Checklist for Mechanical Completion

(1)

Checklist for Mechanical Completion Table of Contents

1. General Procedures 2. Specific Procedures 1. General Procedures

1.1 Vendor and Service Assistance

Ite m

Description Contracto

r

Client

a. If deemed necessary by Contractor, obtain manufacturer's (vendor) assistance to ensure satisfactory installation of equipment

X

b. Obtain manufacturer's (vendor) assistance at Owner's expense if required by Owner for run-in

X

1.2 Inspection

a. Provide inspection of the plant to check conformity to flow diagrams, construction drawings, vendor prints and specifications

X

b. Arrange for any special pre-start up inspections such as

required by insurance or governmental agencies X

c. Perform routine shop inspection X

d. Witness shop inspection as desired X

e. Verify completion of work and approve plant. Check any exceptions and note on a separate work order list (punch list)

X

Note: Equipment which has been shop inspected will not be reopened for inspection in the field except as specifically noted herein.

1.3 Permits

(2)

Contractor for design work or for erection work b. Procure all permits and certifications required to be

secured in the name of Owner for initial operation of the plant

X

c. Secure at Owner's expense all permits to be issued in name of Owner and required for installation, use, occupancy and operation of the plant

X

1.4 Removal of Rust Preventatives

a

. Remove rust preventatives and oils used to protect equipment during the construction period X

1.5 Maintenance and Spare Parts

a. Protect equipment from normal weather conditions, corrosion or damage prior to plant mechanical completion

X

b. Provide company with spare parts lists as recommended by vendors

X

c. Provide spare parts and supplies X

d. Provide maintenance for equipment, including such items as the cleaning of strainers and the repairing of steam traps, after mechanical completion

X

1.6 Housekeeping

a. Provide construction cleanup, including removal of excess materials, temporary facilities and scaffolding, rough sweeping or raking of job sites and trash pickup

X

b. Maintain housekeeping after mechanical completion as required for safe operation

X

(3)

1.7 Instructions

a. Transmit to Owner any vendors' or manufacturers' instructions and drawings, as applicable

X

b. Provide Owner with any special instructions, such as

requirements for drying liners X

c. Maintain vendor instruction file for ready retrieval X

2. Specific Procedures

2.1 Electrical Power and Lighting Systems - Account E

a. Notify Owner of test schedule X

b. Witness tests when notified and record test data if

desired X

c. Make insulation test of all wiring using a megohmmeter X d. Check lighting circuits and intensities X e. Make insulation tests of motor windings and of

transformer windings from phase to phase, and phase to ground using a megohmmeter

X

f. Make grounding system tests to determine continuity of connections and value of resistance to ground X g. Arrange for breakdown tests by manufacturers on oil

samples from oil-insulated transformers larger than 100 kVA. Check oil level of all transformers

X

h. Make trials and adjustments on all motor control and

switchgear equipment X

i. Test and set switchgear and motor control center relays

for proper functioning X

j. Obtain local inspector's/authority approval where required

X

(4)

l. Check phase sequence and polarity X

m. Run electrical motors uncoupled X

n. Check bearing, winding temperatures and vibration X o. Check installation of emergency and instrument power

systems X

p. Check installation of electrical tracing system and

energize same X

q. Provide Owner with record of work completed X

2.2 Instrument Systems - Account K

a. Make non-operating checks to ensure instrument operability, i.e. remove all shipping stops, check pointer travels and verify instrument capability to measure, operate and stroke in the direction and manner required by the process application

X

b. Field calibrate instruments with standard test equipment and make all required adjustments and control point settings

X

c. Fully pressurize and energize the transmitting and control signal system, open process connections at primary sensors and final regulators and make control mode settings for automatic operation of equipment as the plant is brought on stream

X

d. Install and connect all system components and verify their conformance with specifications and design criteria for function and range using dummy-transmitted signals as needed

X

e. Clean all transmission and control tubing by blowing with cooled and filtered clean air prior to connecting to instrument components

X

f. Clean all air supply headers by blowing with clean air

and check for tightness X

g. Leak-test pneumatic control circuits in X h. Check process lead piping for tightness X

(5)

i. Check all electrical signals and alarm wiring for continuity, correct sources of power and polarity

X

j. Check thermocouples for proper joining of wires, position of elements in wells, proper polarity and continuity of receiving instruments

X

k. Identify orifice plates by tagging and deliver to Owner X l. Isolate, or remove, if necessary, inline X

m. Check bores of orifice plates X

n. Install such plates after completion of flushing

operations X

o. Isolate or remove in-line components for flushing operations and reinstall them on the completion of such operations

X

p. Fill air line lubricators with oil supplied by Owner X q. Check designation and function of each isolator and

fuse in electric systems

X

r. Check operation of automatic transfer X

s. Loop check all instrumentation from field to control room.

X

t. Witness all loop checks X

u. Clean gauge glasses and check illuminators X v. Stroke all control valves, on/off valves, lubricate as

required X

w. Check all analyzers, clean and flush lines to/from. Arrange for vendor representation for calibration of analyzers if required (e.g. chromatographs)

X

x. Test and adjust all safety devices and seals where

necessary, use vendor if required X

y. Install all safety devices e.g. pressure relief valves after

testing X

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2.3 Piping - Account C

a. Hydrostatically or pneumatically test all piping as

required by the drawings or specifications X

b. Notify Owner of test schedule X

c. Witness field pressure tests when notified by contractor X d. Provide at owners expense any special media for test

purposes and facilities for their disposal X e. Check pipehangers, supports, guides and pipe

specialities for the removal of all shipping and erection stops, and for the correctness of cold settings for the design service. In addition, provide Owner with instructions for hot settings

X

f. Check pipehangers, supports, guides and pipe specialities for hot settings and make minor adjustments as necessary

X

g. Install carseals on valves where necessary X

h. Check and record position of all carsealed valves X i. Check steam tracing for tightness and continuity (use

steam when available)and check proper tagging of supply and returns

X

j. Install all strainers (temporary and permanent) spades and spectacle blinds as called for on drawings.

