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TABLE OF CONTENTS

1 INTRODUCTION 3
1.1Scope of work 3
1.2Definitions 3
1.3Abbreviations 4
1.3.1 Project Organisation 4
1.3.2 Other 4
1.4Reference documents 4

2 ACTIONS AT WORKS COMPLETION 5

3 PRE-COMMISSIONING 6

4 CERTIFICATION 7

5 COMMISSIONING 7

6 WORK FLOW 8
6.1 Mechanical Completion (Partial) 8
6.2 Mechanical Completion 9

7 ATTACHMENTS 10
7.1 ATTACHMENT I: Punch list for construction works 10
7.2 Attachment 2 - Notification of Expected Date for Mechanical
Completion 11
7.3 Attachment 3 - Notification of Incomplete Works 12
7.4 Attachment 4 - Notification of Mechanical Completion 13
7.5 Attachment 5 - Certificate of Mechanical Completion 14
7.6 Attachment 6 Pre-commissioning responsibility matrix 15

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1 INTRODUCTION

1.1 Scope of work

This document gives a general definition of the work that shall be completed by the Subcontractor,
in order to achieve work completion of any part, or whole, of the Works up to ready for hand over
and Mechanical Completion in accordance with the terms of the Subcontract.

This specification is intended to be multi-disciplinary for a general Subcontractor i.e. where the
Subcontractor is carrying out civil, mechanical, electrical and instrumentation work, etc. If the
Subcontractor is performing only one, or more, of the fore going disciplines, but not all of them,
then he shall refer only to those parts of the specification which are applicable to his Subcontract
scope of Work.

1.2 Definitions

Client name.

Contractor Saipem SpA

Commissioning All activities performed after achievement of Ready for


Commissioning certificate for each Unit/System.

Contract Contract between Company and Contractor with all Annexure


and Attachment.

Home Office Fano (Italy)

Subcontractor means any persons, firm, partnership, corporation or combination


thereof to whom any part of the Works is subcontracted by the
Contractor in accordance with the terms of the Contract, and for
avoidance of doubt includes Vendors

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

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

Commissioning Include all activities required from issue of Mechanical


Completion Certificate up to the achievement of the stable and
satisfaction operation.

Vendor party which supplies equipment, materials and/or services as


specified by Contractor in the scope of supply.

Punch List List of items or activities that are: not completed, outstanding or,
in some way, deficient and fails to meet the requirements of the
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project specifications, drawings, procedures, etc. and are


required to be provided or corrected.

1.3 Abbreviations

1.3.1 Project Organisation

CM Construction Manager
COM Commissioning Manager
DS Discipline Superintendent
FEM Field Engineering Manager
FCQ Field Quality Control
PM-C Project Manager Construction

1.3.2 Other

P&ID Piping and Instrumental Diagram


QA Quality Assessment
QC Quality Control

1.4 Reference documents


00-ZA-E-09400 Site Coordination Procedure
00-ZA-E-09411 Punch List Procedure
00-ZA-E-09404 Pressure Test for Piping Procedure

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2 ACTIONS AT WORKS COMPLETION

The Subcontractor is responsible for the completion of each system, plant area and the entire
facilities to be provided under the contract, ensuring that all work has been completed in
accordance with the contract specifications.

The Subcontractor shall complete any work identified upon the punch lists prepared by its own
inspection department, as required by the contract. The format of the punch lists, including
identification extent of each individual system, will be determined in accordance with Contract
requirements.

A system may constitute a process, civil, mechanical, electrical, instrumentation, structural or


architectural portion of the plant, whether a complete unit, part of a unit or elements within a unit
that allow the Operating Companys operations department to accomplish a specific task or to
support start-up of the facilities.

When the Subcontractor is about to complete the construction of a system, or plant area, he shall
at least 40 days before the expected date of completion. The Subcontractor notifies the Contractor
- refer Attachment I - enclosing punch lists previously prepared and punched out by the
Subcontractor, including a list of works, inspections and checks still to be completed. An example
of this list is shown in Attachment I (to be amended to match Contract requirements).

By receiving this notification, the Contractor shall check the information provided by the
Subcontractor, revising and correcting punch lists if necessary thus obtaining the final punch lists.
Within 10 days, the Contractor will give the final punch lists back to the Subcontractor including the
Notification of Incomplete Works, if required.

All items on the Notification of Incomplete Works/returned punch lists will be prioritised by the
Contractor indicating whether outstanding works must be completed before issuing the Certificate
of Mechanical Completion of the Subcontract Works , or in the commissioning period.

Particular importance will be attributed by the Contractor to the documentation packages required
to be handed over by the Subcontractor, before issuing the Certificate of Mechanical Completion
for Part (or Whole) of the Subcontract Works, relating to the checks, inspections and tests required
to be performed on a system or plant area in accordance with the contract as per quality
specifications and Contract conditions.

Documentation checks shall include, but not be limited to, a review of test reports conducted by the
Subcontractor and the Contractor, such as pressure tests, electrical measurements, loop checks
and rotational direction checks, to ensure that all items have been checked. In addition detailed
inspection tours shall be made to determine that:
features affected by flow direction, such as flow meters, are properly orientated; facilities
for by-passing, blocking and blinding are properly located;
temporary blinds and other provisions required only for testing have been removed;
any other condition which may delay, or complicate, the subsequent commissioning and
start-up has been properly accommodated.
The Subcontractor shall carry out any incomplete work identified by the Contractor on the
Notification of Incomplete works/returned punch lists. The Subcontractor shall sign the column of
the punch list entitled Completion Confirmation as individual items are completed. The Contractor
shall check the work performed and, upon completion and acceptance of each individual work
item, he shall sign the punch list for acceptance alongside the Subcontractor in the column entitled
Completion Confirmation.
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When items in Part A of the punch list (Attachment II) have been completed and signed by the
Subcontractor and the Contractor, the Subcontractor shall notify the Contractor of this event by
forwarding the Notification of Construction Completion (Partial).

At this point the Contractor may carry out a final P&ID check. This will be a thorough line-by-line,
feature-by-feature check of the system or plant area against the flow sheets.

Within 3 days of receiving the Notification of Construction Completion (Partial) from the
Subcontractor, the Contractor may issue a Certificate of Mechanical Completion for Part of the
Subcontract Works, and notify the Subcontractor of any outstanding work on an updated punch
list. The parties shall follow this procedure until the work is completed, when the Contractor shall
issue the Certificate of Mechanical Completion for Part of the Subcontract Works.

The Contractor may choose to issue the above Certificate, either in Part, or in Whole, before the
completion of all punch list items. He may also issue a final punch list together with the Mechanical
Certification. It is understood, that in this event, all issues must be resolved and completed, before
issuing the Certificate of Technical and Administrative Check as stated item 5 herein and in any
case within three months of MCC.

3 PRE-COMMISSIONING

Pre-commissioning activities relate to non-operating adjustments, cold alignment, calibration and


the general checking of components installed in the Work together with such activities as flushing
and cleaning.

During the execution of the construction work, in returning a punch list to the Subcontractor in the
above described procedure, or in preparing the Notification of Incomplete Works, the Contractor
may notify the Subcontractor of any required pre-commissioning work. This is before issuing the
Certificate of Mechanical Completion of the Works and for which the Subcontractor will have been
paid for within the Contract rates.

Attachment II lists, item by item, the pre-commissioning activities that have to be completed by the
Subcontractor prior or after the issue by the Contractor of the Certificate of Mechanical Completion
of the Work.

The Subcontractor is responsible for providing all necessary qualified personnel, operators, labour,
equipment, testing equipment and materials including but not limited to consumable construction
materials, chemicals and temporary spools to ensure execution on time of the pre-commissioning
Work.

All Pre-Commissioning activities are included within Subcontractors scope of work and
payment is to be included within the erection unit prices, rates or lump sums, with the
exception the activities clearly indicated in the price list.

Within Subcontractors scope of work for pre-commissioning, supply of any materials, chemicals,
test equipment, temporary spools, tools necessary for pre-commissioning activities, with the only
exclusion of what is specifically supplied by Contractor and stated in the Contract, is included.

The Subcontractor shall prepare a schedule for the execution of the known pre-commissioning
work to meet the priorities of the Contractor. The schedule shall be approved by the Contractor.
The Subcontractor shall update the schedule at frequent intervals to incorporate any changes
required by the Contractor.

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4 CERTIFICATION

Within 15 days from the construction completion of the whole plant or of a part of it or a system, the
Subcontractor shall notify the CM of this achievement. The notification shall include lists of works,
checks and tests (prepared by the Subcontractor), which do not invalidate the functional
completion of the whole plant, part of it or system subjected to the notification.

Within 10 days from the receipt of the above mentioned notification, the PM-C or CM carries out
the check of the plant, area or system involving the Client, Licensors and Suppliers, completing
where necessary the list prepared by the Subcontractor and obtaining the final punch-list.

The FQC, verifies the documentation related to these checks and tests, pointing out any missing.

The CM if required, submit to the Subcontractor the final punch-list and the notification of non-
complete works.

When the Subcontractor has completed all the remaining items of the punch-list and they are
countersigned by the CM or by the punch list originator, the Subcontractor submits the notification
of construction completion with the updated punch-list signed by the parties (see attachments of
the specification 00-ZA-E-09400 Site Coordination Procedure).

Within 3 days from the receipt by the Subcontractor of the notification of construction completion
and once punch-list items execution have been verified, the PM-C or CM issues the Certificate of
Work Done Ready for Hand-over (see attachments of the specification 00-ZA-E-09400 Site
Coordination Procedure). This certificate is prepared before the execution of checks and tests in
order to ensure that the scope of work contents are ready to be handed over with the possibility to
be used by the Contractor or the Client.

Within 7 days from the issue of the of the Certificate of Work Done Ready for Hand-over, the PM-C
or CM issues the Certificate of Work Completed (see attachments of the specification 00-ZA-E-
09400 Site Coordination Procedure). This document is prepared when works have been
completed or, in case of hand-over by areas with different deadlines, when a single area has been
completed. The date of this certificate rules that application of any penalty for delayed hand-over
and the warranty period as defined in the Contract.

The PM-C or CM issues the Technical/Administrative Check Certificate (see attachment of the
specification 00-ZA-E-09400 Site Coordination Procedure), following the Certificate of Work
Completed. It contains information and references necessary for the elaboration of the final
bookkeeping with the Subcontractor, hence the stoppage or acknowledge of previous accounting
errors, works non executed in accordance with specifications and not corrected, delays in the
works hand-over, penalties, etc.

5 COMMISSIONING

Commissioning activities are associated with making the units, systems and the entire facilities
ready for operation including operating adjustments and hot alignments to simulate actual
operations.

The Subcontractor may be required under the terms of the contract to provide resources to assist
the Contractor and the Operating Company in commissioning the completed plant for a period not
exceeding 3 months after Mechanical Completion. Such resources including labour, plant and
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material will be paid for by the Contractor on a day work basis at the rates stated within the
subcontract.

6 WORK FLOW

6.1 Mechanical Completion (Partial)

Subcontractor Contractor

Notification of Expected Date for Notification of Incomplete Works


Mechanical Completion (+ Punch List prioritised)
(+ proposed Punch List)

Notification of Mechanical NOT OK / OK Certificate of Mechanical Completion


Completion (Partial) (Partial)
(+ Punch List prioritised) (+ Punch List prioritised)

Certificate of Work Done Ready for


Hand Over (Partial) (+ minor items)

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6.2 Mechanical Completion

Subcontractor Contractor

Notification of Expected Date for Notification of Incomplete Works


Mechanical Completion (+ Punch List prioritised)
(+ proposed Punch List)

Notification of NOT OK / Certificate of


Mechanical Completion OK Mechanical Completion
(+ Punch List prioritised) (+ Punch List prioritised)

Certificate of Work Done Ready for


Hand Over
(+ minor items)

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7 ATTACHMENTS

7.1 ATTACHMENT I: Punch list for construction works

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7.2 Attachment 2 - Notification of Expected Date for Mechanical Completion

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7.3 Attachment 3 - Notification of Incomplete Works

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7.4 Attachment 4 - Notification of Mechanical Completion

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7.5 Attachment 5 - Certificate of Mechanical Completion

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7.6 Attachment 6 Pre-commissioning responsibility matrix

KEY FOR CHECKLIST


X Perform the WORK item

R Review Contractor submitted documents and return with or without comments.

