10 00 0-(31/80) 4000-PMT-1EG-000-Z
KHALDA PETROLUM COMPANY
PRE-COMMISSIONING PROCEDURE
FOR
QASR COMPRESSION PROJECT
WESTERN DESERT – EGYPT
1 21/05/2014 FINAL ISSUE A.S H.M W.E
0 13/04/2014 ISSUED FOR APPROVAL SM RK RK
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TABLE OF CONTENTS
1.0INTRODUCTION………...4 2.0 DEFINITIONS………...5 3.0 PRE-COMMISSIONING ORGANIZATION...7 4.0 ACTIVITIES BOARDER………...8 5.0 SYSTEMIZATION………...9 5.1 GENERAL………. . .9 5.2 NUMBERING SYSTEM...9 5.3 PRE-COMMISSIONING SYSTEMS……….10 6.0 SYSTEMSPERIORITIES……..……….14 7.0 PRE-COMMISSIONING PROCEDURES...16 7.1 GENERAL PROCEDURE………...16 7.2 SYSTEM PROCEDURE………...177.3 MAIN PRE-COMMISSIONING ACTIVITIES...18
7.4 MAIN PRE-COMMISSIONING CHECKS...18
7.5 SEQUENTIAL COMPLETION FLOW CHART...47
8.0 CONFORMITY CHECK OF THE PLANT'S EQUIPMENT...49
9.0 SYSTEM DOCUMENTS………...49
10.0 PROGRESS MONITORING………...50
11.0 PUNCH LISTING………...50
12.0 STEPS TO ACHIEVE MECHANICAL COMPLETION AND MECHANICAL COMPLETION CERTIFICATE (MCC)…………...51
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14.0 SYSTEMS COMPONENT LIST………...54 15.0 ATTACHMENTS………...140
ATTACHMENT 1 MARKED UP P&ID’s
ATTACHMENT 2 PRE-COMMISSIONING CHECK FORMS ATTACHMENT 3 PUNCH LIST FORM
ATTACHMENT 4 MECHANICAL COMPLETION CERTIFICATE ATTACHMENT 5 CALIBRATION CERTIFICATE
ATTACHMENT 6 LOOP CHECK SHEET
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 1.0 INTRODUCTION
This Pre-commissioning Procedure has been prepared by ENPPI for KPC, KHALDA PETROLEUM COMPANY. All involved parties shall adhere strictly to these procedures during the pre-commissioning phase of the plant.
The purpose of this document is to describe the specific requirements, principles & responsibilities for the preparation, execution, verification, and documentation of pre-commissioning activities, leading to mechanical completion of the UTILITIES AND OFFSITES PROJECT.
The Completion Process will start with activities related to definition and preparation of systems and will then be followed in the later stages by activities related to verification and execution. The overall scope of pre-commissioning / System acceptance testing is to verify, test and document that the equipment and systems are designed and built to fulfill its purpose according to the specified requirements and safe to operate before turnover to operation team.
With the purpose of facilitating the pre-commissioning activities and surrenders, the plant has been divided into mechanical completion systems; these systems will be included in specific packages. In this respect, all the possible constituents of the plant will be categorized under certain and specific system.
The adequate pre-commissioning tests will be performed on every item of the plant and conveniently reported through the use of pre-commissioning forms on completion of these tests.
1 1 10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 2.0 DEFINITIONS Pre-commissioning
Manager Assigned person who will Manage the pre-commissioning activities With all involved parties until "Ready for Commissioning" (RFC)
Pre-commissioning coordinator
A pre-commissioning engineer from ENPPI, who will be responsible for all plant systems dossiers
preparation and will coordinate punch listing activity Commissioning Integrated
Team (CIT)
A committee chaired by ENPPI and Operation representatives and for checking and testing the Plant systems.
Contractor (PETROJET) Construction contractor for Instrumentation, electrical, mechanical , civil works…..ETC
Supplier Representative Any party who supply equipment, packages, material, main items, minor items and/or services.
Partial Mechanical Completion
The Partial Mechanical Completion is achieved when a separable portion of a plant/facility is available for commissioning as defined by its portion of the approved scope.
Final Mechanical Completion
The Plant is Mechanically Completed when the facility/system/subsystem defined in the approved scope, construction documentation, drawing and specification has been installed, Tested and ready for commissioning.
Discipline
Part of the System indicating the specialization (Civil works, Piping, Static Equipment, Electrical,
Instrumentation, Rotating Machinery, Safety).
Pre-Commissioning
Pre-Commissioning activities are the non-operating adjustments and cold alignment checks.
Pre-Commissioning activities shall be managed, supervised and performed by Commissioning Integrated Team (CIT).
Punch List
A master list of deficiencies/outstanding works identified during final walkthrough/inspection and check-out prepared by client and/or the integrated team comprising items which must be finalized by the contractor prior to issue of the mechanical completion certificate as well as these items should be classified as (A, B & C items) according to EPC scope of work.
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Ready For Commissioning
The plant or part thereof is Ready for Commissioning, when the plant or any part thereof has been erected in accordance with drawing, specifications, instruction, applicable codes, regulations and when the pre-commissioning activities detailed in the contract between KPC and ENPPI have been completed and duly certified by the integrated team and clear or closed the relevant punch list according to agreed methodology.
“Issuance mechanical completion certificate for a system means that this system is ready for
commissioning”
System
Means a part of the plant designated from the
applicable P&ID diagrams for separately performing pre-commissioning.
Each System was divided into disciplines indicating the specialization (Civil works, Piping, Static Equipment, Electrical, Instrumentation, Rotating Machinery, Safety).
Hydrostatic Test A pressure test conducted using water or other approved liquid as the test medium.
Service Test A pressure test performed to prove the integrity of pipelines or plant piping using the service fluid at the maximum attainable operating pressure.
1 KPC PLANT MANAGER 10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 3.0 PRE-COMMISSIONING ORGANIZATION KPC OPERATION TEAM QA/QC ENGINEER
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 4.0 ACTIVITIES BOARDER
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 5.0 SYSTEMIZATION 5.1 General
To enable a staged completion of the project, the entire facilities shall be divided into operational sections based on a unit or area basis, the elected numbering system intends to cover the control and documentation needs in the most appropriate and beneficial way.
The objective of a staged completion is to enable each unit or area to be completed, commissioned, and started up in a sequential order so that the start-up schedule and production targets can be met.
The plant is divided into systems as per the list explained hereinafter. Each system will be clearly defined and marked up on the relevant drawings.
Each system will be divided into disciplines indicating the specialization (civil works, piping, static equipment, electrical, instrumentation, rotating machinery, safety).
Each system shall be checked by disciplines and tested as per the relevant pre-commissioning procedure described hereinafter by construction contractor and commissioning integrated team.
