCE

Contractor

KUP Construction

Other:-

KUP Commissioning


Page: 1

MC Inspection & Test Record T14 Miscellaneous Telecom Equipment MC Package :

Comm. Pack No:


Inspection Checklist : Check nameplate data against data sheet. No mechanical damage. All items securely fixed and supported correctly. Nut and bolts tight. Paintwork good.

1.06 1.07 1.08 1.09 1.10 1.11 1.12

Glanding correct. Protection of 'Live' parts correct. Earthing correct. Earthing securely tight. Unit d isplays an d co ntrols c orrectly i nstalled. All labelling and warning marks correctly in stalled and vi sible. All cabling and auxilliary wiring neat and undamaged.

1.13 1.14 2 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09

Terminal blocks correct. Power supplies correctly installed. Additional Check Items (Add specific checks as required)

2.10

Comments: :

OI D bj ect

D es cr i pt:i o n

Contractor

Data Sheet

KUPConstruction

Other:-

Ch e: ck ed

R em a:rk s

KUPCommissioning




INSULATION /REFRACTORY/FIREP ROOFING MC FORMS

U01

Insulation (Equipment)

U02

Insulation (Piping)

U03

Fireproofing Steelwork

U04

Refractory (Castable Linings)

U05

Fireproofing Equipment

06-Oct-2000 14:58 Page: 12

MC Inspection & Test Record U01 Insulation (Equipment) Rev : 0

Tag No:

CP No:

Descr:

MC No:

Location

P & ID

P.O. Package

Arrng Drwg.

Data Sheet

Remarks

Supplier

Item: 1

OK N/A PL Result/Data: I n s ul at i o n

1.01 1.02 1.03 2 2.01 2.02 2.03 2.04 3 3.01 3.02 3.03 4 4.01 4.02

Confirm Insulation/Jacketing Class. Confirm Insulation Type. Confirm Insulation thickness. Pr e - I n s u l at i o n c h e c k l i s t : Hydrotestc ompleted. Post test punchlist completed. Surfacep reparationa cceptable. Stud, n uts, support ringsi nstalled. R e l e a s e f o r I n s u l at i o n Name. Date. Signature. I n s pe ct i on / Ch e ck l i s t : Insulation correct. Jacketing correct.

4.03 4.04

Sealing. Instrumentsclear.

4.05 4.06

Valve boxesinstalled. Dataplateclear.

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record U02 Insulation (Piping) Rev : 0

MC Pack No :

CP No:

References :

CheckPoints:

Location / Area :

Hydrotest Completed :

Results: ReleaseforInsulation: Release Date :

Insulation Type :

Service Descr :

Post Test Punchlist Completed :

Name :

Jacketing :

Insulation Code No.:

Surface Preparation Acceptable:

Date :

Sealing :

Fully Reinstated :

Sign :

Valve boxes :

Heat Tracing Tape Completed :

Inspection:

Instrument points clear

Mark 'OK' or 'N/A' in Results Box: Design Isometric No :

Iso Rev:

SubContractor

LinN eo :

EPCS

Orig.P&ID :

Company


MC Inspection & Test Record U03 Fireproofing Steelwork Rev : 0

Tag No:

CP No:

Descr:

MC No:

Title Description

Item: 1

OK N/A PL Result/Data: Pr i o r t o I n s t a l l a t i o n

1.01 1.02 1.03 1.04 1.05 2 2.01 2.02 2.03 3 3.01 3.02 4 4.01 4.02

Anchor, hex mesh etc., material type, size, height. Welding Procedures. Qualification Records (PQR). Weld test coupon / sample. Weldingsurface. A f t e r I n s t a l l at i o n Visual inspect welding. Hammer test as specified. Repair, re-test performed. F i br e s - P r i o r t o U s e Chemical analysis of material. Fibre, length, size diameter. F i r e p r o o f i n g - Pr i o r t o I n s t a l l at i o n Correct type / batch of material. Mixing and application procedures.

4.03 4.04

Fibre reinforced mixture. Shipping storage preservation, shelf life of materials, sequence of operations.

4.05 4.06 4.07

Required testing, reports, results in accordance with specifications, procedures. Fireproofing vendor's recommended method for the installation, curing and drying. Optimum water content for each material has been obtained by testing by the installer or by the manufacturer for the installer. Installer has submitted tests performed by the manufacturer of fireproofing and / or fibres.

4.08 4.09 4.10 4.11 4.12 4.13 5 5.01 5.02

Hand packer qualifications. Gunnerq ualifications. Water for mixing has been tested. Test reports, results. Surface to be lined in accordance with specifications and procedures. F i r e p r o o f i n g - D u r i n g I n t a l l at i o n Mixing contents, mixing pr ocedures and a pplication procedures ar e in a ccordance to s pecifications an d procedures. Temperature requirements are being maintained.

5.03 5.04 5.05 6 6.01 6.02 6.03 6.04 6.05 6.06 6.07

Water content of mixture is being recorded. Test cubes are being maintained. Progressive visuali nspection. F i r e p r o o f i n g - A f t e r I n s t a l l at i o n Visual inspect surface of fireproofing coating. Curing and drying is performed in accordance with specifications and procedures. All testing complete, recorded with results submitted as specified. Visual and dimensional inspect surface of lining - proper thickness etc. Hammer test specified. Other inspections : Specify :Method of repair, curing, testing in accordance with specifications and procedures.



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record U04 Refractory (Castable Linings) Rev : 0

Tag No:

CP No:

Descr:

MC No:

Location

Remarks

P.O. Package

Arrng Drwg.

Data Sheet

Remarks

Supplier

Item: 1


1.01 1.02 1.03 1.04 1.05 2 2.01 2.02 2.03 3 3.01 3.02 4 4.01 4.02

Anchor, hex mesh etc., material type, size, height. Welding Procedures. Qualification Records (PQR). Weld test coupon / sample to MET. Weldingsurface. A f t e r I n s t a l l at i o n Visual inspect welding. Hammer test as specified. Repair, re-test prior to shoplining or shipment. F i br e s - P r i o r t o U s e Chemical analysis of material. Fibre, length, size diameter. R e f r ac t o r y - Pr i o r t o I n s t a l l a t i o n Correct type / batch of material. Mixing and application procedures.

4.03 4.04


4.05 4.06 4.07

Required testing, reports, results in accordance with specifications, procedures. Refractory vendor's recommended method for the installation, curing and drying of lining. Optimum water content for each material has been obtained by testing by the installer or by the manufacturer for the installer. Installer has submitted tests performed by the manufacturer of refractory and / or fibres.

4.08 4.09 4.10 4.11 4.12 4.13 5 5.01 5.02

Hand packer qualifications. Gunnerq ualifications. Water for mixing has been tested. Test reports, results. Surface to be lined in accordance with specifications and procedures. R e f r a c t o r y - D u r i n g I n t al l a t i o n Mixing contents, mixing pr ocedures and a pplication procedures ar e in a ccordance to s pecifications an d procedures. Temperature requirements are being maintained.

