LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
1
APPENDIX D
CHECKLIST FOR MECHANICAL COMPLETION
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
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CONTENTS
D.1
PURPOSE ................................................................................................................................................. 3
D.2
GENERAL PROCEDURES .................................................................................................................... 4
D.2.1
D.2.2
D.2.3
D.2.4
D.2.5
D.2.6
D.2.7
D.2.8
D.2.9
D.2.10
D.2.11
D.2.12
D.2.13
D.2.14
D.2.15
D.3
SPECIFIC PROCEDURES ..................................................................................................................... 9
D.3.1
D.3.2
D.3.3
D.3.4
D.3.5
D.3.6
D.3.7
D.4
REMOVAL OF RUST PREVENTIVES ....................................................................................................... 4
LUBRICANTS ....................................................................................................................................... 4
PACKING AND SEALS ........................................................................................................................... 4
REMOVAL OF TEMPORARY BRACING ................................................................................................... 5
ROTATING AND ALIGNMENT ................................................................................................................ 5
TIE-INS AT BATTERY LIMITS ................................................................................................................ 5
LEAK AND PRESSURE TESTS ............................................................................................................... 6
INSPECTION......................................................................................................................................... 6
SAFETY DEVICES ................................................................................................................................. 6
FLUSHING AND CHEMICAL/MECHANICAL CLEANING............................................................................ 7
TEMPORARY SCREENS, STRAINERS AND BLINDS ................................................................................ 7
PURGING/INERTING ............................................................................................................................. 7
HOUSEKEEPING................................................................................................................................... 7
SAFETY ............................................................................................................................................... 8
EQUIPMENT STORAGE ......................................................................................................................... 8
PIPING ................................................................................................................................................. 9
ROTATING EQUIPMENT ........................................................................................................................ 9
ELECTRIC POWER ................................................................................................................................ 9
INSTRUMENTATION ............................................................................................................................. 9
WATER SYSTEMS ( FIRE WATER, RAW WATER SYSTEM)..................................................................... 10
WASTE DISPOSAL .............................................................................................................................. 10
MISCELLANEOUS .............................................................................................................................. 10
SPLITTING OF PRECOMMISSIONING AND COMMISSIONING ACTIVITIES...................... 11
D.4.1
D.4.2
D.4.3
D.4.4
D.4.5
D.4.6
D.4.7
VESSELS ........................................................................................................................................... 11
SHELL AND TUBE HEAT EXCHANGERS ............................................................................................... 11
ROTATING EQUIPMENT (PUMPS AND COMPRESSORS)......................................................................... 12
PIPING SYSTEM ................................................................................................................................. 12
ELECTRIC POWER DISTRIBUTION AND LIGHTING ................................................................................ 13
INSTRUMENTATION ........................................................................................................................... 14
MECHANICAL AND LOADING EQUIPMENT ......................................................................................... 14
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
D.1
3
PURPOSE
The checklists of general and specific procedures are intended to define the operations and tests to be
performed by the CONTRACTOR as the construction of the WORK or of part thereof is being completed.
These lists are intended to show the operations and tests required to demonstrate that the WORK has
been provided and constructed in accordance with the drawings, specifications and applicable codes and
generally with all terms and conditions of the CONTRACT which are applicable at the considered stage of
progress of work.
The performance to the satisfaction of the ENGINEER of the said operations and tests is one of the
conditions for issuance by the ENGINEER of the certificate of MECHANICAL COMPLETION of the entire
WORK and/or of the interim statement of MECHANICAL COMPLETION of any part of the WORK.
CONTRACTOR will have to finalize detailed check lists which have to be approved by ANCAP.
Such checklists shall cover all the procedures to be developed on the basis outlined in D2 and in D3
hereafter when applicable.
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
D.2
4
GENERAL PROCEDURES
The general procedures listed below outline the work to be performed by the CONTRACTOR. Procedures
applicable to specific systems or items of equipment are covered separately in paragraph D.3. and D.4.
thereafter.
Items hereafter have to be considered only if applicable.