After all discipline had been finished all checks / tests and signing the check forms, then clearing the punch list category "A", the system is considered mechanically completed and ready for commissioning
The tracing file showing the status of each system is also attached for reference and will be followed up by the pre-commissioning Manager
5.2 Numbering System
Plant systems tagging is represented by tagging criteria as shown below in the following example
X - 300 - (U) - 01
PRE-COMM. SYSTEM (P) Process PRE-COMM
SYSTEM AREA (U) Utility(TI) Tie-In SYSTEM NUMBER For P&ID’s conformity check, discipline to check last issue of P&ID’s against the pre-commissioning P&ID’s.
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SYSTEM NO. DESCRIPTION
X.80.TI.001 EXISTING PRODUCTION SEPARATOR TIE IN SYSTEM QA-V-3002A
X.80. TI.002 EXISTING PRODUCTION SEPARATOR TIE IN SYSTEM QA-V-3002B
X.80. TI.003 EXISTING PRODUCTION SEPARATOR TIE IN SYSTEM QA-V-3002C
X.80. TI.004 EXISTING PRODUCTION SEPARATOR TIE IN SYSTEM QA-V-4002A
X.80. TI.005 EXISTING PRODUCTION SEPARATOR TIE IN SYSTEM QA-V-4002B
X.80. TI.006 PHASE I GAS MANIFOLD TIE IN
X.80. TI.007 PHASE II GAS MANIFOLD TIE IN
X.80. TI.008 BYPASS BLOW DOWN LINES TIE IN SYSTEM
X.80. TI.009 PHASE I HP FLARE KO DRUM QA-V-3002 TIE IN SYATEM
X.80. TI.010 PHASE I COLD VENT TIE IN SYSTEM
X.80. TI.011 PHASE II COLD VENT TIE IN SYSTEM
X.80. TI.012 METHANOL AND DISTREBUTION TIE IN SYSTEM
X.80. TI.013 PHASE I INSTRUMENT AIR SYSTEM
X.80. TI.014 PHASE II BLACK START FUEL GAS TIE IN SYSTEM
X.80. TI.015 PHASE I BLACK START FUEL GAS TIE IN SYSTEM
X.80. TI.016 PHASE II HP FLARE KO DRUM QA-V-4004 TIE IN SYSTEM
X.80. TI.017 NEW MPU TIE IN SYSTEM
X.80. TI.018 NEW DIESEL TRANSFER PUMP QA-P-8020
X.80. TI.019 TIE IN TO THE EXISTING 11 KV SWG QA-L-8004
X.80. TI.020 PMS TIE IN RELATED TO EXISTING 11 KV SWG QA-L-8001
5.3.2 PROCESS SYSTEMS
SYSTEM NO. DESCRIPTION
X.80.P.001 COMPRESSOR INLET MANIFOLD
X.80.P.002 COMPRESSOR SUCTION DRUM TRAIN-A (QA-V-8001A) SYSTEM
X.80.P.003 COMPRESSOR TRAIN-A (QA-K-8001A) SYSTEM
X.80.P.004 COMPRESSOR DISCHARE COOLER TRAIN-A(QA-E-8001A)SYSTEM
X.80.P.005 COMPRESSOR DISCHARE DRUM TRAIN-A (QA-V-8002A) SYSTEM
X.80.P.006 COMPRESSOR DISCHARGE MANIFOLD SYSTEM
X.80.P.007 COMPRESSOR SUCTION DRUM TRAIN-B (QA-V-8001B) SYSTEM
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X.80.P.009 COMPRESSOR DISCHARE COOLER TRAIN-B(QA-E-8001B)SYSTEM
X.80.P.010 COMPRESSOR DISCHARE DRUM TRAIN-B (QA-V-8002B) SYSTEM
X.80.P.011 COMPRESSOR SUCTION DRUM TRAIN-C (QA-V-8001C) SYSTEM
X.80.P.012 COMPRESSOR TRAIN-C (QA-K-8001C) SYSTEM
X.80.P.013 COMPRESSOR DISCHARE COOLER TRAIN-C(QA-E-8001C)SYSTEM
X.80.P.014 COMPRESSOR DISCHARE DRUM TRAIN-C (QA-V-8002C) SYSTEM
X.80.P.015 COMPRESSOR SUCTION DRUM TRAIN-D (QA-V-8001D) SYSTEM
X.80.P.016 COMPRESSOR TRAIN-D (QA-K-8001D) SYSTEM
X.80.P.017 COMPRESSOR DISCHARE COOLER TRAIN-D(QA-E-8001D)SYSTEM
X.80.P.018 COMPRESSOR DISCHARE DRUM TRAIN-D (QA-V-8002D) SYSTEM X.80.P.019 CONDENSATE SUCTION MANIFOLD
X.80.P.020 CONDENSATE SUCTION DRUMS QA-V-8005A SYSTEM AND PROCESS GAS BALANCE LINE X.80.P.021 CONDENSATE SUCTION DRUMS QA-V-8005 B SYSTEM
X.80.P.022 CONDENSATE EXPOET PUMPS QA-P-8003 A/B/C SYSTEM 5.3.3 UTILITY SYSTEMS
X.80.U.001 AIR GENERATION PACKAGE AQA-K-8002A SYSTEM
X.80.U. 002 AIR GENERATION PACKAGE AQA-K-8002B SYSTEM
X.80.U. 003 AIR GENERATION PACKAGE AQA-K-8002C SYSTEM
X.80.U. 004 AIR DRYER PACKAGE QA-A-8005A SYSTEM
X.80.U.005 AIR DRYER PACKAGE QA-A-8005B SYSTEM
X.80.U.006 UTILITY AIR RECEIVER QA-V-8009 SYSTEM
X.80.U.007 INSTRUMENT AIR RECEIVER QA-V-8010 SYSTEM
X.80.U.008 UTILITY STATION PLANT AIR DISTRIBUTION SYSTEM
X.80.U.009 INSTRUMENT AIR DISTRIBUTION SYSTEM
X.80.U.010 NITROGEN GENERATION PACKAGE QA-A-8003 SYSTEM
X.80.U.011 NITROGEN DISTRIBUTION SYSTEM
X.80.U.012 UTILITY STATION PLANT NITROGEN DISTRIBUTION SYSTEM
X.80.U.013 NITROGEN RECIVER, COMPRESSOR AND LETDOWN PACKAGE
X.80.U.014 HP FUEL FLASH GAS PRE-HEATER FEED
X.80.U.015 H.P. FUEL GAS SYSTEM
X.80.U.016 H.P FUEL GAS PRE-HEATER SYSTEM
X.80.U.017 H.P FUEL GAS SUPER HEATER AND CONSUMERS
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X.80.U.019 L.P FUEL GAS BACK-UP HEATER
X.80.U.020 L.P FUEL GAS SCRUBBER
X.80.U.021 H.P FLARE COLLECTION AND L.P SOURCE TO COLD VENT
X.80.U.022 CLOSED DRAIN COLLECTION
X.80.U.023 CLOSED DRAIN DRUM
X.80.U.024 CLOSED DRAIN DRUM PUMPS
X.80.U.025 CLOSED DRAIN TRANSFER PUMPS
X.80.U.026 NEW EMERGYNCY DEISEL GENERATOR
X.80.U.027 POTABLE WATER SYSTEM DISTRIBUTION SYSTEM
X.80.U.028 POTABLE WATER SODIUM HYPOCHLORITE INJECTION PACKAGE
X.80.U.029 SANITARY SEWAGE LIFTING PUMP AND COLLECTION SUMP
X.80.U.030 SANITARY SEWAGE TREATMENT PACKAGE
X.80.U.031 TREATED SANITARY WATER
X.80.U.032 FIREWATER SODIUM HYPOCHLORITE INJECTION PACKAGE
X.80.U.033 FIREWATER STORAGE TANK
X.80.U.034 FIREWATER JOCKRY PUMPS
X.80.U.035 FIREWATER DEISEL TANKS AND PUMPS
X.80.U.036 FIREWATER NETWORK & EQUIPMENT
X.80.U.037 PHASE I CLOSED DRAIN DRUM PUMP
X.80.U.038 PHASE II CLOSED DRAIN DRUM PUMP
X-80-U-039 HVAC System
X-80-U-040 GASEOUS EXTINGUISHING SYSTEM
X-80-U-041 SAFETY EQUIPMENT SYSTEM
X-80-U-042 CATHODIC PROTECTION SYSTEM
5.3.4 ELECTERICAL SYSTEMS SYSTEM NO. DESCRIPTION X-80-U-043 Power Transformer X-80-U-044 L.V SWG & Motor Control Center