X

k. Waterflush and/or air blow small bore piping. Waterflush all large bore piping

X

l. Carry out chemical cleaning as required per job

specification X

m. Operate steam and water systems for flushing,

cleaning and tracing X

n. Blowdown/clean steam lines with steam e.g. turbines

inlets X

o. Witness flushing and cleaning X

p. Clean strainers after flushing and remove if warranted X

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r. Obtain Owner's approval and permits and make tie-ins as required by applicable specification

X

s. Isolate all systems to allow tie-ins to be made X t. Remove blinds and temporary strainers as required

during start up

X

2.4 Towers - Account A 2.4.1 Shop-Fabricated:

a. Install all internals not already installed in fabricating shop, including trays, caps, grids, demisters, internal piping, packing and linings

X

b. Inspect all internals X

c. Make necessary corrections to internals, remove all

debris and heavy dirt X

d. Carry out final inspection X

e. Do chemical cleaning, if required X

f. Do final flushing and make tightness tests X

g. Perform necessary leakage tests on trays X

2.4.2 Field-Erected:

a. Supervise construction, code testing and installation of internals

X

c. Make final mechanical clean-out X

e. Perform necessary leakage tests on trays X

f. Do chemical cleaning, if required X

(8)

2.5 Vessels - Account MR

a. Open after erection to place any internals requiring field installation and inspect at time of installation. Open internal manways on vessels for inspection by Owner

X

b. Clean out debris, etc. X

c. Witness inspections to the extent desired X

d. Open after dry out and chemical cleaning and charge materials as chemicals, resins, desiccants and catalysts (procurement by Owner)

X

Note: When vessels have been subjected to a shop test, they will not be further tested in the field but may be included as part of a piping system test.

2.6 Tanks - Account M

a. Clean out debris, etc. X

b. Carry out chemical cleaning as required by job specifications

X

c. Cure and dry out any special cement or protective linings in accordance with manufacturers' specifications and instructions

X

d. Test in accordance with applicable specs X

e. Purge systems and charge chemicals as required X

f. Calibration of product tanks X

2.7 Shell and Tube Exchangers - Account T

a. If desired, field inspect exchangers which have been

shop inspected X

b. If desired, field test exchangers which have been subjected to a shop test

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2.8 Air-Cooled Exchangers - Account T

a. Inspect to ensure that temporary shipping supports and erection material have been removed. Check for

damage

X

b. If desired, field test exchangers which have been

subjected to a shop test X

c. Couple fan to motor after motor has been run

uncoupled X

d. Test and balance fans as required. Check blade setting X

e. Test louvers and controls of same X

f. Check of vibration X

2.9 Fired Heaters - Account H

a. Pressure tests in accordance with applicable code, as

required X

b. Provide all non-operating prefiring checks in accordance with specifications and manufacturers' instructions X c. Blow fuel lines, check for cleanliness, and connect

burner piping

X

d. Check proper functioning of registers and dampers, and verify position of indictors

X

e. Dry refractories during initial firing by following manufacturer’s temperature cycles

X

f. Conduct boil-out and chemical cleaning and flushing

operations as required X

g. Obtain and charge liquid heat transfer media, if

required X

h. Conduct light-off, during and purging operations X

(10)

a. Level baseplates and sole plates and grout all bearing surfaces, cold align units and furnish record of

alignment

X

b. Check for and remove any excess piping stresses which may be imposed on the equipment

X

c. Chemically clean the installation of any seal and lube oil system, if specified

X

d. Provide all lubricants required X

e. Charge the lube and seal oil systems X

f. Circulate for cleaning purposes any seal oil, lube oil and

cooling systems X

g. Make vibration tests when driver is coupled. Check temperatures

X

h. Install mechanical seals, permanent packing and accessories if required

X

i. Hot align pumps, compressors and turbines etc. X j. Couple units to drivers after motors have been test run X

k. Install temporary strainers in suction piping X l. Arrange for manufacturers representatives to supervise

erection and perform test on large compressors, turbines

X

m. Loop check auxiliaries on large equipment with vendor representatives

X

n. Witness all tests, checks and test-runs of large

compressors and turbines. X

2.11 Special Equipment - Account G

(Agitators, mixers, rotary filters, weigh scales, materials handling equipment, vacuum equipment)

a. Fully assemble rotary filters except for final filter media (cloth or screens)

X

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c. Level and calibrate weigh scales with assistance of the manufacturer’s representative and set tare weights where possible

X

d. Manually check materials handling equipment for freedom and direction of movement

X

e. Make all final adjustments during run in and any performance tests required

X

f. Obtain vendor's service engineer for start up and final inspection

X

g. Test vacuum equipment, check all joints for leaks X

2.12 Boilers - Account H

a. Make hydrostatic pressure test in accordance with

applicable codes, if required by specifications X b. Inspect installation for completeness and correctness of

installation and make other non-operating prefiring checks in accordance with specifications and manufacturer's instructions

X

c. Check proper functioning of registers and dampers, verify position of indicators, check operation of soot blowers mechanically

X

d. Blow fuel lines, check for cleanliness and connect

burner piping X

e. Dry refractories during initial firing by following manufacturer's temperature cycles

X

f. Purge, flush and drain steam mains as necessary X g. Obtain and charge treated water (per specifications) for

boil-out and initial operation as required X

h. Commission auxiliaries as detailed elsewhere under the appropriate equipment type

X

i. Conduct boil-out and chemical cleaning and flushing operations as required

X

j. Conduct initial light-off with associated checks and

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k. Conduct all operating tests and obtain required certification

X

2.13 Water Treating Plants

a. Inspect for completeness and correctness of installation and make any non-operating checks which may be required