Responsibility of
work
ContracANCAP
tor
Category
of work
Precom- Commismiss'g
sioning
D.2.1 REMOVAL OF RUST PREVENTIVES
Remove all rust preventives and oils used to protect
the equipment during the construction period
whenever these protective materials will be
detrimental to operation.
X
X
X
X
X
X
X
X
Provide ANCAP with a record of work completed.
D.2.2 LUBRICANTS
a/
Provide a list of all necessary lubricants
b/
Install initial charge of all lubricants
c/
Maintain lubrication after initial charge.
X
X
D.2.3 PACKING AND SEALS
a/
b/
Install mechanical seals, permanent
packing and accessories when required
Adjust and replace mechanical seals,
packing and accessories, as necessary.
X
X
X
X
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
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Responsibility of
work
Contrac- ANCAP
tor
Category
of work
Precom- Commismiss'g
sioning
D.2.4 REMOVAL OF TEMPORARY BRACING
Remove all temporary supports, bracing, or other foreign
objects that were installed in vessels, transformers, rotating
machinery, or other equipment to prevent damage during
shipping, storage, erection and repair any damage sustained
X
X
X
X
X
X
D.2.5 ROTATING AND ALIGNMENT
a/
Check rotating machinery for correct direction of
rotation and for freedom of moving parts before
connecting driver.
b/
Make cold alignment to
tolerances and record data.
c/
Operate equipment and check
governor and safety device.
d/
the
manufacturer's
vibration,
trip,
All checks, and any other operating tests and
adjustments as required.
X
X
Make hot alignment and any doweling required.
X
X
D.2.6 TIE-INS AT BATTERY LIMITS
a/
Prepare all systems for safe tie-ins and observe the
systems while tie-ins are being made.
b/
c/
X
X
X
Obtain ANCAP's approval to make the necessary
tie-ins at the battery limits as required by the
specifications.
X
X
X
Make the tie-ins at B.L.
X
d/ Remove blinds, car seals and so forth, as required.
X
X
X
X
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
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Responsibility of
work
Contrac- ANCAP
tor
Category
of work
Precom- Commis
miss'g
sioning
D.2.7 LEAK AND PRESSURE TESTS
a/
Notify ANCAP of the test schedule.
b/
X
X
Make non-operating field leak tests or field
pressure tests on piping and field fabricated
equipment. Conduct all tests in accordance with
applicable codes and specifications. Dispose of the
test media according with ANCAP’s instructions.
X
X
c/
Provide test record for ANCAP.
X
X
d/
Provide any special media for test purposes and
provide facilities for disposal.
X
X
e/
Conduct all operational tightness testing.
X
X
f/
Proceed with hydraulic pressure tests of shell ant tube
heat exchangers when installed and connected to
piping. Nozzles on shell and tube sides shall be closed
by blinds. Test shall be conducted on shell and tube
sides successively. Checking will be made by pressure
gauge and by visual inspection.
X
X
X
X
X
X
g/
Proceed with hydraulic pressure tests of vessels and
air coolers
D.2.8 INSPECTION
a/
b/
Provide inspection of the WORK to check that erected
facilities conform to flow diagrams, construction
drawings, vendor prints and specifications.
Provide for special inspection such as those
required by insurance or governmental agencies.
X
X
X
D.2.9 SAFETY DEVICES
a/
Test and adjust all safety devices and seal
wherever necessary or desirable.
X
X
b/
Install all safety devices (including pressure-relief
valves) after testing and adjustment.
X
X
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
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c/
Provide format for safety records
X
d/
Maintain the necessary records on safety devices
on ANCAP’s format.
X
D.2.10
FLUSHING AND CHEMICAL/MECHANICAL CLEANING
a/
Conduct
all
flushing,
blowing
and
chemical/mechanical cleaning operations and
provide required circulating media and chemicals.
ANCAP designated priorities to be followed.
b/
Dispose of wastes and cleaning media according to
ANCAP’s instructions.
c/
Maintain records, as required
D.2.11
X
X
X
X
X
X
X
X
X
X
X
X
TEMPORARY SCREENS, STRAINERS AND BLINDS
a/
Provide and
strainers.
