Attachment 1: Table – Split of Work for Construction, Pre-commissioning and Commissioning Attachment 2: Pre-Commissioning/Commissioning Organization
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Attachment 1: Table–Split of Work for Construction, Pre-Comm. & Commissioning
Section
Description
1. General 2. Electrical 3. Instrumentation 4. Buildings 5. Air Conditioning 6. Communications Equipment 7. Tie-ins to Existing Facilities8. Safety & Fire Protection Equipment 9. Civil/Structural
10. Piping and Accessories 11. Flare System 12. Vessels 13. Columns 14. Tanks 15. Exchangers 16. Pumps 17. Compressors 18. Gas Turbines 19. Heaters 20. Miscellaneous 21. Chemicals 22. Package Units
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[텍스트 입력] LEGEND:
Cy = Company, Ctr = Contractor,
X = Perform the work, A = Assist as required, W = Witness and sign off, R = Review and Approve, I = Inspect and Approve.
1.0 GENERAL Construction Phase Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy
a) Obtain vendor assistance where necessary for Mechanical Completion, Pre-commissioning and Commissioning.
X X X
b) Obtain any permits and approvals from government and regulatory agencies required in the name of the Contractor.
X A X A
c) Make application to the Company for all necessary
permits issued in the Company’s name that are required for the Work.
X R X R
d) Maintain an adequate vendor instruction file so that
information may be readily reviewed through the Work. X R X R X R
e) Transmit to the Company all ’As Built’ Records,
Operation and Maintenance Manuals, spare parts lists and all other documentation required to obtain
Turnover.
X R
f) Remove all rust preventatives, oils, greases and paints used to preserve equipment during transportation and construction whenever these protective materials will be detrimental to operation.
X W/I
g) Provide a list and the lubricants of Approved
Manufacturer recommended for use in the Facility.
X R
h) Prepare detailed flushing and testing procedures for the specific systems.
X R
i) Flush systems and perform initial charge of all
lubricants. Dispose of all flushing oil in accordance with the Company’s instructions.
X W/I
j) Maintain lubrication after initial charge to achieve Pre- commissioning.
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1.0 GENERAL (Contd.) Construction
Phase Pre- commissionin g Phase Commissioning Phase
k) Remove all temporary supports, bracing or other foreign objects that were installed in vessels, ducts, piping, transformers, machinery, or other equipment to prevent damage during shipment, storage, and erection and repair any damage sustained.
X
l) Inspect and check Work during construction stage and perform such non-operational test as are necessary to assure the integrity of the installation in accordance with the Issued for Construction drawings and specifications.
X W/I
m) Complete all necessary insulation, painting, grating, fencing, paving, touch-up concrete and grouting, and items of like nature.
X I X I
n) Make initial charge of non-production materials, such as desiccants and transformer oil.
X W
o) Make check of lighting intensities in buildings and plant areas in accordance with Project Specifications.
X W
p) Verify that the Work, or portion thereof, is complete and that all required inspections, tests, reviews and approvals are complete and recorded.
X R/I
q) Document all inspections, test and other
Precommissioning activities. Document all deficiencies discovered during the course of the activities along with corrective actions taken.
X R
r) Prepare punchlists, by system, of deficiencies between as-built plant and latest P&ID, specifications and vendor instructions. Correct deficiencies.
X R/I X R/I X R/I
s) Check all items of equipment for adequate, safe and functional access per Project specifications.
X I
t) Provide, install, slip and/or remove all temporary and permanent blinds and spectacle plates required to isolate new systems from existing systems.
X I X I
u) Thirty (30) days prior to expected Mechanical
Completion, the Contractor is to send a notification of impending Mechanical Completion to the Company.
X R
v) Completion of fire-proofing and insulation to limit heat loss during Commissioning and for protection of personnel.
X I
w) Removal of scaffolding and other temporary works, debris, tools, and extraneous material from areas to be turned over.
WARA PRESSURE MAINTENANCE PROJECT
COMMISSIONING PROCEDURE
Class 1 Doc. No. : 11050146-CM-PRO-000-5017 Rev.A Page 35of 63
[텍스트 입력] 1.0 GENERAL (Contd.) Construction Phase Pre- commissioning Phase Commissioning Phase x) Ten (10) days prior to expected Mechanical
Completion, the Contractor is to send request for the Company punchlist, with copy of master punchlist status.
X R/I
y) Prepare and submit notification of Mechanical Completion when all Work items identified by the Contractor and the Company as required for Commissioning are completed. Each notification shall identify plant system(s) submitted for acceptance, copy of master punchlist for those system(s), list of uncompleted (“exception”) items with the reason for their late completion and estimated completion date, inspection and test and check-out reports, and copies of marked-up `As Built’ P&ID’s and one line diagrams and logic diagrams and list of start-up spare parts on site.
