Mechanical Completion Procedure

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MECHANICAL COMPLETION PROCEDURE

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000-ZA-E-09406_0_Mechanical 000-ZA-E-09406_0_Mechanical Completion Procedure This document is the property of Saipem Spa will safeguard its rights according to the civil and penal provisions of the law.

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TABLE OF CONTENTS

1

INTRODUCTION

3

1.1 Scope of work

3

1.2 Definitions

3

Abbreviations 1.3 Abbreviations

4

1.3.1

Project Organisation

4

1.3.2

Other

4

1.4 Reference documents

4

2

ACTIONS AT WORK S COMPLETION

5

3

PRE-COMMISSIONING

6

4

CERTIFICATION

7

5

COMMISSIONING

7

6

WORK FLOW

8

7

6.1

Mechanical Completion (Partial)

8

6.2

Mechanical Completion

9

ATTA CHMENTS

10

7.1

ATTACHMENT I: Punch Punch list for construction works works

10

7.2

Attachment 2 - Notification Notification of Expected Date Date for Mechanical Mechanical Completion

11

7.3

Attachment 3 - Notification Notification of Incomplete Works Works

12

7.4

Attachment 4 - Notification Notification of Mechanical Mechanical Completion Completion

13

7.5

Attachment 5 - Certificate Certificate of Mechanical Mechanical Completion

14

7.6

Attachment 6 – Pre-commissionin Pre-commissioning g responsibility responsibility matrix

15


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INTRODUCTION

1.1

Scope of work

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This document gives a general definition of the work that shall be completed by the Subcontractor, in order to achieve work completion of any part, or whole, of the Works up to ready for hand over and Mechanical Completion in accordance with the terms of the Subcontract. This specification is intended to be multi-disciplinary for a general Subcontractor i.e. where the Subcontractor is carrying out civil, mechanical, electrical and instrumentation work, etc. If the Subcontractor is performing only one, or more, of the fore going disciplines, but not all of them, then he shall refer only to those parts of the specification which are applicable to his Subcontract scope of Work. 1.2

Definitions Client

……………name……….

Contractor

Saipem SpA

Commissioning

All activities performed after achievement of Ready for Commissioning certificate for each Unit/System.

Contract

Contract between Company and Contractor with all Annexure and Attachment.

Home Office

Fano (Italy)

Subcontractor

means any persons, firm, partnership, corporation or combination thereof to whom any part of the Works is subcontracted by the Contractor in accordance with the terms of the Contract, and for avoidance of doubt includes Vendors

Mechanical completion

It is achieved when the facilities or portion thereof have been completed in accordance with the final approved drawings and specifications.

Pre-commissioning

The phase in which all the required cleaning, checks and tests (electrical, instrumental, mechanical), are implemented without introduction of hydrocarbons into the process and generally include all works required from time of mechanical Completion, up to Commissioning

Commissioning

Include all activities required from issue of Mechanical Completion Certificate up to the achievement of the stable and satisfaction operation.

Vendor

party which supplies equipment, materials and/or services as specified by Contractor in the scope of supply.

Punch List

List of items or activities that are: not completed, outstanding or, in some way, deficient and fails to meet the requirements of the 000-ZA-E-09406_0_Mechanical 000-ZA-E-09406_0_Mechanical Completion Procedure

This document is the property of Saipem Spa will safeguard its rights according to the civil and penal provisions of the law.

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project specifications, drawings, procedures, etc. and are required to be provided or corrected.

1.3

Abbreviations

1.3.1

Project Organisation CM COM DS FEM FCQ PM-C

1.3.2

Other P&ID QA QC

1.4

Construction Manager Commissioning Manager Discipline Superintendent Field Engineering Manager Field Quality Control Project Manager Construction

Piping and Instrumental Diagram Quality Assessment Quality Control

Reference docu ments 00-ZA-E-09400 00-ZA-E-09411 00-ZA-E-09404

Site Coordination Procedure Punch List Procedure Pressure Test for Piping Procedure

000-ZA-E-09406_0_Mechanical Completion Procedure This document is the property of Saipem Spa will safeguard its rights according to the civil and penal provisions of the law.

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ACTIONS AT WORKS COMPLETION The Subcontractor is responsible for the completion of each system, plant area and the entire facilities to be provided under the contract, ensuring that all work has been completed in accordance with the contract specifications. The Subcontractor shall complete any work identified upon the punch lists prepared by its own inspection department, as required by the contract. The format of the punch lists, including identification extent of each individual system, will be determined in accordance with Contract requirements. A system may constitute a process, civil, mechanical, electrical, instrumentation, structural or architectural portion of the plant, whether a complete unit, part of a unit or elements within a unit that allow the Operating Company’s operations department to accomplish a specific task or to support start-up of the facilities. When the Subcontractor is about to complete the construction of a system, or plant area, he shall at least 40 days before the expected date of completion. The Subcontractor notifies the Contractor - refer Attachment I - enclosing punch lists previously prepared and “punched out” by the Subcontractor, including a list of works, inspections and checks still to be completed. An example of this list is shown in Attachment I (to be amended to match Contract requirements). By receiving this notification, the Contractor shall check the information provided by the Subcontractor, revising and correcting punch lists if necessary thus obtaining the final punch lists. Within 10 days, the Contractor will give the final punch lists back to the Subcontractor including the Notification of Incomplete Works, if required. All items on the Notification of Incomplete Works/returned punch lists will be prioritised by the Contractor indicating whether outstanding works must be completed before issuing the Certificate of Mechanical Completion of the Subcontract Works , or in the commissioning period. Particular importance will be attributed by the Contractor to the documentation packages required to be handed over by the Subcontractor, before issuing the Certificate of Mechanical Completion for Part (or Whole) of the Subcontract Works, relating to the checks, inspections and tests required to be performed on a system or plant area in accordance with the contract as per quality specifications and Contract conditions. Documentation checks shall include, but not be limited to, a review of test reports conducted by the Subcontractor and the Contractor, such as pressure tests, electrical measurements, loop checks and rotational direction checks, to ensure that all items have been checked. In addition detailed inspection tours shall be made to determine that: 

 

features affected by flow direction, such as flow meters, are properly orientated; facilities for by-passing, blocking and blinding are properly located; temporary blinds and other provisions required only for testing have been removed; any other condition which may delay, or complicate, the subsequent commissioning and start-up has been properly accommodated.

The Subcontractor shall carry out any incomplete work identified by the Contractor on the Notification of Incomplete works/returned punch lists. The Subcontractor shall sign the column of the punch list entitled “Completion Confirmation” as individual items are completed. The Contractor shall check the work performed and, upon completion and acceptance of each individual work item, he shall sign the punch list for acceptance alongside the Subcontractor in the column entitled “Completion Confirmation”. 000-ZA-E-09406_0_Mechanical Completion Procedure This document is the property of Saipem Spa will safeguard its rights according to the civil and penal provisions of the law.

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When items in Part A of the punch list (Attachment II) have been completed and signed by the Subcontractor and the Contractor, the Subcontractor shall notify the Contractor of this event by forwarding the Notification of Construction Completion (Partial). At this point the Contractor may carry out a final P&ID check. This will be a thorough line-by-line, feature-by-feature check of the system or plant area against the flow sheets. Within 3 days of receiving the Notification of Construction Completion (Partial) from the Subcontractor, the Contractor may issue a Certificate of Mechanical Completion for Part of the Subcontract Works, and notify the Subcontractor of any outstanding work on an updated punch list. The parties shall follow this procedure until the work is completed, when the Contractor shall issue the Certificate of Mechanical Completion for Part of the Subcontract Works. The Contractor may choose to issue the above Certificate, either in Part, or in Whole, before the completion of all punch list items. He may also issue a final punch list together with the Mechanical Certification. It is understood, that in this event, all issues must be resolved and completed, before issuing the Certificate of Technical and Administrative Check as stated item 5 herein and in any case within three months of MCC. 3

PRE-COMMISSIONING Pre-commissioning activities relate to non-operating adjustments, cold alignment, calibration and the general checking of components installed in the Work together with such activities as flushing and cleaning. During the execution of the construction work, in returning a punch list to the Subcontractor in the above described procedure, or in preparing the Notification of Incomplete Works, the Contractor may notify the Subcontractor of any required pre-commissioning work. This is before issuing the Certificate of Mechanical Completion of the Works and for which the Subcontractor will have been paid for within the Contract rates. Attachment II lists, item by item, the pre-commissioning activities that have to be completed by the Subcontractor prior or after the issue by the Contractor of the Certificate of Mechanical Completion of the Work. The Subcontractor is responsible for providing all necessary qualified personnel, operators, labour, equipment, testing equipment and materials including but not limited to consumable construction materials, chemicals and temporary spools to ensure execution on time of the pre-commissioning Work. Al l Pre-Com mi ss io ning activ it ies are in cl uded wit hi n Subcont racto r’ s sc ope of work and payment is to be included within the erection unit prices, rates or lump sums, with the exception the activit ies clearly indicated in the price list. Within Subcontractor’s scope of work for pre-commissioning, supply of any materials, chemicals, test equipment, temporary spools, tools necessary for pre-commissioning activities, with the only exclusion of what is specifically supplied by Contractor and stated in the Contract, is included. The Subcontractor shall prepare a schedule for the execution of the known pre-commissioning work to meet the priorities of the Contractor. The schedule shall be approved by the Contractor. The Subcontractor shall update the schedule at frequent intervals to incorporate any changes required by the Contractor. 000-ZA-E-09406_0_Mechanical Completion Procedure


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CERTIFICATION Within 15 days from the construction completion of the whole plant or of a part of it or a system, the Subcontractor shall notify the CM of this achievement. The notification shall include lists of works, checks and tests (prepared by the Subcontractor), which do not invalidate the functional completion of the whole plant, part of it or system subjected to the notification. Within 10 days from the receipt of the above mentioned notification, the PM-C or CM carries out the check of the plant, area or system involving the Client, Licensors and Suppliers, completing where necessary the list prepared by the Subcontractor and obtaining the final punch-list. The FQC, verifies the documentation related to these checks and tests, pointing out any missing. The CM if required, submit to the Subcontractor the final punch-list and the notification of noncomplete works. When the Subcontractor has completed all the remaining items of the punch-list and they are countersigned by the CM or by the punch list originator, the Subcontractor submits the notification of construction completion with the updated punch-list signed by the parties (see attachments of the specification 00-ZA-E-09400 Site Coordi nation Procedure ). Within 3 days from the receipt by the Subcontractor of the notification of construction completion and once punch-list items’ execution have been verified, the PM-C or CM issues the Certificate of Work Done Ready for Hand-over (see attachments of the specification 00-ZA-E-09400 Site Coordination Procedure). This certificate is prepared before the execution of checks and tests in order to ensure that the scope of work contents are ready to be handed over with the possibility to be used by the Contractor or the Client. Within 7 days from the issue of the of the Certificate of Work Done Ready for Hand-over, the PM-C or CM issues the Certificate of Work Completed (see attachments of the specification 00-ZA-E09400 Site Coordination Procedure ). This document is prepared when works have been completed or, in case of hand-over by areas with different deadlines, when a single area has been completed. The date of this certificate rules that application of any penalty for delayed hand-over and the warranty period as defined in the Contract. The PM-C or CM issues the Technical/Administrative Check Certificate (see attachment of the specification 00-ZA-E-09400 Site Coordination Procedure ), following the Certificate of Work Completed. It contains information and references necessary for the elaboration of the final bookkeeping with the Subcontractor, hence the stoppage or acknowledge of previous accounting errors, works non executed in accordance with specifications and not corrected, delays in the works hand-over, penalties, etc.

5

COMMISSIONING Commissioning activities are associated with making the units, systems and the entire facilities ready for operation including operating adjustments and hot alignments to simulate actual operations. The Subcontractor may be required under the terms of the contract to provide resources to assist the Contractor and the Operating Company in commissioning the completed plant for a period not exceeding 3 months after Mechanical Completion. Such resources including labour, plant and 000-ZA-E-09406_0_Mechanical Completion Procedure


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material will be paid for by the Contractor on a day work basis at the rates stated within the subcontract. 6

WORK FLOW

6.1

Mechanic al Completi on (Parti al)

Subcontractor

Contractor

Notification of Expected Date for Mechanical Completion (+ proposed Punch List)

Notification of Mechanical Completion (Partial) (+ Punch List prioritised)

Notification of Incomplete Works (+ Punch List prioritised)

NOT OK / O

Certificate of Mechanical Completion (Partial) (+ Punch List prioritised)

Certificate of Work Done Ready for Hand Over (Partial) (+ minor items)


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MECHANICAL COMPLETION PROCEDURE 6.2

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Mechanic al Completi on Subcontractor

Contractor

Notification of Expected Date for Mechanical Completion (+ proposed Punch List)

Notification of Mechanical Completion (+ Punch List prioritised)

Notification of Incomplete Works (+ Punch List prioritised)

NOT OK / OK

Certificate of Mechanical Completion (+ Punch List prioritised)

Certificate of Work Done Ready for Hand Over (+ minor items)


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MECHANICAL COMPLETION PROCEDURE 7

ATTACHMENTS

7.1

ATTACHMENT I: Punch list for constru ction work s

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Att achment 2 - Notif icati on of Expected Date for Mechanical Completi on


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Attachment 3 - Notification of Incomplete Works


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Attachment 4 - Notification of Mechanical Completion


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Att achment 5 - Certifi cate of Mechanical Completi on


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Attachment 6 – Pre-commissionin g responsibilit y matrix KEY FOR CHECKLIST

X

Perform the WORK item

R

Review Contractor submitted documents and return with or without comments.