5.03 5.04 5.05 6 6.01 6.02 6.03 6.04 6.05 6.06 6.07

Water content of mixture is being recorded. Test cubes are being maintained. Progressive visuali nspection. R e f r a c t o r y - A f t e r I n s t al l at i o n Visual inspect surface of refractory linings. Curing and drying is performed in accordance with specifications and procedures. All testing complete, recorded with results submitted as specified. Visual and dimensional inspect surface of lining - proper thickness etc. Hammer test specified. Other inspections (e.g. optical instruments, boroscope etc) : Specify :Method of repair, curing, testing in accordance with specifications and procedures.



KUPConstruction

Other:-

KUPCommissioning

MC Inspection & Test Record U05 Fireproofing Equipment Rev : 0

Tag No:

CP No:

Descr:

MC No:

Location

System Drwg:

P.O.

Arrg Drwg:

Data Sheet:

Remarks:

Supplier:

Item: 1


1.01 1.02 1.03 1.04 1.05 2 2.01 2.02 2.03 3 3.01 3.02 4 4.01 4.02

Anchor, hex mesh etc., material type, size, height. Welding Procedures. Qualification Records (PQR). Weld test coupon / sample. Weldingsurface. A f t e r I n s t a l l at i o n Visual inspect welding. Hammer test as specified. Repair, re-test performed. F i br e s - P r i o r t o U s e Chemical analysis of material. Fibre, length, size diameter. F i r e p r o o f i n g - Pr i o r t o I n s t a l l at i o n Correct type / batch of material. Mixing and application procedures.

4.03 4.04


4.05 4.06 4.07

Required testing, reports, results in accordance with specifications, procedures. Fireproofing vendor's recommended method for the installation, curing and drying. Optimum water content for each material has been obtained by testing by the installer or by the manufacturer for the installer. Installer has submitted tests performed by the manufacturer of fireproofing and / or fibres.

4.08 4.09 4.10 4.11 4.12 4.13 5 5.01 5.02

Hand packer qualifications. Gunnerq ualifications. Water for mixing has been tested. Test reports, results. Surface to be lined in accordance with specifications and procedures. F i r e p r o o f i n g - D u r i n g I n t a l l at i o n Mixing contents, mixing pr ocedures and a pplication procedures ar e in a ccordance to s pecifications an d procedures. Temperature requirements are being maintained.

5.03 5.04 5.05 6 6.01 6.02 6.03 6.04 6.05 6.06 6.07

Water content of mixture is being recorded. Test cubes are being maintained. Progressive visuali nspection. F i r e p r o o f i n g - A f t e r I n s t a l l at i o n Visual inspect surface of fireproofing coating. Curing and drying is performed in accordance with specifications and procedures. All testing complete, recorded with results submitted as specified. Visual and dimensional inspect surface of lining - proper thickness etc. Hammer test specified. Other inspections : Specify :Method of repair, curing, testing in accordance with specifications and procedures.



KUPConstruction

Other:-

KUPCommissioning


ARCHITECTUR AL MC FORMS

Z01

Architectural

11-Oct-2000 14:41 Page: 13

MC Inspection & Test Record Z01 Architectural Rev : A

Tag No:

CP No:

Descr:

MC No:

Drawing Area Room Arrng Drwg

Item: 1


1.01 1.02

Wall linings, barrier & Insulation Raisedaccessfloor

1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15

Partitions Falseceilings Access and/or escape hatches Floor coating and or covering Doors Stairs Louvres Windowsandglazing Furniture, fixtures, benches, sinks, desks, consoles and fittings Plumbing Sanitaryequipment Drainage Acousticelements

1.16 1.17

Décor Paintwork

1.18 1.19 1.20 1.21 1.22

Penetrationscorrect Redundant penetrations sealed correctly Fire walls and/or blast walls Signsandnotices Final clean-up, including under raised access floors

Comments:



KUPConstruction

Other:-

KUPCommissioning

MC Handbook – Section C Sample Preservation Manual

Oct2000 Edition

Doc. no.: E060-AD-A-KB0001 Rev. no.: 0 Rev. date: 27.10.98 Page 28 of 36 STORAGE, HANDLING AND PRESERVATION MAINTENANCE MANUAL __________________________________________________________________ _ 10

APPENDIX

10.1

Electrical Preservation Maintenance Check Lists

10.2

Instrument Preservation Maintenance Check Lists

10.3

Mechanical Preservation Maintenance Check Lists

10.4

Preservation Record Sheet

10.5

Preservation Label

K:\5622kup\shared\Kupproc\preserve

Doc. no.: E060-AD-A-KB0001 Rev. no.: 0 Rev. date: 27.10.98 Page 29 of 36 STORAGE, HANDLING AND PRESERVATION MAINTENANCE MANUAL __________________________________________________________________ _

10.1

Electrical Preservation Maintenance Check Lists


Preservation Maintenance Check List EP01

ELECTRIC MOTORS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:

Frequency: Description:

PreservationMaterials:

01

1

WARNING : Ensure the motor is not energised other than for heating. If energised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02

1

Check the air humidity in the storeroom is <40%. If >40%, arrange for space heater to be energised from a temporary supply.

03

1

When installed, ensure the space heater is working. Check that indication lights on temporary heating distribution panels are working.

04

2

Inspect units for corrosion, cleanliness and moisture.

05

2

Check all permanent data plates or labels are protected with clear wax coating.

06

2

Manually rotate shaft 2¼ turns. Applicable only to electric motors with ball or roller bearings. For other types, refer to Suppliers’ recommendations.

07

2

Ensure that the protection cover is not damaged and is properly sealed. Repair as required.

Aluminium sheeted glass fibre cloth

08

8

Inspect connection boxes for moisture and replace vapour corrosion inhibitor (VCI) if necessary.

VCI-101/110/150

09

8

Ensure seal is intact and screws are coated with acid-free grease after inspecting connection box. e.g. Poly Butyl Cuprysil grease.

PBC grease

10

8

Megger test and record insulation resistance.

11

8

Ensure preservation oil levels in bearing housings are correct, and vent cap is sealed.

VCI-368,389 or 322 and Vulc-Tape

12

8

Check preservation on exposed shafts and coupling hubs is intact.

VCI-368,389 or 322

13

8

Check external surfaces and verify that preservation is in good condition. Re-apply preservation to machined surfaces if necessary.

VCI-368,389 or 322

14

8

Check drain plugs are removed. ( Small plastic plugs)

VCI-386

'Frequency' means number of weeks between preservation maintenance.


EPCS:

Company:


Battery Chargers, Distr. boards, Relay Boxes, Lighting Distr. Boards, Sub – Distr. Boards & UPS’s. (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

1

Ensure the space heater is working, where installed.

02

1

Ensure all doors on unit are properly locked.