Install
all
required
temporary
X
X
b/
Clean strainers as required during circulation and
remove strainers when adequately cleaned
X
X
c/
Provide, install and remove all blinds required for
flushing or operation.
X
X
d/
Maintain the required records on ANCAP’s format.
X
X
D.2.12 PURGING/INERTING
a/
Install purge/inerting connections
b/
Conduct necessary purge operations.
D.2.13
a/
b/
X
X
X
X
HOUSEKEEPING
At completion of construction provide clean-up of
the WORK area. Remove excess materials,
temporary facilities and scaffolding; rough sweep
or rake the area; and pick up trash. Perform
washing or further clean-up as required.
After completion of construction maintain adequate
housekeeping practices, as required for safe
operation.
X
X
X
X
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
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Responsibility of
work
Contractor
D.2.14
Precom- Commismiss'g
sioning
SAFETY
During precommissioning activities, CONTRACTOR shall
ensure all safety regulations and practices imposed by
ANCAP are strictly followed.
D.2.15
ANCAP
Category
of work
X
X
X
X
EQUIPMENT STORAGE
Protect equipment against weather, corrosion, and/or any
other damage up to commissioning
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
D.3
9
SPECIFIC PROCEDURES
In addition to the work to be performed in accordance with paragraph D.2., the detailed procedures
outlined below further define the work to be performed by the CONTRACTOR for specific systems and
items of equipment, when applicable. ANCAP witnessing and verification are required.
PIPING
See construction and commissioning requirements in Appendix L.
ROTATING EQUIPMENT
a/
Pumps run-in during six consecutive hours (at commissioning stage)
b/
Statement of engine intensity, bearing temperature, vibrations and noise (at commissioning
stage)
c/
Engines alignment with their drivers, in the hot state, during 4 weeks. (The cold alignment
and one hot alignment verification during the period)
ELECTRIC POWER
a/
All equipment installed according to drawings
b/
Insulation resistance of all electrical equipment, power & control cables
c/
Earth connections continuity and grounding system resistance measurement
d/
Illumination levels measurements (at commissioning stage)
e/
Conformity with diagrams
f/
Phase rotation for all electric device and checking of motor rotation direction(at
commissioning stage)
g/
For every high voltage feeder: high voltage test (at commissioning stage)
h/
Protective relays testing and setting according to discrimination studies (at commissioning
stage)
i/
Checking of conformity with applicable codes and regulations
j/
Checking of proper installation of equipment, cables etc
k/
Checking of instruments power supply system (at commissioning stage)
INSTRUMENTATION
a/
Cable insulation ( wire to wire and wire to earth)
b/
Conformity with diagrams
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
D.3.5
c/
Mechanical installation and leak tests for all instruments
d/
Range setting for all instruments and valves in conformity with specifications
e/
Instrument air piping installation and tightness tests
f/
Electrical power supply functional test (at commissioning stage)
g/
Alarms & interlocks testing
h/
Control loops functional tests
i/
Seal pots filling
j/
Check inside diameter & and flow direction for calibrated orifices after line cleaning
k/
Setting of pressure relief valves at test bench
10
WATER SYSTEMS ( FIRE WATER, RAW WATER SYSTEM)
a/
Check completeness & correctness of installation, make non operating checks as necessary
b/
Operate fire pumps, if needed, to check output of system ( at commissioning stage)
c/
Provide insurance company inspection of fire system, as required.
d/
Install all required fire fighting chemicals and portable equipment such as hoses, fire
extinguishers and related equipment.
WASTE DISPOSAL
Inspect facilities for completeness and correctness of installation and make any non-operating
checks to ensure their conformance to specifications.
MISCELLANEOUS
Civil engineering
Conformity with drawings, appearance, anchorage, skirt equipment drain,
paving slope, expansion joints, etc...
Steel structure
Conformity with drawings, welds appearance, rain water drains, safe
thermal expansion, etc...
Earthwork, roads
Conformity with drawings, rain water drain, dikes, etc..
Sewer system
Slope, tightness, flow at the flooding value, holiday checking, etc..
Insulation
Conformity with specifications, thickness material, tightness, plate
overlap, etc..
Painting
Conformity with specifications, sand blasting, thickness, adhesiveness
checking, coats number, etc..