W

Witness WORK Item being performed by being physically present for entire duration and signify that item had been successfully completed by signing of pertinent documents. Contractor shall not perform the WORK item without COMPANY presence or written waiver of this requirement.

I

Physically inspect the WORK Item during and/or after completion and provide written verification of having done so, including a list of any deficiencies that were observed.

A

Assist in the performance of the WORK Item, including providing labour, access, tools, consumables, scaffolding, light, etc. as required.

AD

Assist in the performance of the WORK Item, on a reimbursable basis.

NOTE : THIS WHOLE DOCUMENT SHALL BE READ AS APPLICABLE AND RELATED TO S/C SCOPE OF WORK.

CONTRACTOR

CLIENT


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1.

1.1

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SUB CONTRAC CONTRAC TOR TOR

0

CLIENT NAME

X

I

R

Complete installation of FACILITIES. Check for correct installation per the Job Specification, Vendor instructions, design drawings and applicable codes.

X

I

I/R

Provide proper identification of all equipment. Identification numbers shall be legible from 50 feet away for equipment, 15 feet for Instruments.

X

I

I R

1.4

Assure that all NDE is completed and acceptable for structural steel, piping, vessels, and conduit seals.

X

I/R

R/I

1.5

Remove all rust preventatives, oil and grease, used to preserve equipment during shipping and construction and maintain records of the same. Clean all nameplates.

1.3

1.6

1.7 1.8 1.9

1.10

1.11

IVE

GENERAL

CONTRACTOR shall establish a work permit procedure for the Construction/Precommissioning Period

1.2

CLIENT REPRESENTIT

EXAMPLE X

I

I/R

At the time of 10 day notification of Mechanical Completion, the operating area and platforms shall be secured and free of debris, tools and extraneous materials that could impede operation or cause an unsafe condition. All access ways shall be opened for emergency vehicles. All scaffolding not required for commissioning or start-up shall be removed.

X

I

I

Complete all necessary paving, fencing and items of like nature

X

I

I/R

X

I

I/R

X

X

I/R

Install all road signs, safety signs and other signs. Submit comprehensive list of all test equipment to be used. Test equipment shall have a standard of accuracy better than the Vendor's stated accuracy for item to be tested or as required by COMPANY requirements. Intervals between calibrations shall not exceed three (3) months for all field test equipment. All test equipment shall have a nameplate or label showing the most recent date of calibration. All test equipment requiring AC power will be 120 V AC 60 Hz.

Project Record Books shall have been completed and submitted as per SAEP 122 Project Records

X Each for own scope of supply X Spare parts data packages submitted and accepted Each for by COMPANY. Turnover of specified spare parts and own scope Vendor recommended special tools. of Supply

X Each for own scope of supply X Each for own scope of Supply

R

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CONTRACTOR

Pre-commissioning Activities 1.12

1.13

1.14


CLIENT CLIENT NAME

Install first loading of chemicals and desiccants and other operating materials as required by Contract. Retain samples of all material and turnover to COMPANY. Operating materials to be suitably protected from hazard or degradation by purging/isolation.

AD

I

IW/R

Where required as a site activity, verify wall thickness of pressure vessels, exchanger shells and tanks by ultrasonic thickness testing. Submit all records.

AD

X

I

At the time of Mechanical Completion, all fire proofing and rough insulation shall be complete, i.e., all equipment, piping wiring, instruments, instrument leads, etc., requiring fire proofing or insulation for heat conservation shall be covered so that start-up operations will not be delayed due to lack of adequate fire proofing or excessive heat loss. Insulation required for personnel protection shall also be completed. Only areas that would be required to be open for tightness testing (flanges, valve stems, etc.) will not be covered prior to Mechanical Completion. Exposed insulation is to be properly protected and sealed.

CLIENT REPRESENTIT IVE

EXAMPLE

1.15

1.16

X

I

R I

In addition to 1.14, final insulation jacketing shall be complete enough so that there will not be an excessive amount of scaffolding erected in the plant areas where COMPANY operators will work during start-up. The number of insulation crews still working in the area shall not be excessive.

X

I

I

Inspect and check the WORK during the construction stage, and perform such non-operational tests as are necessary to assure the integrity of the installation in accordance with the issued for Construction Drawings, specifications and Vendor Instructions.

X

I

I

X Each for own scope of Supply

X Each for own scope of Supply

1.17 Control the activities of the Vendor representatives while they are on the project.

1.18

Mobilise and control the activities of licensor representatives during the pre mechanical completion phase of the project

I

X

1.19 Obtain any permits and approvals from government and regulatory agencies required in the name of Contractor.

X Each for own scope

X Each for own scope

R


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CONTRACTOR


1.21

1.22

1.23

1.24

1.25

1.26

1.27

1.28


CLIENT CLIENT NAME

Complete all necessary insulation, painting, grating, fencing, paving, touch-up concrete and grouting, and items of like nature.

X

I

I

Verify that the WORK, or portion thereof, is complete and that all required inspections, tests, reviews and approvals are complete and recorded.

X

I

I/R

Document all inspections, tests and other precommissioning activities. Document all deficiencies discovered during the activities along with corrective actions taken.

X

I

R


EXAMPLE

Document the Vendor representative's check and acceptance of installation and preparation of their equipment for start-up/ operation as required.

Prepare punch lists, by system, of deficiencies between as-built plant and the latest P&IDs, specifications and Vendor instructions. Correct any deficiencies noted 30 days prior to expected Mechanical Completion, CONTRACTOR to send a notification of impending Mechanical Completion to COMPANY.

X X Each for Each for own scope own scope of of Supply Supply X X Each for Each for own scope own scope

R

I/R

A

X

R

X (Install)

X (Supply)

I/R

10 days prior to expected Mechanical Completion, CONTRACTOR to send request for COMPANY punch list, with copy of master punch list status.

A

X

I/R

At the time of 10-day notification of Mechanical Completion, painting shall be complete enough so that an excessive amount of scaffolding is not left standing in areas where COMPANY's operators must work during start-up. In addition, the number of painters still working in the area shall be kept to a minimum.

X

I

I

Supply and Install proper lubricants immediately prior to 10 day notification of Mechanical Completion, after review with COMPANY Operations.


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CONTRACTOR



CLIENT CLIENT NAME

Prepare and submit notification of Mechanical Completion when all WORK items identified by CONTRACTOR, Vendor and COMPANY as required for start-up of the facilities are completed. Each notification shall identify plant system(s) submitted for acceptance, copy of master punch list for those system(s) list of uncompleted ("exception") items with reason for their late completion and estimated completion date, inspection and test and check-out reports, and copies of marked-up "As built" P&IDs and one-line and three-line diagrams, schematics, instrument loop diagrams, and logic diagrams, and list of start-up spare parts on Site. CONTRACTOR shall submit eight (8) copies of each package described above.

A

1.30

Check all items of equipment for adequate, safe and functional access per SAES-B-054 requirements.

X

I

I

1.31

Check that control panels and enclosures meet area classification control.

A

X

R

1.32

Provide and install guards, barriers, warning signs and other safety devices as agreed with COMPANY as necessary during site walk through.

X

I

I

X

I

I

X

I

I/R

X

W

W

X

W

W

X

I

W I

1.33

1.34

2. 2.1 2.1.1

2.1.2

2.1.3

X


I/R

EXAMPLE

Prior to Commissioning/Start-up, remove all temporary fencing and barricades to allow free access to operating unit/system. Supply and install line identification tags and signs. Stencil lines for identification CIVIL/STRUCTURAL Civil Test gravity sanitary sewers, chemical sewers and basins from manhole to manhole, or manhole to sump inlet, by filling the lines to the top of the upper manhole. Test sanitary sewers that have been backfilled for water tightness for 24 hours.

Test sanitary sewer force mains at a minimum of 150 psig or 50 psig above the pump shut-off head, whichever is greater. Test force mains that have been backfilled for water tightness for a period of 24 hours Inspect all sewer lines and check all cleanouts, manholes, and service connections for proper installation and functioning


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CONTRACTOR



CLIENT CLIENT NAME

2.1.4

Check all underground installations for proper invert elevations.

X

I

I/R

2.1.5

Check sewer manholes for leak tightness by filling and then observing the water level for ten hours. All leakage shall be corrected.

X

W

W I

X/O

I

W I

X

W

W

2.1.6

2.1.7 2.1.8

Inspect, test and operate building, plumbing systems to confirm proper functioning and leak tightness. (refer to SAES-S-060) Immediately prior to Mechanical completion, clean and inspect all catch basins, man-holes and sumps

W

W

X

I

I/R

Check and record that underground lines are cathodically protected and isolation spools/flanges have been installed. Cathodic protection shall be fully in service at Mechanical Completion.

X

I/R

R

2.1.11

Provide backfilling compaction and soil particle size test records.

X

R

R

2.2 2.2.1

Foundations Provide approvals to pour concrete signed by COMPANY with concrete slump tests and water tests report and after inspection of rebar, formwork and soil condition of excavation bottom.

X

I

R I

2.1.10

IVE

EXAMPLE

Site (or parts thereof) shall be flood tested to the satisfaction of COMPANY in order to confirm proper functioning of area drainage, per design drawing i.e. runoff, contour, and/or flatness, oily water and contaminated surface water sewers Inspect all structures and concrete placement periodically for cracking, fissuring, settlement, warpage, bending, rusting or any other deficiency. Submit Records. Deficiencies shall be promptly corrected to avoid further degradation, masking by subsequent Work, or subsequent failure.

X

2.1.9

CLIENT REPRESENTIT

2.2.2

Check concrete for any evidence of cracking, cavities, and aggregate separation.

X

I

I

2.2.3

Provide results of 28-day cylinder tests, aggregate and sand sieve tests and other QC tests.

X

R

R

2.2.4 2.3 2.3.1

Ensure concrete structures comply with SAES-Q-001. Structural Steel Check for correct fabrication in accordance with Job Specification and Vendor design drawings and applicable Codes.

X

I

I/R

X X Each for Each for own scope own scope of of Supply Supply

I


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CONTRACTOR

Pre-commissioning Activities 2.3.2

2.3.3

2.3.4

2.3.5

Ensure that seal welding is continuous with a smooth surface.


CLIENT CLIENT NAME

X For Erection Only

I

I

Check bolt torque and ensure that proper washers were used and that washers are against nut if single washers are used.

X

I

R W

Check all grating is fitted in place providing a true and level fit. All cut outs must be banded and cold galvanized. Check that no gaps left in grating, guard- rails, and toe plates. Check all stairways and ladders are installed to COMPANY standards, refer to SAES-B-054

X

I

I

X

I

I

2.3.6

Check that all areas incapable of being sandblasted and/or painted have been permanently welded closed/sealed.

X

I

I

2.3.7

Check ladders, stairs platforms, walkways and general access to equipment comply with SAES-B-054.

X

I

W/I

2.4 2.4.1

Grouting Clean grout area of all oil, grease, debris, dust and rubbish before grouting.

X

I

I

2.4.2

Check for correct installation in accordance with COMPANY and Vender specifications and designs. Ensure there are no voids or cavities within the grout area.

X

I

I

X

I

R

X X X X

I I I/R I

I R W R

X X X

R I I

R/I I I

X

I

I

X

W

I

2.6.5

IVE

EXAMPLE

Check welds on supports, gusset and plates, to ensure they are made with good welding technique and adequate for the intended purpose.

2.4.3 2.5 2.5.1 2.5.2 2.5.3 2.5.4 2.6 2.6.1 2.6.2 2.6.3 2.6.4

CLIENT REPRESENTIT

Perform strength tests on grout samples. Piling (NOT APPLICABLE) Check sand blasting/coating of piles. Check location of piles. Record blow counts per foot and final 3 inches. Check splice and bearing plate welds. Buildings Check building location and dimensions. Inspect finishing work. Inspect excavation for building. Inspect backfill for compaction and material conformance. Inspect formwork, rebar and anchor bolts before pouring concrete. Perform slump test on concrete before pouring. Retain concrete samples and perform strength tests at 7 and 28 days.


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Inspect building electrical and mechanical equipment including HVAC, ducting and insulation. HVAC systems operationally service tested and preliminary flow balancing completed. Check and record pressurization levels where applicable (Refer to SAES-K-002)

2.6.7

Check and service test all piping. All leaks to be corrected. 2.6.8 Functional test plumbing and mechanical systems. 2.6.9 Check that all required areas are fireproofed. 2.6.10 Operate and adjust doors and windows. Buildings shall be tested and documented for leak tightness and maintenance of internal positive pressure. 2.6.11

2.6.12

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EXAMPLE X

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Check for switchgear building floor levelness and compliance with Vendor's recommendation for switchgear installation.

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Flood test battery room floor for proper drainage prior to installation of batteries.