03 04

2 2

Check all permanent data plates or labels are protected with clear wax coating. Ensure that the protection cover is not damaged and is properly sealed. Repair as required.

VCI-386 Aluminium sheeted glass fibre cloth

05

2

Check preservation on cable connections exposed to atmosphere, and re-apply if necessary.

VCI-368/389/322

06

8

Report any damaged instruments, indication lights, paint etc. to the Maintenance Supervisor or Preservation Supervisor.

07

8

Inspect the connection box for moisture and change VCI emitter if necessary.

08

8

Inspect inside unit. Report any corrosion damage, moisture etc. If necessary, carefully clean with dry cloth or vacuum cleaner.

09

8


VCI-368/389/322

10

8

Ensure that all hinges and fasteners are greased, and that openings and glands are properly sealed. e.g. Poly Butyl Cuprysil grease.

PBC grease

VCI-101/110



EPCS:

Company:


AIR-COOLED TRANSFORMERS (POLY RESIN TYPE) (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

1

WARNING : Ensure the transformer is not energised before carrying out any preservation work. If energised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02

1


03

2


VCI-386

04

2



05

8

Report any damage to the transformer or paint to the Maintenance Supervisor or Preservation Supervisor.

06

8

Check terminals are coated with an acid-free grease. e.g. Poly Butyl Cuprysil grease.

PBC grease

07

8

Inspect connection boxes for moisture and replace vapour corrosion inhibitor (VCI) if necessary.

VCI-101



EPCS:

Company:


SWITCHGEAR (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

1

WARNING : Ensure the switchgear is not energised other than for heating. If energised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02

1

Ensure that the heater is working. Check that the individual indicator lights on temporary heating distribution panel are working. (For H.V., 690V and 400V switchboard).

03

2


VCI-386

04

2



05

8


06

8

Report any damaged instruments, indication lights, paint etc. to the Maintenance Supervisor or Preservation Supervisor.

07

8

If the switchgear is field located, check the sealing of all entries, and replace vapour corrosion inhibitor (VCI) necessary.

VCI-101



EPCS:

Company:


PROCESS HEATERS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

1

WARNING : Ensure the heater is not energised before carrying out any preservation work. If energised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02

1

If Heaters are stored, check wooden crates for damage. Report to Maintenance Supervisor or Preservation Supervisor any damage.

03

8

If main cable is not connected, open connection boxes and inspect. Report to Maintenance Supervisor or Preservation Supervisor any corrosion, damage etc. If necessary, carefully clean with a dry cloth. If main cable is connected, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

04

8

Inspect the connection boxes for moisture and change VCI emitter if necessary.

VCI-101/110

05

8

Ensure seal is intact and screws are coated with acid-free grease after inspecting connection box. Add acid-free grease to Exd. flame parts. e.g. Poly Butyl Cuprysil grease.

PBC grease

06

8

Check for damage to Heater or paint, and report to Maintenance Supervisor or Preservation Supervisor if any damage found.

07

8

MeggertestHeaters.



EPCS:

Company:


CONTROL, TRANSFORMER AND BATTERY ROOMS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

1

Check cleanliness and arrange cleaning of rooms if necessary.

02

1

Check by measurement, the relative air humidity in the room. Confirm it is <40%.

03 04

1 1

Ensure that the electric air drying units in the rooms are working. Ensure that all doors on units are properly locked.

05

8

Visually inspect all units within room. Report any corrosion damage, moisture etc. If necessary, carefully clean with a dry cloth or vacuum cleaner.

06

8

Inspect for moisture inside panels. Replace the VCI emitter if necessary.

07

8

Report any damaged instruments, indication lights, paint, electrical connections etc., to the Maintenance Supervisor or Preservation Supervisor.

VCI-101/110



EPCS:

Company:


GENERATORS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

1

WARNING : Ensure that generator is not energised, other than for heating. If energised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02

1


03

1

When installed, ensure the space heater is working. Check that indication lights on temporary heating distribution panels are working.

04

2

Inspect units for corrosion, cleanliness and moisture.

05

2

Ensure that PRESERVATION labels are in position and report any damage to the equipment to Maintenance Supervisor or Preservation Supervisor.

06

2

Manuallyrotateshaft2¼turns. -Applicable only to Generators with ball or roller bearings. For other types, refer to Suppliers’ recommendations.

07

2


VCI-386

08

2



09

8

Inspect connection boxes for moisture and change the VCI emitter if necessary.

VCI-101/110

10

8

Ensure seal is intact and screws are coated with acid-free grease after inspecting connection box. e.g. Poly Butyl Cuprysil grease.

PBC grease

11

8

Megger test and record insulation resistance.

12

8

VCI-368/389/322 and Vulc Tape

13

8

Ensure preservation oil levels in bearing housings are correct, and vent cap is sealed. Check preservation on exposed shafts and coupling hubs is intact. Repair as required.

14

4


VCI-368/389

15

2


VCI-386

16

VCI-386

DELETED

17

4

Check the cooling system is coated with preservation oil.

VCI-322

18

4

Check the level of the fuel/VCI mixture in the fuel system. Top up as required.

VCI-322

19

12

Check Vapour Corrosion Inhibitor in inlet and exhaust manifolds and replace as necessary. Confirm the VCI is attached to the dust blind.

VCI



EPCS:

Company:


LIGHTING FIXTURES (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

4

WARNING : Ensure that no part of the lighting fixture is energised before carrying out any preservation work. If energised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02

4

Check if light fittings, glass, protective cover for damage. Report any damage to Maintenance Supervisor or Preservation Supervisor.

03

8

Check that all lighting fixtures and floodlights in exposed areas are dry and all holes are sealed off.

04

8

Check that flanges on Exd fixtures are correctly greased. e.g. Poly Butyl Cuprysil grease.

PBC grease



EPCS:

Company:


JUNCTION BOXES, SOCKET OUTLETS AND PUSH BUTTONS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2

WARNING : Ensure that no part of the above equipment is energised before carrying out any preservation work. If energised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02 03

2 2


04

8

CheckoperationofPushButtons.

05

8

Inspect boxes for moisture and change the VCI emmiter if necessary.

VCI-101/110

06

8

Ensure seal is intact and screws are coated with acid-free grease after inspecting connection boxes. e.g. Poly Butyl Cuprysil grease.

PBC grease

07

8

Check that acid-free grease is present on the flame path covers on Ex(d) equipment.

PBC grease

08

8

Check for mechanical damage. Report any damage to Maintenance Supervisor or Preservation Supervisor.




EPCS:

Company:


HEAT TRACE CABLE (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:

1


4


Check that all installed heat trace cable is properly protected, either by temporary covers or by srcinal insulation pads.



EPCS:

Company:


OIL FILLED TRANSFORMERS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

4

WARNING : Ensure transformer is not energised before carrying out preservation work. If energised, report to Maintenance supervisor or Preservation Supervisor before proceeding.

02 03

4 4

Check transformer for damage including radiators and conservator. Check transformer, associated pipe work and flanged joints for leaks.