X W
z) Verify all instruments and electrical panels and local instruments and valves are accessible for operation and maintenance.
X I
aa) Conduct all flushing, blowing and
chemical/mechanical cleaning operations where such operations can be accomplished without using permanent installed equipment.
X W
ab) Conduct all flushing and blowing operations where permanently installed equipment must be used to obtain proper line velocities.
X W
ac) Provide any special media for flushing and/or cleaning purposes.
X R
ad) Maintain flushing and/or blowing records as required. X I
ae) Conduct all operational tightness tests. X W/I
af) Prepare detailed purge procedure for specific system.
X R X R
ag) Maintain tightness test records, as required. X I
ah) Install inerting connections. X W
ai) Provide inerting materials and introduce where specified.
X W/I
aj) Submit application for Turnover Certificate when all activities identified by the Contractor and the Company are completed. Each notification shall identify plant system(s) submitted for acceptance and copy of signed-off report forms for
Commissioning activities.
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[텍스트 입력] 1.0 GENERAL (Contd.) Construction Phase Pre- commissioning Phase Commissioning Phase ak) Provide raw materials, such as reservoir crude Feed,
brackish water, utilities etc.
X
al) Check the integrity of system shutdown and prove the reliability before Commissioning.
X W
am) Proceed to Commissioning as per operating manual instructions.
A X
an) Conduct individual equipment noise surveys, as required by the Company’s specifications documents results.
A X
ao) Prepare and submit Performance Testing
procedures. X A
ap) Notify when the system(s) are on stream, at design
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[텍스트 입력] 2.0 ELECTRICAL Construction Phase Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy 2.1 TRANSFORMERS
a) Check physically for damage, oil leaks, etc. X W
b) Check insulation resistance between primary to earth, secondary to earth and primary to secondary.
X W
c) Perform oil dielectric strength tests. Provide samples to Company for independent check. Perform oil filtration, if required.
X W
d) Perform operation of Buchholz relay. X W
e) Check alarm and trip contacts for actuation. X W
f) Check off-load changer for proper mechanical operation.
X W
g) Check polarity of terminals and the phase sequence.
X W
h) Perform High Voltage DC Test in accordance with the Project specification.
X W
2.2 H.V. SWITCHBOARDS
a) Check physically for damage, missing parts, moving parts, clearance, etc.
X W
b) Measure the insulation resistance of each bus from phase to phase and phase to earth with all circuit breakers in service position, but with the circuit breakers open.
X W
c) Draw out each circuit breaker and starter out of the panel and push it back to ensure that the operation is smooth.
X W
d) Draw out each circuit breaker and starter to the isolated position, close them manually and measure the insulation resistance from phase to earth.
X W
e) Draw out each potential transformer to the isolated position and measure the insulation resistance from phase to earth.
X W
f) Check all current transformers by Primary injection testing.
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[텍스트 입력] 2.0 ELECTRICAL (Contd.) Construction Phase Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy
g) Close and open each circuit breaker and starter in test position, electrically using the control switch/push buttons at the H.V. switchboard. Check tripping of the circuit breaker and starter with its emergency mechanical trip device at the H.V. switchboard.
X W
h) Check all interlocking between earthing switches and circuit breakers/starters. Close and open the earthing switches and check for correct operation.
X W
i) Check the control circuit of each circuit breaker and starter with all the interlocks and check for correct operation. Check remote start/stop controls for starters.
X W
j) Check castell key interlocking between the circuit breaker and other devices as applicable.
X W
k) Check the phase sequence. X W/R
l) Check the characteristics and operation of each relay by secondary injection testing.
X W/R
m) Simulate the operation of each of the protective relays, trip receive and auxiliary relays, and ensure energising of the lock-out relays and tripping of the respective circuit breakers.
X W/R
n) Simulate and ensure correct operation of pilot wire feeder protective relay.
X W/R
o) Check the automatic change over from mains supply to stand-by supply and vice versa and ensure correct operation. Check the manual change over scheme mode.
X W/R
p) Set all protective relays to their correct setting. X W/R
q) The Contractor shall establish a Tag and Lock-out Procedure, including a Work Permit Procedure for the construction, Precommissioning and Commissioning (The Company Work Permit Procedure shall be followed to energize circuits for powered checks/tests and start-ups).
X R X R X R
r) Energize all circuits required for the Contractor’s Work responsibilities.
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[텍스트 입력] 2.0 ELECTRICAL (Contd.) Construction Phase Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy
s) Check High Voltage DC Test as per Project Specifications
X W
2.3 440V SWITCHBOARDS
a) Check physically for damage, missing parts, moving parts clearance.