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2.6.13

Perform a half-hour deluge test of all roofing to confirm leak-tightness and proper function of gutters 2.6.14 Test building for leak tightness and maintenance of the required internal positive pressure. (Refer to SAES-J-801 and SAES-K-002) 2.6.15 Provide and install office furniture as described in project Specifications. 2.6.16

Check ventilation for battery rooms or other areas where hazardous vapours may be present.

2.6.17

Check fire detection and protection systems including alarms, sprinklers, hoses, extinguishers, extinguishant release system and others as applicable.

3.


CLIENT

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3.1

General Note: 480 volts and below project activities are undertaken by PID above 480Volts by PDD

3.1.1

Provide two complete packages of all Vendors' wiring X X diagrams, schematics, one-line and three-line diagrams for Each for Each for all equipment installed in the Substations, transformer own scope own scope Of yards, and electrical switching yards. The packages shall Of Supply Supply also contain all interconnecting wiring.

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3.1.3

3.1.4

3.1.5

3.1.6

3.1.7

3.1.8

3.1.9

3.1.10

Calibrate via third party calibration/certification FACILITY all applicable test equipment prior to its initial use. Intervals between calibrations shall not exceed three (3) months for all field test equipment. All test equipment shall have a nameplate or label showing the most recent date of calibration. All test equipment requiring AC power will be 120V AC 60 Hz.


CLIENT CLIENT NAME

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Circuits being tested are designed to be operated in excess of 600 volts between conductors shall have conductors shorted to ground by hot-line grounding device approved for the purpose.

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Before any tests are conducted, check and tighten all cable connections.

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Perform all necessary prestart-up non-operating test and Hi Pot checks on all power cables, generators, switchgear, MCC’s, transformers and grounding resistors following manufactures instructions and guidelines given in the applicable Pre-Commissioning Forms Manual available from Consulting Services Department

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Perform continuity test on all circuits from source of supply to utilization points.

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Megohm test each ungrounded terminal with respect to ground for all electrical equipment and cable. A megohm tester shall be used for this purpose. In performing this test external connections to the equipment shall be disconnected.

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Perform high potential test on equipment rated above 480V and record results.

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Check the continuity and tightness of ground connection between equipment frame and the main ground system and measure and record resistance to remote earth.

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Maintain a record of all calibration results showing type of test equipment, serial numbers, date of calibration, and the results. One copy of these calibration records shall be furnished to COMPANY.


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Check phase sequence in accordance with drawings and specifications and record results. Check that all three phase feeders are terminated at both ends in proper phase X I/R sequence to obtain correct direction of rotation and record results. 3.1.12 Carry out a full visual check of all equipment fittings and components located in hazardous areas to ensure full X I compliance with the relevant Specifications and Standards ‘Certificate ‘Certificates’ of certifying authorities. Contractor shall provide the s’: Each for : Each for its relevant certificates and letters of conformity for all its scope of scope of electrical equipment (including instruments) installed in supply supply hazardous areas. 3.1.13 Perform a final system functional checkout for all equipment and systems including emergency and instrument power systems and power distribution A X management system.

CLIENT CLIENT NAME


3.1.11

3.1.14

3.1.15

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Before an electrical system or piece of electrical equipment can be energized, an 'Energization Authorization Certificate' approved by COMPANY and authorizing such energization must be obtained.

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Check that all roll out type breakers and switches can be easily removed and installed.

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Record torque values of all electrical power terminations.

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Ensure electrical components are painted to COMPANY colour coding requirements.

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Confirm operability and capacity of emergency power systems, UPS and other battery supply systems.

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Perform battery acceptance tests. Check operability of battery chargers.

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Check operability of UPS systems including switching rectification filter (wave form), etc.

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Provide discipline support during energizing of substations and load centres when permanently connected to the electrical distribution system (after obtaining Energizing Authorization Certificate from COMPANY). Correct any construction and installation faults identified.

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3.1.16

3.1.17

3.1.18

3.1.19

3.1.20

3.1.21


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3.1.23

3.1.24 3.1.25

3.1.26

3.1.27

3.1.28

3.1.29

3.2 3.2.1 3.2.1.1


CLIENT CLIENT NAME

Paint and tag all electrical apparatus to COMPANY colour code regulations.

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Install sealing compound where required in seals after cable/loop checks and tests are completed.

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Verify cleanliness and proper silver-plating on all copper bus joints or connections. Insure adequate contact mating surfaces and contact pressure for all circuit breakers, disconnect switches, isolator switches, and motor starting contactors by contact resistance testing. Contractor shall establish a Tag and Lockout Procedure including a Work Permit Procedure for the construction/ Pre-commissioning period. Refer to Construction Health Safety and Environment Plan. Once the system or partial system is MC and switchgear is energized, COMPANY Work Permit procedures (refer to GI-0002.100 Work permit System) shall be followed. Annunciator and instrument tag nameplates shall be checked against design drawings for engraving and proper location. Annunciator operation and point continuity shall be checked by mechanically actuating all trouble contacts for low-high-deviation alarm operation and auxiliary contact operation and sequence. Complete electrical tests as using relevant check lists as listed in CONTRACTOR compiled System Precommissioning Manuals. Transformers Liquid Filled Transformers


EXAMPLE -

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Inspection and checkouts prior to tests: a) Verify proper auxiliary device operation such as fans, pumps, sudden pressure devices, indicators, tap changers and gas pressurization system. b) Check tightness of external bolted joints and/or connections. c) Verify proper transformer neutral connection. d) Check for the presence of combustible gas. e) Test in accordance with ANSI C57.12.1 and record results. 3.2.1.2 Electrical tests for large and medium power transformers:


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Pre-commissioning Activities a) Add filtered insulating oil and complete dress-out of all transformers. Fill under vacuum after internal connection and inspection is complete. Sample insulating oil before, during and after filling in accordance with ASTM D-29375 and laboratory test for the following: - Dielectric strength - Acid neutralization - Interfacial Tension - Colour - Water


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EXAMPLE

Submit certified results of the laboratory tests to COMPANY

b) Perform insulation resistance tests winding to winding and winding to ground with guard circuits over all bushings. c) Perform dielectric absorption tests winding to winding and winding to ground for ten (10) minutes. The polarization index shall be computed as the ratio of the ten (10) minutes to the one minute reading d) Measure dew point and oxygen content of top gas when applicable. e) Determine tap settings. f) Set and check the final tap settings on 15 MVA and smaller transformers. 3.2.2 Dry Type Transformers 3.2.2.1 Visual inspection prior to tests: a) b) 3.2.2.2 a) b) 3.3 3.3.1 3.4 3.4.1 3.4.1.1

3.4.1.2 3.4.1.3 3.4.1.4

Torque all loose bolted joints and/or connections. Verify proper transformer neutral connection Electrical Tests Perform insulation resistance test; winding to winding and winding to ground. Verify proper secondary voltage. Neutral Grounding Resistor Perform hi-pot test on each resistor. The potential application shall be for one (1) minute. Cables General Cables shall be tested after installation in accordance with SAES-P-104. Inspect exposed sections of cable for physical damage. Check cable bends to ensure that no bend has less than manufacturer's minimum allowable bending radius. Inspect for proper grounding, support and termination.

EXAMPLE X

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000-ZA-E-09406_0_Mechanical Completion Procedure


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Pre-commissioning Activities 3.4.2 480V and Below 3.4.2.1 Perform megohm test on each conductor to ground and between phases per SAES-P-104. .(If cable fails, check ends, clear any contact between conductors or between contractors and ground, then retest. If second test fails, remove conductor and install new cables.) 3.4.3 4.16kV and Above 3.4.3.1 Perform megohm test on each conductor to ground and between phases per SAES-P-104 and AEIC standards. 3.4.3.2 Perform DC high potential test as follows: a) Test all conductors individually with adjacent conductors in multi-conductor cables grounded. b) The DC high potential test shall be made in accordance with Materials Specification 15-SAMSS-502 Medium Voltage Power cables 5kV trough 35kV c) The conductor under test shall be raised in four stages to the maximum test voltage and maintained for fifteen (15) minutes and the leakage current shall be verified and reported to COMPANY. d) The conductor test voltage shall be reduced to zero and ground applied for not less than five minutes. e) Failed cables to be replaced. 3.5

Motors

3.5.1

General


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Note. 480 volts and below project activities are undertaken by PID, above 480 volts by PDD 3.5.1.1

Ensure that motor frame is properly grounded.

3.5.1.2 Visually check that all three phase feeders, control wiring, and motor space heater wiring are terminated at both ends in proper phase sequence and locations to obtain correct direction of rotation and operation. 3.5.1.3 Check and record continuity of all welds.

EXAMPLE

3.5.1.4 Check all motors are properly lubricated. 3.5.1.5 Carry out all necessary pre-start checks and nonoperational tests on motors following vendor’s instructions.

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3.5.1.6

Test run all motors for four (4) hours uncoupled. During the test, check the motor for excessive vibration or temperature. Record current and voltage readings.

3.5.1.7 Check nameplate against data sheets for rotation, horsepower, voltage and speed. 3.5.2 Motors Below 480V 3.5.2.1 Perform Megohm test on each motor below 100 hp. (If motor fails, clean, dry in an oven, then retest. If retest fails, repair motor.) 3.5.2.2 Check proper operation of space heaters. 3.5.2.3 For large motors (100 hp and above), obtain and record polarization index using megohm tester. 3.5.3 3.5.3.1 Perform dielectrical absorption test of motor starter winding in accordance with IEEE 43. 3.5.3.2 Perform megohm test on each motor. If motor fails, clean, use DC reduced voltage to dry out, then retest. If motor fails on retest, repair motor. 3.5.3.3 Perform high potential test on each motor energized at 5000 volts or higher voltage. 3.6 Bus Ducts 3.6.1 General 3.6.1.1 Inspect and check all bus duct bolt connections and tighten as required 3.6.1.2 Check bus duct for damage or missing parts, drain holes unplugged, space heaters connected (where applicable), and proper phasing 3.6.2 Electrical test 3.6.2.1 Perform insulation resistance test phase to phase and phase to ground 3.6.2.2 Perform high potential test on each bus section; phase to phase and phase to ground 3.6.2.3 Record all test results 3.7 Switchgear and 13.8kV, 4.16kV and 480 Volt Systems

CLIENT CLIENT NAME

X/O

X/I/W (SP to provide vendor to carryout tests for motors with temperature & vibration monitoring systems

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EXAMPLE

3.7.1

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Note: 480 volts and below project act ivities are undertaken by PID, above 480 volts by PDD General 000-ZA-E-09406_0_Mechanical Completion Procedure


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Pre-commissioning Activities 3.7.1.1 Inspect for proper alignment, anchorage and grounding. 3.7.1.2 Check and adjust contact alignment of breakers making sure spread of secondary contacts is equal and correct for proper contact pressure. 3.7.1.3 Check tightness of bolted bus joints.Torque and test to Vendor’s specifications. 3.7.1.4 Check control power transformer fuse type and size, potential transformer fuse type and size, proper operation of potential transformer draw out mechanism (where applicable), shorting bars removed from current transformers, continuity and correct polarity of current transformer circuit, and connection of space heaters. 3.7.1.5 Check draw-out type breakers for proper operation for spring charging mechanism, trip-free and anti-pump feature, and operation of safety interlocks. 3.7.1.6 Primary current injection tests shall be carried out except where this requires dismantling of main circuit components. In the latter case and for voltage circuits, secondary injection tests shall be carried out.


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EXAMPLE

3.8 Protection Relays and Devices 3.8.1 General 3.8.1.1 Submit two (2) complete packages of the following at least four (4) months prior to substations mechanical completion: a) All electrical one-line diagrams and electrical data sheets. b) All backfill vendor’s one-line and three-line diagrams. c) All switchgear and control gear vendors’ data sheets including bills of materials showing relay types and vendor. d) Relay co-ordination and setting data and calculations. These packages are in addition to all other requirements for copies of drawings. These packages shall be used by COMPANY to verify/check Contractor calculated relay settings. The review shall take a minimum of three (3) months. Submit promptly to COMPANY and other drawings or information requested for purposes of this COMPANY check. 3.8.1.2 Inspect each relay for cover, cover glass, and cover gasket, presence of foreign material, moisture, and condition of spiral spring, disc clearance, and contacts. 3.8.1.3 Check tightness of mounting h ardware and tap screws. 3.8.2 Calibration

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Pre-commissioning Activities 3.8.2.1 Pull and bench calibrate relays and then reinstall. Report all test results on relay setting records. Operating point shall equal the test points ±3% 3.8.3 Relay Setting 3.8.3.1 Set relays in accordance with settings shown on relay setting record agreed by COMPANY (Power Distribution Department). 3.8.3.2 Set and test all transfer differential relays.


Motor Control Centres General Inspect for proper alignment, anchorage and grounding. Check tightness of all bolts and torque to vendor's specifications. 3.9.1.3 Verify that all overload units are properly sized and replace if required. 3.9.1.4 Check that motor control centre space heaters are connected, overload reset buttons free and functional.

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3.8.3.3 Set and test all bus differential relays.