04

4

Checktransformeroillevel.

05

4

CheckVCIemitterinjunction boxes.

06

4

Check Anticondensation heaters are energised in tap changer control panels. ( Large transformes only)

07

4

Check de-hydrating breather desicant. (Colour should be pink) If coloured blue contact transformer vendor.

08

4

Check transformer instrumentation for damage.

09

4

Check paint work for damage and clean/repair if necessary.

10

4

Check transformer bushings for damage.

VCI-101/110



EPCS:

Company:


NEUTRAL EARTHING RESISTORS

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

4

WARNING : Ensure transformer is not energised before carrying out preservation work. If energised, report to Maintenance supervisor or Preservation Supervisor before proceeding.

02

4

Check neutral earthing resistor including resistance elements and cable bushings for damage.

03

4

Check if clear of dust and debris and clean if necessary.



EPCS:

Company:

Doc. no.: E060-AD-A-KB0001 Rev. no.: 0 Rev. date: 27.10.98 Page 30 of 36 STORAGE, HANDLING AND PRESERVATION MAINTENANCE MANUAL __________________________________________________________________ _ 10.2

Instrument Preservation Maintenance Check Lists


Preservation Maintenance Check List JP01

INSTRUMENT AND TELECOM. SYSTEM CUBICLES, PANELS, TERMINATION RACK, JUNCTION BOXES (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

1

WARNING : Ensure the unit is not energised before carrying out any preservation work. If energised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02 03

1 2

Ensure all doors on unit are properly locked and sealed. Check all permanent data plates or labels are protected with clear wax coating.

04

2

If unit is protected with instrument quality air, ensure that inside pressure is maintained at 50mm W.G.

05

2


06

8


07

8

If unit is not protected with instrument quality air, then the moisture content shall be checked and the VCI emitter replaced as necessary.

VCI-101/110

08

8


VCI-368/389

09

8

Report any damaged instruments, indication lights, paint etc. to Maintenance Supervisor or Preservation Supervisor.

10

8

Ensure all hinges and fasteners are greased and that openings and glands are properly sealed. e.g. Poly Butyl Cuprysil grease.

Tape VCI-386


PBC grease



EPCS:

Company:


SOLENOID VALVES, RECEIVER GAUGES, VA METERS, HEAT DETECTORS, PRESSURE/TEMPERATURE/LEVEL TRANSMITTERS AND SWITCHES, ADDRESSABLE

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02 03

2 2

Check all permanent data plates or labels are protected with clear wax coating Ensure that the protection cover is not damaged and is properly sealed. Repair as required.

04

8


05

8

Inspect inside each component for moisture content and replace the VCI emmiter as necessary.

06

8

Report any damaged instruments, indication lights, paint etc. to Maintenance Supervisor or Preservation Supervisor.

07

8

Ensure that all hinges and fasteners are greased, and that openings and glands are properly sealed. e.g. Poly Butyl Cuprysil grease.

PBC grease

08

8


VCI-368/389


VCI-101/110



EPCS:

Company:


ACTUATORS AND ACCUMULATORS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2

WARNING : Ensure the unit is not energised or pressurised before carrying out any preservation work. If pressurised or energised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02 03

2 2


04

8

Check that paint surfaces are undamaged. If damaged report to Maintenance Supervisor or Preservation Supervisor.

05

8

Check that exposed actuator rod is protected.

06

8

Check and replace any missing metal end plugs to cable and tubing entries.

07

12

Check that hydraulic actuator or accumulator is totally filled with clean system oil and, if not piped-up, inlet/ outlet is sealed with metal plugs.

08

12

Check that bleed air holes on diaphragm actuators are protected with metal plugs.

09

12

NOTE: Valve bodies and spindles are to be preserved as for piping valves. Ref. LP01/LP0


Fin Lube Oil and Vulc Tape Clean System Oil



EPCS:

Company:


PRESSURE/TEMPERATURE/LEVEL GAUGES, FLOW GLASS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


VCI-386

02

2



03

8

Ensure that 6mm plywood cover is in place over glass faces. Report any damage to Maintenance Supervisor or Preservation Supervisor.

04

8

Ensure that openings and glands are properly sealed with plugs/caps.

05

8


VCI-368/389



EPCS:

Company:


SMOKE, GAS DETECTORS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02 03

2 2


04

8

Report any damaged detectors, indication lights, etc. to Maintenance Supervisor or Preservation Supervisor.

05

2

IMPORTANTNOTE: SMOKE AND GAS DETECTORS MUST NOT BE EXPOSED TO SILICONE VAPOUR.

VCI-386 Aluminium sheeted glass fibre cloth or alternative cover/hood



EPCS:

Company:


AIR FILTER REGULATOR (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

4


02

12

03

12

Report any damaged Filter/Regulators to Maintenance Supervisor or Preservation Supervisor. Drain the air filter (Push the drain valve to bottom).

04

12

Ensure that inlets/outlets are properly sealed with threaded plugs.

05

12

Ensure that threads on adjusting screws and the air bleed screws are grease lubricated.

Aluminium sheeted glass fibre cloth or alternative cover/hood

Complexfett L2 grease



EPCS:

Company:


ANALYSER PACKAGES, HVAC PANELS, INSTRUMENT HOUSINGS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

1


02 03

1 2

Ensure that all doors on unit are properly locked and taped. Check all permanent data plates or labels are protected with clear wax coating.

04

8

Report any damaged instruments, indication lights, paint, etc. to Maintenance Supervisor or Preservation Supervisor.

05

8

Inspect unit internals. Report any corrosion damage, moisture, etc. to Maintenance Supervisor or Preservation Supervisor. If necessary, carefully clean with dry cloth or vacuum cleaner.

VCI-368/389/322

06

8

Check internals for moisture and replace VCI emmiter if necessary.

VCI-101/110

07

4


VCI-368/389/322

08

8

Ensure that all hinges and fasteners are greased, and that openings and glands are properly sealed.

PBC grease

09

1

NOTE: For the field instruments in the cabinet, refer to JP02, and for gauges refer to JP04.

VCI-386



EPCS:

Company:


ASPIRATOR CABINETS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02 03

2 8

Check all permanent data plates or labels are protected with clear wax coating. Inspect unit internals. Report any corrosion damage, moisture, etc. to Maintenance Supervisor or Preservation Supervisor. If necessary, carefully clean with dry cloth or vacuum cleaner.

04

8

Check internals for moisture and replace VCI emmiter if necessary.

VCI-101/110

05

8


VCI-368/389

06

8


07

8

Ensure that all doors on unit are properly locked and taped.

08

8

Ensure that all hinges and fasteners are greased and that openings and glands are properly sealed.

09

2

NOTE: For the detectors in the cabinet refer to JP05.

PBC grease



EPCS:

Company:


TELECOMMUNICATIONS FIELD EQUIPMENT (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02

2


03

8


04

8

Ensure that any temporary cover is not damaged, missing, or if additional protection is needed.

