15MW DMCI MASBATE POWER PLANT PROJECT

Commissioning Manual

PART I – Volume I

GENERAL PROCEDURES AND DEFINITIONS

PART II – Volume II

TEST FORMS, CHECK SHEETS FOR PLANT PRE COMMISSIONING/COMMISSIONING.

PART III – Volume III

PLANT COMMISSIONING PROCEDURES

Part I - Volume I

General Procedures and Definitions

GENERAL PROCEDURES, DEFINITION OF PRE-COMMISSIONING AND COMMISSIONING

TABLE OF CONTENTS

Page No.

1. GENERAL 4

2. MAIN PLANT COMPONENTS 4-6

3. SCOPE OF SUPPLY 6-8

3.1 Process Systems 6-7

3.2 Packaged Units 7
3.3 Electrical and I & C Systems 7-8

4. OUTLINE OF PRE-COMMISSIONING, COMMISSIONING & START UP 9-19

4.1 General
4.1.1 Overall Project Objectives 9-10
4.1.2 Contractual Completion Date 10
4.1.3 Plant Inspection and Test Program (ITP) 10-11

4.2 Pre-commissioning Plan 12-17

4.2.1 Definition of Pre-commissioning 12
4.2.2 Pre-commissioning Steps 12-13
4.2.3 Interface with Construction Activities 13-15
4.2.4 Pre-commissioning Activities 15
4.2.5 Requirements for Pre-commissioning 16
4.2.6 Responsibilities 16-17

4.3 Commissioning Plan 17-19

4.3.1 Definition of Commissioning 17
4.3.2 Commissioning Steps 18
4.3.3 Commissioning Activities 18-19
4.3.4 Commissioning Requirements 19
4.3.5 Commissioning Responsibilities 19

5. PLANNING AND SCHEDULING 19-21

5.1 Pre-commissioning and Commissioning Organization 20
5.2 Commissioning and Performance Test Run Organization 20-21

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 Page No.

5.3 Pre-commissioning, Commissioning Detailed Program and 21

Progress Monitoring

6. COMMISSIONING PERSONNEL 21-

6.1 Organization 21
6.2 Commissioning Manpower 21
6.3 Vendor Specialists 22
6.4 OWNER’s Operators and Maintenance Staff Involvement During Commissioning 22

7. COMMISSIONING COMPLETION 22-23

8. PERFORMANCE TEST RUNS 23

9. HANDING OVER OF THE PLANT TO THE OWNER 23

10. FOLLOW-UP OF OUTSTANDING ITEMS 23-24

11. SAFETY 24

12. APPENDICES 25-139

Appendix I Commissioning Schedule 26

Appendix II Turnover Procedure 28-36
Appendix III Example of a Turnover Package 37-103
Appendix IV Commissioning Staff Organization 104-111
and Job Descriptions
Appendix V Curriculum Vitae (CV) of Key Personnel 112-113
Appendix VI Inspection and Test Program (ITP) 114-120
Appendix VII Procedure to Establish a System for Punch List 121-126
Appendix VIII Permit to Work (PTW) Procedure 127-134
Appendix IX Procedure for Management of Test Instruments 135-136
Appendix X List of Required Instruments, Tools and Consumables 137-139

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1. GENERAL

This procedure gives an outline of the Pre-commissioning, Commissioning, Start-up,Test-runs, Reliability Test
Run (RTR) and Performance Test (PT) activities to be carried-out by NEPC as EPC Contractor for 15 MW DMTPP
Project.

It describes the coordination between the PARTIES involved in the test and commissioning, operations and the
related responsibilities.

The Overall Test and Commissioning Program shall cover all the activities from erection completion to handing
over of the Plant to the Owner/PMT and provides a procedure to cover the follow-up work during the period from
the Provisional Acceptance to the Final Acceptance of the 15MW DMTPP Project.

2. MAIN COMPONENTS OF THE PLANT

The 15MW DMTPP Project is configured and designed to augment the power generation capacity to supply
electric power to the Masbate Grid and it is located in Barangay Tugbo, Mobo, Masbate beside the existing DMPC
Bunker/Diesel Plant .