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

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

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

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

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

CONTRACTOR CLIENT

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR

1. GENERAL

1.1
CONTRACTOR shall establish a work permit procedure for
the Construction/Precommissioning Period
X I R

1.2 Complete installation of FACILITIES. Check for correct


installation per the Job Specification, Vendor instructions, X I I/R
design drawings and applicable codes.
1.3 Provide proper identification of all equipment.
I
Identification numbers shall be legible from 50 feet away X I
R
for equipment, 15 feet for Instruments.
1.4 Assure that all NDE is completed and acceptable for
X I/R R/I
structural steel, piping, vessels, and conduit seals.
1.5 Remove all rust preventatives, oil and grease, used to
preserve equipment during shipping and construction and
maintain records of the same. Clean all nameplates. X I I/R

1.6 EXAMPLE
At the time of 10 day notification of Mechanical
Completion, the operating area and platforms shall be
secured and free of debris, tools and extraneous materials
that could impede operation or cause an unsafe condition. X I I
All access ways shall be opened for emergency vehicles.
All scaffolding not required for commissioning or start-up
shall be removed.
1.7 Complete all necessary paving, fencing and items of like
X I I/R
nature
1.8 Install all road signs, safety signs and other signs. X I I/R
1.9 Submit comprehensive list of all test equipment to be
used. Test equipment shall have a standard of accuracy
better than the Vendor's stated accuracy for item to be
tested or as required by COMPANY requirements.
Intervals between calibrations shall not exceed three (3)
X X I/R
months for all field test equipment. All test equipment
shall have a nameplate or label showing the most recent
date of calibration. All test equipment requiring AC power
will be 120 V AC 60 Hz.

1.10 Project Record Books shall have been completed X X


and submitted as per SAEP 122 Project Records Each for Each for own
R
own scope scope of
of supply supply
1.11 X X
Spare parts data packages submitted and accepted
Each for Each for own
by COMPANY. Turnover of specified spare parts and I
own scope scope of
Vendor recommended special tools.
of Supply Supply
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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
1.12 Install first loading of chemicals and desiccants and other
operating materials as required by Contract. Retain
samples of all material and turnover to COMPANY. AD I IW/R
Operating materials to be suitably protected from hazard or
degradation by purging/isolation.
1.13 Where required as a site activity, verify wall thickness of
pressure vessels, exchanger shells and tanks by ultrasonic AD X I
thickness testing. Submit all records.
1.14 At the time of Mechanical Completion, all fire proofing
and rough insulation shall be complete, i.e., all equipment,
piping wiring, instruments, instrument leads, etc., requiring
fire proofing or insulation for heat conservation shall be

EXAMPLE
covered so that start-up operations will not be delayed due
to lack of adequate fire proofing or excessive heat loss.
Insulation required for personnel protection shall also be
completed. Only areas that would be required to be open
for tightness testing (flanges, valve stems, etc.) will not be
covered prior to Mechanical Completion. Exposed
X I
R
I

insulation is to be properly protected and sealed.

1.15 In addition to 1.14, final insulation jacketing shall be


complete enough so that there will not be an excessive
amount of scaffolding erected in the plant areas where
X I I
COMPANY operators will work during start-up. The
number of insulation crews still working in the area shall
not be excessive.
1.16 Inspect and check the WORK during the construction
stage, and perform such non-operational tests as are
necessary to assure the integrity of the installation in X I I
accordance with the issued for Construction Drawings,
specifications and Vendor Instructions.
1.17
Control the activities of the Vendor representatives while X X
they are on the project. Each for Each for own I
own scope scope of
of Supply Supply
1.18 Mobilise and control the activities of licensor
representatives during the pre mechanical completion X
phase of the project
1.19
Obtain any permits and approvals from government and X X
R
regulatory agencies required in the name of Contractor. Each for Each for own
own scope scope

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
1.20 Complete all necessary insulation, painting, grating,
fencing, paving, touch-up concrete and grouting, and items X I I
of like nature.
1.21 Verify that the WORK, or portion thereof, is complete
and that all required inspections, tests, reviews and X I I/R
approvals are complete and recorded.
1.22 Document all inspections, tests and other pre-
commissioning activities. Document all deficiencies
discovered during the activities along with corrective X I R
actions taken.

EXAMPLE
1.23 Document the Vendor representative's check and X X
acceptance of installation and preparation of their Each for Each for
R
equipment for start-up/ operation as required. own scope own scope of
of Supply Supply
1.24 Prepare punch lists, by system, of deficiencies between X X
as-built plant and the latest P&IDs, specifications and Each for Each for I/R
Vendor instructions. Correct any deficiencies noted own scope own scope
1.25 30 days prior to expected Mechanical Completion,
CONTRACTOR to send a notification of impending
Mechanical Completion to COMPANY. A X R

1.26 Supply and Install proper lubricants immediately prior to


10 day notification of Mechanical Completion, after X X
I/R
review with COMPANY Operations. (Install) (Supply)
1.27 10 days prior to expected Mechanical Completion,
CONTRACTOR to send request for COMPANY punch A X I/R
list, with copy of master punch list status.
1.28 At the time of 10-day notification of Mechanical
Completion, painting shall be complete enough so that an
excessive amount of scaffolding is not left standing in
areas where COMPANY's operators must work during X I I
start-up. In addition, the number of painters still working
in the area shall be kept to a minimum.

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
1.29 Prepare and submit notification of Mechanical
Completion when all WORK items identified by
CONTRACTOR, Vendor and COMPANY as required for
start-up of the facilities are completed. Each notification
shall identify plant system(s) submitted for acceptance,
copy of master punch list for those system(s) list of
uncompleted ("exception") items with reason for their late
completion and estimated completion date, inspection and A X I/R
test and check-out reports, and copies of marked-up "As-
built" P&IDs and one-line and three-line diagrams,
schematics, instrument loop diagrams, and logic diagrams,
and list of start-up spare parts on Site. CONTRACTOR
shall submit eight (8) copies of each package described
above.
1.30 Check all items of equipment for adequate, safe and
X I I

EXAMPLE
functional access per SAES-B-054 requirements.
1.31 Check that control panels and enclosures meet area
classification control. A X R
1.32 Provide and install guards, barriers, warning signs and
other safety devices as agreed with COMPANY as
X I I
necessary during site walk through.

1.33 Prior to Commissioning/Start-up, remove all temporary


fencing and barricades to allow free access to operating X I I
unit/system.
1.34 Supply and install line identification tags and signs.
Stencil lines for identification X I I/R

2. CIVIL/STRUCTURAL
2.1 Civil
2.1.1 Test gravity sanitary sewers, chemical sewers and basins
from manhole to manhole, or manhole to sump inlet, by
filling the lines to the top of the upper manhole. Test X W W
sanitary sewers that have been backfilled for water
tightness for 24 hours.
2.1.2 Test sanitary sewer force mains at a minimum of 150 psig
or 50 psig above the pump shut-off head, whichever is
greater. Test force mains that have been backfilled for X W W
water tightness for a period of 24 hours

2.1.3 Inspect all sewer lines and check all cleanouts, manholes,
and service connections for proper installation and W
functioning X I
I

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
2.1.4 Check all underground installations for proper invert
elevations. X I I/R
2.1.5 Check sewer manholes for leak tightness by filling and
then observing the water level for ten hours. All leakage W
X W
shall be corrected. I
2.1.6 Inspect, test and operate building, plumbing systems to
W
confirm proper functioning and leak tightness. (refer to X/O I
I
SAES-S-060)
2.1.7 Immediately prior to Mechanical completion, clean and
inspect all catch basins, man-holes and sumps X W W
2.1.8

2.1.9
EXAMPLE
Site (or parts thereof) shall be flood tested to the
satisfaction of COMPANY in order to confirm proper
functioning of area drainage, per design drawing i.e.
runoff, contour, and/or flatness, oily water and
contaminated surface water sewers
Inspect all structures and concrete placement periodically
for cracking, fissuring, settlement, warpage, bending,
X W W

rusting or any other deficiency. Submit Records.


Deficiencies shall be promptly corrected to avoid further X I I/R
degradation, masking by subsequent Work, or subsequent
failure.
2.1.10 Check and record that underground lines are cathodically
protected and isolation spools/flanges have been installed.
Cathodic protection shall be fully in service at Mechanical X I/R R
Completion.
2.1.11 Provide backfilling compaction and soil particle size test
records. X R R

2.2 Foundations
2.2.1 Provide approvals to pour concrete signed by
COMPANY with concrete slump tests and water tests R
report and after inspection of rebar, formwork and soil X I
I
condition of excavation bottom.
2.2.2 Check concrete for any evidence of cracking, cavities,
and aggregate separation. X I I
2.2.3 Provide results of 28-day cylinder tests, aggregate and
sand sieve tests and other QC tests. X R R
2.2.4 Ensure concrete structures comply with SAES-Q-001. X I I/R
2.3 Structural Steel
2.3.1 Check for correct fabrication in accordance with Job X X
Specification and Vendor design drawings and applicable Each for Each for
I
Codes. own scope own scope of
of Supply Supply

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
2.3.2 Ensure that seal welding is continuous with a smooth X
surface. For
I I
Erection
Only
2.3.3 Check bolt torque and ensure that proper washers were
used and that washers are against nut if single washers are R
X I
used. W
2.3.4 Check all grating is fitted in place providing a true and
level fit. All cut outs must be banded and cold galvanized.
Check that no gaps left in grating, guard- rails, and toe- X I I
plates. Check all stairways and ladders are installed to
COMPANY standards, refer to SAES-B-054

EXAMPLE
2.3.5 Check welds on supports, gusset and plates, to ensure
they are made with good welding technique and adequate X I I
for the intended purpose.
2.3.6 Check that all areas incapable of being sandblasted and/or
painted have been permanently welded closed/sealed. X I I
2.3.7 Check ladders, stairs platforms, walkways and general
access to equipment comply with SAES-B-054. X I W/I
2.4 Grouting
2.4.1 Clean grout area of all oil, grease, debris, dust and
rubbish before grouting. X I I
2.4.2 Check for correct installation in accordance with
COMPANY and Vender specifications and designs. X I I
Ensure there are no voids or cavities within the grout area.
2.4.3 Perform strength tests on grout samples. X I R
2.5 Piling (NOT APPLICABLE)
2.5.1 Check sand blasting/coating of piles. X I I
2.5.2 Check location of piles. X I R
2.5.3 Record blow counts per foot and final 3 inches. X I/R W
2.5.4 Check splice and bearing plate welds. X I R
2.6 Buildings
2.6.1 Check building location and dimensions. X R R/I
2.6.2 Inspect finishing work. X I I
2.6.3 Inspect excavation for building. X I I
2.6.4 Inspect backfill for compaction and material
X I I
conformance.
2.6.5 Inspect formwork, rebar and anchor bolts before pouring
concrete. Perform slump test on concrete before pouring.
Retain concrete samples and perform strength tests at 7 X W I
and 28 days.

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
2.6.6 Inspect building electrical and mechanical equipment
including HVAC, ducting and insulation. HVAC systems
operationally service tested and preliminary flow X I/R I
balancing completed. Check and record pressurization
levels where applicable (Refer to SAES-K-002)
2.6.7 Check and service test all piping. All leaks to be
X W I/W
corrected.
2.6.8 Functional test plumbing and mechanical systems. X W W
2.6.9 Check that all required areas are fireproofed. X I I
2.6.10 Operate and adjust doors and windows. Buildings shall

2.6.11

2.6.12
EXAMPLE
be tested and documented for leak tightness and
maintenance of internal positive pressure.
Check for switchgear building floor levelness and
compliance with Vendor's recommendation for switchgear
installation.
Flood test battery room floor for proper drainage prior to
X

X
I/R

I
W/I

installation of batteries. X W W
2.6.13 Perform a half-hour deluge test of all roofing to confirm
X W W
leak-tightness and proper function of gutters
2.6.14 Test building for leak tightness and maintenance of the
required internal positive pressure. (Refer to SAES-J-801 X I W
and SAES-K-002)
2.6.15 Provide and install office furniture as described in project
Specifications. X I W
2.6.16 Check ventilation for battery rooms or other areas where
hazardous vapours may be present. X W R/I
2.6.17 Check fire detection and protection systems including
alarms, sprinklers, hoses, extinguishers, extinguishant I/W
X I
release system and others as applicable.