X

b. Provide and install initial charge of ion-exchange resins

and inert bed material X

c. Make the necessary operating tests and adjustments to

water treatment systems X

d. Provide all water treatment chemicals X

e. Obtain services of water consultant to advise and

monitor X

2.14 Water Systems

(Service Wells, Cooling Towers, Fire Water, Seawater Systems, etc.) a. Inspect for completeness and correctness of

installations and make any non-operating checks required

X

b. Initially clean cooling tower basin and install screens in suction pit prior to water circulation X c. Test well delivery and lush well piping if wells are

furnished by Contractor X

d. Flush, drain and clean cooling water basins X

e. Clean intake screens X

f. Operate fire pumps to check output of systems X

g. Fill reservoirs, head towers, etc. X

h. Arrange for insurance company inspection of fire

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i. Obtain and install all fire fighting chemicals as required and portable equipment such as hoses, fire

extinguishers and related equipment

X

2.15 Waste Disposal

a. Inspect facilities for completeness and correctness of installation and make any non-operating checks to ensure conformance with specifications

X

b. Operate all equipment and supply all chemicals, agents, etc. related to waste treatment

X

2.16 Buildings and Accessories

a. Check installation of any buildings and accessories including all heating, ventilating and air conditioning equipment to ensure completeness and conformance with specifications

X

b. Obtain certification that all plumbing, wiring and elevator installation are in compliance with local governmental regulation

X

c. Test heating, ventilating and air-conditioning units and make all performance tests, if weather permits,

otherwise by Owner

X

d. Obtain certificate for occupancy and use, if required X

2.17 Insulation and Painting - Accounts N and R

a. Inspect and accept all materials and field workmanship X b. Complete all insulation work as specified X*

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* This work may extend beyond the date of mechanical completion.

Checklist for the Mechanical Completion, incl. pre-commissioning activities Table of contents

1. General Procedures 2. Specific Procedures

(15)

1. General Procedures

Contracto

r Client

X

b. Obtain manufacturer's (vendor) assistance at Owner's expense if required by Owner for run in X

1.2 Inspection

X

b. Arrange for any special pre-start up inspections such as required by insurance or governmental agencies

X

1.3 Permits

a. Secure permits and certifications required in name of Contractor for design work or for erection work

X

b. Assist Owner at his expense in the procurement of all permits and certifications required to be secured in name of Owner for initial operation of the plant

X

c. Secure at Owner's expense all permits to be issued in name of Owner and required for installation, use,

(16)

occupancy and operation of the plant

a. Remove rust preventatives and oils used to protect

equipment during the construction period X

X

b. Provide company with spare parts lists as recommended

by vendors X

d. Provide maintenance for equipment, including such items as the cleaning of strainers and the repairing of steam traps, after mechanical completion

X

a. Provide construction clean up, including removal of excess materials, temporary facilities and scaffolding, rough sweeping or raking of job sites and trash pickup

X

b. Maintain housekeeping after mechanical completion as

required for safe operation XX

a. Transmit to Owner any vendors' or manufacturers' instructions and drawings, as applicable

X

b. Provide Owner with any special instructions, such as requirements for drying liners

(17)

2 Specific Procedures

b. Witness tests when notified and record test data if

desired X

X

f. Make grounding system tests to determine continuity of connections and value of resistance to ground

X

g. Arrange for breakdown tests by manufacturers on oil samples from oil insulated transformers larger than 100 kVA. Check oil level of all transformers

X

h. Make trials and adjustments on all motor control and switchgear equipment

X

i. Test and set switchgear and motor control center relays for proper functioning

X

j. Obtain local inspector's/authority approval where required

X

k. Energize all substations after completion of all tests X

n. Check bearing, winding temperatures and vibration XX o. Check installation of emergency and instrument power

systems

X

p. Check installation of electrical tracing system and

(18)

q. Provide Owner with record of work completed X

a. Make non-operating checks to ensure instrument

operability, i.e. remove all shipping stops, check pointer travels and verify instrument capability to measure, operate and stroke in the direction and manner required by the process application

XX

X

d. Install and connect all system components and verify their conformance with specifications and design criteria for function and range using dummy transmitted signals as needed

X

f. Clean all air supply headers by blowing with clean air and check for tightness

X

g. Leak test pneumatic control circuits in accordance with

ISA Recommended Practice RP 7,1 X

h. Check process lead piping for tightness X i. Check all electrical signals and alarm wiring for

continuity, correct sources of power and polarity X j. Check thermocouples for proper joining of wires, position

of elements in wells, proper polarity and continuity of receiving instruments

X

k. Identify orifice plates by tagging and deliver to Owner X l. Isolate, or remove, if necessary, inline components such

as control valves, positive displacement meters, turbine X

(19)

meters, etc. for pressure testing and reinstall such items

n. Install such plates after completion of flushing

operations XX

o. Isolate or remove in line components for flushing

operations and reinstall them on the completion of such operations

XX

p. Fill air line lubricators with oil supplied by Owner X q. Check designation and function of each isolator and fuse

in electric systems X

r. Check operation of automatic transfer systems, reset

mechanisms, etc. XX

s. Loop check all instrumentation from field to control

room. X

required X

w. Check all analyzers, clean and flush lines to/from arrange for vendor representation for calibration of analyzers if required (e.g. chromatographs)

X

x. Test and adjust all safety devices and seals where necessary use vendor if required