X W
b) Measure the insulation resistance of each bus from phase to phase and phase to earth with all circuit breakers, starters, and switchfuse feeders in service position but open.
X W
c) Draw out each circuit breaker, starter and
switchfuse feeder, and push it back to ensure that the operation is smooth.
X W
d) Draw out each circuit breaker and switchfuse
feeder to the isolated position, close them manually and measure the resistance from phase to phase and phase to earth.
X W
e) Close and open each breaker is test position and service position electrically. Check tripping of the circuit breaker with its emergency mechanical trip device.
X W
f) Check the control circuit of each circuit breaker with all interlocks and check for correct operation.
X W
g) Draw out each starter feeder to isolated position and check the insulation resistance from phase to phase and phase to earth on the load side with the starter open, for power and control circuits.
X W
h) Draw out each starter feeder to the test position, use the test control supply and check the starter for correct operation with all the interlocks from remote start and local/remote stop.
X W
i) Close and open switchfuse feeders and ensure correct operation.
X W
j) Check the current transformers by Primary Injection Testing.
X W/R
k) Check the characteristics and operation of each relay by secondary injection.
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[텍스트 입력] 2.0 ELECTRICAL (Contd.) Construction Phase Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy
l) Simulate the operation of each of the protective relays and auxiliary relays and ensure energizing of the lockout relays and tripping of the respective circuit breakers.
X W/R
m) Set all the protective relays to their correct setting. X W/R
n) Set all the thermal overload relays to their correct setting.
X W/R
o) The Contractor shall establish a Tag and Lock-out Procedure including a Work Permit Procedure for the construction, Precommissioning and Commissioning (Company Work Permit Procedure shall be followed to energize circuits for powered checks/tests and start- ups).
X R X R X R
p) Energise all circuits required for the Contractors’ Work responsibilities.
X W/I
2.4 MOTORS
a) Check physically for damage, free rotation of fan and movement of parts.
b) Check the insulation resistance value and dry out the machine if the value is:
- less than 50 megohms for 3.3KV motors - less than 5 megohms for 440V motors.
The method of drying out and retesting shall be in accordance with Approved Manufacturers’ instructions c) Check condition of grease in grease lubricated motor
bearings and lubricate the bearings if necessary.
X W
d) Check and ensure that all electrical connections are tight.
X W
e) Check the direction of rotation running the motor momentarily. Run the motor uncoupled for four (4) hours and check for any abnormalities. The
temperature rise of motor shall be recorded at the end of this period.
X W
2.5 BATTERIES AND CHARGERS a) Check physically for damage.
X W
b) Check the control circuit of charger for correct
operation. Ensure that current limiting circuits, auto- changover circuits from float to boost mode and vice versa are functioning correctly.
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[텍스트 입력] 2.0 ELECTRICAL (Contd.) Construction Phase Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy
c) Top up the electrolyte level in the batteries as required.
X W
d) Boost charge the batteries. X W
e) Energize the charger and keep batteries on float charge.
X W/R
f) Perform battery acceptance tests on batteries X W/R
2.6 CABLES
a) All high voltage (above 1KV grade) cables shall be subjected to high voltage DC test before
termination. Insulation resistance value from phase to phase and phase to earth shall be measured before and after H.V.D.C test.
X W
b) Before making the H.V. cable joint at each location, the insulation resistance shall be measured from phase to phase and phase to earth. After completion of all joints and before termination, the entire cable shall be subjected to high voltage D.C. test followed by insulation resistance check.
X W/R
c) For all low voltage cables (up to 1KV grade), the insulation resistance value from phase to phase and phase to earth shall be measured before termination. Cable conductor continuity shall be checked for each and every cable.
X W
d) For any existing control cable which requires any joint, the insulation resistance shall be measured between conductors to earth before and after completion of the joint. For such cable the voltage at which the insulation resistance check is carried out shall be determined by the Company.
X W/R
e) Phase sequence and matching checks shall be conducted before connection of each and every high voltage cable.
X W/R
f) The insulation resistance checks for 11KV system shall be done with 5KV Megger, and 3.3KV system with 2.5KV Meggars and for LT system with 1000V Meggar.
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2.0 ELECTRICAL (Contd.) Construction Phase
Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy 2.7 EARTHING
a) Measure and record the earth resistance value of each electrode.
X W
b) Check the continuity of the earthing system. X W
c) Ensure that the earth resistance value of the
complete earthing system does not exceed 4 ohms.
X W/R
2.8 LIGHTING AND SMALL POWER
a) Install lamps (incandescent, bulbs, mercury vapour lamps, fluorescent tubes, etc.) required to fill the fixtures, verify all lights and switches operate properly. Test photo cells for proper operation.