3. ELECTRICAL
3.1 General
Note:
480 volts and below project activities are undertaken
by PID above 480Volts by PDD
3.1.1 Provide two complete packages of all Vendors' wiring
X X
diagrams, schematics, one-line and three-line diagrams for
Each for Each for
all equipment installed in the Substations, transformer R
own scope own scope Of
yards, and electrical switching yards. The packages shall
Of Supply Supply
also contain all interconnecting wiring.

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
3.1.2 Calibrate via third party calibration/certification
FACILITY all applicable test equipment prior to its initial
use. Intervals between calibrations shall not exceed three
X X
(3) months for all field test equipment. All test equipment I
shall have a nameplate or label showing the most recent
date of calibration. All test equipment requiring AC
power will be 120V AC 60 Hz.
3.1.3 Maintain a record of all calibration results showing type
of test equipment, serial numbers, date of calibration, and
the results. One copy of these calibration records shall be
furnished to X X I/R
COMPANY.

3.1.4
EXAMPLE
Circuits being tested are designed to be operated in excess
of 600 volts between conductors shall have conductors
shorted to ground by hot-line grounding device approved
for the purpose.
X I I/R

3.1.5
Before any tests are conducted, check and tighten all
X I I
cable connections.

3.1.6 Perform all necessary prestart-up non-operating test and


Hi Pot checks on all power cables, generators, switchgear,
MCCs, transformers and grounding resistors following
X I W
manufactures instructions and guidelines given in the
applicable Pre-Commissioning Forms Manual available
from Consulting Services Department
3.1.7
Perform continuity test on all circuits from source of
X W W
supply to utilization points.
3.1.8 Megohm test each ungrounded terminal with respect to
ground for all electrical equipment and cable. A megohm
tester shall be used for this purpose. In performing this X W W
test external connections to the equipment shall be
disconnected.
3.1.9
Perform high potential test on equipment rated above
X W W
480V and record results.
3.1.10
Check the continuity and tightness of ground connection
between equipment frame and the main ground system and X W W
measure and record resistance to remote earth.

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

EXAMPLE
instrument power systems and power distribution A X
management system. I

3.1.14 Before an electrical system or piece of electrical


equipment can be energized, an 'Energization
A X R/I
Authorization Certificate' approved by COMPANY and
authorizing such energization must be obtained.
3.1.15
Check that all roll out type breakers and switches can be
X I W
easily removed and installed.
3.1.16
Record torque values of all electrical power terminations. X I/R W

3.1.17
Ensure electrical components are painted to COMPANY
X I I
colour coding requirements.
3.1.18
Confirm operability and capacity of emergency power W
A X/O
systems, UPS and other battery supply systems. I

3.1.19
Perform battery acceptance tests. Check operability of
X W W
battery chargers.
3.1.20
Check operability of UPS systems including switching
A X W
rectification filter (wave form), etc.

3.1.21 Provide discipline support during energizing of


substations and load centres when permanently
connected to the electrical distribution system (after
A X W
obtaining Energizing Authorization Certificate from
COMPANY). Correct any construction and
installation faults identified.
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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
3.1.22 Paint and tag all electrical apparatus to COMPANY
X I R
colour code regulations.
3.1.23
Install sealing compound where required in seals after
X I W
cable/loop checks and tests are completed.
3.1.24 Verify cleanliness and proper silver-plating on all copper
X I W
bus joints or connections.
3.1.25 Insure adequate contact mating surfaces and contact
pressure for all circuit breakers, disconnect switches,
X I W
isolator switches, and motor starting contactors by contact
resistance testing.
3.1.26

EXAMPLE
Contractor shall establish a Tag and Lockout Procedure
including a Work Permit Procedure for the construction/
Pre-commissioning period. Refer to Construction Health
Safety and Environment Plan. Once the system or partial
system is MC and switchgear is energized, COMPANY
Work Permit procedures (refer to GI-0002.100 Work
- X R

permit System) shall be followed.


3.1.27 Annunciator and instrument tag nameplates shall be
checked against design drawings for engraving and proper X I I/R
location.
3.1.28 Annunciator operation and point continuity shall be
checked by mechanically actuating all trouble contacts for
X I/W I/W/R
low-high-deviation alarm operation and auxiliary contact
operation and sequence.
3.1.29 Complete electrical tests as using relevant check lists as
listed in CONTRACTOR compiled System X I I/R
Precommissioning Manuals.
3.2 Transformers
3.2.1 Liquid Filled Transformers
3.2.1.1
Inspection and checkouts prior to tests:

a) Verify proper auxiliary device operation such as


fans, pumps, sudden pressure devices, indicators, X I W
tap changers and gas pressurization system.
b) Check tightness of external bolted joints and/or
X I I
connections.
c) Verify proper transformer neutral connection. X I I
d) Check for the presence of combustible gas. X I W
e) Test in accordance with ANSI C57.12.1 and record
X I W/R
results.
3.2.1.2 Electrical tests for large and medium power transformers:

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
a) Add filtered insulating oil and complete dress-out of all
transformers. Fill under vacuum after internal connection
and inspection is complete. Sample insulating oil before,
during and after filling in accordance with ASTM D-293-
75 and laboratory test for the following:
- Dielectric strength
I
- Acid neutralization X I
W

EXAMPLE
- Interfacial Tension
- Colour
- Water

Submit certified results of the laboratory


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

a) Torque all loose bolted joints and/or connections. X I I


b) Verify proper transformer neutral connection X I I
3.2.2.2 Electrical Tests
a) Perform insulation resistance test; winding to winding
X W W
and winding to ground.
b) Verify proper secondary voltage. X I W
3.3 Neutral Grounding Resistor
3.3.1 Perform hi-pot test on each resistor. The potential I
X W
application shall be for one (1) minute. W
3.4 Cables
3.4.1 General
3.4.1.1 Cables shall be tested after installation in accordance with
X I R
SAES-P-104.
3.4.1.2 Inspect exposed sections of cable for physical damage. X I I
3.4.1.3 Check cable bends to ensure that no bend has less than
X I I/R
manufacturer's minimum allowable bending radius.

EXAMPLE
3.4.1.4 Inspect for proper grounding, support and termination. X I I
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CONTRACTOR CLIENT

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

Note. 480 volts and below project activities are


undertaken by PID, above 480 volts by PDD

3.5.1.1
Ensure that motor frame is properly grounded. X I I/R
3.5.1.2 Visually check that all three phase feeders, control
wiring, and motor space heater wiring are terminated at
X I I
both ends in proper phase sequence and locations to obtain
correct direction of rotation and operation.
3.5.1.3 Check and record continuity of all welds.

EXAMPLE
X I W
3.5.1.4 Check all motors are properly lubricated. X I W
3.5.1.5 Carry out all necessary pre-start checks and non-
operational tests on motors following vendors X W W
instructions.

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
3.5.1.6 X/I/W
(SP to
provide
vendor to
Test run all motors for four (4) hours uncoupled. During carryout tests
the test, check the motor for excessive vibration or X/O for motors W
temperature. Record current and voltage readings. with
temperature
& vibration
monitoring
systems
3.5.1.7 Check nameplate against data sheets for rotation,
X I R
horsepower, voltage and speed.
3.5.2 Motors Below 480V
3.5.2.1 Perform Megohm test on each motor below 100 hp. (If
motor fails, clean, dry in an oven, then retest. If retest X W W
fails, repair motor.)
3.5.2.2 Check proper operation of space heaters. X W W
3.5.2.3 For large motors (100 hp and above), obtain and record
X W W
polarization index using megohm tester.
3.5.3
3.5.3.1 Perform dielectrical absorption test of motor starter
X W W
winding in accordance with IEEE 43.
3.5.3.2 Perform megohm test on each motor. If motor fails,
clean, use DC reduced voltage to dry out, then retest. If X W W
motor fails on retest, repair motor.
3.5.3.3 Perform high potential test on each motor energized at
X W W
5000 volts or higher voltage.
3.6 Bus Ducts
3.6.1 General
3.6.1.1 Inspect and check all bus duct bolt connections and
X I I/R
tighten as required
3.6.1.2 Check bus duct for damage or missing parts, drain holes
unplugged, space heaters connected (where applicable), X I I
and proper phasing

EXAMPLE
3.6.2 Electrical test
3.6.2.1 Perform insulation resistance test phase to phase and
X I I
phase to ground
3.6.2.2 Perform high potential test on each bus section; phase to
X I W
phase and phase to ground
3.6.2.3 Record all test results A X R/I
3.7 Switchgear and 13.8kV, 4.16kV and 480 Volt Systems

Note: 480 volts and below project activities are


undertaken by PID, above 480 volts by PDD
3.7.1 General
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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
3.7.1.1 Inspect for proper alignment, anchorage and grounding. X I I
3.7.1.2 Check and adjust contact alignment of breakers making
sure spread of secondary contacts is equal and correct for X I I
proper contact pressure.
3.7.1.3 Check tightness of bolted bus joints.Torque and test to
X I I
Vendors specifications.
3.7.1.4 Check control power transformer fuse type and size,
potential transformer fuse type and size, proper
operation of potential transformer draw out
mechanism (where applicable), shorting bars X I I
removed from current transformers, continuity and
correct polarity of current transformer circuit, and
connection of space heaters.
3.7.1.5 Check draw-out type breakers for proper operation for
spring charging mechanism, trip-free and anti-pump X I W
feature, and operation of safety interlocks.
3.7.1.6 Primary current injection tests shall be carried out except
where this requires dismantling of main circuit
components. In the latter case and for voltage circuits,
secondary injection tests shall be carried out. X I W

3.8
3.8.1 General

completion:
EXAMPLE
Protection Relays and Devices

3.8.1.1 Submit two (2) complete packages of the following at


least four (4) months prior to substations mechanical

a) All electrical one-line diagrams and electrical data sheets.


A

A
X

X
R

R
b) All backfill vendors one-line and three-line diagrams. A X R
c) All switchgear and control gear vendors data sheets
including bills of materials showing relay types and A X R
vendor.
d) Relay co-ordination and setting data and calculations.
These packages are in addition to all other requirements
for copies of drawings. These packages shall be used by
COMPANY to verify/check Contractor calculated relay
A X R
settings. The review shall take a minimum of three (3)
months. Submit promptly to COMPANY and other
drawings or information requested for purposes of this
COMPANY check.
3.8.1.2 Inspect each relay for cover, cover glass, and cover
gasket, presence of foreign material, moisture, and X I I
condition of spiral spring, disc clearance, and contacts.
3.8.1.3 Check tightness of mounting hardware and tap screws. X I I
3.8.2 Calibration

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
3.8.2.1 Pull and bench calibrate relays and then reinstall. Report
W
all test results on relay setting records. Operating point X I
I
shall equal the test points 3%
3.8.3 Relay Setting
3.8.3.1 Set relays in accordance with settings shown on relay
W
setting record agreed by COMPANY (Power Distribution X I
I
Department).
3.8.3.2 W
Set and test all transfer differential relays. X I
I
3.8.3.3 Set and test all bus differential relays.
W
X I
I
3.9 Motor Control Centres
3.9.1 General
3.9.1.1 Inspect for proper alignment, anchorage and grounding. X I I
3.9.1.2 Check tightness of all bolts and torque to vendor's
X I W
specifications.

EXAMPLE
3.9.1.3 Verify that all overload units are properly sized and
replace if required.
3.9.1.4 Check that motor control centre space heaters are

3.9.2
connected, overload reset buttons free and functional.

Tests
X

X
I

I
I/R

3.9.2.1 Perform insulation resistance test phase to phase and


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

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
3.9.3.7 Pull and bench calibrate relays and then reinstall. Report
all test results, report open relay settings. Operating times X I W
shall equal the set points 3%.
3.9.4 Record all test data and torque values. A
(SP to
provide X R/I
VENDOR
data)
3.10
3.10.1

3.10.2

3.10.3
Lighting

EXAMPLE
Check location and installation of lighting provisions per
project and vendor design drawings and applicable Codes.
Install lamps (incandescent bulbs, fluorescent tubes, etc.)
in all fixtures.
Verify all lights and light switches operate properly. Test
X

X W
I

W
I

photo cells for proper operation.