X

testing X

z. Supply and install sealing liquids X

a. Hydrostatically or pneumatically test ll piping as required

by the drawings or specifications X

(20)

c. Witness field pressure tests when notified by Contractor X d. Provide at owners expense any special media for test

purposes and facilities for their disposal

X

e. Check pipehangers, supports, guides and pipe

X

f. Check pipehangers, supports, guides and pipe

specialities for hot settings and make minor adjustments as necessary

X

steam when available) and check proper tagging of supply and returns

X

j. Install all strainers (temporary and permanent) spades and spectacle blinds as called for on drawings. X k. Waterflush and/or air blow small bore piping. Waterflush

large bore piping X

l. Carry out chemical cleaning as required per job specification

X

m. Operate steam and water systems for flushing, cleaning and tracing

X

n. Blowdown/clean steam lines with steam e.g. turbines

inlets X

p. Clean strainers after flushing and remove if warranted XX

q. Maintain records of blinds installed X

r. Obtain Owner's approval and permits and make tie ins as required by applicable specification X

s. Isolate all systems to allow tie ins to be made X t. Remove blinds and temporary strainers as required

(21)

2.4 Towers - Account A 2.4.1 Shop-fabricated:

X

c. Make necessary corrections to internals, remove all debris and heavy dirt

X

e. Do chemical cleaning, if required XX

f. Do final flushing and make tightness tests X

g. Perform necessary leakage tests on trays X

a. Supervise construction, code testing and installation of

internals X

c. Make final mechanical clean out X

e. Perform necessary leakage tests on trays X

f. Do chemical cleaning, if required XX

g. Do final flushing and tightness test X

a. Open after erection to place any internals requiring field installation and inspect at time of installation. Open X

(22)

external manways on vessels for inspection by Owner

b. Clean out debris etc X

XX

Note: When vessels have been subjected to a shop test, they will not be further tested in the field but may be included as part of a piping system test.

b. Carry out chemical cleaning as required by job

specifications XX

X

d. Test in accordance with applicable specs X e. Purge systems and charge chemicals as required XX

f. Calibration of product tanks X

a. If desired, field inspect exchangers which have been shop inspected

X

2.8 Air-cooled Exchangers - Account T

a. Inspect to ensure that temporary shipping supports and erection material have been removed. Check for damage

(23)

X

c. Couple fan to motor after motor has been run uncoupled X d. Test and balance fans as required. Check blade setting X

f. Check for vibration X

2.9 Fired Heaters - Account H

a. Pressure test in accordance with applicable code, as

required X

b. Provide all non-operating prefiring checks in accordance with specifications and manufacturers' instructions

X

c. Blow fuel lines, check for cleanliness, and connect burner piping

XX

d. Check proper functioning of registers and dampers, and

verify position of indicators X

e. Dry refractories during initial firing by following

manufacturer's temperature cycles X

f. Conduct boil out and chemical cleaning and flushing

g. Obtain and charge liquid heat transfer media, if required XX

h. Conduct light off, drying and purging operations X

2.10 Pumps, Compressors and Turbine Drivers - Account P-PC

a. Level baseplates and sole plates and grout all bearing surfaces, cold align units and furnish record of alignment

X

b. Check for and remove any excess piping stresses which may be imposed on the equipment

X

(24)

system, if specified

e. Charge the lube and seal oil systems XX

cooling systems XX

g. Make vibration tests when driver is coupled. Check

temperatures X

X

i. Hot align pumps, compressors, turbines, etc. X j. Couple units to drivers after motors have been test run X

k. Install temporary strainers in suction piping X l. Arrange for manufactures representatives to supervise

erection and perform test on large compressors, turbines X

m. Loop check auxiliaries on large equipment with vendor

representatives X

n. Witness all tests, checks and test runs of large

X

b. Install all final filter media (cloth, precoat, etc.) X c. Level and calibrate weigh scales with assistance of the

manufacturer's representative and set tare weights where possible

X

d. Manually check materials handling equipment for

freedom and direction of movement X

(25)

performance tests required

f. Obtain vendor's service engineer for start up X g. Test vacuum equipment, check all joints for leaks X

a. Make hydrostatic pressure test in accordance with applicable codes, if required by specifications

X

b. Inspect installation for completeness and correctness of installation and make other non-operating pre-firing checks in accordance with specifications and

manufacturer's instructions

X

c. Check proper functioning of registers and dampers and verify position of indicators check operation of soot blowers mechanically

X

d. Blow fuel lines, check for cleanliness and connect burner piping

X

f. Purge, flush and drain steam mains as necessary XX g. Obtain and charge treated water (per specifications) for

boil out and initial operation as required

X

h. Commission auxiliaries as detailed elsewhere under the appropriate equipment type

X

i. Conduct boil out and chemical cleaning and flushing

operations as required XX

j. Conduct initial light off with associated checks and

adjustments X

X

(26)

X

b. Provide and install initial charge of ion exchange resins and inert bed material

X

c. Make the necessary operating tests and adjustments to water treatment systems

X

e. Obtain services of water consultant to advise and monitor

X

(Service wells, cooling towers, fire water, seawater systems, etc.) a. Inspect for completeness and correctness of installations

and make any non-operating checks required

X

b. Initially clean cooling tower basin and install screens in suction pit prior to water circulation X c. Test well delivery and flush well piping if wells are

furnished by Contractor X

d. Flush, drain and clean cooling water basins XX

e. Clean intake screens XX

h. Arrange for insurance company inspection of fire system

as required X

i. Obtain and install all fire fighting chemicals as required and portable equipment such as hoses, fire extinguishers and related equipment

X

(27)

X

b. Operate all equipment and supply all chemicals, agents, etc. related to waste treatment

X

otherwise by Owner

X

c. Complete all painting as specified, weather permitting X*

* This work may extend beyond the date of mechanical completion.