05

8

Ensure that all hinges and fasteners are greased and that openings and glands are properly sealed.

PBC grease

06

8


VCI-368/389

Aluminium sheeted glass fibre cloth or alternative cover/hood



EPCS:

Company:


SAFETY RELIEF VALVES (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:


01


BEFOREINSTALLATION

02

12

BEFORE INSTALLATION : Check preservation on flange faces and internal surfaces, and refit 10mm plywood flange covers and rubber gaskets.

03

12

BEFORE INSTALLATION : Report any corrosion or damage to internals etc. to Preservation Supervisor.

04

12

BEFORE INSTALLATION : Check that plastic caps and thread protectors are in position.

05

VCI-368/389

AFTERINSTALLATION

06

4

AFTER INSTALLATION : Check pilot operated valves have no damage to sensor pipework. Pilot filters to be drained off.

07

4

AFTER INSTALLATION : Check that calibration seal is intact and no visible damage.



EPCS:

Company:


ORIFICE PLATES (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:


01 02


OrificeFittings 8

Orifice Fittings : Check that there is no external damage and that cover plate seals are intact. Report any damage to Maintenance Supervisor or Preservation Supervisor. OrificePlates

04

8

Orifice Plates : Check that the preservation on the orifice plates is not damaged.

05

8

Orifice Plates : Check that there is no damage to the disc surfaces, i.e. indentations, marks, scratches.

06

8

NOTE ! Orifice plates to remain in the stores until specifically requested by the Company.

03

Denso tape or VCI Stretchfilm



EPCS:

Company:


BURSTING DISCS

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

8

Bursting discs shall remain at all times in the original packing, and stored in a dry place until commencement of system commissioning. They shall not be inspected or touched, nor shall the protective box be opened.

02

8

Check the condition of the original packing. Report any damage to the Maintenance Supervisor or Preservation Supervisor.

03

8

NOTES: 1. Storage conditions shall be as for sensitive electronic equipment. 2. Commissioning personnel shall be responsible for supervising the removal from stores for installation.



EPCS:

Company:


Mechanical Preservation Maintenance Check Lists


Preservation Maintenance Check List MP01

MAIN AIR COMPRESSOR PACKAGE (CENTRIFUGAL) (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2

WARNING : Ensure the unit is not energised or pressurised before carrying out any preservation work. If energised or pressurised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02

2

NOTE! If the compressor internals are removed and preserved for long term storage, separate from the compressors, the crate with the compressor internals shall not be unpacked unless Supplier’s representative is present.

03

2

Ensure piping connections are closed with dust blinds to prevent ingress of water and dirt etc.

04

2

Check the lube oil system of the compressor packages for leakage. Report to Maintenance Supervisor or Preservation Supervisor if any discrepancies are found.

05

2


VCI-386

06

2

Ensure that the protection cover and the plywood sheeting is not damaged and is properly sealed. Repair as required.

Aluminium sheeted glass fibre cloth and 10mm thick plywood.

07

4

Check condition of wooden box containing coupling spacer. If damaged, report to Maintenance Supervisor or Preservation Supervisor.

08

8

Check preservation of all machined unpainted surfaces and re-apply when necessary.

09

8

Inspect external surfaces and, if necessary, clean up and repair any damaged coating, in accordance with relevant paint specification.

10

8

Check preservation on the coupling hubs. Re-apply if necessary.

VCI-368/389

11 12

12 12

Check all instruments are adequately protected, and instrument nozzles blinded off. Check preservation on exposed shafts, reapply if nessesary.

VCI-368

13

12

Check Vapour Corrosion Inhibitor in compressor casing. Replace as necessary.

VCI

14

12

Check preservation on coupling spacer in stored wooden box. Touch up as required.

VCI-368/389

VCI-368/389



EPCS:

Company:


TURBO EXPANDER PACKAGE (Rev B)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2

NOTE : Refer to Suppliers documentation. The packages shall be preserved in accordance with the above documentation and in conjunction with this check list.

02

2


VCI-386

03

2



04

2

Ensure piping connections are closed with dust blinds to prevent ingress of water and dirt etc.

05

4


06

8


07

8


08

8

Check preservation on the coupling hubs. Re-apply if necessary.

09

12

Check all instruments are adequately protected, and instrument nozzles are blinded off.

10

12

Check preservation on exposed shaft, reapply if necessary

VCI-368

11

12

Check Vapour Corrosion Inhibitor in compressor casing. Replace as necessary.

VCI

12

12


VCI-368/389/322

13

2

NOTE! Lube Oil System When the commissioning activities are finished, the compressors shall be represerved by energising the lube oil system for continuous oil circulation.

14

1

The expander-compressor units and lube oil/seal gas support system to be purge with dry nitrogen, 0.33 bars ( 5 psig ). NOTE ! Vendor requirements to be followed.

VCI-368/389/322

VCI-368/389/322



EPCS:

Company:


HYDRAULIC POWER PACKS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2

Check all permanent data plates or labels are protected with clear wax coating

02

2

Ensure external hydraulic piping is not hooked up to unit unless it has been chemically cleaned (to avoid possible contamination).

03

4

Inspect outside surface and, if necessary, clean up and repair any damaged coating in accordance with the relevant paint specification.

04

4

Check that all hydraulic lines and oil side of accumulators are filled with hydraulic oil. Release all air.

05

2

Check all open ended pipes and tappings are plugged.

06

4

Check nitrogen pressure in the nitrogen system. (N2 cylinder and accumulators).

07

4

Ensure that 6mm plywood cover is in place over pressure gauges and instrument glass.

08

4

Checkinstrumentsandlocalpanels.

09

12

Check internals for moisture content and change the Vapour Corrosion Inhibitor if necessary.

VCI-386

Clean system oil

Nitrogen

VCI



EPCS:

Company:


DIESEL ENGINES (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2

WARNING : Ensure the unit is not pressurised before carrying out any preservation work. If energised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02 03

2 4

Check all permanent data plates or labels are protected with clear wax coating. Check external surfaces and verify that preservation is in good condition. Re-apply preservation to machined surfaces if necessary.

VCI-386 VCI-368/389

04

4

Check the cooling system is coated with preservation oil or filled up with a glycol/water VCI mixture.

VCI-368/389

05

4

Check the level of the fuel/VCI mixture in the fuel system. Top up as required.

VCI mixture

06

4

Checkthattheairfilterissealed.

07

12

Check Vapour Corrosion Inhibitor in inlet and exhaust manifolds and replace as necessary. Confirm the VCI is attached to the dust blind.

VCI



EPCS:

Company:


GAS TURBINE (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2

Ref. to suppliers documentation. The package shall be preserved in accordance with the above documentation and in conjunction with this check list.

02

2


VCI-386

03

2



04

2

Checkinlet/exhaustclosed.

05

2

Check enclosure vent ducting closed. ( Inlet / Outlet )

06

2

CheckGTcompressorrotorinhibited.