3.10.4 Make check of lighting intensities in accordance with
A X W
SAES-P-123.
3.10.5 Confirm the actuation of emergency lighting in the event W
X I
of normal power failure. I
3.10.6 Check the operation of the blackout system. X W W
3.11 Grounding
3.11.1 Test continuity of all connections to the grounding system
for all equipment bonds made at Site. Include the main
X W R/W
cabling systems and their connections to ground
electrodes.
3.12 Telecommunications
3.12.1 X/I
Complete the installation of FACILITIES. Check for
(SP to R
correct installation per the Specifications, vendor X
provide I
instructions, design drawings and applicable codes
vendor)
3.12.2 All telecommunications equipment (transmission
switches, muxes data equipment alarms etc), public
W
address and general alarm stations to be installed, checked, X I/W
I
calibrated, tested and placed in service as per Project
Specification.
3.12.3 OSP: cables, manholes, conduits, protection and
X I I
termination
3.12.4 Tower, structure and foundation, wave bridge, grounding
X I I
etc.
3.12.5 Buildings and Support utilities; grounding, etc. X I I
3.12.6 W
Power: DC Plant, Standby, etc. X I
I
3.12.7 Ensure communication equipment correctly installed and
A A X
pre-commissioned.
4. PIPING AND ACCESSORIES
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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.1 General
4.1.1 R
Check, repack and lubricate valves and necessary. X I I

4.1.2 Field fabricated vessels, above ground piping, below


ground piping, and vendor packages piping (such as lube

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

4.1.3 Tight shut-off valves shall be individually bubble tested


to ANSI/FCI 70-2 prior to installation in addition to any
X W W
other strength or tightness testing required by SAES-A-
004 and the other requirements of the job specification.
4.1.4
Compile QA and QC procedure for control of piping e.g.
X I R
nuts, bolts and gasket, to ensure correct installation

4.1.5 Check all bolts on flange connections for correct length


X I I/R
and class.
4.1.6 Install jacking bolts on all flanges with spectacle blinds. X I I/R
4.1.7 Check and certify that all radiographic requirements have
been performed and accepted by COMPANY and that all X I R
required records have been completed satisfactorily.
4.1.8 Check and certify that all post weld heat treatment
requirements have been performed and accepted by
X I R
COMPANY, and that all required records have been
completed satisfactorily.
4.1.9
Verify that all compressor suction piping is internally
clean of mill scale and debris after performing chemical
W
cleaning and before start up.NB: Remove all internal AD W
I
coatings prior to chemical cleaning

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.1.10 Co-ordinate the flushing, cleaning, pressure testing and
corrosion prevention requirements with all other Pre-
commissioning activities such as vessel/exchanger internal
inspections, oil system cleaning and flushing, run-in,
tightness testing and all other WORK activities.
X I/W R

4.1.11 EXAMPLE
Verify that pipe guides and anchors on flare strings and
pipe allow for thermal expansion.
4.1.12 Check piping for correct slope and, for process gas lines,
X I
I
R

that no "pocketed" sections exist upstream of gas X I I


compressors of flare. Correct any defects.
4.1.13 Check that all line vents, drains, strainers- both temporary
and permanent, blinds and non-return valves shown on X I I
drawings and specification, are installed
4.1.14 Provide and install other temporary blinds and bypasses
required for start-up, as specified by COMPANY's AD A X
Operating Organization.
4.1.15 X
For Water,
I
Air up to
X
7barg
(supply of
Provide all new replacement gasket spool, pieces, hoses, flushing &
replacement
temporary connections, rigging/hoisting, scaffolding blowing and
gaskets,
blinds and media (water demin water, chemicals, air, Oil flushing
chemical
steam, oils, nitrogen, fuel etc.) required for cleaning, W
cleaning,
treating, and flushing/blowing drying and inerting AD
steam
activities. Supply supervised labour and necessary (for
blowing &
tools/equipment and instruments to undertake the activities chemical
Nitrogen
cleaning and
Supply)
steam
blowing)

4.1.16 CONTRACTOR to supply and use water of correct X


quality(<50 ppm chlorides) for the hydrotest and flushing (As per I I
of stainless steel pipe and equipment BoQ)
4.1.17 Inject lubricant into grease points as required. Confirm
use of correct type as specified by Vendor/Supplier. X I R/W

4.1.18 Inject sealant into all sealant ports.


X I R/W

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.2 Pre-Pressure Test Requirements
4.2.1 General
CONTRACTOR shall compile hydrotest packs which
will typically contain:

1. marked up P&IDs

EXAMPLE
2. marked up isometrics A X R
3. hydrotest procedure
4. pre-test inspection certificate
5. hydrotest certificate
6. post-test inspection certificate

4.2.2 Visually inspect each test envelope, checking and


certifying that the following items conform to the project
I
drawings and specifications. X I
R

4.2.3 Check all piping is adequately supported and properly


installed maintaining contact with the pipe supports. I
X I
Spring hangers to have stops installed as required for R
hydro testing loads.
4.2.4 Check anchors, guides and wear pads are correctly I
X I
installed and are at their designated locations. R
4.2.5 Check All valves are installed in the direction of flow as
I
required and are at their designated locations, and are both X I
R
operable and accessible in their installed position.
4.2.6 Check All flanged connections have gaskets installed in I
X I
accordance with the applicable line class specifications. R
4.2.7 Check All seal welding, bridge welding and/or bracket I
X I
welding has been completed satisfactorily. R
4.2.8 Check All temporary blanks, plugs, caps, temporary and
permanent spectacle plates, blinds, temporary gaskets, and
I
temporary spools required for pre-flushing and/or pressure X I
R
testing are installed in their correct locations and positions
according to hydrostatic test pack diagrams.
4.2.9 Check All orifice plates, strainers, control valves and W
other items, which may be damaged during pre-flushing X I R
and testing, are removed from the system.
4.2.10 Check All valves in the system are installed in their
correct position (open or closed) as indicated on the I
X I
hydrostatic test diagrams. R
4.2.11 Provide list and location of all blinds installed with I
X I/R
reference to the relevant P&ID. R

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.2.12 X
(Except for
Remove instrumentation and other items, blind
Chemical
equipment, disconnect flanges, and install temporary R
Cleaning I
spools and supports, and all other set-ups required for pre- W
and Steam
flushing and/or cleaning.
Blowing)

4.2.13 Check that all Exposed stems of valves are covered with
X I R
canvas sleeves.
4.2.14 I
X

Clean out or pre-flush piping prior to commencement of


X
pressure testing as required by SAES-A-004 and SAES-L- AD
(For Chem. W
050. When chemical cleaning is employed, Contractor (For
Cleaning)
shall provide all chemicals. Chemical
(SUBCONT
Cleaning)
RACTOR)

4.2.15 Certify that pre-flushing has been performed, witnessed


X I R
and documented in accordance with SAES-A-004.
4.2.16 Check all items and piping water flushed shall either be
blown or wiped dry or strength tested within 48 hours.
X I I/R

4.3 Strength Testing


4.3.1 As required by SAES-A-004 and pressure test diagrams,
prepare instrumentation, piping, temporary supports and
other equipment items for strength testing. Install
X I I/R
temporary, calibrated relief valves as required by SAES-
A-004 and test plans. Install calibrated test recorders as
required by SAES-A-004.
4.3.2 Strength test all items of equipment and piping as
required by SAES-A-004 and pressure diagrams. Test
fluids shall be in accordance with SAES-A-007. Where
pneumatic testing is proposed, this shall be approved by X W W
COMPANY in accordance with SAES-A-004, and shall
be indicated by Contractor in the Pre-commissioning and
Mechanical Completion Plan.
4.3.3 Check and certify that when filling the system, the test
fluid is injected at the lowest point and all high point vents X I I

EXAMPLE
are open.
4.3.4 Set up all safety barriers required for personnel and
X I I/R
equipment safety.

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.3.5 Check and certify that the pressure the test gauges, and
PZVs, are currently certified/tested and properly X I I
connected.
4.3.6 Check and certify that temperature and equilibrium was
attained between the test fluid and the system before X I I
applying pressure.
4.4 Post Strength Test
4.4.1 Check and certify that all required records pertaining to
X R R
the pressure test have been completed satisfactorily.
4.4.2 Check and certify that all temporary blanks, plugs, caps,
spectacle blinds, temporary spools, test gauges and PZVs X I I
installed for the pressure test have been removed.
4.4.3
Check and certify that all valves etc. removed for pre-
flushing and pressure test are reinstalled and are both
X I I
operable and accessible in accordance with the applicable
standards and specifications.

4.4.4 Check and certify that all flanged joints disturbed during
or after the hydrostatic test, and all temporary gaskets
installed for hydrostatic testing have had new gaskets X I I
installed that conform to their applicable line class
specifications.
4.4.5 Check and certify that items that were damaged during
pre-flushing or pressure testing activities have been X I I
satisfactorily repaired or replaced.
4.4.6 R
Check the packing, packing materials and lubrication of
X I I
all valves, repair and lubricate as necessary.
4.4.7 Check and certify that all seal welding requirements,
including threaded plugs strictly used for hydro testing, X I I
have been performed after pressure testing.
4.4.8 On completion of reinstatement after hydro test, leak
(tightness) test as required by SAES-L-056, to ensure that W
all equipment or lines disconnected, removed and blinded X I
R
off for hydro testing have been reinstalled correctly.
4.4.9

EXAMPLE
Repair any leaks found during tightness test. Check all
nuts and bolts to confirm that threads are fully engaged.
4.4.10 All torque procedures for bolting and bolt pre-loads shall

4.5
be verified on high-pressure piping and equipment where
applicable.
Flushing and Blowing of Line Work Systems
X

X
I/W

I
W
R

W
R

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.5.1
Water flush or air blow line work systems to ensure the
operational flow routes are clean and unrestricted.
Generate detailed flushing procedures to include definition R
X I/W
of isolation points, and lists of items to be removed and W
reinstated for the flushing or air blowing exercise.
Provide all temporary equipment and fittings as required.

4.5.2 Compile steam blowing disturbance factor calculations to


confirm adequacy of steam blowing line cleaning
AD X R
activities.
Provide steam blowing noise calculations
4.5.3 Steam blow all steam piping to atmosphere until proven
clean. CONTRACTOR to provide criteria and
methodology to confirming cleanliness. Steam supply
headers to be installed with sufficient flanged blank ends
and intermediate exhaust points to allow efficient blowing
of steam systems. Blows and thermal cycling shall be
repeated for the number of times necessary to demonstrate
that the piping has been blown clean of all loose material,
millscale and friable material. Contractor shall provide
temporary connection piping, valves, silencers, piping
materials (gaskets, nuts, bolts etc.) utilities, target plates AD X I/W/R
supervised labour, all necessary tools/equipment
rigging/hoisting, scaffolding, temporary insulation,
instrumentation CONTRACTOR shall supply steam for
blowing activities.

Steam piping supplying steam turbines or similar


equipment shall be steam blown to polished target plates
located at the inlet flange of each equipment item. Target

EXAMPLE
plate impact criteria to be agreed between all relevant
parties i.e. VENDOR , CONTRACTOR and COMPANY
4.5.4 On completion of flushing and blowing reinstate all
W
control valves and in-line equipment using permanent X I
I
gaskets.
4.5.5
Check and certify that all control valves, check valves
and all other in-line items have been reinstalled in the W
X I
system, and are in their correct orientation as indicated by I
the P&IDs and specifications.

4.5.6
Check and certify that spring support travel/hydro test
stops have been removed in accordance with the W
X I
applicable design data sheets and securely linked to the I
spring support housing for future use.