X-80-U-045 Neutral Grounding Resistor
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) X-80-U-046 Small Power Distribution Panel
X-80-U-047 LTG And Small Power System
X-80-U-048 Raceways And Supports
X-80-U-049 Grounding
X-80-U-050 Battery And Battery Charger Assemblies
X-80-U-051 Uninterruptible Power Supply ( UPS) System
X-80-U-052 Lightening System
X-80-U-053 Existing MV Switchgear and Motor Control Gear
X-80-U-054 LV Bus Bar Trunking
X-80-U-055 MV Bus Bar Trunking
X-80-U-056 Power factor Equipment
X-80-U-057 Variable speed drive
X-80-U-058 Supervisory Digital Control System (SDCS)
X-80-U-059 11 kV Switchgear 5.3.5 INSTRUMENTATION SYSTEMS SYSTEM NO. DESCRIPTION X-80-U-060 ESD SYSTEM and Main Cables
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) X-80-U-061 DCS SYSTEM and Main Cables (PCS instead of DCS)
X-80-U-062 Vibration Monitoring System (VMS)
X-80-U-063 F&G SYSTEM and Main Cables
5.3.6 TELECOMMUNICATION SYSTEMS
SYSTEM NO. DESCRIPTION
X-80-U-064 PAGE / PARTY SYSTEM
X-80-U-065 PRIVET AUTOMATIC BRANCH EXCHANGE SYSTEM (PABX)
NOTES:
1. The boundary between utility systems and distribution systems (i.e. utility air, drain …etc) is limited to the last block valve on the system P&ID.
2. Suppliers pre-commissioning check lists which in their operating manuals to be used in conjunction with ENPPI pre-commissioning check lists.
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 6.0 SYSTEMS PRIORITIES
The systems shall be prioritize in the following consequences in order to facilitate smooth pre-commissioning and allow overlapping with pre-commissioning activities in the plant and minimize the time required for performing the activities, generally priorities as follow:
1) Electrical Systems Priorities: 1. Grounding.
2. Lightening system. 3. HVAC system. 4. LV BUS bar trunking.
5. LV SWG & motor control center. 6. MV BUS bar trunking.
7. 11 KV switchgear.
8. Existing MV switchgear and motor control gear. 9. LTG and small power system.
10. Battery and battery charger assemblies. 11. Small power distribution panel.
12. Neutral grounding resistor. 13. Power transformer.
14. Uninterruptible power supply (UPS) system. 15. Variable speed drive.
16. Supervisory digital control system (SDCS). 17. Cathodic protection system.
2) Instrumentation Systems Priorities: 1. ESD system and main cables.
2. DCS system and main cables (PCS instead of DCS). 3. Vibration monitoring system (VMS).
3) Utilities and Tie-Ins Systems Priorities: 1. New Instrument & utility air system 2. Existing instrument air system tie-in. 3. New Diesel system.
4. existing diesel system tie-in. 5. Fire Water System
6. F&G System
7. New HP/LP fuel gas system 8. Existing fuel gas system tie-in.
9. New HP flare and LP cold vent collection. 10. Existing HP flare and clod vent system tie-ins
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11. Nitrogen generation and distribution system. 12. Closed drain system.
13. Existing methanol system tie-in. 14. Potable water and distribution system. 15. Sanitary sewage system.
16. Phase I&II closed drain drum pump system. 4) Process and Tie-Ins Systems Priorities:
1. Existing production separators (Phase I/II) tie-ins 2. Phase I/II Gas manifold Tie-Ins.
3. Process gas compressor trains’ systems
4. Existing Phase I/II condensate manifold Tie-Ins. 5. New condensate systems
1 1 10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 7.0 PRE-COMMISSIONING PROCEDURES 7.1 General Procedure
The pre-commissioning task will be performed in accordance with the following steps:
7.1.1 Construction contractor shall notify ENPPI site Coordinator and the disciplines representatives when the system is ready for the pre-commissioning activities (Construction Completion).
Commissioning Integrated Team (CIT) which is a team of multi disciplines from ENPPI and KPC operation /projects team shall perform an inspection addressed to the relevant System and the Pre-commissioning activities of the specific Discipline could be started, punch items to be issued and classified A, B or C.
7.1.2 The Pre-commissioning activities will be performed by Construction contractor/ Vendor representative and punch list is cleared by Commissioning Integrated Team (CIT).
7.1.3 During the pre-commissioning phase, checks and tests items specified in this section shall be carried out as per the attached Pre-commissioning check forms and Commissioning Integrated Teamwill prepare the punch list, if applicable.
7.1.4 Upon signing all pre-commissioning check forms and clearing all punch list items category "A" then “ System Mechanical Completion Certificate “ shall be issued 7.1.5 Plant “Mechanical Completion Certificate “shall be issued when all systems in the
plant shall have the system Mechanical Completion Certificate. 7.2 System Procedure
The pre-commissioning work shall be carried out for the Equipment, Packages, Piping, Instruments, Fire Detection, Electrical, etc.
Civil work, Steel Structure and Buildings, Will not have pre-commissioning activities and will be mechanically completed upon clearance of punch list items - created after construction contractor confirm system completion - without category A items.