07

2

Checkalldoorsclosed/sealed.

08

2

Ensure piping connections are closed with dust blinds to prevent ingress of water dirt etc.

09

4


10

8


11

8


12

8

Check preservation on the coupling hub. Re-apply if necessary.

13

12

Check all instruments are adequately protected, and instrument nozzles of removed instruments are blinded off.

14 15

12 12

Check preservation on exposed shafts, reapply if necessary. Check Vapour Corrosion Inhibitor in compressor casing. Replace as necessary.

VCI-368 VCI

16

12


VCI-368/389/322

17

2

NOTE! Lube Oil System When the MC activities are finished, the compressors shall be represerved by energising the lube oil system for continuous oil circulation.

VCI-368/389/322

VCI-368/389/322



EPCS:

Company:


PUMPS (ALL TYPES) (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2

WARNING : Ensure the unit is not pressurised or pressurised before carrying out any preservation work. If pressurised or pressurised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02 03

2 2

Check all permanent data plates or labels are protected with clear wax coating. Ensure that the protection cover and the plywood sheeting is not damaged and is properly sealed. Repair as required.

04

2

Manuallyrotateshafts2¼turns.

05

2

Check preservation on exposed pump shaft and repair as necessary.

06

2

Check wooden box containing pump coupling spacer for damage. Report any damage to Maintenance Supervisor or Preservation Supervisor.

07

4

Check that all dust blinds and sealing plugs are tight and that any valves used for isolating purposes are closed. Where pipes are connected, 1mm galvanised plate with ample size red painted spade handle shall be used as dust blinds.

08

12

Check sealing of bearing housing vent. NOTE: If blinds or sealing plugs have been removed or valves opened, report to Maintenance Supervisor or Preservation Supervisor before proceeding.

Denso tape

09

12

Check levels of preservation oil and top up as required in bearing housing, oil cooler and lube oil system. If amount added appears excessive look for leaks and report to Maintenance Supervisor or Preservation Supervisor.

VCI-322

10

12

11

12

VCI-368 Check and add preservation as required to exposed machined surfaces on pump and baseplate. Report any damage to pump or paint to Maintenance Supervisor or Preservation Supervisor. VCI-368 Check pump carbon steel inlet/outlet flanges for preservation coating, and replace neoprene gaskets and 10mm plywood blinds (ensure minimum of 4 bolts are used on the blinds) Re-wrap blank/flange circumference with waterproof adhesive tape.

12

12

Check pump coupling spacer in its wooden box. Re-apply preservation oil as necessary, and re-wrap in oil paper or VCI-Film (Plastic).

Aluminium sheeted glass fibre cloth and 10mm thick plywood. VCI-368

VCI-368 and VCI-Film(Plastic) or Oil Paper



EPCS:

Company:


PRESSURE VESSELS, ATMOSPHERIC TANKS AND SHELL/TUBE HEAT EXCHANGERS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



VCI-386

01

2


02

2

Check tarpaulin weather protection is fitted correctly.

03

2

Where heat exchanger shall be nitrogen filled, check nitrogen pressure in the exchanger.

04

12

Check that all dust blinds and sealing plugs are tight and that any valves used for isolating purposes are closed. Where pipes are connected, 1mm galvanised plate with ample size red painted spade handle shall be used as dust blinds. NOTE: If blinds have been removed, report to Maintenance Supervisor or Preservation Supervisor.

05

12

VCI-368 Check carbon steel inlet/outlet flanges for preservation coating, and replace neoprene gaskets and 10mm plywood blinds (ensure minimum of 4 bolts are used on the blinds)

06

12

Check external surfaces and verify that preservation is in good condition. Report any damaged paint to Maintenance Supervisor or Preservation Supervisor.

Nitrogen



EPCS:

Company:


PLATE HEAT EXCHANGERS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2

WARNING : Ensure the unit is not pressurised before carrying out any preservation work. If pressurised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02 03

2 2

Check all permanent data plates or labels are protected with clear wax coating. Ensure weather protection and 10mm plywood protection cover is fitted correctly. Report any damage to Maintenance Supervisor or Preservation Supervisor.

04

12

Check that all dust blinds and sealing plugs are tight and that any valves used for isolating purposes are closed. Where pipes are connected, 1mm galvanised plate with ample size red painted spade handle shall be used as dust blinds. NOTE: If blinds have been removed or valves opened, report to Maintenance Supervisor or Preservation Supervisor.

05

12

Check external surfaces and verify that preservation is in good condition. Report any damaged paint to Maintenance Supervisor or Preservation Supervisor.

06

12

Check tensioning bolts are coated with grease, and plastic or rubber protection sleeve is in position.

VCI-386

Complexfett L2 or VCI-369 Cor-Lube



EPCS:

Company:


RECOMPRESSION, REINJECTION, PIPELINE GAS COMPRESSORS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2

WARNING : Ensure the unit is not pressurised or energised before carrying out any preservation work. If energised or pressurised, report to the Maintenance Supervisor or Preservation Supervisor before proceeding.

02

2

NOTE : Ref. to suppliers documentation. The package shall be preserved in accordance with Suppliers recommendations, specifications and this check list.

03

2


VCI-386

04

2

Ensure that the protection cover and the plywood sheeting is not damaged and that the sealing is intact. Repair as required.


05

2

Ensure piping connections are closed with dust blinds to prevent ingress of water, dirt etc.

06

12

Check protection cover is in place. Report to maintenance supervisor any damage to the casings, valves, piping/tubing, actuators, instruments, cabinets, cables or applied external preservation.

07

12

Check all instruments are adequately protected, and instrument nozzles of removed instruments are blinded off.

08

2

NOTE! Lube Oil System When the MC activities are finished, the compressors shall be represerved by energising the lube oil system for continuous oil circulation.



EPCS:

Company:


METERING PACKAGES (Rev B)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02 03

2 2

Check all permanent data plates or labels are protected with clear wax coating. Ensure piping connections are closed with dust blinds to prevent ingress of water and dirt etc.

VCI-386

04

2


Aluminium sheeted glass fibre cloth and 10 mm thick plywood

05

8

Check preservation on all machined unpainted surfaces and re-apply when necessary.

VCI-368/389/322

06

8

Inspext external surfaces and, if necessary, clean up and repair any damaged coating, in according to relevant paint specification.

07

12

Check all instruments are adequately protected and instrument nozzles are blinded off.

08

INTERNAL INSPECTION ( CARBON STEEL PIPING ) : Upon arrivel at site ( or when ever acces is possible ) a one-off inspection to be done. Re-apply VCI, if required, by "fogging". NOTE : In accordance with Supliers instructions.



EPCS:

Company:


OVERHEAD TRAVELLING CRANES (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02 03

2 12

Check all permanent data plates or labels are protected with clear wax coating. Check levels of preservation oil in gearboxes. Top up as required. If amount added appears excessive, check for leaks and, if necessary, report to Maintenance Supervisor or Preservation Supervisor.