3.9 3.9.1 3.9.1.1 3.9.1.2

CLIENT CLIENT REPRESENTIT IVE

EXAMPLE

3.9.2 Tests 3.9.2.1 Perform insulation resistance test phase to phase and phase to ground. 3.9.2.2 Perform high potential test on main bus phase to phase and phase to ground. Potential application shall be for one (1) minute. 3.9.2.3 Measure main contact resistance of all contactors. 3.9.3 Functional Checkout 3.9.3.1 Check and adjust contact alignment of contactors. 3.9.3.2 Check contactors for proper cubicle alignment and stab penetration. 3.9.3.3 Check each contactor compartment shutter assembly to confirm proper operation. 3.9.3.4 Apply control voltage and verify proper operation and calibration of all voltmeters and watt-hour demand meters. Pull potential transformer fuses before performing this test. 3.9.3.5 Check control circuits by applying control voltage, operating all internal contacts and simulating external signals. 3.9.3.6 Apply control voltage and verify proper operation of all relays, breakers, meters, controls, alarms and enunciators.


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Pre-commissioning Activities 3.9.3.7 Pull and bench calibrate relays and then reinstall. Report all test results, report open relay settings. Operating times shall equal the set points ±3%. 3.9.4 Record all test data and torque values.

3.10 3.10.1 3.10.2 3.10.3 3.10.4 3.10.5 3.10.6 3.11 3.11.1

3.12 3.12.1


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EXAMPLE

Lighting Check location and installation of lighting provisions per project and vendor design drawings and applicable Codes. Install lamps (incandescent bulbs, fluorescent tubes, etc.) in all fixtures. Verify all lights and light switches operate properly. Test photo cells for proper operation. Make check of lighting intensities in accordance with SAES-P-123. Confirm the actuation of emergency lighting in the event of normal power failure.

Check the operation of the blackout system. Grounding Test continuity of all connections to the grounding system for all equipment bonds made at Site. Include the main cabling systems and their connections to ground electrodes. Telecommunications

Complete the installation of FACILITIES. Check for correct installation per the Specifications, vendor instructions, design drawings and applicable codes 3.12.2

All telecommunications equipment (transmission switches, muxes data equipment alarms etc), public address and general alarm stations to be installed, checked, calibrated, tested and placed in service as per Project Specification. 3.12.3 OSP: cables, manholes, conduits, protection and termination 3.12.4 Tower, structure and foundation, wave bridge, grounding etc. 3.12.5 Buildings and Support utilities; grounding, etc. 3.12.6 Power: DC Plant, Standby, etc. 3.12.7 4.

Ensure communication equipment correctly installed and pre-commissioned.

X

PIPING AND ACCESSORIES 000-ZA-E-09406_0_Mechanical Completion Procedure


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Pre-commissioning Activities 4.1 4.1.1

CLIENT NAME


General

Check, repack and lubricate valves and necessary. 4.1.2


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Field fabricated vessels, above ground piping, below ground piping, and vendor packages piping (such as lube X oil systems) shall be pre-flushed and pressure tested for strength and cleaned in accordance with SAES-A-004 and (Except for field SAES-G-116. Testing shall be performed after installation fabricated of the material or piping in its final position, even in vessels) circumstances where the item was prior tested during fabrication (except as allowed by SAES-A-004).

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Tight shut-off valves shall be individually bubble tested to ANSI/FCI 70-2 prior to installation in addition to any other strength or tightness testing required by SAES-A004 and the other requirements of the job specification.

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Compile QA and QC procedure for control of piping e.g. nuts, bolts and gasket, to ensure correct installation

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Check and certify that all radiographic requirements have been performed and accepted by COMPANY and that all required records have been completed satisfactorily.

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Check and certify that all post weld heat treatment requirements have been performed and accepted by COMPANY, and that all required records have been completed satisfactorily.

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EXAMPLE

4.1.3

4.1.4

4.1.5 4.1.6 4.1.7

4.1.8

4.1.9

Check all bolts on flange connections for correct length and class. Install jacking bolts on all flanges with spectacle blinds.

Verify that all compressor suction piping is internally clean of mill scale and debris after performing chemical cleaning and before start up.NB: Remove all internal coatings prior to chemical cleaning


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EXAMPLE

4.1.11

Verify that pipe guides and anchors on flare strings and pipe allow for thermal expansion.

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4.1.12

Check piping for correct slope and, for process gas lines, that no "pocketed" sections exist upstream of gas compressors of flare. Correct any defects.

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Check that all line vents, drains, strainers- both temporary and permanent, blinds and non-return valves shown on drawings and specification, are installed

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4.1.14

4.1.15

Provide and install other temporary blinds and bypasses required for start-up, as specified by COMPANY's Operating Organization.

X For Water, I Air up to X 7barg (supply of Provide all new replacement gasket spool, pieces, hoses, flushing & replacement temporary connections, rigging/hoisting, scaffolding blowing and gaskets, blinds and media (water demin water, chemicals, air, Oil flushing chemical steam, oils, nitrogen, fuel etc.) required for cleaning, cleaning, treating, and flushing/blowing drying and inerting AD steam activities. Supply supervised labour and necessary (for blowing & tools/equipment and instruments to undertake the activities chemical Nitrogen cleaning and Supply) steam blowing)

4.1.16

CONTRACTOR to supply and use water of correct quality(<50 ppm chlorides) for the hydrotest and flushing of stainless steel pipe and equipment 4.1.17 Inject lubricant into grease points as required. Confirm use of correct type as specified by Vendor/Supplier. 4.1.18

IVE

Co-ordinate the flushing, cleaning, pressure testing and corrosion prevention requirements with all other Precommissioning activities such as vessel/exchanger internal inspections, oil system cleaning and flushing, run-in, tightness testing and all other WORK activities. X

4.1.13

CLIENT REPRESENTIT

Inject sealant into all sealant ports.

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CLIENT CLIENT NAME

marked up P&ID’s marked up isometrics hydrotest procedure pre-test inspection certificate hydrotest certificate post-test inspection certificate

EXAMPLE A

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Check All valves are installed in the direction of flow as required and are at their designated locations, and are both operable and accessible in their installed position.

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4.2.6

Check All flanged connections have gaskets installed in accordance with the applicable line class specifications.

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4.2.7

Check All seal welding, bridge welding and/or bracket welding has been completed satisfactorily.

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4.2.8

Check All temporary blanks, plugs, caps, temporary and permanent spectacle plates, blinds, temporary gaskets, and temporary spools required for pre-flushing and/or pressure testing are installed in their correct locations and positions according to hydrostatic test pack diagrams.

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4.2.3

4.2.4 4.2.5

Visually inspect each test envelope, checking and certifying that the following items conform to the project drawings and specifications.

Check all piping is adequately supported and properly installed maintaining contact with the pipe supports. Spring hangers to have stops installed as required for hydro testing loads. Check anchors, guides and wear pads are correctly installed and are at their designated locations.

4.2.9

Check All orifice plates, strainers, control valves and other items, which may be damaged during pre-flushing and testing, are removed from the system. 4.2.10 Check All valves in the system are installed in their correct position (open or closed) as indicated on the hydrostatic test diagrams. 4.2.11

IVE

Pre-Pressure Test Requirements General CONTRACTOR shall compile hydrotest packs which will typically contain: 1. 2. 3. 4. 5. 6.

4.2.2

CLIENT REPRESENTIT

Provide list and location of all blinds installed with reference to the relevant P&ID.

W R

X

I

X

I

I R

X

I/R

I R

EXAMPLE



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CONTRACTOR

Pre-commissioning Activities 4.2.12 Remove instrumentation and other items, blind equipment, disconnect flanges, and install temporary spools and supports, and all other set-ups required for preflushing and/or cleaning. 4.2.13

Check that all Exposed stems of valves are covered with canvas sleeves.

4.2.14

4.3.4

NAME

I

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I

X (For Chem. Cleaning) (SUBCONT RACTOR)

X

I

R

X

I

I/R

As required by SAES-A-004 and pressure test diagrams, prepare instrumentation, piping, temporary supports and other equipment items for strength testing. Install temporary, calibrated relief valves as required by SAESA-004 and test plans. Install calibrated test recorders as required by SAES-A-004.

X

I

I/R

Strength test all items of equipment and piping as required by SAES-A-004 and pressure diagrams. Test fluids shall be in accordance with SAES-A-007. Where pneumatic testing is proposed, this shall be approved by COMPANY in accordance with SAES-A-004, and shall be indicated by Contractor in the Pre-commissioning and Mechanical Completion Plan.

X

W

W

Check and certify that when filling the system, the test fluid is injected at the lowest point and all high point vents are open.

X

I

I

Set up all safety barriers required for personnel and equipment safety.

X

I

I/R

Certify that pre-flushing has been performed, witnessed and documented in accordance with SAES-A-004. 4.2.16 Check all items and piping water flushed shall either be blown or wiped dry or strength tested within 48 hours.

4.3.3

X

CLIENT

AD (For Chemical Cleaning)

4.2.15

4.3.2

X (Except for Chemical Cleaning and Steam Blowing)

X Clean out or pre-flush piping prior to commencement of pressure testing as required by SAES-A-004 and SAES-L050. When chemical cleaning is employed, Contractor shall provide all chemicals.

4.3 4.3.1


CLIENT

W

Strength Testing

EXAMPLE


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4.3.6

Check and certify that the pressure the test gauges, and PZVs, are currently certified/tested and properly connected. Check and certify that temperature and equilibrium was attained between the test fluid and the system before applying pressure.


CLIENT CLIENT NAME

X

I

I

X

I

I

X

R

R

4.4 4.4.1

Post Strength Test Check and certify that all required records pertaining to the pressure test have been completed satisfactorily.

4.4.2

Check and certify that all temporary blanks, plugs, caps, spectacle blinds, temporary spools, test gauges and PZVs installed for the pressure test have been removed.

X

I

I

Check and certify that all valves etc. removed for preflushing and pressure test are reinstalled and are both operable and accessible in accordance with the applicable standards and specifications.

X

I

I

Check and certify that all flanged joints disturbed during or after the hydrostatic test, and all temporary gaskets installed for hydrostatic testing have had new gaskets installed that conform to their applicable line class specifications.

X

I

I

Check and certify that items that were damaged during pre-flushing or pressure testing activities have been satisfactorily repaired or replaced.

X

I

I

X

I

R I

X

I

I

X

I

W R

4.4.3

4.4.4

4.4.5

4.4.6

4.4.7

4.4.8

Check the packing, packing materials and lubrication of all valves, repair and lubricate as necessary. Check and certify that all seal welding requirements, including threaded plugs strictly used for hydro testing, have been performed after pressure testing. On completion of reinstatement after hydro test, leak (tightness) test as required by SAES-L-056, to ensure that all equipment or lines disconnected, removed and blinded off for hydro testing have been reinstalled correctly.

IVE

EXAMPLE

4.4.9

Repair any leaks found during tightness test. Check all nuts and bolts to confirm that threads are fully engaged.

X

I/W

W R

4.4.10

All torque procedures for bolting and bolt pre-loads shall be verified on high-pressure piping and equipment where applicable.

X

I

W R

4.5

CLIENT REPRESENTIT

Flushing and Blowing of Line Work Systems


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CLIENT CLIENT NAME


4.5.1

4.5.2

4.5.3

4.5.4

4.5.5

Water flush or air blow line work systems to ensure the operational flow routes are clean and unrestricted. Generate detailed flushing procedures to include definition of isolation points, and lists of items to be removed and reinstated for the flushing or air blowing exercise. Provide all temporary equipment and fittings as required.

X

I/W

R W

Compile steam blowing disturbance factor calculations to confirm adequacy of steam blowing line cleaning activities. Provide steam blowing noise calculations

AD

X

R

AD

X

I/W/R

Steam blow all steam piping to atmosphere until proven clean. CONTRACTOR to provide criteria and methodology to confirming cleanliness. Steam supply headers to be installed with sufficient flanged blank ends and intermediate exhaust points to allow efficient blowing of steam systems. Blows and thermal cycling shall be repeated for the number of times necessary to demonstrate that the piping has been blown clean of all loose material, millscale and friable material. Contractor shall provide temporary connection piping, valves, silencers, piping materials (gaskets, nuts, bolts etc.) utilities, target plates supervised labour, all necessary tools/equipment rigging/hoisting, scaffolding, temporary insulation, instrumentation CONTRACTOR shall supply steam for blowing activities. Steam piping supplying steam turbines or similar equipment shall be steam blown to polished target plates located at the inlet flange of each equipment item. Target plate impact criteria to be agreed between all relevant parties i.e. VENDOR , CONTRACTOR and COMPANY On completion of flushing and blowing reinstate all control valves and in-line equipment using permanent gaskets.

EXAMPLE X

I

W I

Check and certify that all control valves, check valves and all other in-line items have been reinstalled in the system, and are in their correct orientation as indicated by the P&IDs and specifications.

X

I

W I

Check and certify that spring support travel/hydro test stops have been removed in accordance with the applicable design data sheets and securely linked to the spring support housing for future use.

X

I

W I

4.5.6


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CLIENT CLIENT NAME

Check and certify that all spring support assemblies have been set in accordance with the applicable design data sheet. Provide hot and cold setting data.

X

I

W I

4.5.8

Check that both temporary and permanent strainers required for start-up are installed.

X

I

R I

4.5.9

Check and certify that spectacle and isolation blinds are installed in their correct locations as per the P&ID’s.