To have system mechanical completion the following should be considered: - Signing all related check forms.
- Clearing all punch items category "A".
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7.3 Main Pre-Commissioning Activities
The General pre-commissioning activities of the system are mentioned below.
Witness Water Flushing
Witness Air Blowing
Lube Oil Flushing
P&ID's conformity checks
Punch list clearing
Instruments Bench Calibration
Instruments installation verification
Safety valves Bench Calibration
Instrument cables meggering and continuity checks
Electrical cables meggering and continuity checks
Electrical appliances meggering (ACC motors, compressor motors, generator motors, etc,).
Instrument control loops checking
Electrical systems Energization (S/S, battery charger, UPS, Emergency power supply...etc.)
Telecommunication cables meggering and continuity checks
Fiber optics cable check
Static equipment External/internal inspection & boxing up
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7.4 Main Pre-Commissioning Checks
7.4.1 Vessels
Verify and check the following:
Conformity with project documentation. Pressure, temperature, rating.
Nozzles, sizes and orientation.
Internals: types, dimensions, metallurgy and installation. Instrument nozzles and types.
Ladders, platforms, walkways: Location, size and accessibility. Nameplate information/data.
Grounding connections.
Vents, drains, relief valves provided as specified. Nozzles elevation and standout
Insulation (thermal/PP) Fireproofing
Anchor bolt verification
Manhole bolt verification (torque or tensioning) (after internals verification). Piping connections (are all nozzles connected to the correct pipeline)
Levelness of the vessels
Removal of preservation/transportation materials
For instrumentation nozzles, the installed instrument are correct and installed properly (orientation, tightened bolts etc).
1 10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 7.4.2 Piping
Verify and check the following: Conformity with P&ID’s. Size.
3 Pipe: flanges, gaskets, fittings, valves in conformity with specifiedpiping classes High point vents and low point drains.
Pipe supports and spring hangers.
Flange bolting tightness: nuts and bolts are properly installed. Orifice plates in correct location and direction.
Valve flow direction. Insulation kits
Temporary strainers (location, direction) Slope/levelness of the pipeline
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7.4.3 VENDOR SKID INSTALLATION
Verify and check the following:
1 Check against drawings, specs and data sheets
.
2 Check name / data plate
.
3 Check skid is undamaged
.
4 Check shipped loose items
.
5 Remove preservation material
.
6 Foundations and holding down bolting check
.
7 Check skid is leveled & dowelled (where applicable)
.
8 Check skid drainage
.
9 Check battery limit flanges are made up correctly & permanent gaskets fitted
.
10 Check bonding / grounding
.
11 Check Nozzles location, size and rating, elevation et
12 Check Piping connections (are the nozzle connected)
13 Check Remove temporary materials (which were required for transport etc)
7.4.4 COMPRESSORS INSTALLATION
Verify and check the following:
1 Check against drawings, specs & data sheets
2 Check name / data plate
3 Skid / base leveling/ dowelling satisfactory.
4 Check vibration mountings
5 Remove preservation materials
6 Remove temporary blinds from suction & discharge nozzles (where applicable).
7 Install permanent gaskets & check stress free alignment
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 8 Install temporary strainers and bypasses (Where applicable).
9 Check PSV's installed and correctly tagged.
10 Check lube oil pumps piped up correctly (Where applicable).
11 Check lube oil cooler clean and free from obstruction
12 Check lube oil reservoir is clean & free of debris
13 Fill lube oil systems with flushing oil (per lubrication schedule)
14 Install temporary lube oil filters for flushing purposes
15 Check instrumentation installed.
7.4.5 GAS COMPRESSOR
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 4 instruction regarding anchor bolt assembly installation and
grouting. 5 Align the parallelism of the coupling hub faces (as per supplier
recommendation). 6 Check the direction of rotation of the motors for the compressor
package auxiliary. 7 Perform the oil flushing and check the cleanliness of oil system
(by-passing the bearing). 8 Charge the first fill of lubricating oil.
9 Check the set point of all alarm and shut down switches.
1 0 perform the sequence check of control system (suction
discharge - anti surge valves) 1 1 Check the function of ESD push button on panel.
1 2 Check the function of low lube oil pressure switch.
1 3 Start grouting of compressor base plate using non-shrinkage
epoxy grout. All concrete top surfaces must be covered with grout, even if not underneath skid.
1 4 Lube oil cooler is mounted on steel structure supplied loose to be assembled. A small vent pipe is connecting top of cooler to gas turbine reservoir (as deemed necessary by the gas turbine manufacturer). lube oil cooler fan motor assembly must be greased and free to rotate by hand
1 5 Ensure good alignment between motor and fan pulleys, unless
fans are directly driven by motor. 1 6 Installation of seal air cooler with interconnecting piping and
moisture drain pipe, if applicable. 1 7 Installation of combustion air filter, elements, flexible element,
exhaust fans to expel sand laden air,… etc. 1 8 Installation of enclosure ventilation system.
1 9 Installation of firefighting system, CO2 cylinders cabinet, piping,
inside enclosure gas detectors on compressor skid ... Etc. Interconnecting CO2 piping must be St.St. 304 or 316 as a minimum.
2 0 Installation of fuel gas filter/heater (conditioning) skid with
interconnecting piping. 2 1 Installation of service platforms and ladders.
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 7.4.6 TURBINE DRIVERS
Verify and check the following:
1 Adjust leveling of the turbine skid with reference to the concrete
foundation. 2 Check the alignment of coupling hubs on turbine and gear box
output shaft before and after the connection of process piping (as per supplier recommendation).
3 Align the parallelism of the coupling hub faces (as per supplier
recommendation). 4 Check the direction of rotation of the motors for the turbine
package auxiliary. 5 Check the set point of all alarm and shut down switches
6 Perform the sequence check of control system (suction
-discharge - anti surge valves) 7 Check the function of ESD push button on panel.
8 Check the function of all protections of the turbine.
9 Verify vendor site documentation is complete and attached.
10 Check against drawings, specs and data sheets.
11 Remove preservation materials (where applicable).
12 Check lube /seal oil reservoirs are clean & free from debris.
13 Fill reservoirs with flushing oil (Per vendors recommendations)
14 Install temporary flushing strainers where applicable.
15 Fill lube / seal oil systems with correct oil after flushing (per
lubrication schedule) 16 Check lube / seal oil pumps correctly piped up.
17 Check lube./ seal oil coolers free from obstruction
18 Check hydraulic oil pump piped up correctly (Where applicable).
19 Check hydraulic oil cooler clean & free from obstruction (If
applicable). 20 Check seal oil pumps are piped up correctly (Where applicable).
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 21 Check seal oil cooler clean & free from obstruction (Where
applicable) 22 Check emergency lube / seal oil pump piped up correctly (where
applicable) 23 Check emergency lube oil cooler clean & free from obstruction (If
applicable) 24 Check all local instruments correctly installed.