VCI-322

04

12

Check protection cover and preservation on open gears, wire and rope guide and, if necessary, apply grease.

Wiersmøremiddel WRP.

05

12

Check and add preservation as required to exposed machined surfaces on crane. Report any damage to crane or paint to the Maintenance Supervisor or Preservation Supervisor.

VCI-368/389

06

2

Ensure eletric heater for hoist motor is energised and functioning.



EPCS:

Company:


MANUAL CHAIN HOIST (rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


VCI-386

02

12

Check open gears, chains and chain guide and, if necessary, apply grease.

VCI-369 Cor-Lube H

03

12

Check and addany preservation required exposed surfacesSupervisor on chain or VCI-368/389 hoist. Report damage toas chain hoisttoor paint tomachined the Maintenance Preservation Supervisor.



EPCS:

Company:


FANS (DIRECT AND BELT DRIVEN) (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02 03

2 2

Check all permanent data plates or labels are protected with clear wax coating. Manuallyrotatetheshaft2¼turns.

04

4

Move vane handle. Vanes to be left in closed position.

05

4

Check that blinds and protection are in position. NOTE: If blinds have been removed, report to Maintenance Supervisor or Preservation Supervisor.

06

12

Check preservation of all external machined unpainted surfaces, and re-apply preservation where necessary.

VCI-386

VCI-368/389



EPCS:

Company:


HEATING AND COOLING COILS (HVAC SYSTEM) (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02 03

2 8

Check all permanent data plates or labels are protected with clear wax coating. Check surface protecting plates and report to Maintenance Supervisor or Preservation Supervisor any damaged cooling fins.

04

8

Check that all blinds and sealing plugs are tight.

05

8

Check if internal preservation is intact.

VCI-386

VCI



EPCS:

Company:


DAMPERS (VCI)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02 03

2 4

Check all permanent data plates or labels are protected with clear wax coating. Inspect outside surface and if necessary clean up and report any damaged coating to Maintenance Supervisor or Preservation Supervisor.

04

4

Checkthatallsealingplugsaretight.

05

4

Check external condition of actuator and report any damage to Maintenance Supervisor or Preservation Supervisor.

VCI-386



EPCS:

Company:


DUAL AGENT UNITS, HOSE REELS, FIRE MONITORS ETC. (Rev B)

Originator :

KUP MC

Doc No :

Issued :

25.03.99

Supplier :

PONo :

C-309522

Supplier Doc No : E060-AD-A-KB0107

Norfass

Ref :

Item:



01

2


VCI-386

02

2



03

8

Check that all inlets are plugged/blinded.

04

8

Checkopenthreadsandbearingsand re-apply preservation as necessary.

05

12

Check preservation of all external machined unpainted surfaces, and re-apply preservation where necessary.

06

12

Inspect external surface and, if necessary, clean up and repair any damaged coating, in according with relevant paint spesification.

07

12

Lubricate hinges and door-locks on cabinets and skids.

08

12

DelugeValveSkids: If heaters are not connected, bleed valve to be opened to avoid entraped water.

09

12

MonitorTowers: Verify monitor gear lubrication and refill if required.

VCI-368/389



EPCS:

Company:


CO2 EXTINGUISHERS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02

2

Visually inspect all CO2 cylinder pressures on gauge. If leakages are observed, Maintenance Supervisor or Preservation Supervisor to arrange re-fill by Supplier.

03

8

Visually inspect all components for mechanical damage. Report to Maintenance Supervisor or Preservation Supervisor, if required.

04

2

NOTE: No corrective action to be carried out by unauthorised personnel.

VCI-386



EPCS:

Company:


WEATHER LOUVRES (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

4

Visually check that all temporary protection in areas subject to mechanical damage is in place. Replace where necessary.

02

4

03

4

Visually inspect panels for weld spatter. Report to Maintenance Supervisor or Preservation Supervisor if weld spatter is on thin plate elements or louver blades. Preservationasrequired:Clean all joints, louvred cassettes and fixing points after any sandblasting etc. in the vicinity, to stop possibility of galvanic corrosion.



EPCS:

Company:


FIRED HEATERS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02 03

2 2

Check all permanent data plates or labels are protected with clear wax coating Refer to Vendor preservation requirements.

VCI-386



EPCS:

Company:


Originator :

LOADING ARMS (Rev C)

KUP MC

Issued : PONo :

C-309521

Doc No :

MP20 Rev. B

Supplier :

FMC EnergySystems

Supplier Doc No : E060-AD-A-KB0047

Ref :

Item:



01

2


02 03

2 2

Check all permanent data plates or labels are protected with clear wax coating Check and maintain a nitrogen pressure ( 0,05 bar - 0,3 bar ) in the product line and swivel joints.

VCI-386 Nitrogen.

NOTE : Check that equipment is clearly marked with the appropriate yellow warning labels. 04

4

Inspect outside surface and, if necessary, clean up and repair any damaged coating in accordance with the relevant paint specification. Repassivate if required, damaged areas of stainless steel parts.

05

12

Lubricate the swivels and the drive shaft with grease ( ref. FMC's maintenance manual ).

Wiresmøre-middel WRP

06

12

Check pantograph and drive cables, and sheaves are coated. Re-apply grease if necessary.

Wiresmøre-middel WRP

07

Note : Event 03. Nitrogen pressure to be maintained and logged daily on 47-MU211 & 47-MU-212. Nitrogen circulation through the swivel joint drying lines on 47-MU-210 & 47-MV210 twice a week for 1 hour duration.



EPCS:

Company:

Preservation Maintenance Check List MPX1

Temporary Mechanical Checklist for Seawater Intake Equipment (Suppliers Docs. Not available.)

Originator :

KUP-MC

Doc No :

Issued :

09.11.98

Supplier :

PONo :

Various

Supplier Doc No :

Ref :

Item:



01

8


VCI-386

02

8

Check open gears, chains and chain guide and, if necessary, apply grease.

VCI-369 Cor-Lube H

03

8

Check and add preservation required to exposed machined surfaces on to the chains/gear wheels . Reportas any damage to chains/gear wheels or paint Maintenance Supervisor or Preservation Supervisor.

VCI-368/389

04

8

Generalvisualinspection.



EPCS:

Company:

Preservation Maintenance Check List LP01

VALVES (HAND OPERATED & CHECK VALVES) CORRODABLE MATERIALS (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

2


02

4


03

4

Check and confirm that all hand operated valves are in closed position, except for ball, globe and fail safe OPEN valves, which shall be in the open position.

04

12

For valves in storage, check that all inlet/ outlet flanges are plugged or blinded.

05

12

Check that internal preservation is in good condition. Re-apply as necessary.

06

12

Check that stuffing box is sealed and tightening bolts are hand tight only.

07

12

Check that preservation of carbon steel valve spindles and all threaded spindles is intact.