This power generation facility consists of the following main components:

• One CFB boiler with rated steam flow of 75 t/h, 5.3 MPa rated pressure and 495°C rated SH steam
temperature

• One steam turbine generator and auxiliaries capable of generating 17 MWe

• Thermal cycle systems for the Unit

• Boiler Feedwater Pump System

• Condenser and Ball Cleaning System

• Vacuum Pumps

• Condensate Extraction Pumps

• Deaerator and LP Heat Exchanger

• Chemical Dosing System

• Coal and biomass storage facilities, crushing and handling systems

• Limestone Powder System

• Boiler Bed Material System

• Electrostatic Precipitator (ESP)

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 • Fly and Bottom Ash Handling Equipment

• Compressed Air System

• Water Treatment System:

• Desalination RO units

• Demineralization Plant

• Seawater Intake, Filtration and Water Cooling Circulating System

• Chlorination System

• CCWS system

• I & C and Thermodynamic Automation:

• Distributed Control System (DCS)

• Data Acquisition System(DAS)

• Boiler Safety Supervisor System (BSSS)

• Turbine Safety Monitoring Instrumentation (TSMI), etc.

• 69kV AIS Substation

• MCB, Power and Aux.Transformers, Bus Ducts, MV and LV distribution Systems, Switchgears, Relay
Protection System

• Emergency Safety Power Supply:

• DC System

• UPS

• Emergency Diesel-Generator.

• Cathodic Protection

• Lighting and Socket System

.
• Grounding and Lightning Protection Systems

• Waste Water Treatment System

• Overhead Travelling Crane in Turbine Hall, Maintenance Cranes and Hoists

• HVAC

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 • Fire Fighting Detection, Alarm and Suppression Systems

• Telecommunication System

3. SCOPE OF SUPPLY

The major components and systems have been presented above in order to give the main features and
characteristic of the plant as a whole.

3.1 Process Systems

STEAM TURBINE

ITEM DESCRIPTION CODE NUMBER

1 Main Live Steam
2 Auxiliary and Start-up Steam System
3 Turbine Shaft Sealing (Gland Sealing)
4 Turbine, Vent, Drain and Exhaust Systems
5 Steam Extraction System
6 Lube Oil System and Oil Purifier
7 EH and Jacking Oil System
8 Turbine Alarms, Interlocks, Protection and FG Logic System
9 Feedwater System and Deaerator
10 LP Heater Vents and Drainages
11 Condenser Tube Cleaning Device
12 Turbine Vacuum Extraction
13 Condensate and Make-up System
14 Closed Cooling Water System

STEAM BOILER

ITEM DESCRIPTION CODE NUMBER

1 Light Fuel Oil System
2 Limestone Powder Conveying System
3 Coal Feeding System
4 Biomass Feeding System
5 Start-up Material Conveying System
6 Boiler Feedwater Supply System
7 Startup Burner and Ignition System
8 PAF-SAF-IDF & Dampers
9 HP Fluidizing and Sealing Air System
10 Boiler Flue Gas System

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 11 Boiler SH and RH Live Steam
12 Electrostatic Precipitator (ESP)
13 Bottom Ash Handling
14 Fly Ash Handling
15 Boiler Vent, Blowdown and Drain Systems
16 Sootblowers System
17 Chemical Dosing and Injection System
18 Steam and Water Sampling & Analyzer System
19 Boiler Safety Valves
20 Exhaust Gas Emission Control System (CEMS)

COAL AND BIOMASS HANDLING SYSTEMS

1 Coal Conveying System

2 Biomass Conveying System
3 Dust Suppression System
4 Water Spray System
5 Coal Handling Maintenance Hoist

3.2 Packaged Units

BALANCE OF PLANT (BOP)

1 Seawater Intake and Circulating Water System

2 Seawater Desalination System
3 Electrochlorination System
4 Service and Instrument Air System
5 Plant Airconditioning and Ventilation System
Fire Protection, Alarm and Distribution
6
System

3.3 Electrical and I & C System

ELECTRICAL SYSTEM

Substation PLC, HMI, CONTROL SYSTEM AND

1
METERING AND PROTETION RELAYS
2 Generator Transformer
3 Auxiliary Transformers 13.8/.48kV
3.1 Unit Auxiliary Transformer

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 3.2 Stand-By Unit Auxiliary Transformer
3.3 Start-up Transformer
4 High-voltage Distribution Panel
4.1 13.8kV High-voltage Distribution Panel
4.2 St 13.8kV High-voltage Start-up Panel
5 13.8kV High-voltage Bus-duct
6 480V Low Voltage Bus-duct
7 Emergency Diesel Generator
8 Low Voltage MCC
8.1 Low Voltage Unit UAT PC Panel
8.1 480V Emergency MCC
8.2 480V Unit Auxiliary MCC
8.3 Lighting Power MCC
8.4 Control Power MCC
9 LV Transformer
9.1 Control Transformer
9.2 Lighting Transformer
10 110V DC System (Battery and Charger)
11 UPS System
12 Grounding and Lightning System
13 Lighting System
14 MV and LV Cables
14.1 MV Cables
14.2 LV Cables
15 Electrical Motors
16 Communication and CCTV System
17 Fire Detection and Alarm System
18 Generator Panels
18.1 Generator VT Panel
18.2 Generator Neutral Panel
18.3 Generator Control panel