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MECHANICAL COMPLETION PROCEDURE

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.5.7 Check and certify that all spring support assemblies have
W
been set in accordance with the applicable design data X I
I
sheet. Provide hot and cold setting data.
4.5.8 Check that both temporary and permanent strainers R
X I
required for start-up are installed. I
4.5.9 Check and certify that spectacle and isolation blinds are R
X I
installed in their correct locations as per the P&IDs. I
4.6 Chemical cleaning

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.6.1 CONTRACTOR shall compile detailed chemical cleaning
procedures for review and approved by COMPANY.
These will include, as a minimum:
1. marked-up drawings defining the
cleaning circuit(P&IDs, isometrics, schematics
etc.). these shall indicate size and type of all
cleaning connections, locations of all blinds, high
point vent and low point. NB: All internal pipe
coatings shall be removed on all pipes to be
chemically cleaned prior to erection.
2. Marked-up drawings (plot plans etc.)
indicating the location of temporary area fencing
3. List of valves, equipment etc. remaining
in line during the cleaning activities
4. List of valves, equipment etc removed
prior to chemical cleaning

EXAMPLE
5. Methods of isolating items not included
in chemical cleaning
6. Full chemical cleaning methodology.
This will include chemicals to be used, AD X R
concentrations, means of introduction, contact
times, temperature and pressure, inhibitor to be
used with manufactures recommendations for use
and will also including check list such as pre and
post cleaning inspection sheets
7. Sampling and testing schedule, including
responsible individuals and their contact details,
potential dangers, incident action plans, area
segregation, personnel protection equipment to be
worn, Material data Sheets (MSDS) etc.
8. Inspection methods and acceptance
criteria including check/records sheets
9. Effluent disposal methods (refer To
SAEP-327)

SAE-1028 defines the minimum requirements for


chemical cleaning and flushing of lube/seal oil and fluid
power systems. The procedure also provides to list of
relevant Client procedures and standards
4.6.2 CONTRACTOR shall review the FACILITIES and
Client procedures and standards to confirm the full extent
of chemical cleaning and compile a list of systems
requiring chemical cleaning. AD X R
CONTRACTOR shall identify on P&IDs and the line
index the full extent of chemical cleaning in accordance
with SAES-L050

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.6.3 CONTRACTOR shall supply all materials equipment,
tools, specialist contractors, labour, chemicals, utilities and
AD X R
inspection equipment necessary to perform all chemical
cleaning activities to the satisfaction of COMPANY
4.6.4 CONTRACTOR shall be responsible for performing all
chemical cleaning activities and will ensure that only AD X R/W/I
suitably qualified personnel undertake the work
4.6.5 On completion of chemical cleaning, CONTRACTOR
shall dispose of all effluent in accordance with SAEP-327 W
AD X
and reinstate all valves, equipment etc. removed for I
chemical cleaning using new permanent gaskets
4.6.6 Check and certify that all control valves, check valves
and all other in-line items have been reinstalled in the W
AD X
system, and are in their correct orientation as indicated by I

EXAMPLE
the P&IDs and specifications
4.7 Corrosion Prevention
4.7.1 After hydro testing or water flushing, equipment items or
piping sections shall be air dried to protect from
subsequent corrosion within 48 hours. Where materials
are to remain open to atmosphere, all standing water shall R
X I
be removed immediately after hydro testing or flushing. W

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

4.7.3 Any protective chemical dosing shall be maintained until


Mechanical Completion. Regular inspections to confirm
the maintenance and top up of filled or positive pressure
purged systems shall be performed and documented on
X R
check sheets. Blinds and other isolations installed for lay- I
W
up purposes shall be recorded on a blind list and
confirmed periodically.

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MECHANICAL COMPLETION PROCEDURE

CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.8 Tie-Ins
4.8.1 General
CONTRACTOR shall compile tie-in packs which
typically will contain:
1. Marked-up P&IDs
2. Marked-up isometrics with tie-in detail
A X R
3. Tien-in/test procedure
4. Pre tie-in inspection certificate
5. Hydrotest certificate

4.8.2
6.
7.
EXAMPLE
Post tie-in inspection certificate
Material inspection certificates
Perform and test all tie-ins to existing systems in
accordance with SAES-L-052 and other COMPANY
standards and procedures. All requests for X-ray in lieu of
strength testing of connection shall be per SAES-A-004.
X
No tie-in activities shall be performed into existing
(Cold Tie W I/W/R
systems without proper Work Permit authorization from
Ins ONLY)
COMPANY (refer to GI-0002.100 Work permit System).

4.8.3 CONTRACTOR to review all tie-ins, in particular drains


and sewers, in detail with the Operations group. Specific
points to be considered are potential hazards and condition X I R
and the ability to adequately clean system for tie-in and
any special precautions which need to be taken
4.8.4 CONTRACTOR shall provide all materials, equipment
(scaffolding, rigging etc.) tools, labour, supervision etc. X I R/I
required to perform the tie-in
4.8.5 CONTRACTOR shall be responsible for isolating system
and installing temporary isolation blinds as required. X I R/I

4.8.6 Painting and insulation shall be repaired as required after


cleaning, testing and correction of deficiencies. I
X I
R

4.9 Other
4.9.1 Test performance of insulating flanges by discontinuity
W
testing. Record results. X R
I
4.9.2 Check and certify that all Cu-Ni piping has been
adequately isolated from steel pipe and supports. X I I

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MECHANICAL COMPLETION PROCEDURE

CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
4.9.3 Check and certify that all thermal insulation, personal
protection and weatherproof jacketing is properly installed
and all protrusions and cut-outs are properly sealed with X I I
weatherproofing mastic or flashing.

4.9.4 Check and verify that the internals of socket weld ball
valves were reinstalled after welding into line.
X I I

4.9.5 Install corrosion probes where specified on the P&IDs

4.9.6
EXAMPLE
Check and certify that all the piping has been properly
X I I

colour coded and banded as required by SAES-B-067 and


that the direction of the flow, commodity and line
identification markings have been clearly and correctly X I I
indicated on the pipe.

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

4.9.8 Check and certify that 'quick-connect' type couplings


have been correctly fitted to the utility stations and
installed as required by SAES-L-042. X I I

4.9.9 Check and certify that cathodic protection systems for all
underground piping are connected, tested and fully
functional.
X W/R I/W

5. MECHANICAL EQUIPMENT
5.1 General

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.1.1 CONTRACTOR shall provide a list to COMPANY of all X X
rotating and other equipment that cannot be run-in on air, (EACH (EACH FOR
nitrogen, water or inert fluids. contractor shall give reason FOR OWN OWN R
to COMPANY why each identified piece of equipment SCOPE OF SCOPE OF
cannot be run-in SUPPLY) SUPPLY)
5.1.2 Run-in and operate rotating and other equipment on air,
nitrogen, water or other inert fluids. CONTRACTOR shall
provide all procedures for COMPANY approval.
AD X I/W/R
CONTRACTOR shall provide experienced personnel for
this WORK, with all temporary equipment and monitoring
devices
5.2 Pumps, Fans, Blowers and Mixers
5.2.1 Check installation for compliance with Job Specification
X I I
and Vendor design drawings and applicable codes.
5.2.2 Rotate the equipment by hand to ascertain that they turn
X I I
freely. Check rotating element clearances on fans.

EXAMPLE
5.2.3
Cold align the various elements of all pump trains (driver,
pump, gearbox, shaft, bearings, and couplings). Process
piping disconnected. All alignments shall be done with
dual dial type micrometers using the reverse alignment
I/R
graphing technique. Records shall be maintained for all X W
W
mechanical alignment graphs with bolt target and actual
alignments, actual alignment readings, coupling spacing
(as applicable), end float (as applicable), date of
alignment, time of alignment, ambient temperature etc.
5.2.4 Piping to and from all pump trains shall be made up with
dial indicators on pump and driver to assure piping puts
zero strain on pump or driver. After alignment of pump
I/R
train and connection of piping, the piping shall be X W
W
disconnected again to verify that piping has been made up
without strain to the pump train. Furnish record of
alignment to COMPANY.
5.2.5 X
Shim, dowel, and grout the pump trains in a proper
(SP to W
manner, in order to preserve the validity of the various I
provide I
alignment checks.
dowel)
5.2.6 Provide, install and remove, clean and reinstate temporary I
X I/R
strainers in pump suction pipe work.
5.2.7 Check that base plate drains properly to correct sewer. X I I
5.2.8 W
Clean and flush lube/seal oil systems as required by
X (First fill by I
SAES-G-116. Install first fill of lubricants.
SP)
5.2.9 Confirm operation of oil mist and cooling water supplies.
X I W/I
Check pump drains and vents clear.

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.2.10 Motor checks-Confirm direction of rotation, run-in for R
X I
four hours uncoupled and check the bearings. W
5.2.11 Provide labour procedures, discipline and vendor support
(where required) for coupled run of pump and driver. A
Uncouple and recouple pump to driver as required. For run-in /
Perform vibration and alignment checks. X
X/O I/W/R
For couple /
uncouple

5.2.12
EXAMPLE
If a new pump is to be used for flushing, install temporary
packing or mechanical seal is not suitable for flushing.
Project pump may only be used for flushing with prior
approval of COMPANY.
X I R

5.2.13 Reinstall mechanical seal or permanent packing on any


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

5.2.17 Rotate mixers by hand to ascertain that they turn freely. X W W


5.2.18 Check alignment and set blades at proper height per
X I I/R
Vendor requirements.
5.2.19 Confirm rotation is correct for blade installation. X I W
5.2.20 Conduct 4-hour uncoupled running test for motor. R
X I
W
5.3
5.3.1 Install compressor piping and make piping corrections as
required by manufacturer's tolerances. Set and cold align
I
compressor and driver. As per VENDOR X W
W
recommendation furnish records of alignment to
COMPANY.

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.3.2 Mechanically and/or chemically clean suction piping of X I/W
Compressors as appropriate and in accordance with for Mech for Mech
vendor instructions cleaning cleaning
W
I
AD X
for Chem. Chem.

EXAMPLE
cleaning Cleaning
5.3.3 For all compressors, provide compressor suction piping,
lube and seal oil piping in clean condition, free of mill
scale, weld spatter and all loose and foreign material.
W
Disassemble and reassemble piping for cleanliness X I
I
inspection as required. Suction systems to reciprocating
and centrifugal compressors shall be visually inspected for
cleanliness whenever possible.
5.3.4 Install temporary/permanent compressor suction strainers
X I I
and coalescers where specified.
5.3.5 Check installation for completeness and proper
X I I
connection and tie-in of auxiliary equipment and utilities.
5.3.6 Check for correct rotation of driven and driving R
X I
equipment. W
5.3.7 Check equipment data plates for operating speed, critical
A X I
speeds, horsepower, temperatures, and pressures.
5.3.8 Check compressor bearing vibration probes and shaft
condition. Remedy any problems based on Vendors' A WI/X W
instructions.
5.3.9 X
for Mech
Lube oil and seal oil system shall be mechanically and cleaning
chemically cleaned prior to installation. Refer to SAES-G- I
116. AD
for Chem.
cleaning
5.3.10
Flush lube and seal oil system, heat and circulate the oil,
and replace with clean oil and test for cleanliness, as X I/O I
required to prepare the system for operation.

5.3.11 Confirm cable installation. Meghom test cable, with


readings recorded and sign-off by COMPANY. (List
X W/R W/R
cable numbers or highlight cables on copy of
cable/conduit schedule).
5.3.12
With "T" leads disconnected, confirm proper operation of
X W W
starters, conductors and controls.