X

I

R I

4.6


Chemical cleaning


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CONTRACTOR shall compile detailed chemical cleaning procedures for review and approved by COMPANY. These will include, as a minimum: 1. marked-up drawings defining the cleaning circuit(P&ID’s, isometrics, schematics etc.). these shall indicate size and type of all cleaning connections, locations of all blinds, high point vent and low point. NB: All internal pipe coatings shall be removed on all pipes to be chemically cleaned prior to erection. 2. Marked-up drawings (plot plans etc.) indicating the location of temporary area fencing 3. List of valves, equipment etc. remaining in line during the cleaning activities 4. List of valves, equipment etc removed prior to chemical cleaning 5. Methods of isolating items not included in chemical cleaning 6. Full chemical cleaning methodology. This will include chemicals to be used, concentrations, means of introduction, contact times, temperature and pressure, inhibitor to be used with manufactures recommendations for use and will also including check list such as pre and post cleaning inspection sheets 7. Sampling and testing schedule, including responsible individuals and their contact details, potential dangers, incident action plans, area segregation, personnel protection equipment to be worn, Material data Sheets (MSDS) etc. 8. Inspection methods and acceptance criteria including check/records sheets 9. Effluent disposal methods (refer To SAEP-327)


CLIENT CLIENT NAME


EXAMPLE

4.6.2

SAE-1028 defines the minimum requirements for chemical cleaning and flushing of lube/seal oil and fluid power systems. The procedure also provides to list of relevant Client procedures and standards CONTRACTOR shall review the FACILITIES and Client procedures and standards to confirm the full extent of chemical cleaning and compile a list of systems requiring chemical cleaning. CONTRACTOR shall identify on P&ID’s and the line index the full extent of chemical cleaning in accordance with SAES-L050

AD

X

R

AD

X

R


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CONTRACTOR


4.6.4

4.6.5

4.6.6

4.7

4.7.1

4.7.2

4.7.3

CONTRACTOR shall supply all materials equipment, tools, specialist contractors, labour, chemicals, utilities and inspection equipment necessary to perform all chemical cleaning activities to the satisfaction of COMPANY CONTRACTOR shall be responsible for performing all chemical cleaning activities and will ensure that only suitably qualified personnel undertake the work On completion of chemical cleaning, CONTRACTOR shall dispose of all effluent in accordance with SAEP-327 and reinstate all valves, equipment etc. removed for chemical cleaning using new permanent gaskets Check and certify that all control valves, check valves and all other in-line items have been reinstalled in the system, and are in their correct orientation as indicated by the P&ID’s and specifications


CLIENT CLIENT NAME

AD

X

R

AD

X

R/W/I

AD

X

W I

AD

X

W I


EXAMPLE

Corrosion Prevention

After hydro testing or water flushing, equipment items or piping sections shall be air dried to protect from subsequent corrosion within 48 hours. Where materials are to remain open to atmosphere, all standing water shall be removed immediately after hydro testing or flushing.

In the event that the forecast start-up date is more than 60 days from the time of hydrostatic testing or flushing, protection shall be provided by the application of layup procedures described in SAES-A-007. Air drying alone shall not be considered satisfactory for fulfilment of layup requirements. Stainless steel materials shall be laid up using methods and timing according to SAES-A-007. Lay-up method for piping and systems shall be defined by Contractor in the appropriate SYSTEM Precommissioning Manual

Any protective chemical dosing shall be maintained until Mechanical Completion. Regular inspections to confirm the maintenance and top up of filled or positive pressure purged systems shall be performed and documented on check sheets. Blinds and other isolations installed for layup purposes shall be recorded on a blind list and confirmed periodically.

X

I

R W

X

I

R W

I

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X


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4.8.2

4.8.3

4.8.4

4.8.5 4.8.6

4.9

4.9.1

4.9.2


Tie-Ins General CONTRACTOR shall compile tie-in packs which typically will contain: 1. Marked-up P&ID’s 2. Marked-up isometrics with tie-in detail A 3. Tien-in/test procedure 4. Pre tie-in inspection certificate 5. Hydrotest certificate 6. Post tie-in inspection certificate 7. Material inspection certificates Perform and test all tie-ins to existing systems in accordance with SAES-L-052 and ot her COMPANY standards and procedures. All requests for X-ray in lieu of strength testing of connection shall be per SAES-A-004. X No tie-in activities shall be performed into existing (Cold Tie systems without proper Work Permit authorization from Ins ONLY) COMPANY (refer to GI-0002.100 Work permit System).

X

CLIENT CLIENT NAME


R

EXAMPLE W

I/W/R

X

I

R

X

I

R/I

X

I

R/I

X

I

I R

Test performance of insulating flanges by discontinuity testing. Record results.

X

R

W I

Check and certify that all Cu-Ni piping has been adequately isolated from steel pipe and supports.

X

I

I

CONTRACTOR to review all tie-ins, in particular drains and sewers, in detail with the Operations group. Specific points to be considered are potential hazards and condition and the ability to adequately clean system for tie-in and any special precautions which need to be taken CONTRACTOR shall provide all materials, equipment (scaffolding, rigging etc.) tools, labour, supervision etc. required to perform the tie-in CONTRACTOR shall be responsible for isolating system and installing temporary isolation blinds as required. Painting and insulation shall be repaired as required after cleaning, testing and correction of deficiencies.

Other


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4.9.4

4.9.5

Check and certify that all thermal insulation, personal protection and weatherproof jacketing is properly installed and all protrusions and cut-outs are properly sealed with weatherproofing mastic or flashing. Check and verify that the internals of socket weld ball valves were reinstalled after welding into line.


CLIENT CLIENT NAME

X

I

I

X

I

I


Install corrosion probes where specified on the P&ID’s

EXAMPLE 4.9.6

4.9.7

4.9.8

4.9.9

X

I

I

X

I

I

Check and certify that all valves have been thoroughly greased and stroked after completion of final painting and touch-up work.

X

I

I

Check and certify that 'quick-connect' type couplings have been correctly fitted to the utility stations and installed as required by SAES-L-042.

X

I

I

X

W/R

I/W

Check and certify that all the piping has been properly colour coded and banded as required by SAES-B-067 and that the direction of the flow, commodity and line identification markings have been clearly and correctly indicated on the pipe.

Check and certify that cathodic protection systems for all underground piping are connected, tested and fully functional.

5.

MECHANICAL EQUIPMENT

5.1

General


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5.1.2

5.2 5.2.1

5.2.2 5.2.3

5.2.4

5.2.5

5.2.6 5.2.7 5.2.8

5.2.9


CONTRACTOR shall provide a list to COMPANY of all X rotating and other equipment that cannot be run-in on air, (EACH nitrogen, water or inert fluids. contractor shall give reason FOR OWN to COMPANY why each identified piece of equipment SCOPE OF cannot be run-in SUPPLY) Run-in and operate rotating and other equipment on air, nitrogen, water or other inert fluids. CONTRACTOR shall provide all procedures for COMPANY approval. AD CONTRACTOR shall provide experienced personnel for this WORK, with all temporary equipment and monitoring devices Pumps, Fans, Blowers and Mixers Check installation for compliance with Job Specification X and Vendor design drawings and applicable codes.

CLIENT CLIENT NAME

X (EACH FOR OWN SCOPE OF SUPPLY)

R

X

I/W/R

I

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I

I

Rotate the equipment by hand to ascertain that they turn freely. Check rotating element clearances on fans.

X

Cold align the various elements of all pump trains (driver, pump, gearbox, shaft, bearings, and couplings). Process piping disconnected. All alignments shall be done with dual dial type micrometers using the reverse alignment graphing technique. Records shall be maintained for all mechanical alignment graphs with bolt target and actual alignments, actual alignment readings, coupling spacing (as applicable), end float (as applicable), date of alignment, time of alignment, ambient temperature etc.

X

W

I/R W

Piping to and from all pump trains shall be made up with dial indicators on pump and driver to assure piping pu ts zero strain on pump or driver. After alignment of pump train and connection of piping, the piping shall be disconnected again to verify that piping has been made up without strain to the pump train. Furnish record of alignment to COMPANY.

X

W

I/R W

I

W I


EXAMPLE

Shim, dowel, and grout the pump trains in a proper manner, in order to preserve the validity of the various alignment checks. Provide, install and remove, clean and reinstate temporary strainers in pump suction pipe work. Check that base plate drains properly to correct sewer.

X (SP to provide dowel) X X

Clean and flush lube/seal oil systems as required by SAES-G-116. Install first fill of lubricants.

X

Confirm operation of oil mist and cooling water supplies. Check pump drains and vents clear.

X

I

I/R

I W (First fill by SP)

I

I

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Motor checks-Confirm direction of rotation, run-in for four hours uncoupled and check the bearings. 5.2.11 Provide labour procedures, discipline and vendor support (where required) for coupled run of pump and driver. Uncouple and recouple pump to driver as required. Perform vibration and alignment checks.

5.2.12

X A For run-in / X For couple / uncouple

CLIENT NAME

I

R W

X/O

I/W/R


EXAMPLE

If a new pump is to be used for flushing, install temporary packing or mechanical seal is not suitable for flushing. Project pump may only be used for flushing with prior approval of COMPANY.

5.2.13

Reinstall mechanical seal or permanent packing on any pump used for flushing. 5.2.14 Make final check of cold alignment on any pump used for flushing per items 5.2.12 and 5.2.13., and also on completion of any test runs in 5.2.11 5.2.15 If existing firewater pumps are to be used to supply water for construction purposes, such plans must be approved in advance by COMPANY. If used, they may only be operated under Work Permit conditions issued by COMPANY (refer to GI-0002.100 Work Permit System) and operated by Operations personnel. ALL WORK necessary to safeguard the equipment must be complete. 5.2.16 Maintenance of pumps covered by item 5.2.15 will be by CONTRACTOR. at the end of Construction, pumps are to be put in as-new condition by CONTRACTOR. 5.2.17 5.2.18

Rotate mixers by hand to ascertain that they turn freely. Check alignment and set blades at proper height per Vendor requirements. 5.2.19 Confirm rotation is correct for blade in stallation. 5.2.20 Conduct 4-hour uncoupled running test for motor. 5.3 5.3.1


CLIENT

Install compressor piping and make piping corrections as required by manufacturer's tolerances. Set and cold align compressor and driver. As per VENDOR recommendation furnish records of alignment to COMPANY.

X

I

R

X

W

W

X

W

W

A

A

O/X

X

I

W I

X

W

W

X

I

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X

I

W

X

I

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X

W

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CLIENT NAME

X for Mech cleaning

I/W for Mech cleaning

AD for Chem. cleaning

X Chem. Cleaning

For all compressors, provide compressor suction piping, lube and seal oil piping in clean condition, free of mill scale, weld spatter and all loose and foreign material. Disassemble and reassemble piping for cleanliness inspection as required. Suction systems to reciprocating and centrifugal compressors shall be visually in spected for cleanliness whenever possible.

X

I

W I

5.3.4

Install temporary/permanent compressor suction strainers and coalescers where specified.

X

I

I

5.3.5

Check installation for completeness and proper connection and tie-in of auxiliary equipment and utilities. Check for correct rotation of driven and driving equipment. Check equipment data plates for operating speed, critical speeds, horsepower, temperatures, and pressures.

X

I

I

X

I

R W

A

X

I

A

WI/X

W

5.3.3

5.3.6 5.3.7 5.3.8

Mechanically and/or chemically clean suction piping of Compressors as appropriate and in accordance with vendor instructions



W I

EXAMPLE

Check compressor bearing vibration probes and shaft condition. Remedy any problems based on Vendors' instructions.

5.3.9 Lube oil and seal oil system shall be mechanically and chemically cleaned prior to installation. Refer to SAES-G116.

X for Mech cleaning I AD for Chem. cleaning

5.3.10

5.3.11

5.3.12

Flush lube and seal oil system, heat and circulate the oil, and replace with clean oil and test for cleanliness, as required to prepare the system for operation.

X

I/O

I

Confirm cable installation. Meghom test cable, with readings recorded and sign-off by COMPANY. (List cable numbers or highlight cables on copy of cable/conduit schedule).

X

W/R

W/R

With "T" leads disconnected, confirm proper operation of starters, conductors and controls.

X

W

W


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Confirm grounding connections are tight and test grounding. 5.3.14 Confirm all electrical connections are tight. Visually check electrical components for final assembly. Confirm system is ready for energization.

5.3.15

CLIENT NAME

X

W

W/I

X

I/W

W/I


EXAMPLE

Contractor/Vendor to pre-commission compressor skids. The following checks should be made:

i) Confirm power circuits to skid/compressor area are complete and ready. ii) Confirm proper operation of all heaters. iii) Confirm proper operation of all ligh ting controls, alarms, interlocks and shutdown loops/circuits for th is system. iv) Confirm all junction boxes and panels are closed tight.

v) Confirm all breakers except for heaters and motors are open and "locked-out". 5.3.16 Complete instrumentation work required for loop checks: i) Completion of process control and safety systems. ii)


CLIENT

Completion of instrument air system.