I & C SYSTEM

1 Local PLC Control System

2 Distributed Control System (DCS)
3 Data Acquisition System

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4. OUTLINE OF PRE-COMMISSIONING, COMMISSIONING AND START-UP

4.1 General

The Pre-commissioning and Commissioning Plans mainly define the following:

- The activities that must be carried-out to reach a safe and successful start-up of the Unit.

- The activities necessary to be completed before the conduct of pre-commissioning and commissioning
activities.

- Time frame of the main activities that must be completed in order to reach the target dates of
Provisional or Final Acceptance in accordance with the Overall Project Master Schedule.

- Main checks and tests with brief procedures/instructions to be carried out as part of pre-commissioning

- Commissioning, Start-up Procedures and Test Run to be carried out as part of Commissioning.

- Commissioning organization and manpower deployment in accordance with the schedule and as per
priorities and in accordance with the agreed schedule.

- The coordination procedures among the various groups involved in the test & commissioning and plant
operations, identifying individual responsibilities.

- Involvement of the Owner/PMT during pre-commissioning and commisioning.

- Sequence of operations leading to start-up and Provisional or Final Acceptance.

- Documents to be prepared for Owner/PMT’s approval and future use.

4.1.1 Overall Project Objectives

The construction/installation activities in their final phase shall lead to erection completion. At this
stage, the facilities shall be ready for the pre-commissioning activities and eventually for
commissioning activities. The later shall employ the use of process fluids in actual operation
conditions leading to start-up of the Unit.

The main objectives while carrying out these activities shall be:
- To provide a safe and reliable functioning of the systems/units, with an aim to achieve the goal of
producing the contractual electrical power;
- To ensure proper documentation for Owner’s future use;
- Ensuring that Owner’s operational staff are capable of handling the operations through proper
involvement in accordance with the training programs;

The Pre-commissioning and Commissioning Plan for various Systems/Units shall be prepared
indicating all the inputs, supports required and their timing well defined.

The Plant shall be subdivided into Turnover Packages (TOPs) so that each one can be pre-
commissioned separately without interfering with the others, either still under construction or not

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 completely ready for pre-commissioning (refer to Appendix II - Turnover Procedure).

The procedures shall include the list of documents and test records that shall be used and generated
in obtaining Commissioning Completion Report for each turnover package.

A full-pledged team to carry out these activities under the leadership of the NEPC Commissioning
Manager shall be mobilized at site in accordance with the Construction/Commissioning Schedule.

The Commissioning schedule and manpower plans are discussed in a subsequent section of this
manual.

4.1.2 Contractual Completion Date

The Guaranteed Project Completion Date for 15MW DMTPP Project as per DMPC-NEPC EPC
Contract is 16-October-2019.

4.1.3 The Inspection and Test Program (ITP)

The Inspection and Test Program is the basic element of pre- commissioning and commissioning
documentation. The ITP lists and defines all the activities to be carried-out and the forms to be used for
the parts or components to be commissioned.

It shows the inspection and test sequences to be performed to bring the plant from initial condition of
erection completion up to the final condition of “plant in operation” on each system/unit included in the
scope of supply. It gives reference to documents, procedures, test forms, checklists, applicable
drawings and manuals to be used as guideline for the specific step, and the type of quality record.

A graphical representation of the inspection and test program in the next page shows diagrammatically
the composition of the documentation associated to each system/unit of the plant.

The ITP gives the indication about the “witness” or “hold” points by NEPC, Owner/PMT or Third
Parties (if required).

Witness and hold points agreed with Owner/PMT are entered into the final negotiated version of the
ITP. The Owner/PMT will be informed of readiness for such witnessing within the period agreed upon.

In case of inspections defined and agreed as witness points but the witnessing party is unable to
participate on an agreed date, the inspection will be performed by NEPC and the work will be
continued.

In case of acceptance test by official authorities, the work will be stopped until the witnessing party is
able to attend. In such case, NEPC shall not be held responsible for the delay.

Where a joint inspection is mentioned, it is proposed that both NEPC and Owner/PMT’s
representatives attend to witness the inspection.