Checklist for Preparation for Start-Up Table of Contents

1. General Procedures 2. Specific Procedures

(28)

1. General Procedures

Contracto r

Client

X

b. Obtain manufacturer's (vendor) assistance at Owner's expense if required requested by Owner for run in

X

1.2 Inspection

X

b. Arrange for any special pre-start-up inspections such as

required by insurance or governmental agencies X

X

1.3 Permits

a. Secure permits and certifications required in name of Contractor for design work or for erection work

X

b. Assist Owner at his expense in the procurement of all permits and certifications required to be secured in name of Owner for initial operation of the plant

X

(29)

name of Owner and required for installation, use, occupancy and operation of the plant

a. Remove rust preventatives and oils used to protect equipment during the construction period

X

b. Provide Company with spare parts lists as recommended by vendors

X

d. Provide maintenance for equipment, including such items as the cleaning of strainers and the repairing of steam traps, after plant mechanical completion

X

a. Provide construction clean up, including removal of excess materials, temporary facilities and scaffolding, rough sweeping or raking of job sites and trash pickup

X

b. Maintain housekeeping after mechanical completion as required for safe operation

X X

a. Transmit to Owner any vendors' or manufacturers'

(30)

b. Provide Owner with any special instructions, such as requirements for drying liners

X

2. Specific Procedures

b. Witness tests when notified and record test data if desired

X

f. Make grounding system tests to determine continuity of connections and value of resistance to ground

X

g. Arrange for breakdown tests by manufacturers on oil samples from oil-insulated transformers larger than 100 kVA. Check oil level of all transformers

X

h. Make trials and adjustments on all motor control and switchgear equipment

X

i. Test and set switchgear and motor control center relays for proper functioning

X

j. Obtain local inspector's/authority approval where

required X

k. Energize all substations after completion of all tests X

n. Check bearing, winding temperatures and vibration X o. Check installation of emergency and instrument power X

(31)

systems

p. Perform all necessary pre-start up checks on generators in accordance with vendors instruction

X

q. Assume responsibility for maintenance and operation of energized electrical facilities after acceptance

X

r. Provide Owner with record of work completed X

a. Make non-operating checks to ensure instrument

operability, i.e. remove all shipping stops, check pointer travels and verify instrument capability to measure, operate and stroke in the direction and manner required by the process application

X

d. Install and connect all system components and verify their conformance with specifications and design criteria for function and range using dummy transmitted signals as needed

X

f. Clean all air supply headers by blowing with clean air

and check for tightness X

g. Leak test pneumatic control circuits in accordance with

ISA Recommended Practice RP 7,1 X

h. Check process lead piping for tightness X i. Check all electrical signals and alarm wiring for

(32)

j. Check thermocouples for proper joining of wires, position of elements in wells, proper polarity and continuity of receiving instruments

X

k. Identify orifice plates by tagging and deliver to Owner X l. Isolate, or remove, if necessary, inline components such

as control valves, positive displacement meters, turbine meters, etc. for pressure testing and reinstall such items

X

n. Install such plates after completion of flushing operations

X

o. Isolate or remove in-line components for flushing

operations and reinstall them on the completion of such operations

X

p. Fill air line lubricators with oil supplied by Owner X q. Check designation and function of each isolator and fuse

in electric systems X

r. Check operation of automatic transfer systems, reset

mechanisms, etc. X

s. Loop check all instrumentation from field to control room.

X

required X

w. Check all analyzers, clean and flush lines to/from arrange for vendor representation for calibration of analyzers if required (e.g. chromatographs)

X

x. Test and adjust all safety devices and seals where

necessary use vendor if required X

testing X

z. Assume responsibility for maintenance and operation of all instrument facilities after acceptance

(33)

a. Hydrostatically or pneumatically test all piping as

required by the drawings or specifications X

b. Notify Owner of test schedule X

c. Witness field pressure tests when notified by Contractor X d. Provide at owners expense any special media for test

purposes and facilities for their disposal X e. Check pipehangers, supports, guides and pipe

X

f. Check pipehangers, supports, guides and pipe

specialities for hot settings and make minor adjustments as necessary

X

steam when available) and check proper tagging of supply and returns

X

j. Install all strainers (temporary and permanent) spades and spectacle blinds as called for on drawings.

X

k. Waterflush and/or air-blow small bore piping X l. Carry out chemical cleaning as required per job

specification

X

m. Operate steam and water systems for flushing, cleaning and tracing

X

n. Blowdown/clean steam lines with steam e.g. turbine inlets

X

p. Clean strainers after flushing and remove if warranted X

q. Maintain records of blinds installed X

(34)

as required by applicable specification

s. Isolate all systems to allow tie ins to be made X t. Remove blinds as required during start up X

2.4 Towers - Account A 2.4.1 Shop-fabricated:

X

c. Make necessary corrections to internals, remove all

debris and heavy dirt X

d. Do chemical cleaning, if required X

e. Do final flushing and make tightness tests X f. Perform necessary leakage tests on trays X g. Carry out final inspection and formally accept vessel,

issue permit to close

X

h. Final close vessel X

a. Supervise construction, code testing and installation of

internals X

c. Make final mechanical clean out X

d. Perform necessary leakage tests on trays X

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f. Do final flushing and tightness test X g. Carry out final inspection and formal accept vessel, issue

permit to close

X

h. Final close vessel X

a. Open after erection to place any internals requiring field installation and inspect at time of installation. Open external manways on vessels for inspection by Owner

X

b. Clean out debris, etc. X

X

e. Hot bolt vessels after heat up X

f. Final inspection, and formally accept vessel, issue permit to close if applicable

X

Note: When vessels have been subjected to a shop test, they will not be further tested in the field but may be included as part of a piping system test.

b. Carry out chemical cleaning as required by job specifications

X

d. Test in accordance with applicable specs X

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f. Final inspection, and formally accept vessel, issue permit to close if applicable

X

g. Close vessel X

a. If desired, field inspect exchangers which have been shop

inspected X

X

c. Hot bolt equipment after heat up X

2.8 Air-cooled Exchangers - Account T

a. Inspect to ensure that temporary shipping supports and erection material have been removed. Check for damage

X

c. Couple fan to motor after motor has been run uncoupled X d. Test and balance fans as required. Check blade setting X

f. Final inspection and formally accept air cooler X

2.9 Fired heaters - Account H

a. Pressure test in accordance with applicable code, as required

X

b. Provide all non-operating prefiring checks in accordance with specifications and manufacturers' instructions