A

X/I

W

A

X/W

W

A

X

W

A

X/I

W/I

A

X/I

W/I

X

I

X

I

iii) Completion of continuity and megger testing of plant and X skid wiring. iv) Completion of calibration of plant and skid instruments X associated with system. v) Completion of instrument installation checks. X vi) Completion of instrument tubing/piping clean-out and X pressure testing. 5.3.17 X Correct design/installation/calibration defects identified (Installation during loop checking. ) 5.3.18 Commission control loops. A Mark all plugs, vents, drains used during hydro test. COMPANY Operating Organization to indicate which connections are required for plant operation; Contractor to seal weld all other (construction) connections, where appropriate 5.3.20 Inert system vessels/piping after drainage of hydro test water and dry-out check. 5.3.21 Align/adjust piping and supports on compressor as required to achieve compressor alignment.

R I R I

W

W

I

W/I

I

W/I

W

W/I

X

W

I

X

X

I

R

X

I/W

I

X

I

W

5.3.19

EXAMPLE



CLIENT

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Leak (Tightness) test piping flanges and screwed connections and valve glands with tape and soap/bubble solution. Tighten connections or replace gasket/gland.


CLIENT CLIENT NAME

X

W

W

X

I

I

A

I

X

A

X/O

W I

A

X/O

W I

Complete all piping work and connections. Measure and record alignment with piping bolted and unbolted. Piping shall not be "cold sprung" into position after compressor alignment; adjust piping, supports, guides etc., as required to connect to tough aligned compressor with loads on compressor nozzles within allowable valves. Projected loads and Vendor allowance values to be reviewed with COMPANY before connection.

X

W

R/W

Check compressor bearings, seals, etc., prior to compressor close-up and system leak ( tightness tests).

A

X

W R

Complete PZV testing/tagging. Return PZV s to site and reinstall.work to completed within 90 days of Mechanical Completion 5.3.24 COMPANY check of correct installation of PZV, painting and car-seal blocking of PZV block valves. 5.3.25 After COMPANY check of all instrument system, run in driver as required by specification and conduct motor run four (4) hour test run 5.3.26 Re-couple compressor to driver after successful run-in of


5.3.23

driver. Complete the cold alignment of the compressor train 5.3.27

5.3.28 5.3.29

5.3.30

5.3.31

5.3.32 5.3.33

Complete all pre-start-up tests and checkouts required by the vendor.

W

Confirm satisfactory performance of lubrication, nitrogen purge and cooling systems.

-

X

R/I

Check and run-in compressor on air or inert gas to obtain satisfactory dynamic mechanical performance. Provide the necessary procedures and vendor and discipline support (where COMPANY deems this to be part of the Mechanical Completion scope).

A

X/O

I/W

Make comprehensive vibration check of rotating elements and auxiliary equipment.

-

X

I

A

X Hot Align

W

Check hot alignment of compressor and driver and do any required doweling of the compressor and driver. 5.3.34 Correct any piping misalignment or deficiency, which may be necessary after the run-in of th e compressor. 5.4

Details Details refer refer to to other items other items

EXAMPLE X

I

W



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CLIENT CLIENT NAME

5.4.1

Check the nameplate for correctness and reference to process fluids and conditions.

X

I

I

5.4.2

Remove construction debris, clean interior, and hydrotest tanks and vessel.per SAES-A-004. dry cleaning is normally preferred

X

I

I W

X

I

W/I

X

W

W I

X

I

R I

5.4.3 5.4.4

Wipe the vessel clean and dry upon conclusion of any flushing or wet cleaning/testing procedures. Install appurtenances and test. Follow the vendor recommendations as to the installation of internals. Check all internals for secure installation according to specification, weir height, down comer clearance, weir to shell clearance, level of weirs and trays

5.4.5

Paint tanks and vessels, as required

5.4.6

Perform a detailed inspection of the vessel internal and external coatings, holiday detection, surface and thickness.

X

X/I

I W

5.4.7

Perform hydraulic water tests on column internals to demonstrate performance of seal trays, spray distributors, and tray leakage tests. Adjust internals as required. Check all process piping inlets and outlets are clear, vortex breakers secured.

X

W

W I

Check all internal instrumentation and position/cleanliness of all instrument taps.

X

I

R/I

5.4.9

Check that tank grounding and cathodic protection of tank bottoms has been installed.

X

I

I

5.4.10

Check that sacrificial anodes have been installed in vessel and tank internals.

X

I

I

5.4.11

Check grouting, vessel identification, insulation/fireproofing and platforms/ladders.

X

I

I

5.4.12

Cure and dry out internal castable linings and coatings. Provide procedures and inspection records.

AD

AD

W I

AD

X

W/I

X

I

W I

5.4.8

5.4.13 5.4.14 5.4.15

Charge chemicals to vessels, as required Close all internal tray manways and final torque all internal fasteners.


EXAMPLE

Requirements for testing, corrosion prevention lay-up, leak (tightness) testing, and blanketing prior to commissioning and start-up, shall be fulfilled. 5.4.16 Perform 'final' closure of vessel with new gaskets. A vessel closure certificate shall first be obtained from COMPANY.

X

X

I/W

R W

W

W


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Check tank foundation compaction tests, dimensional inspection record, and settlement during water filling test.

5.5

5.5.1 5.5.2

5.5.3 5.5.4

5.5.5

5.5.6

5.5.7 5.5.8 5.5.9 5.5.10

CLIENT NAME

X

R/I

X

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AD

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5.4.18

Water flood floating roof rainwater sumps and test for leaks an swivel joints subsequent to floating the roof 5.4.19 Verify the proper operation of the floating roof and ensure all pressure release systems and vacuum breakers are clear and functional 5.4.20 Test the manifolded foam fire protection system for storage tanks, if provided, is in accordance with GI-1782001 5.4.21 Strap tanks for volume calibration, as required.

CLIENT

X


Shell and Tube Heat Exchangers

Check the nameplate data for correctness and reference to process fluids and conditions. Check that slide plates have been installed, the sliding end will allow movement and guides for hot position. Check that the nuts are loose on anchor bolts in sliding plates. (double nutted bolts and loose washer are required). Also check anchors, supports and guides for hot position. Check that thermal safety relief valves are fitted as specified. Check any shipping bolts or desiccant packs removed. Inspect nozzles for internals cleanliness before flange boltup. Open the exchanger and Inspect internals prior to hydro testing. If required at site Check tube cleanliness, cleanliness of turbolators (if used), and cleanliness of header boxes. Clean oil coolers in conjunction with compressor oil system cleaning/ flushing procedure. Perform final closure on oil coolers prior to flushing. Hydro test (for aftercoolers/reheater) or commodity test (oil coolers) exchangers per AES-A-004 and AES-A-007. Clean and dry out after hydro test. Inspect process exchangers internals after hydro testing; signify complete and ready for final closure.

EXAMPLE X (Visual)

I

R I

Issue to Contractor, in writing, instructions to final close each exchanger.

-

-

X

Install new gaskets on all broken connections and then close all ports to the exchanger following the correct torquing procedure

X

I

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Check for damage to tubes and tube sheet


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CLIENT CLIENT NAME

5.5.11

Perform low pressure tightness test on exchanger. Refer to SAES-A-004

X

W

W I

5.5.12

Ensure shop inspection records confirm leak tests performed on all joints. Correct gaskets installed for operational service.

A

X

W/R

5.6

Check levels and dimensions of substructure, machinery and fan ring. Furnish record of measurements.

X

I

R I

5.6.2

Check motor nameplate with datasheet for speed horsepower current and voltage.

X

I

I

5.6.3

Check motor direction of rotation and drive pulley alignment.

X

I

W

5.6.4

Clean the inside of hood and coils. Remove any shipping tie bolts and other extraneous material

X

I

W I

5.6.5

Perform uncoupled 4-hour motor run test. Check vibration levels and correct as necessary Set and adjust drive belts tension. Check for proper installation of vibration switches and calibrate setting. Check functionality of the same. Set and align fan assembly, fan shaft, shreave and driver Check coil fins and straighten as required.

X/O

I/W

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X

I/X

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X X

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5.6.8 5.6.9 5.6.10 5.6.11 5.6.12 5.6.13 5.6.14 5.6.15 5.6.16

Check and verify fan tip clearances. Lubricate all bearings. Confirm lubrication points serviceable. Ensure proper direction of rotation, blade pitch angle Record blade serial numbers and position installed. Perform 4-hour fan run test. Record fan pitch. Motor amps to be checked for variable pitch fans.

EXAMPLE

Flush and hydro test coolers as per SAES-A-004. All header box plugs and seal washers checked for tightness.

5.6.17

IVE

Air Fin Coolers

5.6.1

5.6.6 5.6.7

CLIENT REPRESENTIT

Louvers checked for full movement and po sitioner marked at open/closed. Adjust as necessary. 5.6.18 Machinery guards fitted. 5.6.19 Header box nozzles viewed for cleanliness before piping flanges made up.

X For Installation AD For Hydro Test

I For Installation AD For Hydro Test

W

X

I

W

X

I

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X

I

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Issue to Contractor, in writing, instructions to final close each exchanger. 5.6.21 Operate fans for simulation runs. 5.6.22 Check and adjust belts after running at operating conditions.


CLIENT CLIENT NAME

-

-

X

AD

X/O

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X

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X

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AD

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AD

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X

I

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5.7

5.7.1 5.7.2 5.7.3 5.7.4

5.7.5 5.7.6 5.7.7

5.7.8

5.7.9

Verify compliance with the Job specification and vendor drawings and applicable Codes Check to see if provision has been made for thermal expansion of all boiler parts and attached piping Prepare boiler dry-out procedure Verify proper relief valve rating, certification and installation. Verify that final assembly is complete with no missing bolts, loose nuts, missing washers and no missing safety devices. Perform a hydrotest test on boiler pressure parts in accordance with SAES-A-004 Check and verify proper operation of instrumentation and controls. Dry out, boil out, and chemical clean in accordance with vendor and project specifications, and SAEP-1025 (if deemed by COMPANY to be part of the Mechanical Completion scope). Open and inspect internal surfaces of drums, remove all debris, perform required remedial work, and close after boil out and/or acid cleaning. Lay up boiler after boil out and cleaning if required as per SAEP-1026.

EXAMPLE

Operate boiler and ancillary equipment to perform in-situ relief valve pop testing and blowdown adjustment, and confirm functioning of all boiler safety trips. Operate boiler as required to perform steam cleaning activities on 5.7.10 associated new steam distribution line work (if deemed by COMPANY to be part of the Mechanical Completion scope). 5.8

5.8.1

Verify compliance with the Job Specification and vendor drawings and applicable Codes


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5.8.2

5.8.3

5.8.4

5.8.5

5.8.6

5.8.7

5.8.8

5.8.9

Check to see if provision has been made for thermal expansion of all boiler/gas turbine parts and attached piping Prepare HRSG dry-out procedure including vendor recommendations and review with proponent 90 days in advance of turnover Verify proper relief valve rating, certification and installation.

Verify that the final assembly is complete with no missing bolts, loose nuts, missing washers and no missing safety devices. Perform a hydrotest test on boiler pressure parts in accordance with SAES-A-004. Empty the test water completely after test and dry or layup according to vendor recommended procedures. Check and verify proper operation of instrumentation and controls. Dry out, boil out, and chemical clean in accordance with vendor and project specifications, and SAEP-1024 and SAEP-1025 (if deemed by COMPANY to be part of the Mechanical Completion scope).

Open and inspect HRSG, remove all debris, perform required remedial work to refractory as required. Lay up HRSG after boil out and inspection/cleaning if required as per SAEP-1026.


CLIENT CLIENT NAME

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AD

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X


EXAMPLE

When GTG available, operate HRSG and ancillary equipment to perform in-situ relief valve pop testing and blowdown adjustment, and confirm functioning of all 5.8.10 boiler safety trips.

AD

X

W/I/R

X

I

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CONTRACTOR to supply all consumables for operation of the HRSG e.g. demin water, dosing chemicals, fuel etc. 5.9

5.9.1

5.9.2

Install, set and align turbine, gearbox and HRSG in accordance with vendor procedures and tolerances Provide all new ancillary piping fuel, cooling, lube o il and hydraulic system in clean condition in accordance with vendors’ requirements. Circulate and heat lube oil systems to establish cleanliness


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5.9.3

5.9.4

5.9.5

5.9.6

5.10

Clean fuel gas supply piping to vendor specification (up to and including chemical cleaning)

Function test all auxiliary systems, fuel systems, air inlet filters, air doors, starting system, enclosures. Calibrate and function check all safety devices, control systems, synchronisation instrumentation, power supplies, battery packs, HVAC, pressurisation and extinguishing systems. Provide labour, tools and equipment to support testing and operational proving runs on gas turbine/generator units if deemed by COMPANY to be part of the Mechanical Completion Scope. Also to provide same if tests are carried out post Mechanical Completion.

Install, set and align according to Vendor requirements and specifications. Install and full function test starting power/air system, 5.10.2 cooling water systems, fuel systems, and ancillaries Run engine light and coupled for simulation runs. 5.10.3 Function test safety cut out devices. Perform final adjustments, alignments and Load Test.