In case of inspections defined as Owner/PMT’s hold points, the work will be stopped until witnessing
party will be able to attend or witnessing is officially waived. Delay resulting from failure to respond to
the notification will not be the responsibility of NEPC.

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 The ITP for the whole plant is shown in Appendix III. The test forms are in a separate volume titled
“Commissioning Manual (Volume II, Part II – Standard Test Forms)

DIAGRAMMATIC DEFINITION OF INSPECTION AND TEST PROGRAM

Erection
Completion

Turn Over
Package

INSPECTION AND
TEST PROGRAM

Forms I&C KKK

Forms MEC XXX
Forms ELE YYY
PRE
COMMISSIONING
Ready for Start

Vendor’s Documents

Drawings/P&ID,Flow COMMISSIONING
Diagrams Special Procedures
(If applicable)

(If applicable)

(If applicable)

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4.2 Pre-commissioning Plan

4.2.1 Definition of Pre-commissioning

Pre-commissioning is defined as those activities and tests necessary to achieve readiness for
commissioning stage and carried-out in accordance with contractual requirements.

The pre-commissioning is carried out on the individual equipment of a turnover package without the
final fluid but with auxiliary electrical power and main electrical power supply.

During this stage, the following minimum requirements shall be made available:

• Auxiliary and main power supplies for motor bumping, phase rotation checks and for flushing and
blowing operation.
• Accessories for flushing and blowing-out
• Instrument air
• I&C systems (DCS-PLC)

4.2.2 Pre-commissioning Steps

NEPC can start pre-commissioning after the issuance of the Handing Over Certificate as described
Appendix II - Turnover Procedure.

Prior the start of pre-commissioning, the Turnover Package (TOP) must be put in a clean, tight and
secured condition, properly managed with defined battery limits.

Prior the start of pre-commissioning, all punch list works are completed to the extent that it will not
affect the conduct of pre-commissioning activities. Clearing of all Category A punch list points is
defined in Appendix VII - Punch List Procedure.

The pre-commissioning activities on each turnover package are indicated in the Inspection and Test
Program (ITP). In this program, the referenced design document or the standard test form or the
relevant special procedures that are to be considered for each activity listed is also indicated. A brief
explanation of the tests to be performed and a log sheet for recording the data in the field are outlined
in each of the standard test forms.

The ITP also shows an indication for the tests in which the witnessing by the Owner/PMT is required
as per previous agreement.

NEPC’s Commissioning Team shall perform the following activities with the support of the
subcontractor’s labor (in certain cases with the presence of the Owner’s operators), prior the
declaration that the unit/system is ready for commissioning.

• Equipment Inspection
• Flushing, blowing, drying of lines and equipment
• P & ID conformity check
• Loop checking with DCS or PLC energized
• Valve Stroking (motor operated and pneumatic actuated)

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 • Cold test of trip and interlocks with DCS or PLC energized
• Installation/removal of accessories for pre-commissioning
• Load chemicals, resins, etc.
• Check rotation alignment for rotating machinery
• Status of locked-open/locked-closed valves
• Valves line-up
• Pre-energization test and checks on electrical equipment
• Documentation check-out

4.2.3 Interface with Construction Activities

For each Turnover Package, the completion activities to be performed in the final stage of construction
are identified and listed to give input to the Erection Team in planning their priorities and at the same
time allow the Commissioning Team to perform the necessary checks and inspection accordingly.
This kind of interface helps to facilitate the pre-commissioning activities to be successfully and
meaningfully carried-out.

The activities normally carried by the Erection Team in the final phase of construction with the pre-
commissioning checks and inspection being carried-out simultaneously can be broadly listed as
follows:

a. Vessels
- Internal inspection and cleaning of vessels, before installation of internals
- Field installation of internals in the erected vessels duly inspected before hand-over and
checks to be carried-out in accordance with erection specifications
- Hydrostatic testing, when required
- Perform purging of equipment, when required
- Checking of insulation

b. Heat Exchangers
- Check of supports, guides and anchors to ascertain that they can expand in the correct
manner
- Check tube bundles, nozzles, etc.
- Cleaning and flushing of tubes

c. Pumps/Compressors and Drivers

- Installation and cold alignment of pumps with appropriate drives
- Final cold coupling of pumps, pump drives with piping connected
- Installation of temporary gland seal, if final mechanical seal is not suitable for flushing
- Cleaning of piping
- Lube oil flushing
- Installation and cold alignment of compressors with appropriate drives
- Cold alignment of drives and auxiliary machines with appropriate auxiliary drives
- Check of possible piping stresses on nozzles/flanges due to connections
- Inspection of connected pipes to verify their cleanliness and to ensure that there is no welding
imperfections/wastes
- Installation of provisional and/or final filters on sections/sides of machines
- Direction of rotation on de-coupled conditions
- Change of lube oil, seal oil, etc. as per Vendor’s instruction