X

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piping

d. Check proper functioning of registers and dampers, and verify position of indicators

X

f. Conduct boilout and chemical cleaning and flushing

g. Obtain and charge liquid heat transfer media, if required X h. Conduct light off, drying and purging operations X

2.10 Pumps, Compressors and Turbine Drivers - Account P-PC

a. Level baseplates and sole plates and grout all bearing surfaces, cold align units and furnish record of alignment X b. Check for and remove any excess piping stresses which

may be imposed on the equipment X

c. Chemically clean the installation of any seal and lube oil system, if specified

X

e. Charge the lube and seal oil systems X

cooling systems X

g. Make vibration tests when driver is coupled. Check

temperatures X

X

i. Hot align pumps, and turbines etc., and dowel if required X j. Couple units to drivers after motors have been test run X

k. Install temporary strainers in suction piping X l. Arrange for manufactures representatives to supervise

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m. Loop check auxiliaries on large equipment with vendor representatives

X

n. Witness all tests, checks and test-runs of large

X

b. Install all final filter media (cloth, precoat, etc.) X c. Level and calibrate weigh scales with assistance of the

manufacturer's representative and set tare weights where possible

X

d. Manually check materials handling equipment for

freedom and direction of movement X

e. Make all final adjustments during run in and any

performance tests required X

f. Obtain vendor's service engineer for start up X g. Test vacuum equipment, check all joints for leaks X

a. Make hydrostatic pressure test in accordance with applicable codes, if required by specifications

X

b. Inspect installation for completeness and correctness of installation and make other non-operating pre-firing checks in accordance with specifications and

manufacturer's instructions

X

c. Check proper functioning of registers and dampers and

verify position of indicators X

d. Blow fuel lines, check for cleanliness and connect burner

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X

f. Purge, flush and drain steam mains as necessary X g. Obtain and charge treated water (per specifications) for

boil out and initial operation as required

X

h. Commission auxiliaries as detailed elsewhere under the

appropriate equipment type X

i. Conduct boil out and chemical cleaning and flushing

j. Conduct initial light off with associated checks and

adjustments X

X

2.13 Water Treating Plants

X

b. Install initial charge of ion exchange resins and inert bed

material (supply by Owner) X

c. Make the necessary operating tests and adjustments to

water treatment systems X

e. Obtain services of water consultant to advise and

monitor X

(Service wells, cooling towers, fire water, seawater systems, etc.) a. Inspect for completeness and correctness of installations

and make any non-operating checks required X b. Initially clean cooling tower basin and install screens in X

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suction pit prior to water circulation

c. Test well delivery and flush well piping if wells are furnished by Contractor

X

d. Flush, drain and clean cooling water basins X

e. Clean intake screens X

h. Arrange for insurance company inspection of fire system as required

X

i. Obtain and install all fire fighting chemicals as required and portable equipment such as hoses, fire extinguishers and related equipment

X

j. Establish water treating program X

2.15 Waste Disposal

X

b. Operate all equipment and supply all chemicals, agents,

etc. related to waste treatment X

X

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otherwise by Owner

c. Complete all painting as specified, weather permitting X*

* This work may extend beyond the date of start up.

Environmental, Health and Safety Policy, Safety Rules and Site Regulations Table of contents

1. General 2. Safety Policy

3. Responsibility and Authority 4. Site Rules and Regulations 5. Reporting

6. Safe Practice Rules 7. Fire Prevention

8. First Aid Arrangements 9. Security

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1. General

This document is to provide information to SUBCONTRACTOR for executing the WORK. It gives minimum requirements and may be augmented by Company to give additional requirements that are specific to a certain location or OWNER.

It does not release SUBCONTRACTOR in any way from his obligation to observe the applicable legal regulations and requirements.

Key words are as defined in the General Conditions of Subcontract. Such words are shown in capitals.

2. Safety Policy 2.1 Introduction

It is Company's policy to ensure that each person at the SITE works in a safe and healthful environment. It is Company's objective to have an accident-free SITE.

To accomplish this, Company has their own Safety, Health, Welfare and Environmental (SHWE) Program. The purpose of Company's Safety Program is primarily preventive. Company aims to provide a work environment in which accidents cannot happen. Conditions which may cause accidents must be located and corrected in a timely way in order to accomplish this aim.

SUBCONTRACTOR shall prepare his own Safety Plan for the WORK which, as a minimum, shall cover the requirements as specified in this document.

SUBCONTRACTOR's Safety Plan shall also cover any specific safety items which are related to the type of WORK which SUBCONTRACTOR is executing.

SUBCONTRACTOR shall submit his Safety Plan to Company for approval. When necessary Company will augment SUBCONTRACTOR's Safety Plan from their own Safety Plan for the WORK.

Written safety programs do not always cover a specific work operation. It is expected that SUBCONTRACTOR will consult with Company regarding safety aspects of all nonstandard operations and shall perform work location and hazard analysis.

In the final analysis, a common sense approach on the part of everyone concerned is the best asset in achieving an accident-free SITE.

3. Responsibility and Authority 3.1 Safety Management

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Company's SITE Safety Management along with the Safety Representative nominated by SUBCONTRACTOR have responsibility in providing management with the necessary services and guidance relating to an effective Safety, Health, Welfare and Environmental Program.

3.2 Line Management

Construction line management at the SITE level is the key to safe working conditions and must bear the principal responsibility for safety. SUBCONTRACTOR must see that his line management is properly aware of this responsibility.

3.3 Craft Labor

SUBCONTRACTOR must communicate all SHWE requirements to his personnel.

SUBCONTRACTOR shall ensure that this communication is done in a language which is understandable for his personnel at SITE.

This must be done through an induction program on arrival at SITE, through regular toolbox meetings and through daily communication between craft supervision and craft personnel.