25 Check fuel lines & valves are piped up correctly.
26 Check starter gas lines & valves are piped up correctly (if
applicable). 27 Check air intake filters installed correctly.
28 Check enclosure fans and vents free from obstruction.
29 check fire / gas detectors installed correctly
30 check turbine enclosure installed correctly
31 chemical cleaning of lube oil & F.G. piping completed
32 Operation and maintenance access satisfactory.
7.4.7 INSTRUMENT / UTLITY AIR COMPRESSOR SYSTEM
Verify and check the following:
1 Air compressor mechanically complete
2 Air regulators and pressure switches checked and set for normal
operation.
3 Air dryer support screen properly installed and no holes larger than the
desiccant and desiccant installed.
4 Air dryer cycle has been set, checked, and ready to operate.
5 Compressor solo motors run in – Data record and compare with design.
10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 6 Interconnection signals between the package PLC and the ICS is properly
connected 7 Check package items completeness against vendor items.
Valves and instruments must be tagged. Check electric power connections to control panel and all motors.
8 Check mounting bolts tightening for compressor, electric motor, and
other package items.
9 Remove any preservatives from interior to exterior surfaces of all items
as per vendor instructions. Remove all temporary material used during shipment.
10 Check the direction of rotation of electric motor by pushing the start
then in a second the stop switches. Make the same test for all auxiliary electric motor in the package. Make sure that all motors rotate freely by hand before switching them to start.
11 If this is feasible when the couplings can be disconnected. Make solo
runs for four hours for all uncoupled electric motors and record line currents, vibrations, bearings temp.
12 Make complete functional testing of all instruments and control loops
as per vendor instrument and control listing.
13 Check the presence of air filter element in good condition in inlet filter
housing, lube oil filter element, air dryer pre-filter and after filter elements.
14 Observe proper tightening of all valves, piping, fittings, instruments
and controls. Check operation of manual valves (stem greasing).
15 Blow compressor discharge air through the wet air receiver to the drain
of vessel by-passing the automatic moisture separator, while outlet pipe to the dryer is isolated.
16 Isolate all sub-headers from the wet air manifold and instrument air
manifold until the manifolds are blown to become super clean.
17 After cleaning all interconnecting piping to the dryer, introduce air to
the dryer system, to the dry air receiver and blowing all air through its drain until ensuring its super cleanliness.
18 Start sequentially cleaning individual sub headers and branching using
the same system described above for the wet air as well the dry air system.
19 Check dryer silica gel is in good operating condition as specified by
manufacturer
20 Check dryer is working properly and interchanging between the two
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:
Wet air receiver is purged by compressor until it is proven very clean. Piping to dryer are purged prior to admitting wet air to dryers, followed by purging of dry air receiver through its drain connection prior to purging the instrument air header. Wet air header shall also be purged prior to individual purge of sub headers. The same shall be applied to dry air sub and then sub-sub headers down to all individual user tie-in connections. 7.4.8 DIESEL ENGINE
Verify and check the following:
1 Check against drawings, specs and data sheets
.
2 Vendor documentation attached
.
3 Alignment checked for engine & generator (where applicable)
.
4 Check engine mountings
.
5 Check base plate bolts and dowels
.
6 Check fuel piping installation
.
7 Check lubrication system / filters
.
8 Check fuel strainer. (Install temporary strainer if applicable)
.
9 Check engine cooling system
10 Check engine exhaust system
11 Check engine air intake dampers & filters
12 Check engine house ventilation (if applicable)
13 Check starting system installation
14 Check firefighting and fire alarm systems installed correctly
15 Operation / maintenance access satisfactory
.
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Verify and check the following:
Conformity with project specifications and design requirements. Type of pump
Piping arrangement to permit removal or replacement of pump and driver.
Piping independently supported and not tightly connected to the pump, i.e. Pump will not be pulled out of alignment when lines get hot.
No vapor pockets in piping.
Suction strainers easily removable for cleaning. Strainers fit well so no bypassing can occur.
Discharge pressure gauge readable from discharge block valve. Suction/discharge valves easily accessible, operable, and near to
pump.
Accessibility of auxiliary piping and controls. NPSH requirements.
Base plate grouting complete
Power supply to pump motor is installed. Check that motor rotation is correct.
Adequate means for venting and draining pump casing available. Pumps and drivers aligned correctly.
Check valves of proper type and installed in correct direction. All open drains from pumps and associated piping and instrumentation routed to open drain systems.
All piping connected tightly and that no induced piping strains exist on pump flanges. Cold alignment (hot if required) seals are installed First cold alignment without coupling installation. Suction and discharge pipes connected to pump nozzles with not tightened bolts. Solo motor run test for two or four hours (Check no load current, noise, bearing temperature, vibrations). Data report and compare with design.
Instrumentation installed and calibrated
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Verify and check the following:
1 Check against drawings, specifications and data sheets
2 Check data plate
3 Check base plate is level & dowelled (where applicable)
4 Check / remove all preservation materials .
5 All relief valves installed
6 Check oil external coolers (where applicable)
7 Check suction & discharge valves installed correctly (where applicable)
8 Check suction strainer (install temporary strainer if required) .
9 Check discharge non return valve installed correctly (where applicable) .
10 Install lube oil filters (where applicable)
11 Charge system with lube oil (Per lubrication schedule)
12 Stress free alignment check .
13 Check motor / pump alignment (where applicable) .
14 Check venire control operation & set to zero (where applicable)
15 Check bypass / minimum flow valve return to tank (where applicable)
16 Check drain lines are unobstructed
17 Check pulsation dampers installed (where applicable) .
18 Check instruments installed
19 Operation and maintenance access satisfactory
7.4.11 OVERHEAD CRANE
Verify and check the following:
1 Check all crane motions are moving easily .
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3 Check crane and its steel structure are capable to handle maximum capacity by
adding weights equal to crane maximum capacity .
4 meggering for electrical components 7.4.12 HVAC SYSTEM
Verify and check the following:
1 Check arrangement of the Packaged units and fans as per HVAC drawings.
2 Check mounting bolts and fixations of the Packaged units
3 Check the belt pulley alignment and belt proper tension of the Packaged units.
4 Check the motor direction of the Packaged units and fans.
5 Check the duct work as per HVAC drawings.
6 Check the insulation of duct work as per HVAC drawings.
7 Check the control devices of the Packaged units.
8 Check the control devices of the fans.
9 Check the MCC of HVAC equipment.
10 Check the drainage piping as per HVAC drawings.
7.4.13 PACKAGED UNITS
Verify and check the following:
1 Verify correct installation of the packaged units .
2 Motor has been greased and ensure correct direction of rotation,
belts check .