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 - Presence of Vendor’s specialist during these phases, when required
- All checks as per P & IDs

d. Boiler
- Check that refractory materials have been correctly laid
- Check and removal of all temporary supports and blocks
- Check that various components can expand in accordance with drawings and specifications.
- Hydraulic testing
- Removal of testing water
- Cleaning of boiler by boil-out or chemical methods
- Checking against P & ID’s
- Package Control System checks

e. Piping
- Check of valve glands
- Check of piping arrangement in general, installation of valve & instruments as per P & ID’s
- Hydrostatic or pneumatic test, as required by the codes, specifications, supply and installation
of temporary blinds
- Flushing and draining of the systems after hydraulic test
- Draining of the system, removal of temporary blinds, and installations of gaskets, as required
- Checking that no water remains in piping and equipment
- Check of pipe hangers, supports, guides, expansion joints, etc. to verify the removal of all
shipping and erection stops and the correctness of cold setting for the design service
- Flushing steam of steam pipelines
- Air blowing of large lines, as required

f. Miscellaneous Mechanical Equipment

- Check the mechanical equipment such as overhead travelling cranes, mixers, fans, filters,
steam traps, etc. are installed in accordance with Contractor’s and/or Vendor’s requirements
and approved drawings

g. Tanks
- Check that instruments and accessories are correctly assembled
- Hydraulic test and check of foundation settlement
- Removal of foreign bodies from roof and bottom
- Fit final gaskets and close flanged connections and manholes
- Check of cathodic protection installation

h. Instrumentation
- Conduct any non-operating checks to ensure instrument operability
- Clean all transmissions, air supply header control tubing by blowing cooled & filtered clean air
- Carry out hydraulic or pneumatic tests of process primary connections
- Check connections on ”control loops and interlock system” both for pneumatic and electrical/
electronic instruments
- Check installation of all thermometers and pressure gauges - check proper connections,
tightness of joints
- Calibration of set point of pressure switches, thermostats, level switches
- Installation and connection of all system components and verification of their conformance to
specifications

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 - Check out associated PLC’s

i. Packaged Units
- Check that mechanical/electrical/instrumentation equipment are installed in accordance with
Project Specification and approved Vendors’ Drawings.
- Make all non-operating checks that may be required.
- Check conformity of Package & Plant P & I D’s.

j. Electrical Parts
- Insulation tests on all wiring
- Insulation tests on motor and transformer windings from phase to phase and phase to group
- Grounding system tests to determine the continuity of connections and the value of resistance
to ground
- Perform trial and adjustment on LV switchboards and motor control equipment
- Checks of all control system wiring
- Testing and setting switchgears and circuit breaker relays for proper coordination
- Check of installation of emergency power and lighting system, including illuminated levels
- Check of the interlocking system of motor and motorized valve
- Check of cathodic protection installation

4.2.4 Pre-commissioning Activities

With the above checks and tests and when the Plant is mechanically and structurally complete, all
systems have been put in a tight and clean condition, all punch list points have been attended to and
vendors requirements have been taken into consideration, the subsequent pre-commissioning
activities can be started.

The detailed list of pre-commissioning activities are shown in Inspection and Test Program, which in
general can be summarized as follows:

- Flush or blow the Systems

- Remove, test and re-install safety valves
- Check electrical equipment and circuits
- Run-in electric motors
- Check instrument loops
- Test control valves
- Prepare and install temporary strainers
- Water fill equipment for pumps run-in
- Run-in pumps and drain water
- Clean strainer and re-install
- Check machine alignment after flushing
- Fill rotating machine with lube oil
- Circulate rotating machine lube oil
- Check rotating machine alarm and shut-down systems
- Check system tightness
- Check fire fighting equipment
- Charge fuel system
- Energize electrical equipment

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4.2.5 Requirement for Pre-commissioning

In order to perform the pre-commissioning activities in a smooth and uninterrupted manner the
following pre-requisites are to be considered:

- All the necessary tools and equipment required for testing are available in proper working
conditions and duly calibrated (see Appendix X - List of Tools, Instruments and
Consumables);

- The working group such as the operators and technicians are fully familiarized with the process
and operation of the plants;

- The main utility, which is the uninterrupted and regulated electric power is available.

The dedicated substations are ready to be energized and the “Work Permit System/Forms” has
been prepared and applied as described in Appendix VIII - Permit to Work Procedure during
Commissioning.