NAME


I

I AD (Chemical Cleaning)

X (Chemical Cleaning)

AD

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W/R I

EXAMPLE

Miscellaneous Mechanical Equipment

5.11.1 General 5.11.1. All equipment and components not otherwise addressed 1 by this list shall be installed, adjusted, cleaned, confirmed for proper functioning, and inspected prior to Mechanical Completion. 5.11.1. Maintain, ensure proper lubrication and finally adjust all 2 equipment prior to Mechanical Completion. 5.12

X By air & Water ONLY

CLIENT

Diesel Generator Sets

5.10.1

5.11


CLIENT

Air Conditioning and Air Handling Equipment


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5.12.2

5.12.3

5.12.4


CLIENT CLIENT NAME

Air conditioning and air handling units, individual components thereof, appurtenances, piping and wiring connected to the units, and instrumentation controlling the units shall all be installed and prepared for operation per the vendor requirements and specifications.

X

I/W/R

Provide all cooling medium and charge or recharge the air conditioning units. As required

X

I

R I

All ductwork shall be inspected prior to closing to verify that all fittings and air volume control devices and duct heaters have been properly fabricated, installed and operate properly.

X

W

W I

All dampers shall be thoroughly cleaned to ensure proper operation. Ducts, plenums and casings shall be cleaned of all debris and blown free of particles of fibreglass, dust and rubbish before installation of registers and grilles. Equipment shall be properly lubricated.

X

I

W I

Obtain all COMPANY approvals and certifications and provide all utilities including temporary power required to allow running as soon as possible for the protection of equipment and comfort of personnel. All WORK necessary to safeguard the equipment must be complete

X

I/R

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X

I

I


W I

5.12.5

5.12.6

filters and strainers used during construction shall be cleaned or replaced prior to Mechanical Completion. 5.12.7 Provide and install any sunshades, covers, filters, insulation guards, barriers, piping drains or any other items required to protect the units or other equipment to reduce noise or vibration to acceptable levels.

EXAMPLE X

I

W/I

Start air conditioning system, per manufacturer instructions, after all start-up preparations are complete.

A

I

X/O

Conduct capacity tests of air conditioning and air handling units, and "balance" the air distribution system per design requirements.

X/O

W

W I

5.12.1 Demonstrate proper operation of building pressurization 0 system including make-up air volume check.

X

W

W

5.12.1 1

X

W

W

5.12.8

5.12.9

Conduct the building fire damper “closure” test.


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Lifting Equipment

5.13.1 Install and checkout lifting equipment in accordance with manufacturer's recommendations, COMPANY standards and specifications, and other applicable portions of this list. 5.13.2

Stencil maximum working load (in English and Arabic) on lifting equipment. 5.13.3 Perform the testing of lifting equipment, which shall be witnessed by Inspection department’s Crane Inspector. Obtain COMPANY Crane Inspection sticker on completion of the successful tests

I/W/R

R W

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X

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X

X

5.14

Set and cold align turbine and associated piping. Check 5.14.1 parallel flange alignment. Furnish record of alignment to COMPANY 5.14.2 5.14.3

Chemically clean lube, seal, flushing and control lines

Flush seal and lube oil systems with flushing oil before installing lube and seal oil. Lube oil/seal oil reservoirs and piping typically require acid cleaning then flush per SAESG- 115 and 116. Install first fill of lube oils.

EXAMPLE

Check installation for completeness, proper 5.14.4 connection and tie-in of auxiliary equipment.

5.14.5

Check for proper rotation of driven and driving equipment.

Install all permanent packing and accessories prior 5.14.6 to first run. Check equipment nameplate for operating speed, critical speeds, horsepower, temperatures and 5.14.7 pressures. 5.14.8 5.14.9 5.14.1 0

Provide procedures and vendor support as required for run-in of turbines Perform Vendor required turbine tests Recouple turbine to driven equipment.

Provide temporary mothballing if turbine is not to be 5.14.1 operated for an extended period of time. 1

X

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Pre-commissioning Activities 6. 6.1 6.1.1


CLIENT CLIENT NAME

X

I

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6.1.2

Install mounting brackets for safety equipment in locations marked by COMPANY.

X

I

I/R

6.1.3

Remove and replace after testing, and adjust all safety devices, such as rupture discs, which cannot conveniently be tested and adjusted in place. Test, adjust and seal as necessary all safety devices other than safety valves.

X

I

I/R

X

I/R

I/W/R

X

W

I/W/R

A

A

X

X X

I/W/R I/W/R

I/W/R I/W/R

Conduct a capacity test of the firewater system to confirm and document compliance with standards and specifications. Clean up areas and make adjustments as required after testing and inspection.

A

X/O

I/W/R

Conduct function testing of all deluge and sprinkler systems. Clean up areas and vessels after testing. Ensure nozzle arrangement provides full coverage.

A

X/O

I/W/R

Carbon Dioxide/Extinguishing Systems Check all extinguishing equipment and associated piping.

X

I/W/R

I/W/R

Test the smoke detection system.

X

W

W/R

6.1.5

6.1.6

6.2

6.2.1 6.2.2 6.2.3

6.2.4

6.3

6.3.1 6.3.2

IVE

FIRE AND SAFETY SYSTEMS General

Paint and/or tag all safety valves, car sealed valves, and safety equipment in colours designated by COMPANY standards.

6.1.4

CLIENT REPRESENTIT

Install and precommission the following Fire and Safety system 1. Emergency air packs and containers 2. Deluge system sprinkler system 3. Gas detection system 4. Fire detection system Prepare/update emergency response plans for the facilities and position the assembly area signs. Firewater System Capacity Testing Completely check out all fire protection equipment. Test all Fire system audible and visual alarms.

EXAMPLE


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6.3.3

6.3.4

6.3.5

6.3.6

6.3.7

Each entire CO2/extinguishant release system shall be discharge tested for satisfactory operations prior to Mechanical Completion. Approved material shall be used in the discharge tests. The sampling points shall be monitored simultaneously to indicate the percent of extinguishant concentration achieved at each point.

A

X/O

I/W/R

The system shall be checked for proper operation of all actuators (both manual and automatic) override devices, detectors, alarms and interlocks.

X

I/W/R

I/W/R

After discharge testing, restore the system to proper operating condition, including immediate replacement of all discharged storage cylinders with properly charged and weighed spare storage cylinders.

X

I

I

After the system has been restored to operating condition, ensure that a minimum of one (1) complete set of cylinders for each system or zone, properly charged and weighed, are available at all times for use as spares.

A

X

I

Warning signs in Arabic and English shall be in place at all times after installation of the extinguishant to warn against inadvertent discharge.

X

I

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X

W

I

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I

6.4 6.4.1

Fireproofing Check that the installation is to the requirements of Job Specification and meets the requirements of SAES-B-006.

6.4.2

Confirm that surface preparation prior to installation is complete.

X

6.4.3

Check and verify that all valve actuator fireproofing blankets have been installed on PZV valves where specified on the drawings and specifications.

X

I

I

Supply all permanent fire extinguishers. Test and tag all fire extinguishers through COMPANY FACILITY.

A (Install ONLY)

X

I

Install all handheld and wheeled fire extinguishers in specified locations with suitable brackets/clips as required by SAES-B-019. Extinguisher locations to be colour coded and tagged as required by SAES-B-067.

X

I

I

6.5 6.5.1

6.5.2

6.6

EXAMPLE

Fire Extinguishers

Fire Hoses/Hydrants and Monitors


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CLIENT CLIENT NAME

Check that fire hoses and hose cabinets have been correctly fitted, are in an operable condition, and can be fully withdrawn from the hose cabinet.

X

I

I

Check and certify that the hand crank mechanism and the angle valve of each hose reel station is well greased and operable.

X

I

I

6.6.3

Check and certify that each fire monitor operates freely and correctly.

X

I

I

6.6.4

Check location and visually inspect each hydrant and monitor. Safety Showers and Eyewashes

X

I

I

Ensure that safety showers and eyewashes have been located throughout the FACILITIES as required by SAESB-069.

X

I

I

Test each eyewash and safety shower to ensure for required flow, pressure and temperature not to exceed 39. Apply heat to piping to ensure that the water temperature control device is functioning as required. Ensure that required piping is underground or insulated to prevent excessive temperatures temperatures due to solar gain.

X

W

I/W

6.6.2

6.7 6.7.1

6.7.2

7. 7.1 7.1.1

7.1.2 7.1.3 7.1.4

7.1.5

7.1.6


CONTROL SYSTEM/INSTRUMENT SYSTEM/INSTRUMENTATION ATION General

EXAMPLE X Loop Folder prep

I/R

R

X

I

I

Install instruments and make all specified connections.

X

I

W I

Provide certification of calibration of standart instruments. These standard instruments shall not be used for testing or checkout in the field

X

I

Check continuity and identification of transmission and control system for each instrument to ensure proper hookup and compliance with with specifications. (This applies to both pneumatic and electrical - analogue and digital systems).

X

W

W/R I

Check pneumatic and electrical instrumentation systems for proper installation including tagging, supports, accessibility, correct material, ratings and calibrating fittings. Synchronize transmitter transmitter and receiver readings readings for each instrument.

X

I

W/R I

Provide COMPANY with a list of all equipment required for loop testing Check instruments and tag data supplied against specifications sheet (type, range, materials, etc.).

I/R


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7.1.7

7.1.8

Prepare and submit to COMPANY loop check data packages. Data package shall contain (as a minimum and as applicable to each loop) installation check sheets, calibration sheets, wire and tubing test sheets, instrumentation check sheets, with copy of the respective loop diagram and P&ID and instrument specification/data sheets. Other drawings/diagrams to include, as appropriate: JB interconnection diagrams, I/O termination drawings, cable lists, hook-up drawings, etc. This package shall also include instrument and loop diagrams for packaged equipment.


X

I

CLIENT CLIENT NAME


R/I

Prepare calibration sheets for each calibration to be submitted as part of the loop check data package. Theses sheets shall show, as a minimum the following:

EXAMPLE

- Date of calibration - Instrument tag number - Instrument specification sheet number 1. Readings before and after calibrating. Any problems noted and corrected. 2. Description of calibration method/equipment - Name of person doing calibration, and indication of acceptance when achieved 3. Reference to other instruments calibrated simultaneously. 7.1.9

Contractor shall produce daily, weekly and monthly reports to provide complete detailed current status of the loop Pre-testing/testing activities for each system. Contractor shall design the report formats and presented for COMPANY COMPANY review and approval. Each daily report for each system shall include the following information: 1) Provide the status of each field instrument (On site, Calibrated, Field Mounted, Labelled), and provide total instruments against completed for each filed.

X

I

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X

R

R

X

R

R


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7.2.2

7.2.3

CLIENT NAME

2) Provide the status of field wiring of each instrument (On site, pulled between instrument and junction box, continuity tested, tagged at the instrument side, tagged at the junction box side, terminated at the instrument side, terminated at the junction box side), and provide totals completed for each field.

X

R

R

3) Provide the status of each multi-core cable for each junction box. (On site, pulled between junction box and Marshalling Cabinet, continuity tested, tagged at the Junction Box side, tagged at the Marshalling Cabinet side, terminated at the Junction Box side, and terminated at the Marshalling Cabinet side). And provide totals against totals completed for each Junction Box.

X

R

R

X

R

R

4) Provide a Daily status for each loop on each system (Passed/Failed/Not Tested), and provide total loops against completed loops for each system. 7.2 7.2.1



EXAMPLE

Calibration and Checkout

All instrumentation items shall be calibrated and/or bench-checked for operability. Each item shall be labelled with its associated tag number, checks performed, date and person performing checks. Unless otherwise stated, analogue equipment shall be calibrated at five standard points -0, 25, 50 and 75 and 100% of span. All special instrumentation, including, but not limited to, emergency shutdown systems, data highways, microprocessors, metering and vibration monitors, shall be calibrated and checked using Vendor specified simulator equipment. Calibration records shall be maintained for all instrumentation.

X

I/W/R.

I/W/R

Rotameters shall be installed as received. received. Ensure shipping stops have been removed and floats installed. Where rotameters have transmitting mechanisms, the float shall be mechanically raised and lowered and the output checked.

X

I

I/W/R

Turbine meters and/or positive displacement meters shall not be installed until testing and flushing of lines is completed. Installation shall be in accordance accordance with manufacturer's instructions, i.e. flow direction, and removal of shipping stops.

X

I/W/R

I/W/R


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CLIENT CLIENT NAME

Orifice plates shall be visually checked against the specification for nameplate data and for an upstream sharp edge. Bore shall be calliper checked for compliance with specifications. Venturi and flow nozzles shall be checked for proper high and low connections as stamped on the element. All flow elements shall be properly stored until immediately prior to installation. Each normally concealed flow element shall be tagged as being properly installed and certified by COMPANY. Meter element checks and installation shall be recorded on a check sheet.

X

I/W

I/W/R

7.2.5

Gauge glass illuminators and other accessories shall be checked for proper installation and operation.

X

I

W/I/R

7.2.6

Air supply shall be checked and set at specified pressure. Valve position shall be checked for proper action on air supply failure. Control valves and accessories, such as hand-wheels, booster relays, limit switches and trip actions shall be comprehensively checked out for operational serviceability and documented on a check sheet record. Air supply failure system shall be checked for proper function. All switch points shall be set to specified value. Check lubrication.