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.3.13 Confirm grounding connections are tight and test
X W W/I
grounding.
5.3.14 Confirm all electrical connections are tight. Visually
check electrical components for final assembly. Confirm
system is ready for energization. X I/W W/I

5.3.15

EXAMPLE
Contractor/Vendor to pre-commission compressor skids.
The following checks should be made:
i) Confirm power circuits to skid/compressor area are
complete and ready.
A X/I W
ii) Confirm proper operation of all heaters. A X/W W
iii) Confirm proper operation of all lighting controls, alarms,
A X W
interlocks and shutdown loops/circuits for this system.
iv)
Confirm all junction boxes and panels are closed tight. A X/I W/I
v) Confirm all breakers except for heaters and motors are
A X/I W/I
open and "locked-out".
5.3.16 Complete instrumentation work required for loop checks:
i) R
Completion of process control and safety systems. X I
I
ii) R
Completion of instrument air system. X I
I
iii) Completion of continuity and megger testing of plant and
X W W
skid wiring.
iv) Completion of calibration of plant and skid instruments
X I W/I
associated with system.
v) Completion of instrument installation checks. X I W/I
vi) Completion of instrument tubing/piping clean-out and
X W W/I
pressure testing.
5.3.17 X
Correct design/installation/calibration defects identified
(Installation X W
during loop checking.
)
5.3.18
Commission control loops. A I X
5.3.19 Mark all plugs, vents, drains used during hydro test.
COMPANY Operating Organization to indicate which
connections are required for plant operation; Contractor to X I R
seal weld all other (construction) connections, where
appropriate
5.3.20 Inert system vessels/piping after drainage of hydro test
X I/W I
water and dry-out check.
5.3.21 Align/adjust piping and supports on compressor as
required to achieve compressor alignment. X I W

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EXAMPLE
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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.3.22 Leak (Tightness) test piping flanges and screwed
connections and valve glands with tape and soap/bubble X W W
solution. Tighten connections or replace gasket/gland.
5.3.23 Complete PZV testing/tagging. Return PZV s to site and
reinstall.work to completed within 90 days of Mechanical X I I
Completion
5.3.24 COMPANY check of correct installation of PZV,
A I X
painting and car-seal blocking of PZV block valves.
5.3.25 After COMPANY check of all instrument system, run in
W
driver as required by specification and conduct motor run A X/O
I
four (4) hour test run
5.3.26 Re-couple compressor to driver after successful run-in of
W
driver. Complete the cold alignment of the compressor A X/O
I
train
5.3.27 Complete all piping work and connections. Measure and
record alignment with piping bolted and unbolted. Piping
shall not be "cold sprung" into position after compressor
alignment; adjust piping, supports, guides etc., as required
X W R/W
to connect to tough aligned compressor with loads on
compressor nozzles within allowable valves. Projected
loads and Vendor allowance values to be reviewed with
COMPANY before connection.
5.3.28 Check compressor bearings, seals, etc., prior to W
A X
compressor close-up and system leak ( tightness tests). R
5.3.29 Details
Complete all pre-start-up tests and checkouts required by Details refer
refer to W
the vendor. to other items
other items
5.3.30
Confirm satisfactory performance of lubrication, nitrogen
- X R/I
purge and cooling systems.
5.3.31
Check and run-in compressor on air or inert gas to obtain
satisfactory dynamic mechanical performance. Provide
the necessary procedures and vendor and discipline A X/O I/W
support (where COMPANY deems this to be part of the
Mechanical Completion scope).

5.3.32 Make comprehensive vibration check of rotating elements


- X I
and auxiliary equipment.
5.3.33 Check hot alignment of compressor and driver and do any X
A W
required doweling of the compressor and driver. Hot Align
5.3.34 Correct any piping misalignment or deficiency, which

EXAMPLE
may be necessary after the run-in of the compressor. X I W

5.4

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.4.1 Check the nameplate for correctness and reference to
X I I
process fluids and conditions.
5.4.2 Remove construction debris, clean interior, and hydrotest
I
tanks and vessel.per SAES-A-004. X I
W
dry cleaning is normally preferred
5.4.3 Wipe the vessel clean and dry upon conclusion of any
X I W/I
flushing or wet cleaning/testing procedures.
5.4.4 Install appurtenances and test. Follow the vendor
recommendations as to the installation of internals.
W
X W
Check all internals for secure installation according to I
specification, weir height, down comer clearance, weir to
shell clearance, level of weirs and trays
5.4.5 R
Paint tanks and vessels, as required X I
I
5.4.6 Perform a detailed inspection of the vessel internal and I
X X/I
external coatings, holiday detection, surface and thickness. W
5.4.7 Perform hydraulic water tests on column internals to
demonstrate performance of seal trays, spray distributors,
W
and tray leakage tests. Adjust internals as required. X W
I
Check all process piping inlets and outlets are clear, vortex
breakers secured.
5.4.8
Check all internal instrumentation and
X I R/I
position/cleanliness of all instrument taps.
5.4.9 Check that tank grounding and cathodic protection of
X I I
tank bottoms has been installed.
5.4.10 Check that sacrificial anodes have been installed in vessel
X I I
and tank internals.
5.4.11 Check grouting, vessel identification,
X I I
insulation/fireproofing and platforms/ladders.
5.4.12 Cure and dry out internal castable linings and coatings. W
AD AD
Provide procedures and inspection records. I
5.4.13
Charge chemicals to vessels, as required AD X W/I
5.4.14 Close all internal tray manways and final torque all W
internal fasteners. X I
I

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

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.4.17 Check tank foundation compaction tests, dimensional
X R/I
inspection record, and settlement during water filling test.
5.4.18 Water flood floating roof rainwater sumps and test for
X W
leaks an swivel joints subsequent to floating the roof
5.4.19 Verify the proper operation of the floating roof and
ensure all pressure release systems and vacuum breakers X W
are clear and functional
5.4.20 Test the manifolded foam fire protection system for
storage tanks, if provided, is in accordance with GI-1782- X W W
001
5.4.21 Strap tanks for volume calibration, as required. X W
5.5 Shell and Tube Heat Exchangers
5.5.1 Check the nameplate data for correctness and reference to
X I I
process fluids and conditions.
5.5.2 Check that slide plates have been installed, the sliding
end will allow movement and guides for hot position.
Check that the nuts are loose on anchor bolts in sliding W
X I
plates. (double nutted bolts and loose washer are I
required). Also check anchors, supports and guides for hot
position.
5.5.3 Check that thermal safety relief valves are fitted as
X I I
specified.
5.5.4 Check any shipping bolts or desiccant packs removed.
Inspect nozzles for internals cleanliness before flange bolt- X I I
up.
5.5.5 Open the exchanger and Inspect internals prior to hydro
testing. If required at site Check tube cleanliness,
cleanliness of turbolators (if used), and cleanliness of R
AD AD
header boxes. Clean oil coolers in conjunction with I
compressor oil system cleaning/ flushing procedure.
Perform final closure on oil coolers prior to flushing.
5.5.6 Hydro test (for aftercoolers/reheater) or commodity test
R
(oil coolers) exchangers per AES-A-004 and AES-A-007. AD X
I
Clean and dry out after hydro test.
5.5.7 Inspect process exchangers internals after hydro testing; W
signify complete and ready for final closure. AD X
I
5.5.8

EXAMPLE
X R
Check for damage to tubes and tube sheet I
(Visual) I
5.5.9 Issue to Contractor, in writing, instructions to final close
- - X
each exchanger.
5.5.10
Install new gaskets on all broken connections and then
R
close all ports to the exchanger following the correct X I
I
torquing procedure

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MECHANICAL COMPLETION PROCEDURE

CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.5.11 Perform low pressure tightness test on exchanger. Refer W
X W
to SAES-A-004 I
5.5.12 Ensure shop inspection records confirm leak tests
performed on all joints. Correct gaskets installed for A X W/R
operational service.
5.6 Air Fin Coolers
5.6.1 Check levels and dimensions of substructure, machinery R
X I
and fan ring. Furnish record of measurements. I
5.6.2 Check motor nameplate with datasheet for speed
X I I
horsepower current and voltage.
5.6.3 Check motor direction of rotation and drive pulley
X I W
alignment.
5.6.4 Clean the inside of hood and coils. Remove any shipping W
X I
tie bolts and other extraneous material I
5.6.5 Perform uncoupled 4-hour motor run test. Check W
X/O I/W
vibration levels and correct as necessary I
5.6.6 Set and adjust drive belts tension. X I W
5.6.7 Check for proper installation of vibration switches and
X I/X I/W
calibrate setting. Check functionality of the same.
5.6.8 Set and align fan assembly, fan shaft, shreave and driver X I W
5.6.9 Check coil fins and straighten as required. X I I
5.6.10 W
Check and verify fan tip clearances. X I
I
5.6.11 Lubricate all bearings. Confirm lubrication points
X I I/W
serviceable.
5.6.12
Ensure proper direction of rotation, blade pitch angle X I W/I
5.6.13 Record blade serial numbers and position installed. X I R
5.6.14 Perform 4-hour fan run test. AD X R/W
5.6.15 Record fan pitch. Motor amps to be checked for variable
X I R/W
pitch fans.

EXAMPLE
5.6.16 X I
For For
Flush and hydro test coolers as per SAES-A-004. All Installation Installation
W
header box plugs and seal washers checked for tightness. AD AD
For Hydro For Hydro
Test Test
5.6.17 Louvers checked for full movement and positioner
X I W
marked at open/closed. Adjust as necessary.
5.6.18 Machinery guards fitted. X I I
5.6.19 Header box nozzles viewed for cleanliness before piping
X I I
flanges made up.
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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.6.20 Issue to Contractor, in writing, instructions to final close
- - X
each exchanger.
5.6.21 Operate fans for simulation runs. AD X/O I
5.6.22 Check and adjust belts after running at operating
X I/W W
conditions.
5.7
Verify compliance with the Job specification and vendor
5.7.1 X I I
drawings and applicable Codes
Check to see if provision has been made for thermal
5.7.2 X I I/R
expansion of all boiler parts and attached piping
Prepare boiler dry-out procedure
5.7.3 X R
Verify proper relief valve rating, certification and
5.7.4 installation. X I I

Verify that final assembly is complete with no missing


5.7.5 bolts, loose nuts, missing washers and no missing safety X I I
devices.
Perform a hydrotest test on boiler pressure parts in
5.7.6 X W W
accordance with SAES-A-004
Check and verify proper operation of instrumentation and
5.7.7 controls. X I I

Dry out, boil out, and chemical clean in accordance with


vendor and project specifications, and SAEP-1025 (if
5.7.8 deemed by COMPANY to be part of the Mechanical AD X W/I/R
Completion scope).

Open and inspect internal surfaces of drums, remove all


debris, perform required remedial work, and close after
5.7.9 boil out and/or acid cleaning. Lay up boiler after boil out AD X I/R

5.7.10
EXAMPLE
and cleaning if required as per SAEP-1026.

Operate boiler and ancillary equipment to perform in-situ


relief valve pop testing and blowdown adjustment, and
confirm functioning of all boiler safety trips. Operate
boiler as required to perform steam cleaning activities on
associated new steam distribution line work (if deemed
AD X W/I/R
by COMPANY to be part of the Mechanical Completion
scope).

5.8
Verify compliance with the Job Specification and vendor
5.8.1 X I I
drawings and applicable Codes

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
Check to see if provision has been made for thermal
R
5.8.2 expansion of all boiler/gas turbine parts and attached X I
I
piping
Prepare HRSG dry-out procedure including vendor
5.8.3 recommendations and review with proponent 90 days in X R
advance of turnover
Verify proper relief valve rating, certification and
installation. R
5.8.4 X I
I

Verify that the final assembly is complete with no


missing bolts, loose nuts, missing washers and no missing
5.8.5 X I I
safety devices.

Perform a hydrotest test on boiler pressure parts in


accordance with SAES-A-004. Empty the test water
W
5.8.6 completely after test and dry or layup according to vendor X W
I
recommended procedures.

Check and verify proper operation of instrumentation and


5.8.7 controls. X I I

Dry out, boil out, and chemical clean in accordance with


vendor and project specifications, and SAEP-1024 and
5.8.8 SAEP-1025 (if deemed by COMPANY to be part of the AD X W/I/R
Mechanical Completion scope).

Open and inspect HRSG, remove all debris, perform


required remedial work to refractory as required. Lay up W
5.8.9 AD X
HRSG after boil out and inspection/cleaning if required as I

EXAMPLE
per SAEP-1026.

When GTG available, operate HRSG and ancillary


equipment to perform in-situ relief valve pop testing and
blowdown adjustment, and confirm functioning of all
5.8.10 boiler safety trips. AD X W/I/R

CONTRACTOR to supply all consumables for operation


of the HRSG e.g. demin water, dosing chemicals, fuel etc.
5.9
Install, set and align turbine, gearbox and HRSG in
5.9.1 X I W
accordance with vendor procedures and tolerances
Provide all new ancillary piping fuel, cooling, lube oil
and hydraulic system in clean condition in accordance
5.9.2 X I I
with vendors requirements. Circulate and heat lube oil
systems to establish cleanliness
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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
X
By air & I
Water
Clean fuel gas supply piping to vendor specification (up ONLY
5.9.3 to and including chemical cleaning) I
AD X
(Chemical (Chemical
Cleaning) Cleaning)

Function test all auxiliary systems, fuel systems, air inlet


5.9.4 filters, air doors, starting system, enclosures. AD X I

Calibrate and function check all safety devices, control


systems, synchronisation instrumentation, power supplies,
5.9.5 battery packs, HVAC, pressurisation and extinguishing AD X W
systems.