- Instrument Air System is available;

- Treated water for various purposes such as flushing & hydrotest is available;

- Fire fighting is tested and in service;

- Oil free air is available to blow the biggest lines/equipment. For this purpose, portable air
compressors may be utilized instead of main air compressors in case of non-availability of the
Plant’s main air system.

- For boiler auxiliary burner firing, the light fuel oil is available, which means that it shall be already
hydraulically tested and flushed with valves/instrumentation systems properly checked and
tested.

4.2.6 Responsibilities

NEPC shall be responsibility in the proper Planning and Scheduling of its activities, submit to
Owner/PMT the detailed schedule and procedures and co-ordinate the activities in the field involving
the subcontractors and Vendors personnel/specialists.

NEPC personnel, who shall report to NEPC Commissioning Manager, shall coordinate and supervise
all the operations/activities to be performed during Pre-commissioning, Commissioning, Reliability
Test Run (RTR) and Performance Test (PT). They shall also ensure that all the activities performed
conform to the relevant specifications, operating instructions and established procedures.

Vendor specialist services shall be called with the specific duty to check the equipment or package
installed.

Upon arrival of the Vendor’s representative at Site, a brief meeting, attended by NEPC and

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 Owner/PMT representatives, will be held to discuss Pre-commissioning and Commissioning Plan and
personnel requirements.
Prior to leaving the Site, each Vendor’s representative shall prepare a report summarizing the checks
and test performed.

The authorized Owner/PMT’s representatives, as the witnessing parties, shall countersign the report
issued for most of the pre-commissioning activities.

NEPC shall perform all the required pre-commissioning activities, accordingly to established standards
and the standard operating procedures.

NEPC shall keep a correct and complete record of all pre-commissioning activities and shall prepare
and submit appropriate reports to Owner/PMT.

NEPC inform the Owner/PMT regarding the readiness of turnover packages and notify them for
proceeding with the pre-commissioning activities for the said package.

NEPC shall carry-out rectification/addition/completion of work within the limits of the contract, if so
required by the Owner/PMT.

Upon completion of pre-commissioning of the portion or section of the Plant, NEPC shall submit to
Owner/PMT all documents pertaining to the pre-commissioning activities.

4.3 Commissioning Plan

4.3.1 Definition of Commissioning

Commissioning means all the works, activities and tests associated with start up, performance tests
and operation of the installations up to the plant Provisional or Final Acceptance.

The commissioning starts with the operational tests of the package or system with the final fluids
being loaded and the process starts to work to produce energy, steam or water as per intended
purpose.

These include but not limited to: running-in of equipment, performing all the possible mode of
operations, tuning in steady conditions, test and the stability of the protections, tuning in transient
conditions, test of the stand-by equipment, etc.

During this period, it is NEPC’s responsibility to make continuous adjustments to reach the best
system operation configuration.

When the adjustments are completed and the Plant has its final configuration, it is declared as ready
for start up.

The start-up is defined as the activities and tests that can prove its operability in transient and steady
conditions without any further adjustments.

The Performance Tests are the steady condition tests having the scope to demonstrate the specific
performance guarantees.

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 For these last tests, special instrumentation shall be used and a dedicated procedure shall be issued.
4.3.2 Commissioning Steps

The commissioning can start when all the pre-commissioning activities related to a commissioning
package are mechanically completed and certified.

The commissioning activities to be carried out in each commissioning package are listed in the
Inspection and Test Program (ITP) and are described in details for each equipment or component in
the corresponding test forms or special procedures/instructions. The forms include also the checklists
to verify readiness for start-up.

A certain sequence must be followed as there are requirements necessary to start the commissioning
of a package that are available only from other commissioning packages and/or systems. This
commissioning sequence can be traced from the commissioning program described in Section 5 of
this manual.

In the ITP, as previously explained in the section of pre-commissioning, the tests that are required to
be witnessed by the Owner/PMT Inspectors are indicated.

All procedures and documents related to a commissioning package together with those for pre-
commissioning shall be submitted to Owner/PMT prior the start of commissioning.

NEPC shall request in writing the requirements for fuel oil, coal and other media requirements and
shall coordinate with Owner/PMT’s personnel for the introduction of the same into the Plant for
commissioning in a timely manner.

At the end of the commissioning activities, the duly filled-up and signed documents shall be compiled
by the NEPC Commissioning Manager and submit them together with the Commissioning Completion
Report.