X

I

I/W/R

7.2.7

7.2.8


EXAMPLE

Self-contained pressure regulators shall be checked for proper inlet and outlet ports and nameplate data.

X

I

I/R/W

X

I

W/I/ R

X

I

I/W/R

X

I/W/R

I/W/R

X/O

I/W

I/W/R

X

I

I/R

7.2.9

Butterfly valves shall be checked to see the vanes move freely into the upstream and downstream piping. Check lubrication. 7.2.10 Pneumatic block valves (AOV, ZV) shall be stroked and limit switches and stops checked for correct operation in conjunction with indicator lights, where applicable. Check lubrication. The actions of all ZV isolation valves shall be tested through the system from the initiation signal. 7.2.11 Motor operated valves shall be hand stroked, open and closed and limit switches set and then operated under power. Torque and limit switches shall be checked for correct operation in conjunction with indicator lights where applicable. The electrical testing and documentation required by this specification shall also be performed. Check lubrication. 7.2.12

Steam traps, vacuum traps and continuous drainers shall be checked against the applicable design and installation specifications.


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7.2.14


CLIENT CLIENT NAME

Annunciator and instrument tag nameplates shall be checked against design drawings for engraving and proper location.

X

I

I/R

Annunciator operation and point continuity shall be checked by mechanically actuating all trouble contacts for low-high-deviation alarm operation and auxiliary contact operation and sequence.

X

I/W

I/W/R

X

I/W

I/W/R

X

I/W

I/W/R


7.2.15

Solenoid valves, electrical relays, timers, pushbuttons, switches and other miscellaneous electrical devices shall be checked for proper operation. 7.2.16 Package instrumentation systems shall be checked for calibration and set to specifications and/or Vendor's recommendations. All of the requirements in this list for calibration, accuracy, labelling, record keeping, and checkout apply to the individual components of packaged systems. 7.2.17

7.2.18

EXAMPLE

All local panels, auxiliary panels, racks and control panels shall be function checked.

All instrument nameplates, both front and rear, and all panel board nameplates shall be checked for tag number, service and proper location. 7.2.19 Prior to installation, cables with pre-wired connectors shall be checked for continuity and identified as b eing checked. 7.2.20 Individual cores or multicore cables and individual wires

connected to terminals shall be identified by numbered and lettered ferrules as shown on construction drawings where permanent identification marks are not furnished with cables. Individual to/from designations are required. 7.2.21

7.2.22

7.2.23

7.2.24

A check using the piping and instrument diagram (P&IDs), instrument points and line drawings and the instrument specifications shall be made after installation to make sure all instruments are in their proper place. Each instrument installation shall be checked for conformance with the proper instrument installation detail drawings, e.g. proper hook-up of flow meters, correct materials and fitting ratings. All valves marked as 'TSO' on the P&IDs plus all ZVs will be tested to ANSI/FCI 70-2 in the field. Perform required pressure tests on instrument take-off piping, air piping and tubing.

X

I/W (Provide Vendor)

I/W/R

X

I

I/W/R

X

I

W/I/R

X

I

I/R

X

I

I/R

X

I

W

X

W

W

X

W

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Blow-out instrument air piping with dry air, reconnecting after pressure tests and site instrument air regulators. 7.2.26 Clean transmission and control tubing by blowing with clean dry air prior to instrument component connection. 7.2.27

7.2.28

7.3 7.3.1


CLIENT CLIENT NAME

X

I

W/I

X

I

W

X

I

R I

X

I

I

Check thermocouples/RTD for correct position and wiring polarity. Loop Checking and Function Checking

X

I/W

I/W

7.3.2

After loop checking, all controllers shall be left with reasonable start-up control response settings.

X

I/W/R

I/W/R

7.3.3

Test annunciator and individual alarms by simulating alarm conditions or, where this is not possible, by mechanically operating the field contacts. Check annunciator alarm sequences, test, acknowledge and rest function. These tests shall include annunciator and alarm functions in the distributed control system and the support computer. Alarm tests shall be documented and submitted to COMPANY.

A

X

R/W

Many signals are channelled via multiplexer units or other data highway devices. These units shall be included in the loop checks. Vendor instructions for checkout and testing shall be followed.

X

I

W

Check proper point identification for multipoint temperature indicators and recorders by paralleling a portable potentiometer set at high output across the field end of thermocouples terminals, witch will show if the wiring is to the correct point.

X

I/R

I/W/R

Check shielding and drain wire connections. Check for double reversals. Check for proper instrument reversals. Check for proper instrument grounding, including all DCS racks and consoles.

X

I

I/W

All interlocking and shutdown systems including package equipment shall be tested.

A

X

W/I/R

7.3.5

7.3.6

7.3.7

IVE

Provide and install sealing fluids.

Perform five (5) point full loop check on all instrument loops, Input/output signals equivalent to 0, 25, 50, 75 and 100% of control range shall be generated to confirm functionality of all components within the complete loop over the full control range.

7.3.4

CLIENT REPRESENTIT

EXAMPLE


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7.3.9

7.3.10

7.3.11

During testing of the shutdown systems and packaged equipment, all operator shutdown circuits shall be individually tested from the initiator through to the end devices for proper functioning and action. On request of COMPANY, certain end devices (ZVs, AOVs, LCVs, etc.) shall have their final actuating signals interrupted to prohibit actuation of the devices. Each end device so interrupted shall be documented. Each push-button shall be actuated to initiate the shutdown sequence and the various means of confirming proper functioning (such as pressure gauges, action of the end devices, and LEDs) shall be observed. The system shall be reset after each test. At the conclusion of the tests, the shutdown systems integrity shall b e reestablished by removal of all signal interrupting devices and the documentation so noted.

NAME

A

X/O

W/I/R

A

X/O

W/I/R


EXAMPLE A

X

W/I/R

During testing of shutdown systems and packaged equipment, all interfaces with the Distributed Control System shall be individually tested for proper functioning.

A

X

W

X

I

I/R

X

I Media by SNAMP

I/R

X

I

I/R

Other

7.4.1

Properly seal all instruments as required.

7.4.3

CLIENT

During testing of the shutdown systems and packaged equipment, all of the various modes of operation of the systems (shutdown, permissive pre start, and permissive post-start) shall be individually tested. Each input, logic accumulation, and output signal shall be serially tested. All input signals shall be removed and a set of shorting plugs installed per input group. The installation of any shorting plug or other jumper device for any reason, shall be clearly documented. As these plugs are installed the associated LEDs shall be read and results documented at the conclusion of testing. All shorting plugs or jumpers shall be removed, such removal noted on documentation, and the system integrity re-established.

7.4

7.4.2


CLIENT

Fill manometers, draft gauges and like instruments with proper fluid, adjust zero of transmitters where necessary. Install proper recorder charts and link as required.


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7.4.5

7.4.6 8 8.1

At conclusion of all instrumentation testing prior to Mechanical Completion, inspect all instrument items to confirm proper complete installation, that all test interruption and inhibit devices have been removed, that all documentation is accurate, and that the instrumentation is ready for use during commissioning and start-up. Set up block valves and bypasses on instrument piping as requested by COMPANY. Complete Site Acceptance Tests and records for Control Systems, ESD Systems, and F&G Systems, Metering Systems, and package equipment controls as per SAEP16. Calibrate analyzers and align for normal operation. PRESSURE RELIEF AND DISPOSAL SYSTEM Check the pressure relief valves (PZV), pressure relief and blowdown piping for completeness and proper line-up prior to placing the facility in service. Check that all relief headers and subheaders are sloped properly and free of pockets All inlet and outlet block valves for PZV's shall be painted orange.


CLIENT CLIENT NAME

X

I/W

I/R

AD

X

W I

X

I/R

W/R

I

I

X

I

I

X

I

I

X

I

W I

Bench test and seal all safety relief valves, provide calibration records and install according to SAES-J-600 and referenced procedures. Colour code to COMPANY requirements.

X

I/W

W/I/R

Produce schedules for relief valve testing for agreement by COMPANY, All relief valves to be tested within 90 days before Mechanical Completion Acceptance.

A

X

R

9.3

Transport relief valves to and from a test FACILITY approved by COMPANY.

X

I

9.4

Remove and reinstate relief valves as necessary for inspection, testing, relief header blowing, flushing, cleaning or retesting.

X

I

8.3

8.4

9.

9.1

9.2

IVE

EXAMPLE X

8.2

CLIENT REPRESENTIT

Check that the outlets and vents of all PZV's to atmosphere are routed to a safe location away from equipment, piping, access ways and working platforms Check that all Construction material and debris have been removed and lines cleaned. SAFETY RELIEF VALVES

I


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Inspect the installation of all pressure safety valves (PZV's) to check the proper tag number, location, test seals are in place and unbroken, and the set pressure is in accordance with the P&ID setting, immediately prior to turnover. Ensure that all temporary transportation plugs have been removed i.e. check for warning labels on the PZV and refer to vendor IOM's.

9.6

Company to check that all block valves on the PZV's are car-sealed in their proper positions as per P&ID's. The inlet block valve to the PZV in service shall be open. The inlet block valve to the stand-by PZV shall be closed and all PZV outlet block valves shall be car-sealed open. PZV bypass valves are normally closed.


X

I

CLIENT CLIENT NAME


I

EXAMPLE

Important Safety Note: - Equipment should normally be purged free of air before opening up PZV's to the Flare system to avoid flammable/explosive mixtures occurring in the flare headers in the event that the PZV lifts or is passing.

10.

A

A

X/O

GENERAL PREPARATIONS FOR SERVICE

10.1

Raw water and drinking water lines shall be flushed, cleaned and disinfected in accordance with SASC-S-17, and bacterial tested (SNAMP) prior to being handed over for service.

X except for disinfection A for disinfection only

I/W/R except for disinfection I/W/R X for disinfection


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10.3

In preparation of the FACILITIES to receive commissioning and start-up fluids, carry out operational leak (tightness) testing using compressed air, nitrogen or the normal service fluid (for certain utilities Systems). This shall confirm the containment integrity of all piping and equipment within whole Systems or combinations of Systems. Generate procedures including definition of isolation points for the envelope to be tested, and the testing parameters. Procedures to be approved by COMPANY. Provide discipline support and all temporary equipment and fittings as required. Provide, store, protect and install the first fill of media, catalyst, chemicals and other process consumables. Where COMPANY provides catalyst or chemicals, furnish supervised labour and temporary equipment, and install. Provide vendor support as required. Inert, isolate or otherwise protect the catalyst and chemicals to prevent deterioration or unsafe conditions. All fluids/gases to be labelled and location in a safe and proper area outside the FACILITIES area until ready for installation.


CLIENT CLIENT NAME


R W

X

I/W

AD

X

AD

X

W/I

A

X/O .

I/W/R

X For Supply

W

EXAMPLE

10.4

10.5

10.6

Provide and install first charge and start-up spare quantities of all chemicals and other material (antifoam, DGA, caustic, corrosion inhibitors, sand, coat, ceramic balls, molecular sieve, etc.) Carry out equipment simulation runs on major items of rotating equipment to confirm mechanical operability. Such runs and tests shall involve circulation through permanent plant systems to simulate hydrocarbon operational duty, and may involve water circulation for pumps or nitrogen circulation for compressors. Contractor shall provide all procedures, Vendor support, temporary piping and monitoring devices. Simulation runs shall be carried out on recycle compressors, feed pumps and other critical services. Supply, replace and/or refill fluids with permanent charge where required. This includes but is not limited to; compressor lube oil/seal oil (after disposal of flushing oil), extinguishing agents (after discharge test) and nitrogen (for inerting and/or tightness testing).

X

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10.8

In preparation of the FACILITIES to receive commissioning and start-up fluids, carry out inerting using gaseous nitrogen or the normal service fluid (for certain utilities Systems). This shall confirm that all piping and equipment within whole Systems or combinations of Systems is air/oxygen free. Generate procedures including definition of isolation points for the envelope to be tested, and the testing parameters. Procedures to be approved by COMPANY. Provide discipline support and all temporary equipment and fittings as required. Prepare boilers and HRSGs for boil out. Provide procedures, labour, discipline support water and chemicals for steam generation system cleaning and boil out. Procedures to include details of quantity and composition of all effluents generated during the boil out activity and method of disposing of these Provide manpower and materials for internals inspection remedial work and reinstatement after boil out.


A

X

CLIENT CLIENT NAME


I/W/R

EXAMPLE

10.9

10.10

Provide procedures for degreasing of the amine regenerators, absorbers and distribution piping by circulating the total amine flow path. Procedures to be approved by COMPANY. Provide labour, discipline support, temporary piping, equipment and chemicals for these operations. Provide manpower and materials for any remedial work required after degreasing operations. COMPANY will perform the operation for degreasing of amine facilities where COMPANY determines this to b e an integral part of commissioning activities.(HOLDDegreasing requirement) Provide procedures for all commissioning and start-up activities that occur after Mechanical Completion Acceptance Notice. The procedures generally fall within the scope of the Operations Instruction Books and shall include, but shall not be limited to, nitrogen purging, vacuum testing, steam testing, catalyst conditioning, water treatment, process drying, chemical treatment, integrated trip testing, commissioning, start-up, p erformance testing and normal operation.

AD

X

W/I/R

W/I/R AD

X (O)

-

X

R


Mechanical Completion Procedure

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