3.4 Authority

3.4.1 Company expects that SUBCONTRACTOR will give his line management full

authority to correct an unsafe condition. SUBCONTRACTOR's safety personnel shall have authority to stop work and direct remedial action relative to an unsafe condition.

3.4.2 Similarly, Company management and safety personnel have authority to stop SUBCONTRACTOR's work and direct remedial action.

3.5 Safety Meetings

SUBCONTRACTOR shall be properly represented in all safety meetings. Normally such representation shall consist of SUBCONTRACTOR's Site Manager and its Safety

Representative, as required.

4. Site Rules and Regulations 4.1 Introduction

The rules and regulations included in this section shall be strictly followed by SUBCONTRACTOR and all personnel on SITE.

4.2 Personnel Control 4.2.1 Daily Force Reports

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A complete list of all SUBCONTRACTOR personnel present on SITE must be in Company's possession by 09.00 hours each work day.

4.2.2 Head Counts

Company may make head counts of SUBCONTRACTOR's personnel on SITE on a regular basis and SUBCONTRACTOR's Timekeeping Department shall cooperate with Company in properly correlating head counts with SUBCONTRACTOR's daily force reports and time books if necessary.

4.2.3 Discipline

All personnel are expected to behave in an orderly fashion and observe all the rules and regulations laid down herein or issued otherwise by Company or other recognized authority. SUBCONTRACTOR is expected to properly discipline those persons who do not act properly.

4.2.4 Restricted Areas

Various areas of the SITE may be designated from time to time as restricted for some reason. Notices of these areas will be issued by Company in writing. All personnel are expected to observe the conditions laid down in these notices.

4.2.5 Traffic

The applicable traffic rules and regulations with respect to driving on the SITE, shall be strictly adhered to. National or OWNER rules and regulations may be augmented by Company to suit circumstances at SITE.

4.2.6 Contact Person Outside Normal Working Hours

SUBCONTRACTOR shall submit a list of names and telephone numbers of persons to be contacted in case of accident or emergency outside normal working hours.

4.3 Control of Construction Equipment

4.3.1 On a weekly basis, SUBCONTRACTOR shall furnish to Company a list showing number and type of all CONSTRUCTION EQUIPMENT utilized on SITE.

4.3.2 SUBCONTRACTOR shall maintain an inspection schedule for his CONSTRUCTION EQUIPMENT.

4.3.3 Rules applicable to equipment deployment and traffic control will be issued by Company to suit conditions of the particular SITE and location.

4.4 Subcontractor Area

4.4.1 SUBCONTRACTOR shall provide a plan to Company for approval showing how the area allotted to SUBCONTRACTOR for TEMPORARY FACILITIES will be utilized.

4.4.2 SUBCONTRACTOR shall furnish adequate change room facilities for his personnel. With Company's approval, eating facilities may also be furnished. The TEMPORARY

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FACILITIES shall be maintained in accordance with the highest standard of cleanliness and hygiene. The eating facilities shall be open at times approved by Company. 4.4.3 Lodging facilities are not permitted on SITE.

4.4.4 Parking areas will be designated by Company. Rules applicable to control of company and personal vehicles will be issued by Company.

4.4.5 Company and OWNER's staff will have free access at any time to any building or area of the SUBCONTRACTOR at SITE.

4.5 Personal Protective Clothing, Safety Gear and Equipment

Hard hats and safety shoes shall be worn at all times by all personnel on SITE, except in the office. Other protective gear, such as gloves, safety glasses, goggles, face shields, ear protection, toe guards and safety belts and respiratory equipment, shall be issued by SUBCONTRACTOR and shall be used when required. Additional safety devices may be required for certain activities or areas.

4.6 Emergency Procedures

4.6.1 Company shall issue instructions which are SITE specific, setting up procedures for warnings of emergency, evacuation arrangements, communication arrangements and responsibilities for action in an emergency.

4.7 Miscellaneous Regulations and Rules of Conduct 4.7.1 Gambling on SITE is forbidden.

4.7.2 Possession or carrying of weapons or firearms on SITE is prohibited.

4.7.3 Selling, advertisement, promotion and distribution on SITE of newspapers, leaflets or other material of a political, religious, immoral or subversive nature is forbidden. 4.7.4 Erection of any type of signboard or publicity poster on or adjacent to the SITE is subject to Company's approval.

4.7.5 Taking photographs or motion pictures on SITE is forbidden. Cameras are to be left at the gatehouse.

4.7.6 It is forbidden to make or repair items for private purposes on SITE. 4.7.7 Any general assembly on SITE except for properly authorized meetings is prohibited.

4.7.8 Animals are not allowed on SITE.

4.7.9 Personnel piracy is not allowed. SUBCONTRACTOR shall respect employment agreements of others.

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4.7.10 All personnel on SITE are required to conform to the following minimum rules of conduct relating to safety while on the SITE and while away from the SITE in performing work duties.

4.7.11 All personnel on SITE shall wear clothing appropriate to their individual work assignments in accordance with normal work dress standards. Excessively loose,

severely torn clothing and ties shall not be worn by personnel whose work exposes them to rotating or reciprocating equipment, such as pipe machines or mechanical hack saws, band saws, table saws etc. "Tank top" shirts, short sleeve shirts and leisurewear shorts are prohibited. Nylon/synthetic clothing shall not be worn when working with or exposed to flammable or volatile substances.

4.7.12 Selling or possessing drugs or intoxicants and alcoholic beverages on the SITE are prohibited. Any person whose actions and demeanor show symptoms of possible narcosis or drunkenness shall be removed from the SITE.

4.7.13 Indulgence in practical jokes, horseplay, scuffling, wrestling or fighting on SITE is forbidden.

4.7.14 Destroying or tampering with safety devices, signs and signals, or the willful and unnecessary discharging of fire extinguishers is prohibited.