Provide labour, tools and equipment to support testing


and operational proving runs on gas turbine/generator
units if deemed by COMPANY to be part of the
5.9.6 AD X W
Mechanical Completion Scope. Also to provide same if
tests are carried out post Mechanical Completion.

5.10 Diesel Generator Sets


Install, set and align according to Vendor requirements
5.10.1 X I I
and specifications.
Install and full function test starting power/air system,
5.10.2 X W I/W
cooling water systems, fuel systems, and ancillaries

5.11
EXAMPLE
Run engine light and coupled for simulation runs.
5.10.3 Function test safety cut out devices. Perform final
adjustments, alignments and Load Test.
Miscellaneous Mechanical Equipment
5.11.1 General
AD X W

5.11.1. All equipment and components not otherwise addressed


1 by this list shall be installed, adjusted, cleaned, confirmed W/O
X I/W/R
for proper functioning, and inspected prior to Mechanical I
Completion.
5.11.1. Maintain, ensure proper lubrication and finally adjust all W/R
2 X I/W/R
equipment prior to Mechanical Completion. I

5.12 Air Conditioning and Air Handling Equipment

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Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.12.1
Air conditioning and air handling units, individual
components thereof, appurtenances, piping and wiring W
connected to the units, and instrumentation controlling the X I/W/R I
units shall all be installed and prepared for operation per
the vendor requirements and specifications.

5.12.2
Provide all cooling medium and charge or recharge the air R
X I
conditioning units. As required I
5.12.3 All ductwork shall be inspected prior to closing to verify
that all fittings and air volume control devices and duct W
X W
heaters have been properly fabricated, installed and I
operate properly.
5.12.4
All dampers shall be thoroughly cleaned to ensure proper
operation. Ducts, plenums and casings shall be cleaned of
W
all debris and blown free of particles of fibreglass, dust X I
I
and rubbish before installation of registers and grilles.
Equipment shall be properly lubricated.

5.12.5
Obtain all COMPANY approvals and certifications and
provide all utilities including temporary power required to
allow running as soon as possible for the protection of X I/R R
equipment and comfort of personnel. All WORK
necessary to safeguard the equipment must be complete

5.12.6 filters and strainers used during construction shall be


X I I
cleaned or replaced prior to Mechanical Completion.
5.12.7 Provide and install any sunshades, covers, filters,
insulation guards, barriers, piping drains or any other

5.12.8
EXAMPLE
items required to protect the units or other equipment to
reduce noise or vibration to acceptable levels.

Start air conditioning system, per manufacturer


instructions, after all start-up preparations are complete.
X

A
I

I
W/I

X/O

5.12.9 Conduct capacity tests of air conditioning and air


W
handling units, and "balance" the air distribution system X/O W
I
per design requirements.
5.12.1 Demonstrate proper operation of building pressurization
0 X W W
system including make-up air volume check.
5.12.1
1 Conduct the building fire damper closure test. X W W

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MECHANICAL COMPLETION PROCEDURE

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SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
5.13 Lifting Equipment
5.13.1
Install and checkout lifting equipment in accordance with
manufacturer's recommendations, COMPANY standards R
X I/W/R
and specifications, and other applicable portions of this W
list.

5.13.2 Stencil maximum working load (in English and Arabic) X R


I
on lifting equipment. I
5.13.3 Perform the testing of lifting equipment, which shall be
witnessed by Inspection departments Crane Inspector.
X I/W R
Obtain COMPANY Crane Inspection sticker on
completion of the successful tests
5.14
Set and cold align turbine and associated piping. Check
I
5.14.1 parallel flange alignment. Furnish record of alignment to X I
W
COMPANY
W
5.14.2 Chemically clean lube, seal, flushing and control lines AD X
I
5.14.3 Flush seal and lube oil systems with flushing oil
before installing lube and seal oil. Lube oil/seal oil
reservoirs and piping typically require acid cleaning W
X I/O
then flush per SAESG- 115 and 116. Install first fill of I
lube oils.

5.14.5
EXAMPLE
Check installation for completeness, proper
5.14.4 connection and tie-in of auxiliary equipment.

Check for proper rotation of driven and driving


equipment.
X

X
I

I
R
W
I

Install all permanent packing and accessories prior


5.14.6 to first run. X W W

Check equipment nameplate for operating speed,


critical speeds, horsepower, temperatures and
5.14.7 X I I
pressures.

Provide procedures and vendor support as required


5.14.8 X R
for run-in of turbines
Perform Vendor required turbine tests
5.14.9 X W W
5.14.1 Recouple turbine to driven equipment.
X I W
0
Provide temporary mothballing if turbine is not to be
5.14.1 W
operated for an extended period of time. X I
1 I
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TOR NAME IVE
TOR
6. FIRE AND SAFETY SYSTEMS
6.1 General
6.1.1
Paint and/or tag all safety valves, car sealed valves, and
R
safety equipment in colours designated by COMPANY X I
I
standards.
6.1.2 Install mounting brackets for safety equipment in
X I I/R
locations marked by COMPANY.
6.1.3 Remove and replace after testing, and adjust all safety
devices, such as rupture discs, which cannot conveniently X I I/R
be tested and adjusted in place.
6.1.4 Test, adjust and seal as necessary all safety devices other
than safety valves. X I/R I/W/R
6.1.5 Install and precommission the following Fire and Safety
system
1. Emergency air packs and containers
2. Deluge system sprinkler system X W I/W/R
3. Gas detection system
4. Fire detection system

6.1.6
Prepare/update emergency response plans for the
A A X
facilities and position the assembly area signs.

6.2 Firewater System Capacity Testing


6.2.1 Completely check out all fire protection equipment. X I/W/R I/W/R

EXAMPLE
6.2.2 Test all Fire system audible and visual alarms. X I/W/R I/W/R
6.2.3 Conduct a capacity test of the firewater system to confirm
and document compliance with standards and
A X/O I/W/R
specifications. Clean up areas and make adjustments as
required after testing and inspection.
6.2.4 Conduct function testing of all deluge and sprinkler
systems. Clean up areas and vessels after testing. Ensure A X/O I/W/R
nozzle arrangement provides full coverage.
6.3 Carbon Dioxide/Extinguishing Systems
6.3.1 Check all extinguishing equipment and associated piping. X I/W/R I/W/R
Test the smoke detection system. X W W/R
6.3.2

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TOR NAME IVE
TOR
6.3.3
Each entire CO2/extinguishant release system shall be
discharge tested for satisfactory operations prior to
Mechanical Completion. Approved material shall be used
A X/O I/W/R
in the discharge tests. The sampling points shall be
monitored simultaneously to indicate the percent of
extinguishant concentration achieved at each point.

6.3.4 The system shall be checked for proper operation of all


actuators (both manual and automatic) override devices, X I/W/R I/W/R
detectors, alarms and interlocks.
6.3.5 After discharge testing, restore the system to proper
operating condition, including immediate replacement of
X I I
all discharged storage cylinders with properly charged and
weighed spare storage cylinders.
6.3.6 After the system has been restored to operating condition,
ensure that a minimum of one (1) complete set of cylinders
A X I
for each system or zone, properly charged and weighed,
are available at all times for use as spares.
6.3.7 Warning signs in Arabic and English shall be in place at
all times after installation of the extinguishant to warn X I I
against inadvertent discharge.
6.4 Fireproofing
6.4.1 Check that the installation is to the requirements of Job
Specification and meets the requirements of SAES-B-006. X W I
6.4.2 Confirm that surface preparation prior to installation is
X I I
complete.

EXAMPLE
6.4.3 Check and verify that all valve actuator fireproofing
blankets have been installed on PZV valves where X I I
specified on the drawings and specifications.
6.5 Fire Extinguishers

6.5.1 A
Supply all permanent fire extinguishers. Test and tag all
(Install X I
fire extinguishers through COMPANY FACILITY.
ONLY)
6.5.2 Install all handheld and wheeled fire extinguishers in
specified locations with suitable brackets/clips as required
X I I
by SAES-B-019. Extinguisher locations to be colour
coded and tagged as required by SAES-B-067.
6.6 Fire Hoses/Hydrants and Monitors

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TOR NAME IVE
TOR
6.6.1 Check that fire hoses and hose cabinets have been
correctly fitted, are in an operable condition, and can be X I I
fully withdrawn from the hose cabinet.
6.6.2 Check and certify that the hand crank mechanism and the
angle valve of each hose reel station is well greased and X I I
operable.
6.6.3 Check and certify that each fire monitor operates freely
X I I
and correctly.
6.6.4 Check location and visually inspect each hydrant and
X I I
monitor.
6.7 Safety Showers and Eyewashes
6.7.1 Ensure that safety showers and eyewashes have been
located throughout the FACILITIES as required by SAES- X I I
B-069.
6.7.2 Test each eyewash and safety shower to ensure for
required flow, pressure and temperature not to exceed
39. Apply heat to piping to ensure that the water
X W I/W
temperature control device is functioning as required.
Ensure that required piping is underground or insulated to
prevent excessive temperatures due to solar gain.
7. CONTROL SYSTEM/INSTRUMENTATION
7.1 General

EXAMPLE
7.1.1 X
Provide COMPANY with a list of all equipment required
Loop I/R R
for loop testing
Folder prep
7.1.2 Check instruments and tag data supplied against
X I I
specifications sheet (type, range, materials, etc.).
7.1.3 W
Install instruments and make all specified connections. X I
I
7.1.4 Provide certification of calibration of standart
I/R
instruments. These standard instruments shall not be used X I
for testing or checkout in the field
7.1.5
Check continuity and identification of transmission and
control system for each instrument to ensure proper hook-
W/R
up and compliance with specifications. (This applies to X W
I
both pneumatic and electrical - analogue and digital -
systems).

7.1.6 Check pneumatic and electrical instrumentation systems


for proper installation including tagging, supports,
W/R
accessibility, correct material, ratings and calibrating X I
I
fittings. Synchronize transmitter and receiver readings for
each instrument.

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

7.1.8 Prepare calibration sheets for each calibration to be


submitted as part of the loop check data package. Theses
sheets shall show, as a minimum the following:

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

7.1.9 Contractor shall produce daily, weekly and monthly


reports to provide complete detailed current status of the
loop Pre-testing/testing activities for each system.
Contractor shall design the report formats and presented X R R
for COMPANY review and approval. Each daily report
for each system shall include the following information:

1) Provide the status of each field instrument (On site,


Calibrated, Field Mounted, Labelled), and provide total X R R
instruments against completed for each filed.

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TOR NAME IVE
TOR
2) Provide the status of field wiring of each instrument (On
site, pulled between instrument and junction box,
continuity tested, tagged at the instrument side, tagged at
X R R
the junction box side, terminated at the instrument side,
terminated at the junction box side), and provide totals
completed for each field.
3) Provide the status of each multi-core cable for each
junction box. (On site, pulled between junction box and
Marshalling Cabinet, continuity tested, tagged at the
Junction Box side, tagged at the Marshalling Cabinet side, X R R
terminated at the Junction Box side, and terminated at the
Marshalling Cabinet side). And provide totals against
totals completed for each Junction Box.
4) Provide a Daily status for each loop on each system
(Passed/Failed/Not Tested), and provide total loops
against completed loops for each system. X R R

7.2

EXAMPLE
Calibration and Checkout
7.2.1 All instrumentation items shall be calibrated and/or
bench-checked for operability. Each item shall be labelled
with its associated tag number, checks performed, date and
person performing checks. Unless otherwise stated,
analogue equipment shall be calibrated at five standard
points -0, 25, 50 and 75 and 100% of span. All special
X I/W/R. I/W/R
instrumentation, including, but not limited to, emergency
shutdown systems, data highways, microprocessors,
metering and vibration monitors, shall be calibrated and
checked using Vendor specified simulator equipment.
Calibration records shall be maintained for all
instrumentation.
7.2.2 Rotameters shall be installed as received. Ensure
shipping stops have been removed and floats installed.
Where rotameters have transmitting mechanisms, the float X I I/W/R
shall be mechanically raised and lowered and the output
checked.
7.2.3 Turbine meters and/or positive displacement meters shall
not be installed until testing and flushing of lines is
completed. Installation shall be in accordance with X I/W/R I/W/R
manufacturer's instructions, i.e. flow direction, and
removal of shipping stops.