3 Check the filter and filter accessibility .
4 Ensure drain pipe and connections as per specifications .
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6 Check the space between packaged units as per manufacture
catalogue .
7 Check the evaporator coil and fins .
8 Check the power and control cables as per manufacturing wiring
diagram .
9 Check the duct insulation and cladding as per ENPPI
specifications .
10 Check the direction of the rotation of the fan .
7.4.14 ACCUMULATORS & PULSATION DAMPERS INSTALLATION
Verify and check the following:
1 Check against drawings, specs and data sheets .
2 Check data plate .
3 Check accumulator is undamaged .
4 Remove preservation material .
5 Check vent line is fitted and routed to safe location .
6 Check priming nozzle is clean and protective plug fitted
7 Insulation complete (where applicable) .
8 Check maintenance access satisfactory .
7.4.15 ALIGNMENT
Verify and check the following:
1 Remove spacer and flexible coupling and check type
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3 Check & eliminate soft foot (max allowable 0.005mm)
4 Carry out alignment using the face and periphery method according to normal
engineering practice and specifications, record results .
5 Complete nozzle stress free alignment
6 Check the alignment as the following -: 0 ° Face Reading A1 270 ° 90 ° 180 °
HOLDING DOWN BOLTS AND PIPEWORK LOOSE 1 A1 B1 0 ° 90 ° 180 ° 270 ° NOTES:
1. Final cold alignment, coupling installation and tightening of suction and discharge flanges are Commissioning activities.
2. Hot alignment shall be performed during start-up phase when normal operating temperatures will be achieved and if it will be required.
Rim Reading B1 0 ° 270 ° 90 ° 180 °
HOLDING DOWN BOLTS AND PIPEWORK TIGHT 3 A1 B1 0 ° 90 ° 180° 270°
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7.4.16 Vent and Pressure Relief
Verify and check the following:
Purge gas system complete and functional.
Relief valves are in place, correct and ready to operate. Functional check of ESD valves.
Pressure Safety Valves (PSV) bench calibration (Pop test) and register.
T.S.O. classified valves: tightness test. 7.4.17 Instrument and Utility Air
Verify & check the following:
1 Air compressor mechanically complete
2 Air regulators and pressure switches checked and set for normal operation.
3 Air dryer support screen properly installed and no holes larger than the desiccant and desiccant installed.
4 Air dryer cycle has been set, checked, and ready to operate. 5 Compressor solo motors run in – Data record and compare with design. 7.4.18 AIR COOLER
Verify & check the following :
1 Motor, fan belts, gear drives bearings and fans are properly installed,
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recommendations ) 3 Alignment of motor drive pulley, fan pulley and belt tension.
4 Fan bearings and motor bearings are greased.
5 Rotate fans by hand to make sure they are not obstructed.
6 Installation and operation of vibrating switches and/or transmitters.
7 All shipping braces and/or bolting are removed and the bundles are free
to move with temperature changes. 8 All the tube fins are in proper position and clean
9 Set the fan pitch properly and check alignment/rotation of motor and shaft.
10 No louvers are used in both coolers.
11 Measure electric motor current, Solo motor run in – Data record, and
compare with design. 12 Install belt guards.
7.4.19 Electrical Systems
7.4.19.1 General
Before starting any Pre-commissioning activity within the plant all the electric systems must be checked out by an electrical specialist responsible for the installation. Sufficient tests shall be made on all installations and equipment to assure that proper operation can be expected when the facility is put in operation. A Commissioning responsible electrical engineer must also be present for the first start-up of all rotating equipment.
NOTE: MCC, power and control cables belong to the System where the electric user is located.
N.B: Precautions regarding the connection of power & control cable shall be considered during checking operation functions of switchgears.
7.4.19.2 CABLING SYSTEM (For More Details See Electrical Mechanical Completion and Pre-Commissioning Checks for LV Cable “EL-30A”).
Using megger meter to make insulation test for all cables between each conductor to ground, all other conductors and sheath
grounded.
Continuity tests for cables and wires.
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Cable markers check according to engineering documents. Check and inspection of terminations according to engineering documents and Supplier recommendation.
2
7.4.19.3 GROUNDING (For more details see electrical mechanical completion and pre-commissioning checks for grounding “EL-33 A”)
Check and inspect the grounding system connections.
Check for continuity of the main ground system loop and continuity of the taps of equipment.
Check grounding resistance.
Check of ground connection to equipment tightness.
Check of adequate mechanical protection of ground wire (if required).
Continuity test for grounding mesh branches. Ground grid and ground loop wire sizes.
7.4.19.4 LIGHTING SYSTEM (For more details see electrical mechanical completion and pre-commissioning checks for lighting and small power system “EL-23 A”)
Checking of all lighting system panels, cabling, trays, junction boxes, fittings, fixtures...etc.
Testing of all lighting circuits.
Testing functional operation of photocells.
Normal lighting power shall be momentarily interrupted for checking of functional operation of emergency lights.
7.4.19.5 SWITCHGEAR & MCC CHECKS (For more details see electrical mechanical completion and pre-commissioning checks for LV switchgear and motor control center “EL-04 A”)
Complete component and interconnection and cable terminations inspection according to manufacturer's final approved drawings. Inspection, testing and functional check shall be according to supplier instruction.
Make all necessary adjustment to switch gear and motor control center equipment.
Test and calibration of all switch gear relays (using primary and secondary injection as applicable), metering, lights, indicators,
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space heater, and check proper coordination and setting. Check the phase sequence and polarity of all equipment
Functional check of all motor starters, circuit breakers' incomers, outgoing feeders and bus ties.
Perform operational tests on all motor control circuits, interlock system, indicating lights, meters and all other devices.
Check circuit breakers, motor starters, relays and other
equipment for loose connections (both mechanical and electrical). Verify that contacts and working parts are correctly aligned and free from dust and foreign matter.
Inspect circuit breakers with adjustable trips, checking both thermal (if any) and magnetic settings for proper protection. Also check thermal overload relay settings according to vendor
documents.
Check and sequence test for alarms, interlocks, auto-transfer, ... etc.
Functional checking of switchgear and MCC from remote locations such as Control Room.
Energizing the substation for readiness of plant start-up.
7.4.19.6 ELECTRIC MOTORS ( For more details see electrical mechanical completion and pre- commissioning checks for motors “EL-22 A”)
Insulation testing resistance to ground by 500 VDC meager. Check correct rotation.
Solo motor Running test for two hours duration. Data record.
7.4.19.7 BATTERY CHARGER SYSTEM CHECKS (For more details see electrical mechanical completion and pre-commissioning checks BATTERY CHARGER SYSTEM “EL-08 A”)
Check equipment earthing connections to the earthing system. Insulation test of both the main and aux. circuits, this shall be carried out between phases and phases to ground.
Batteries are installed as Indicated in the design. Batteries rack to be connected to the earthing system.