4.3.3 Commissioning Activities

The main activities to be carried out during commissioning include but not limited to the following:
- Run-in electric motors
- Water fill equipment for pumps run-in
- Run-in pumps and drain water
- Energize electrical equipment
- Hot alignment checks, necessary adjustments and running of component parts as a unified
system
- Electrical protection stability test, turbine and boiler protection test
- Overall plant operation and functional test
- Steady operation, transient operation and process tuning at various loads
- Emergency take-over of main auxiliary
- Cold, warm and hot plant start-up
- Load run back test and load rejection test
- Overall Test on Completion, flue gas emission, noise measurement test, liquid effluent test
- Fire alarms and gas detectors functional checks
- Fire fighting system functional checks

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 - PLC and DCS functional tests (cabinets)
- First filling of chemicals
- Running-in of pumps
- Maintain daily commissioning log sheet of running equipment
- Verify proper operability of equipment
- Instrument testing
- Setting and tuning of control system

After commissioning and start-up activities, Performance Test runs shall be carried out leading to
Provisional or Final Acceptance.

4.3.4 Commissioning Requirements

To carry out the commissioning activities, NEPC and Owner/PMT shall provide the following
requirements in compliance with contractual obligations:

NEPC shall:

• Ensure that all consumables and chemicals to operate the equipment and systems are readily
available.
• Provide qualified commissioning staff and specialized manpower to carry out commissioning
activities in accordance with the contract.
• Be responsible for the timely presence of Vendors specialists who shaill assist NEPC’s
commissioning personnel during commissioning and start-up of the Unit.

OWNER shall:

• Provide NEPC the fuels and other consumables according to the contract and load configuration
requirements
• Allow NEPC to store or use the water produced by the Water Treatment Plant prior the Provisional
or Final Acceptance.
• Ensure that the operators and maintenance staff are available for the required orientation and
training as per required discipline and agreed number.

4.3.5 Commissioning Responsibilities

At the completion of all the activities, the NEPC Commissioning Manager, after collecting all the
supporting documents (signed forms/checklists, special procedures and instructions, ITP
requirements, etc.) shall issue the Commissioning Completion Report to the Owner/PMT.

5. PLANNING AND SCHEDULING

The Overall Teast and Commissioning Program has been developed based on the operational priorities
respecting the contractual completion dates for Provisional or Final Acceptance:

The program has been developed taking into account that some utilities could be temporarily provided in the initial
stage prior commissioning of the main unit such as instrument air and demineralized water supply.

Temporary electrical power (13.8kV) must be made available at the substation from the very beginning of pre-

Page 19 of 139
commissioning activities for the energization of substation boards until stable power is provided from a permanent
source.

A detailed commissioning schedule shown on Appendix 1 has been prepared by NEPC for 15MW DMTPP Project
taking into account the use of all the permanent Power Plant facilities and equipment.

The commissioning sequence takes into consideration the following steps:

1. Energization of DC system, 69kV AIS Substation, Main Transformers, MV System, Control Room Systems
2. Start-up of fire fighting
3. Start-up of other Sea Water Cooling System, Chlorination, R.O., Demi Water, CCWS
4. Start-up of Main Boiler
5. Start-up of package units and process systems like Coal Handling, Compressed Air ,etc.
6. Start-up of Thermal Cycle and Steam Turbine
7. Generator Protection Stability Test and Synchronization Test

5.1 Pre-commissioning and Commissioning Organization

All pre-commissioning and commissioning activities for the whole plant shall be performed by specialized
manpower provided by NEPC in accordance with its contractual obligations.

These activities shall be performed under the supervision of NEPC Commissioning Manager and his staff in
close coordination with the Owner/PMT.

NEPC commissioning personnel shall prepare the equipment or packages assisted by skilled personnel
provided by Sub-contractor and in special cases at the presence of the Vendor Specialists.

During pre-commissioning and commissioning activities, the Owner’s operating personnel shall follow all the
required operations carried out under the responsibility of NEPC commissioning personnel, and coordinated
by NEPC’s Training Coordinator.

The Pre-commissioning activities shall be intended as the best time for the Owner/PMT’s operations and
maintenance personnel to:

- Familiarize with the Unit

- Familiarize with all the procedures and sequence involved in the subsequent start-up
- Participate even on shift schedule, in specific operations such as machinery running-in, loading or other
test on-load
- Be involved in pre-commissioning operations in collaboration with NEPC personnel
- Participate and witness the testing and energizing of electrical equipment
- Associate with Vendors specialists in setting-up machinery and performing special test

5.2 Commissioning and Performance Test Run Organization

• Commissioning operations will be performed by NEPC commissioning personnel supported by

Owner/PMT’s operation personnel and assisted by NEPC’s construction specialized manpower and
discipline engineers.
• Vendors’ representatives will assist the commissioning personnel during the first period of operation of
special equipment or system.