VCI-386

VCI-368/389/322 Fin Lube Oil and Vulc Tape



EPCS:

Company:


BALL VALVES, GLOBE VALVES (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



VCI-386

01

2


02

4


03

12

Check that internal preservation is in good condition. Re-apply as necessary.

04

4

Check and confirm that all hand operated valves are in closed position, except for ball, globe and fail safe OPEN valves, which shall be in the open position.

05

12

For valves in storage, check that all inlet/ outlet flanges are plugged or blinded.

06

12

Check that preservation of carbon steel valve spindles and all threaded spindles is intact.

Fin Lube Oil and Vulc Tape

07

12

Check that stuffing box is sealed and tightening bolts are hand tight only.

Denso tape or Vulc Tape

VCI-368/389/322



EPCS:

Company:


PIPES AND FITTINGS (ALL CONSTRUCTION PHASES) (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

1

Check that all spools and lines during the construction and installation phases have all open ends capped with heavy plastic caps, which are sealed with Denso tape.

Vulc Tape

02

1

Check that all long and short term stored pipe spools have all open ends capped with heavy plastic caps, which are sealed with Denso tape.

Vulc Tape

03

8

Ensure that preservation is intact on carbon steel flange faces.

VCI-368



EPCS:

Company:


PIPING SYSTEM (Dry air or corrosion inhibitor preservation) (Rev A)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

12


02 03

12 12

NOTE : Dry Air Preservation or corrosion inhibitor to be used as applicable. Check internal coating of pipe for VCI coverage. Re-preserve as required. NOTE : USE MUST BE APPROVED BY KUP HSE !

04

12

NOTE : Inspection to be carried out before commissioning. Perform a video inspection of the, pipe internals to check for corrosion and cleanliness. If pipe dimension or configuration does not allow for use of a video camera, visual inspection methods such as boroscope or naked eye shall be adopted.

05

12

NOTE : Ensure draining/drying made after hydrotest.

Cortec VCI-309/609



EPCS:

Company:

Preservation Maintenance Check List QP01

COMPUTER ACCESS FLOORS (RAISED)

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

4

Visually check that floor panels are either properly located in the floor grid or properly stored. Rectify as required.

02

4

Visually inspect installed floor panel finishes for mechanical damage or delamination. Report any damage to Maintenance Supervisor or Preservation Supervisor.

03

4

Visually inspect underfloor substructure for: - Stability - Loose pedestals - Damage and corrosion Rectify as required.



EPCS:

Company:


FLOOR FINISHES, PARTITIONS, GLAZED PANELS

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:

01


4


Visually check that protection is intact and there is no mechanical damage to applied finishes. Rectify as required. Report damage to Maintenance Supervisor or Preservation Supervisor.



EPCS:

Company:


SUSPENDED CEILINGS

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:



01

4

Visually check that ceiling panels are either properly installed, or properly stored. If stored, check that the polythene foil protection to the insulation is intact. Rectify as required.

02

4

Visually inspect ceiling panels for mechanical damage or distortion. Report damage to Maintenance Supervisor or Preservation Supervisor.



EPCS:

Company:

Preservation Maintenance Check List UP01

DRY FIX INSULATION

Originator :

Doc No :

Issued :

Supplier :

PONo :

Supplier Doc No :

Ref :

Item:

01


4


Visually check insulation and vapour barrier for mechanical damage. Report any damage to Maintenance Supervisor or Preservation Supervisor.



EPCS:

Company:

Preservation Maintenance Check List PAR01

Final Preservation Checklist Prior to Transportation (Rev 0)

Originator :

KUP MC

Doc No :

Issued :

10.01.98

Supplier :

PONo :

C309418

Supplier Doc No :

Grootint, Holland

Ref :

Item:



01

1

Check that all open ended piping has plastic end caps installed and that these are taped secure to prevent ingress of water/moisture.

End Caps/Waterproof Tape

02

1

Blanks/Bolts/Waterproof Tape

03

1

Check that all open flanges have a blank installed (bolted) and taped secure to prevent ingress of water/moisture. Check that all piping insulation terminations are suitably sealed to prevent ingress of water/moisture.

04

1

Check that all junction boxes and thermostats covers are securely fastened and taped to prevent ingress of water/moisture.

Waterproof Tape

05

1

Check that all spare glands in junction boxes and thermostats are sealed with correct type of blank plugs.

Blank Plugs

06

1

Check that all electric heat tracing tape free ends are suitably end sealed.

End Seals

07

1

Check that all power cable free ends are suitably end sealed.

End Seals

08

1

Check that all lighting fixture have gaskets installed and that covers are securely fastened.

09

1

Check that all spare glands in lighting fixtures are sealed with correct type of blank plugs.

Blank plugs



EPCS:

Company:

Preservation Maintenance Check List PAT01

Originator :

Final Preservation Checklist Prior to Transportation (Rev A)

KUP-MC

Issued : PONo : Ref :

C309405

Doc No :

E060-ED-A-YE00...001

Supplier :

Fabricom, Belgium

Supplier Doc No : E060-ED-A-YE00...001

PAT-6..

Item:



01

1



02

1


03

1


04

1

Check that all junction boxes and thermostats covers are securely fastened and taped to prevent ingress of water/molsture.

Waterproof Tape

05

1


Blank Plugs

06

1


End Seals

07

1


End Seals



EPCS:

Company:

Preservation Maintenance Check List PAU-

Final Preservation Checklist Prior to Transportation (Rev A)

Originator :

KUP-MC

Doc No :

E060-ED-A-YE0062.001

Issued :

22.03.99

Supplier :

Fabricom, Belgium

PONo :

C309405

Supplier Doc No : E060-ED-A-YE0062.001

Ref :

PAU-106

Item:



01

1



02

1


03

1


04

1

Check that all junction boxes and thermostats covers are securely fastened and taped to prevent ingress of water/molsture.

Waterproof Tape

05

1


Blank Plugs

06

1


End Seals

07

1


End Seals



EPCS:

Company:


Preservation Label

FRONS T IDE


REAR SIDE


Preservation Verification Certificate


Preservation Verification Certificate ( PVC01 ) Commissioning Pack : Title

Part System :

:

Statement

It is hereby verified that the equipment and items included in the referenced Commissioning Package have been preserved and maintained in accordance with the Storage, Handling and Preservation Maintenance Manual E060-AD-A-KB 0001, Suppliers recommendations and the preservation status report attached. Any deviation or outstanding work shall be listed below. Reference shall be made to punch list and item number as appropriate. Status report reference:

Comments:

Prepared/A ccept edby:PR( M ech )

Prepared/Accepted by:ABB (E/I)

A cceptedbyC onstr ucti on

Acceptedby:C omm i ssi on i n g

Name :

Name :

Name :

Name :

Sign :

Sign :

Sign :

Sign :

Date :

Date :

Date :

Date :

PIMS 97 Preservation (Concept by Omega AS)

04-okt-2000 15:32 Page: 1

MC Handbook

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