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10 00 0-Z -0 00 -G E 1-T M P -0 00 4 (0 8/ 13 ) 7.4.20 Instrumentation 7.4.20.1 Equipment Check
Instrument equipment need to be inspected and the specification data sheets checked against the nameplate. The following points to be verified:
Instrument tagging.
Model number and instrument classification. Size and connections.
Material of construction.
Instrument range and calibration.
Valve action and air/electrical failure positions Control modes on controller.
Restriction orifice shall be inspected for a smooth face. The orifice diameter shall be measured with an inside micrometer compared with specification.
The flow inlet side of the handle to be painted in red color for easy checks, at any time, after installation.
7.4.20.2 Instruments Calibration
Calibration involves checking and adjusting instrument devices against a known precise reference to ensure performance complying with the manufacturers published specifications and accuracy. Instruments include the following:
Level DP transmitters.
Pressure transmitters/switches. Indicators.
Transducers.
Positioners & control valves.
Level displaced transmitters / switches.
After completion of this work QA/QC stickers should be fixed on the instruments, then, the check form shall be signed by all concerned parties.
Pressure and temperature gauges
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7.4.20.3 Perform Loop Checks
The purpose of this checks is to ensure that the instruments on field (transmitters, valves...) are correctly calibrated, connected and addressed to the PCS and ESD systems. The link (marshalling) between the instrument and the PCS and ESD or sub-system will be established at this phase. The test is performed on loop basis and it will be executed for each loop.
Pre-commissioning of instruments is done by checking the inputs/outputs of the control systems from the field up to PCS and ESD consoles and the local indications/controls. This includes the instruments on the packages.
The configuration part on system/sub-system will be checked: the tag descriptions, process displays (including dynamic color change indications, trend displays, scales, alarm settings, alarm thresholds, physical units, the specific parameters if applicable: controller action, parameters values (PID), digital output (maintained or pulsed) and digital inputs (limit switches, alarms).
Each instrument loop should have a separate loop file including the following contents: - Loop diagram
- I/O list
- Alarm and Set point values - Data sheet
- Calibration certificate 7.4.20.4 Installation Check
Check that all sample process piping/tubing to instruments have been installed per hook-up drawings. Verify that control valves and regulators are oriented in the proper flow direction, positioners function properly.
7.4.20.5 Hydro test Of Sample Lines
All sample lines and tubing connections to instruments shall be hydro tested to 1.5 times the design conditions of vessels and/or piping.
7.4.20.6 Leak Test - Pneumatic Signal Tubing
Pneumatic transmission and output control lines are to be disconnected from all instruments (pressure switches, relays, controllers, and actuated devices (control valves), and blown through to remove deposits. The lines are then to be reconnected to all the instruments and pneumatically tested for leaks.
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down, then reconnected and actuated for the leak test. The lines are then to be reconnected to the actuated device and subjected to the leak test.
Pneumatic leak test is 1.1 times the design pressure.
7.4.20.7 PSV Calibration
All PSV's shall be bench tested and calibrated in accordance with the relevant API recommended codes. Compressed air shall be normally used and PSV is set according to specifications.
Check properly:
Name plate setting pressure and identification number. Orifice size.
Bellow tightness (if any) at 0.5 ATM. Right gaskets are used.
PSV's are installed in the correct places, directions and vertical position.
Atmospheric PSV vents shall be drain hold at lowest point and well supported.
Up-stream and downstream the PSV block valves if any, have been sealed open/closed as per P&ID's.
No liquid can be collected and be stagnant in the discharge/line to B.D. header.
Once the PSV has been checked, ensure that: - Lead sealed.
- Record card filled for future reference. 7.4.20.8 Control Valves
All control valves shall be calibrated. Check that:
Proper gaskets are used. Valve seats are clean. Direction of flow is correct.
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Stainless Steel tubing connections are fixed.
Check proper spring action according to P&ID’s requirements (FO/ FC)
7.4.20.9 Restriction/ Orifice Plates Installation
Before installation, orifice plates shall be checked by the instrument inspector for conformity with specifications.
Hole size shall be reported.
Orifice flanges connected with guaranteed utilities consumption and with fiscal feed inlet and product outlet shall be inspected for smoothness at the welded joints.
Once orifice plates are installed check the correct place (line where installed) and correct flow direction.
The flow inlet side of the handle to be painted in red color for easy checks, at any time, after installation.
Meter run for orifice plates shall be checked
7.4.21 Fire And Gas System
7.4.21.1 Equipment Check
Fire alarm devices need to be inspected and the specification data sheets checked against the nameplate. The following points to be verified:
7.4.21.2 Devices
Calibration
Calibration involves checking and adjusting Gas devices against a known precise reference to ensure performance complying with the manufacturers published specifications and accuracy.
7.4.21.3 Perform Loop Checks
1 Device tagging.
2 Model number and instrument classification. 3 Size and connections.
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Loop checks are required to ensure that each fire and gas device in the plant functions in the correct sequence and with the proper action. All individual components in the system must be installed and checked.
7.4.21.4 Installation Check
Check that all devices are installed according to the installation drawing of the system supplier.
7.4.22 TELECOM SYSTEM
7.4.22.1 Page / Party System
7.4.22.2 Privet Automatic Branch Exchange System (PABX)
7.4.22.3 Fiber Optic Cable
7.4.23 CATHODIC PROTECTION SYSTEM
Check that the current values from the transformers to the protected equipment/ pipe are within the recommended limits and is stable.
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7.4.24 Flushing Or Blowing The Plant
It is important to plant, schedule to record all the preparatory operations and to co-ordinate the works so that they comply with the overall commissioning schedule.
Small pieces of mill scale, weld rod stubs, weld spatter, insulation, paper, wood and other debris are sometimes unavoidably left in piping and equipment on completion of construction. A systematic program for flushing with water or blowing with air will eliminate most of the debris that might obstruct control valves and orifice plate’s restriction orifices or damage machinery.
The flushing and cleaning entails whatever work is necessary to obtain a clean unit ready for process operation. Part of this work can be accomplished after hydraulic test execution and before final reinstatement of the piping.
7.4.25 Recommendations
- Only fresh water which also shall be suitable for the system selected (Chlorite content max. 30 ppm for Austenitic stainless and duplex steels for example and compressed air should be used.
- Dirt and debris should be flushed from the unit and not into it.
- Water is supplied with temporary flexible hoses. Prior to flushing, make a manual cleaning to minimize obstruction.
- The P&I Diagrams are used to prepare the flushing sequence and to follow the progress of flushing. Finally, manual fine cleaning may be necessary.
- The fire water circuit should be washed.
- All control valves should be removed and flushed from both directions using the bypass and in-line valves, if possible. Otherwise, open and clean all control valves after flushing are completed, where will be difficult to remove them.