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
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Notes
D.4
1/
All the damaged equipment shall be retested (if required, competent Authorities shall be
present during such tests).
2/
All the equipment, built completely or partially on the site shall be hydraulically tested (if
required, competent Authorities shall be present during such tests).
SPLITTING OF PRECOMMISSIONING AND COMMISSIONING ACTIVITIES
Based on and in addition to the specific procedures as defined in D3, is presented hereafter a breakdown
of activities into precommissioning and commissioning. For each activity the involvement of Contractor and
ANCAP is indicated.
Responsibility of
work
Contrac- ANCAP
tor
Category
of work
Precom- Commis
miss'g
sioning
D.4.1 VESSELS
a/
Open vessels after mounting on their foundations.
Open access and nozzles for inspection by
ANCAP.
X
X
b/
Dry internal parts as necessary.
X
X
c/
Close vessel.
X
X
D.4.2 SHELL AND TUBE HEAT EXCHANGERS
a/
Proceed with inspection and tests which
might be necessary after installation at site.
X
X
b/
Proceed with pressure tests as described in
D.2.7.f.
X
X
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
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Responsibility of
work
Contractor
ANCAP
Category
of work
Precom- Commismiss'g
sioning
D.4.3 ROTATING EQUIPMENT (PUMPS AND COMPRESSORS)
a/
Install and grout equipment on their
foundations.
X
X
b/
Correct any abnormal effort on equipment
due to piping connections
X
X
X
X
c/
Proceed with cold line-up
d/
Proceed with hot line-up
e/
Proceed with initial filling of lubricants
X
X
X
X
X
X
X
X
X
X
X
X
D.4.4 PIPING SYSTEM
a/
Proceed with all pressure tests
b/
Install insulation only after pressure tests
c/
Proceed with all line flushing (without
orifice plates or meters)
d/
Install orifice plates or meters after
pressure tests and lines flushing under
the supervision of ANCAP.
e/
Check and adjust pipe supports and
guides in hot conditions
X
X
f/
Correct any problem of support, vibration,
thermal expansion
X
X
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
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Responsibility of
work
Contractor
ANCAP
Category
of work
Precom- Commismiss'g
sioning
D.4.5 ELECTRIC POWER DISTRIBUTION AND LIGHTING
a/
Check continuity of electric connections
X
X
b/
Check insulation of all the cable system
X
X
c/
Check insulation of equipments (electric
motors,
transformers,
accessories,
lighting devices, etc.)
X
X
d/
Check earthing system (continuity and
resistance)
X
X
e/
Calibrate the relays and protection
system to obtain a good selectivity
X
X
Check phase sequences, correct rotation
of motors, polarity
X
X
g/
Check UPS systems
X
X
h/
Connect electric power to substation after
finalization of tests and with participation
of ANCAP
X
f/
X
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LICITACION PUBLICA INTERNACIONAL N° 1600152400
APPENDIX D – CHECKLIST FOR MECHANICAL COMPLETION
14
Responsibility of
work
Contractor
ANCAP
Category
of work
Precom- Commismiss'g
sioning
D.4.6 INSTRUMENTATION
a/
Cleaning and pressure test of hook-up
lines
X
X
b/
Cleaning and pressure test of instrument
air headers
X
X
c/
Check
continuity
of
connections, polarity, etc.
instrument
X
X
d/
Check thermocouples
correct connection, etc.
continuity,
X
X
e/
Identifying and marking the orifice plates
and meters
X
X
Remove, if necessary, the control valves,
the positive displacement turbine meters
during pressure tests of piping line and
re-install them after tests.
X
X
Disconnect hook-up lines during pressure
test of piping
X
X
Calibration of instruments and control of
control loop continuity
X
X
f/
g/
h/
i/
j/
for
Pressure and energize the control
system, open hook-up line after oil-in,
proceed with fine tuning of control loops
after oil in.
Check and adjust set point of relief valves
X
X
X
X
X
X
X
X
X
D.4.7 MECHANICAL AND LOADING EQUIPMENT
a/ Cleaning and pressure test
b/ Check assembly and readiness for operation
14