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CONTRAC REPRESENTIT
TOR NAME IVE
TOR
7.2.4
Orifice plates shall be visually checked against the
specification for nameplate data and for an upstream sharp
edge. Bore shall be calliper checked for compliance with
specifications. Venturi and flow nozzles shall be checked
for proper high and low connections as stamped on the
X I/W I/W/R
element. All flow elements shall be properly stored until
immediately prior to installation. Each normally
concealed flow element shall be tagged as being properly
installed and certified by COMPANY. Meter element
checks and installation shall be recorded on a check sheet.
7.2.5 Gauge glass illuminators and other accessories shall be
X I W/I/R
checked for proper installation and operation.
7.2.6 Air supply shall be checked and set at specified pressure.
Valve position shall be checked for proper action on air X I I/W/R
supply failure.
7.2.7 Control valves and accessories, such as hand-wheels,

EXAMPLE
booster relays, limit switches and trip actions shall be
comprehensively checked out for operational
serviceability and documented on a check sheet record.
Air supply failure system shall be checked for proper
function. All switch points shall be set to specified value.
Check lubrication.
X I I/R/W

7.2.8 Self-contained pressure regulators shall be checked for


X I W/I/ R
proper inlet and outlet ports and nameplate data.
7.2.9 Butterfly valves shall be checked to see the vanes move
freely into the upstream and downstream piping. Check X I I/W/R
lubrication.
7.2.10 Pneumatic block valves (AOV, ZV) shall be stroked and
limit switches and stops checked for correct operation in
conjunction with indicator lights, where applicable.
X I/W/R I/W/R
Check lubrication. The actions of all ZV isolation valves
shall be tested through the system from the initiation
signal.
7.2.11 Motor operated valves shall be hand stroked, open and
closed and limit switches set and then operated under
power. Torque and limit switches shall be checked for
correct operation in conjunction with indicator lights X/O I/W I/W/R
where applicable. The electrical testing and
documentation required by this specification shall also be
performed. Check lubrication.
7.2.12 Steam traps, vacuum traps and continuous drainers shall
be checked against the applicable design and installation X I I/R
specifications.

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TOR NAME IVE
TOR
7.2.13 Annunciator and instrument tag nameplates shall be
checked against design drawings for engraving and proper X I I/R
location.
7.2.14 Annunciator operation and point continuity shall be
checked by mechanically actuating all trouble contacts for
X I/W I/W/R
low-high-deviation alarm operation and auxiliary contact
operation and sequence.
7.2.15 Solenoid valves, electrical relays, timers, pushbuttons,
switches and other miscellaneous electrical devices shall X I/W I/W/R
be checked for proper operation.
7.2.16 Package instrumentation systems shall be checked for
calibration and set to specifications and/or Vendor's
recommendations. All of the requirements in this list for
calibration, accuracy, labelling, record keeping, and X I/W I/W/R
checkout apply to the individual components of packaged
systems.
7.2.17

7.2.18
EXAMPLE
All local panels, auxiliary panels, racks and control
panels shall be function checked.
All instrument nameplates, both front and rear, and all
panel board nameplates shall be checked for tag number,
service and proper location.
X

X
I/W
(Provide
Vendor)

I
I/W/R

I/W/R

7.2.19 Prior to installation, cables with pre-wired connectors


shall be checked for continuity and identified as being X I W/I/R
checked.
7.2.20 Individual cores or multicore cables and individual wires
connected to terminals shall be identified by numbered
and lettered ferrules as shown on construction drawings X I I/R
where permanent identification marks are not furnished
with cables. Individual to/from designations are required.
7.2.21 A check using the piping and instrument diagram
(P&IDs), instrument points and line drawings and the
X I I/R
instrument specifications shall be made after installation to
make sure all instruments are in their proper place.
7.2.22 Each instrument installation shall be checked for
conformance with the proper instrument installation detail
drawings, e.g. proper hook-up of flow meters, correct X I W
materials and fitting ratings.

7.2.23 All valves marked as 'TSO' on the P&IDs plus all ZVs
will be tested to ANSI/FCI 70-2 in the field. X W W

7.2.24 Perform required pressure tests on instrument take-off R


X W
piping, air piping and tubing. I

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Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
7.2.25 Blow-out instrument air piping with dry air, reconnecting
X I W/I
after pressure tests and site instrument air regulators.
7.2.26 Clean transmission and control tubing by blowing with
clean dry air prior to instrument component connection. X I W

7.2.27 Provide and install sealing fluids.


R
X I
I

7.2.28 Check thermocouples/RTD for correct position and


wiring polarity. X I I

7.3 Loop Checking and Function Checking


7.3.1 Perform five (5) point full loop check on all instrument

EXAMPLE
loops, Input/output signals equivalent to 0, 25, 50, 75 and
100% of control range shall be generated to confirm X I/W I/W
functionality of all components within the complete loop
over the full control range.
7.3.2 After loop checking, all controllers shall be left with
X I/W/R I/W/R
reasonable start-up control response settings.
7.3.3 Test annunciator and individual alarms by simulating
alarm conditions or, where this is not possible, by
mechanically operating the field contacts. Check
annunciator alarm sequences, test, acknowledge and rest
A X R/W
function. These tests shall include annunciator and alarm
functions in the distributed control system and the support
computer. Alarm tests shall be documented and submitted
to COMPANY.
7.3.4 Many signals are channelled via multiplexer units or
other data highway devices. These units shall be included
X I W
in the loop checks. Vendor instructions for checkout and
testing shall be followed.
7.3.5 Check proper point identification for multipoint
temperature indicators and recorders by paralleling a
portable potentiometer set at high output across the field X I/R I/W/R
end of thermocouples terminals, witch will show if the
wiring is to the correct point.
7.3.6 Check shielding and drain wire connections. Check for
double reversals. Check for proper instrument reversals.
X I I/W
Check for proper instrument grounding, including all DCS
racks and consoles.
7.3.7 All interlocking and shutdown systems including package
A X W/I/R
equipment shall be tested.

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

7.3.10

EXAMPLE
During testing of the shutdown systems and packaged
equipment, all of the various modes of operation of the
systems (shutdown, permissive pre start, and permissive
post-start) shall be individually tested. Each input, logic
accumulation, and output signal shall be serially tested.
All input signals shall be removed and a set of shorting
plugs installed per input group. The installation of any A X W/I/R
shorting plug or other jumper device for any reason, shall
be clearly documented. As these plugs are installed the
associated LEDs shall be read and results documented at
the conclusion of testing. All shorting plugs or jumpers
shall be removed, such removal noted on documentation,
and the system integrity re-established.
7.3.11 During testing of shutdown systems and packaged
equipment, all interfaces with the Distributed Control A X W
System shall be individually tested for proper functioning.
7.4 Other
7.4.1 Properly seal all instruments as required. X I I/R
7.4.2 Fill manometers, draft gauges and like instruments with I
proper fluid, adjust zero of transmitters where necessary. X Media by I/R
SNAMP
7.4.3 Install proper recorder charts and link as required. X I I/R

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Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
7.4.4 At conclusion of all instrumentation testing prior to
Mechanical Completion, inspect all instrument items to
confirm proper complete installation, that all test
interruption and inhibit devices have been removed, that
X I/W I/R
all documentation is accurate, and that the instrumentation
is ready for use during commissioning and start-up. Set
up block valves and bypasses on instrument piping as
requested by COMPANY.
7.4.5 Complete Site Acceptance Tests and records for Control
Systems, ESD Systems, and F&G Systems, Metering W
AD X
Systems, and package equipment controls as per SAEP- I
16.
7.4.6 Calibrate analyzers and align for normal operation. X I/R W/R
8 PRESSURE RELIEF AND DISPOSAL SYSTEM
8.1 Check the pressure relief valves (PZV), pressure relief

EXAMPLE
and blowdown piping for completeness and proper line-up
prior to placing the facility in service. Check that all relief X I I
headers and subheaders are sloped properly and free of
pockets
8.2 All inlet and outlet block valves for PZV's shall be
painted orange. X I I

8.3 Check that the outlets and vents of all PZV's to


atmosphere are routed to a safe location away from X I I
equipment, piping, access ways and working platforms
8.4 Check that all Construction material and debris have been
W
removed and lines cleaned. X I
I

9. SAFETY RELIEF VALVES


9.1 Bench test and seal all safety relief valves, provide
calibration records and install according to SAES-J-600
X I/W W/I/R
and referenced procedures. Colour code to COMPANY
requirements.
9.2 Produce schedules for relief valve testing for agreement
by COMPANY, All relief valves to be tested within 90 A X R
days before Mechanical Completion Acceptance.
9.3 Transport relief valves to and from a test FACILITY
X I
approved by COMPANY.
9.4 Remove and reinstate relief valves as necessary for
inspection, testing, relief header blowing, flushing, X I I
cleaning or retesting.

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

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

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

10. GENERAL PREPARATIONS FOR SERVICE


10.1
X
I/W/R
except for
except for
Raw water and drinking water lines shall be flushed, disinfection
disinfection
cleaned and disinfected in accordance with SASC-S-17,
I/W/R
and bacterial tested (SNAMP) prior to being handed over A
X
for service. for
for
disinfection
disinfection
only

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TOR NAME IVE
TOR
10.2 In preparation of the FACILITIES to receive
commissioning and start-up fluids, carry out operational
leak (tightness) testing using compressed air, nitrogen or
the normal service fluid (for certain utilities Systems).
This shall confirm the containment integrity of all piping
and equipment within whole Systems or combinations of
R
Systems. X I/W
W
Generate procedures including definition of isolation
points for the envelope to be tested, and the testing
parameters. Procedures to be approved by COMPANY.
Provide discipline support and all temporary equipment
and fittings as required.
10.3 Provide, store, protect and install the first fill of media,
catalyst, chemicals and other process consumables. Where
COMPANY provides catalyst or chemicals, furnish
supervised labour and temporary equipment, and install.
Provide vendor support as required. Inert, isolate or
AD X

EXAMPLE
otherwise protect the catalyst and chemicals to prevent I/W/R
deterioration or unsafe conditions. All fluids/gases to be
labelled and location in a safe and proper area outside the
FACILITIES area until ready for installation.

Provide and install first charge and start-up spare


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

000-ZA-E-09406_0_Mechanical Completion Procedure

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CONTRACTOR CLIENT

SUB CLIENT
Pre-commissioning Activities CONTRAC CLIENT
CONTRAC REPRESENTIT
TOR NAME IVE
TOR
10.7
In preparation of the FACILITIES to receive
commissioning and start-up fluids, carry out inerting using
gaseous nitrogen or the normal service fluid (for certain
utilities Systems). This shall confirm that all piping and
equipment within whole Systems or combinations of
A X I/W/R
Systems is air/oxygen free. Generate procedures including
definition of isolation points for the envelope to be tested,
and the testing parameters. Procedures to be approved by
COMPANY. Provide discipline support and all temporary
equipment and fittings as required.
10.8 Prepare boilers and HRSGs for boil out. Provide
procedures, labour, discipline support water and chemicals
for steam generation system cleaning and boil out.
Procedures to include details of quantity and composition
of all effluents generated during the boil out activity and

EXAMPLE
method of disposing of these AD X W/I/R
Provide manpower and materials for internals inspection
remedial work and reinstatement after boil out.

10.9 Provide procedures for degreasing of the amine


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

000-ZA-E-09406_0_Mechanical Completion Procedure

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

00

PLANT
SPC. 0000-ZA-E-09406

PROJECT / UNIT Rev.


Sh. 69 of 69 0
MECHANICAL COMPLETION PROCEDURE

000-ZA-E-09406_0_Mechanical Completion Procedure

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