- Instruments must be disconnected or isolated. Restriction orifice, thermo wells, vortex flow meter; flow sight glasses and Rota meter; etc… must be taken away, if have been installed.
- Circulated flushing of the piping system within the plant may be carried out, where it is possible. If water circulated flushing, using process pumps, is applied for system cleaning, special care for over load trip must be taken `90 due to higher density than design condition.
- Provisional strainers are installed and periodically cleaned. Spraying nozzles must be installed after relevant lines have been flushed to avoid clogging. If necessary, take out the flapper of check valves (previous check of the availability of spare gaskets).
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- Vessels with de-misters or any other internals must be flushed from the bottom taking into consideration the water level. It’s better to install de-misters and packing after flushing / air blowing.
- Internal man-ways have to be installed after flushing/air blowing of columns with trays.
- Lines connected to vessels without internals can be flushed into the vessel itself. After the flushing, the vessel must also be cleaned.
- Check that stroke movement; of any valve that was cut in during the flushing, are free and complete. - All blinds inserted into lines or equipment must be recorded, and drawn out after flushing. The
water should be drained from every low point.
- Use compressed air for piping blow down after flushing.
- Special attention must be paid to certain piping systems such as lubricating oil and mechanical seal circulation systems where small orifices and openings are present. It may be necessary to dismantle the piping to clean it mechanically or by pickling. Once these systems are clean, they must be kept clean to prevent repetition of the cleaning operations.
- For temporary flushing, use grainger sheet fabricated on site gasket. Insert proper gasket only for the final re-assembling of the unit.
- Final reinstatement of piping after flushing/blowing/cleaning activities shall be supervised by Commissioning Integrated Team (CIT) engineers to report the conformity with the design.
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7.4.26 Pre-commissioning Check Form List.
7.4.11.1 EQUIPMENT CHECK FORMS
DESCRIPTION CHECK LIST NO.
Centrifugal Pump ME-01A
Reciprocating Pump ME-02A
Compressors ME-08A
Air cooler PR-18A
Filter PV-01-A
Fixed roof Tank PV-04-A
Vessel PV-06-A
A/G piping system PI-03-A
Pipe supports PI-04-A
U/G Drain system PI-06-A
FIRE WATER HYDRANT LP-01A
HOSE HOUSE LP-02A
FIRE WATER MONITOR LP-03A
GASEOUS EXTINGUISHING SYSTEMS LP-05A
FIRE AND GAS ALARM SYSTEM LP-10A
FIRE AND GAS CABLE LP-11A
FIRE AND GAS JUNCTION BOX LP-12A
DETECTOR LP-13A
CONDUIT LP-14A
AIR HANDLING UNIT HV-01 A
CONDENSING UNIT HV-02 A
VENTILATION FANS HV-05 A
PACKAGED WATER COOLED CHILLERS HV-06 A
PUMPS FOR HVAC HV-09 A
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EXPANSION AND COMPRESSION TANKS HV-11 A
DAMPERS HV-12 A
DUCTWORKS HV-13 A
AIR OUTLETS HV-14 A
FAN COIL UNITS HV-16 A
PRIVET AUTOMATIC BRANCH EXCHANGE
SYSTEM TE-01-A
PUBLIC ADDRESS & GENERAL ALARM
SYSTEM TE-02-A
FIBER OPTICS CABLE TE-04-A
DATA COMMUNICATION SYSTEM TE-09-A
Control Valves & Regulator IC-02-A
Shutdown & Blow down Valve IC-03-A
Junction Box IC-04-A
Pressure -Flow -Level-Temperature Transmitter IC-05-A
Orifice Plates & Ventures IC-06-A
Local Pressure Gauge _DP & Temp Gauge IC-09-A
DCS Panel Cabinet Console IC-10-A
ESD Panel Cabinet Console IC-11-A
Analyzers IC-18-A
Instrument Cables above Ground IC-23-A
Switches IC-24-A
Safety & Relief Valve PR-08-A
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7.4.11.2 ELECTRICAL CHECK FORMS
For Pre-commissioning Check Forms refer to attachment II
DESCRIPTION CHECK LIST NO.
POWER TRANSFORMERS EL-02 A
MV SWITCHGEAR AND MOTOR CONTROL
GEAR EL-03 A
LV SWITCHGEAR AND MOTOR CONTROL
CENTER EL-04 A
BUS BAR TRUNKING SYSTEM EL-07 A
BATTERY & CHARGER ASSEMBLIES EL-08 A
NEUTRAL GROUNDING RESISTOR EL-09 A
AC UNINTERRUPTABLE POWER SUPPLY EL-12 A
VARIABLE SPEED DRIVE EL-19 A
POWER FACTOR IMPROVEMENT
EQUIPMENT EL-21 A
MOTORS EL-22 A
LIGHTING AND SMALL POWER MATERIAL EL-23 A
SUPERVISORY CONTROL AND DATA
ACQUISITION SYSTEM EL-26 A
RACEWAYS AND SUPPORTS EL-27 A
LOW VOLTAGE CABLES EL-30 A
GROUNDING SYSTEM EL-33 A
MOTOR CONTROL STATIONS EL-35 A
LIGHTNING PROTECTION SYSTEM EL-37 A
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7.5 Sequential Completion Flow Chart
Equipment Erection &Piping
Installation
Piping Flushing and Cleaning Conformity
Checks and punch list issuance
Stable operation and performance test Plant start up and
Initial operation Commissioning
Activities Hydro-testing and
re-instatement
Clear punch list category (B) Clear punch list
category (A) Pre commissioning activities Systems Dossiers Completion Mechanical Completion Certificate
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8.0 CONFORMITY CHECK OF THE PLANT'S EQUIPMENT
Each system of the Plant will be inspected for conformity with project documentation, specifications, technical reviews and design reviews (HAZOP, ….etc.) and a punch list is drawn up to record any deviations requiring further construction work or modification.
After the completion of each activity, the relevant check lists will be filled out and signed by all parties.
Plant inspection and conformity check shall cover all equipment, packages, skids, piping, valves, instruments, .etc. taking in consideration that they will be finalized and inspected by Operations All inspection shall be performed against design, specifications and drawings and any defects or deviation should be cleared prior mechanical completion or plant start-up according to its criticality
9.0 SYSTEM DOCUMENTS
To enable a staged completion of the Project, the entire Facilities shall be divided into systems based on a Unit or Area basis, the elected numbering system intends to cover the control & documentation needs in the most appropriate and beneficial way.
Each system shall be stand-alone during pre-commissioning and will have a mechanical completion certificate as well as a separate file
System file shall include as a minimum the following:
- Marked up P&ID indicating system boundary (updated marked up P&ID's will be issued as required).
- List of all component in the system such as instruments, equipment, - Related hydro-test loops included in the system
- Hydro-test completion certificates
- All pre-commissioning check forms related to the system - Punch list
- Leak testing certificate