4.7.15 Sleeping on the SITE is prohibited.

4.7.16 Smoking on the SITE within areas posted with "No Smoking" signs is prohibited. The carrying of strike-anywhere matches and coverless cigarette lighters is forbidden in areas where such items are prohibited.

4.7.17 Unauthorized operation of powered construction equipment is prohibited. Vehicle drivers shall have a valid vehicle operator's permit. Equipment operators shall have successfully demonstrated that they are able to operate the equipment.

4.7.18 Insubordination toward any supervisor or management personnel in respect to the carrying out of properly issued instructions or orders for safety and health purposes shall be sufficient cause for initiating disciplinary action.

4.8 Housekeeping Rules

SUBCONTRACTOR shall take all necessary steps to ensure that the SITE and the TEMPORARY FACILITIES are maintained in a safe, clean, healthy and sanitary condition and that the environment is preserved. Rules of cleanliness and orderliness shall be enforced amongst all personnel working at the SITE.

Contaminated soil, waste, refuse and scrap while on SITE shall all be properly stored in suitable containers and/or at areas designated and must be moved off SITE at regular intervals so as not to create a danger to personnel and/or the environment.

Government/legal requirements in this respect shall be adhered to. Trucks carrying such material are subject to the same regulations as other vehicles relative to permits for removing material from SITE.

In lunch areas, all trash and scrap food shall be discarded in containers placed in the lunch area for that purpose. Beverages in glass bottles are prohibited. Only thermos, paper, metal or plastic containers/bottles and cups and the like may be used.

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Roads and walkways shall be maintained clean and every effort shall be made to keep mud, slush and other slippery substances off roads and walkways.

Electrical extension cables and welding cables, water and air hoses shall be placed where they cannot be damaged, and where they cannot cause damage or injury. If placed in roadways or pipeways, the cables and hoses shall be placed in a protected trough or be suspended above the road or pavement surface. In roadways, the height shall be at least 6 meters; in pipeways, 2 meters. Excess cables, hoses, etc. are to be removed and cleared away each day.

Spilled oil, grease and other slippery substances shall be cleaned up immediately, temporarily isolated until cleaned up or sprinkled with enough dirt or sand to absorb the material and to eliminate slipperiness.

SUBCONTRACTOR shall keep a record of chemicals in use or stored on the SITE and indicate potential hazards and exposure limits as well as protective clothing/equipment necessary, fire prevention and first aid requirements. The record shall include chemicals used for passivation, cleaning, pickling, adhesives, epoxy resins and man-made fibres. All chemical containers shall be properly labelled and spillage and/or disposal in the

environment must be prevented and, if occurred, reported to Company immediately. MATERIALS and CONSTRUCTION EQUIPMENT not being used shall be stored safely in such a way that they will not obstruct other SITE activities.

5. Reporting

5.1 Reporting Injuries and Accidents

Reporting shall be done by SUBCONTRACTOR in line with Company's instructions for reporting and record keeping of occupational injuries and illnesses.

Each occupational injury and illness shall be reported promptly to SUBCONTRACTOR's safety representative and to Company in order to ensure that proper and adequate first aid or medical attention is obtained.

Occupational injuries and illnesses, the first symptoms of which become evident after completion of the working day, shall be reported to SUBCONTRACTOR's safety

representative and to Company at the start of the next regularly scheduled working day. All accidents in which SUBCONTRACTOR's employees are involved or which result in injury or illness to one or more employees of another SUBCONTRACTOR, or other

persons, such as a private vehicle driver, passenger or pedestrian or a SITE visitor, shall be reported promptly to SUBCONTRACTOR's safety representative and to Company. All accidents which result in damage to any constructed or partially constructed facility, or to CONSTRUCTION EQUIPMENT or private property, shall be reported promptly to SUBCONTRACTOR's safety representative and to Company.

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Any unsafe or hazardous condition shall be promptly reported to SUBCONTRACTOR's safety representative and to Company, so that timely corrective action can be taken to prevent injuries or damage.

5.3. Reporting "Near Miss" Situations

Any "near miss" situation, which shall be deemed a dangerous occurrence, shall be promptly reported to SUBCONTRACTOR's safety representative and to Company, so that action can be taken to avoid such accidents in the future.

A definition of a dangerous occurrence is an unplanned event which has no detrimental end result but could easily have so resulted.

When a dangerous occurrence is reported an investigation must be undertaken by the SUBCONTRACTOR who committed the offence and a report submitted to Company. The investigation must find out why the occurrence happened and what measures will be undertaken to ensure that it does not happen again with disastrous results. The

Company Safety Engineer will ensure that all dangerous occurrences are discussed at safety meetings. SUBCONTRACTOR must ensure that such occurrences are discussed during "toolbox" meetings.

6. Safe Practice Rules

6.1 Machinery and Tool Guards

Machinery and tool guards are provided for protection against revolving or reciprocating parts. These guards shall be in place before the machine or tool is used and shall not be removed or made inoperative.

6.2 Scaffolds

6.2.1 Scaffolds shall be made of materials and constructed as approved by Labor Inspection/applicable authority.

Scaffolds shall be substantially constructed to carry the loads imposed upon them and to provide safe work platforms. All scaffolds shall have approved guard rails on all exposed ends and sides. Toe boards and screens shall be provided on all scaffolds. Toe boards shall have a minimum height of 15 cm. Scaffolds shall be plumb and level at all times. In erecting scaffolds prescribed (manufacturer or local authority code) base width and height relation must be taken into account.

Barrels, boxes and other makeshift substitutes for scaffolds shall not be used. Scaffolds shall not be used as hoisting towers or to support pipe or equipment.

Scaffold planks shall be no less than 5 cm thick x 20 cm wide (nominal scaffold grade). Platforms shall be no less than 60 cm wide. All platform planks shall be secured to prevent displacement; if nailed, single headed nails shall be used only. Planking shall not be painted: this conceals defects.