X W
b) Verify that all lights are operational using normal
and emergency power. X W/R
c) Test small power systems for correct operation. X W/R
2.9 CONTROL PANELS FOR 11KV AND 3.3KV SWITCHBOARDS
a) Check physically for damage.
X W
b) Close and open each circuit breaker and starter from control panel and ensure correct operation.
X W
c) Check and ensure correct operation of the Variable Speed Drive Control Panel.
X W
d) Check and ensure correct operation of the annunciator.
X W
2.10 UNINTERRUPTIBLE POWER SUPPLY SYSTEM
a) Carry out checks and tests for the battery and charger of UPS as in Clause 2.6 (a) to (f) above.
X W X W/R
b) Check circuits of inverter for correct operation. Check the output waveforms including harmonic
distortion. Verify the current limiting circuit. X W/R
c) Check the bypass transformer and associated AVR circuits.
X W/R
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[텍스트 입력] 2.0 ELECTRICAL (Contd.) Construction Phase Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy
e) Initiate transfer from one source to another, verify the transfer timings, transient voltage dips. recovery times, etc.
X W/R
f) Check all alarms and signalling circuits. X W/R
g) Energize all circuits required for the Contractors’ Work responsibilities.
X W/I
2.11 MISCELLANEOUS
a) Check out cathodic protection system.
X W/R
b) Paint or tag all electrical apparatus (switchboards, breakers, push button boxes, connecting boxes, etc.) according to the Company’s colour code or regulation.
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[텍스트 입력] 3.0 INSTRUMENTATION Construction Phase Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy
a) Check instruments and tag data supplied against specifications sheet (type, range, material).
X I
b) Install instruments and make all specified connections.
X W/I
c) Perform required pressure tests on instrument take- off piping and air piping and tubing.
X W/I
d) Blow-out instrument air piping with dry air reconnecting after pressure tests, and site instrument air regulators.
X W/I
e) Check continuity and identification of transmission and control system for each instrument to ensure proper hook up and compliance with Project specifications. This applies both to pneumatic and electrical, analog and digital-systems. Perform insulation test with instruments isolated or removed for instrument electrical wiring.
X R/I
f) Check pneumatic and electrical instrument systems for proper installation including tagging, supports, accessibility, correct material, ratings and calibrated fittings. Synchronise transmitter and receiver readings for each instrument.
X R/I
g) Remove control valves, flowmeters, venturis, orifice plates, and other in-line instruments prior to pipe cleaning/flushing and hydrotesting.
X R/I
h) Leak-test `tight shutoff’ rates safety and control valves at grade before installation.
X W/I
i) Install instrument after line flushing/cleaning and hydrotesting.
X I
j) Perform all instrument calibrations at site before installation.
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Class 1 Doc. No. : 11050146-CM-PRO-000-5017 Rev.A Page 45of 63
[텍스트 입력] 3.0 INSTRUMENTATION (Contd.) Construction Phase Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy
k) Prepare calibration sheets for each calibration, showing as a minimum the following:
- date of calibration - instrument tag number
- instrument spec. sheet number
- reading before and after calibration, problems noted and corrected
- description of calibration, method/equipment - name of person doing calibration, and indication of
acceptance when achieved
- reference to other instruments calibrated simultaneously.
These sheets shall be submitted as part of the loop check data package.
X R
l) Inspect all flow elements. Micrometer check at grade.
X W
m) Check all emergency and safety systems for operability, by simulation, including bypass switches/lights and resets.
X W/I
n) Perform site acceptance tests on computerised Distributed Control System (DCS) in accordance with Approved Manufacturers test procedures. The DCS may not be powered up until the UPS is completely checked out and operable. (item 2.11 & a)
X W
o) Perform site acceptance tests on computerised Integrated Control System/Distributed Control System (ICS/DCS) in accordance with approved Manufacturers test procedures. The ICS/DCS may not be powered up until the UPS is completely checked out and operable. (Item 2.11 & a)
X W
p) Provide sealing fluids (for example, manometers, gauges, etc.) where required.
X I
q) Test annunciators and individual alarms by simulating alarm conditions where possible.
X W/I
r) Stroke control valves, solenoid valves and
emergency isolation/shutdown valves, adjust the valve movements, limit switch and air operation/air failure actions as required.
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[텍스트 입력] 3.0 INSTRUMENTATION (Contd.) Construction Phase Pre- commissioning Phase Commissioning Phase Ctr Cy Ctr Cy Ctr Cy
s) Operate and adjust as necessary timers, switches, relays, push buttons, interlocks and other instrumentation components.
X W
t) Confirm that all elements in each instrument loop have been checked and tested for compliance with the drawings and specifications, after the loop