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 • All personnel involved in start-up activities, shall work round the clock on eight or twelve hours shifting,
as the case may require.
• NEPC’s commissioning organization chart and the staff assignment chart are shown in Appendix IV –
Commissioning Staff Organization and Job Description.

5.3 Pre-commissioning, Commissioning Detailed Program and Progress Monitoring

A detailed program is developed based on the established Overall Project Master Schedule previously
agreed by NEPC and Owner/PMT.

Each activity on the master schedule shall be broken down further (Detailed Schedule) to show a more
detailed sequence of the tasks to be performed.

This Detailed Schedule shall be used as reference in implementing the day-to-day activities and in
monitoring progress of pre-commissioning, commissioning, and start-up.

Each task shown on detailed schedule activity shall be weighted based on estimated manhours calculated
from the quantity of work to be performed (e.g. no. of loops, no. of drives, etc.) and NEPC’s standard
productivity for the respective tasks. These task’s weight shall be used to roll up the progress of the master
schedule activity which in turn shall be used in updating the Overall Project Schedule from where the
required progress curves (S-curves) are generated.

The detailed schedule of commissioning activities for 15MW DMTPP Project is shown in Appendix I.

6. COMMISSIONING PERSONNEL

6.1 Organization

The organization chart for NEPC commissioning staff is shown in Appendix IV – Commissioning Staff
Organization and Job Descriptions.

Owner’s personnel having undergone intensive classroom training sessions shall be associated with the
NEPC Commissioning team in their respective disciplines.

NEPC shall utilize OwnerPMT personnel during the commissioning in a manner to take the Unit towards
successful Provisional or Final Acceptance and also to prepare them to take over the responsibilities of the
operations thereafter. However, the entire responsibility for the commissioning activities remains under
NEPC’s obligation.

6.2 Commissioning Manpower

Skilled manpower and technicians to support the commissioning engineers shall be NEPC’s direct hire
personnel though to some extent shall be provided by erection sub-contractors, if any, as they are already
aware of the activities carried-out during construction on the various equipment and systems and they are
already familiar with the method of work.

NEPC personnel assignment chart (mobilization schedule) is shown in Appendix IV - Commissioning Staff
Organization and Job Descriptions.

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 6.3 Vendor Specialists

Vendors specialist will be called to the site with at least two (2) weeks advance notice according to the
commissioning schedule.

They shall be selected considering:

• High performance machinery

• Specific and sophisticated equipment
• Packages unit
• Special contractual requirements

These specialists shall assist NEPC commissioning personnel in the preparation of relevant equipment or
package. They will be coordinated by NEPC commissioning engineers.

Before leaving the site, each Vendor shall prepare a suitable Report and Test Forms summarizing the tests
performed, the reading parameters and situation of the equipment or package, specifying on details:

• Missing parts and expected delivery date

• Faulty devices and expected replacement date
• Faulty performance and propose change / actions to overcome the deficiencies.

A Vendor assistance schedule of pre-commissioning and commissioning activities shall be prepared in

accordance with the detailed commissioning program. (The vendor assistance can be rescheduled
accordingly to the work progress).

Assistance of Vendors not foreseen in the schedule may be requested when strictly necessary to solve
specific problems and when the need arises.

6.4 Owner’s Operation and Maintenance Staff Involvement during Commissioning

During the commissioning, NEPC shall fully involve the Owner personnel whom, after having undergone
training and having been associated with some pre-commissioning activities, would be by then, fully
acquainted with operational aspects of the Unit.

It is during the commissioning phase that the Owner’s Operations personnel shall obtain the complete
command over the operating parameters, calibrations and controls, settings, start-up and shutdown
sequence, DCS operations, generation of reports, etc.

The Owner’s Maintenance staff shall as well get a great advantage of being involved in the preparation of
equipment and machinery.

7. COMMISSIONING COMPLETION

Upon completion of the commissioning works as documented via test certificates and reports duly-noted,
witnessed and accepted by the Owner/PMT related to each turnover package, such that they are fully ready for

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 operation, a commissioning completion report shall be prepared and submitted by NEPC to Owner/PMT.
The standard format in the preparation of completion report is shown in Appendix V- Commissioning
Completion Report.

8. PERFORMANCE TEST RUNS

Plant Performance Test Runs shall be performed by NEPC together with Owner/PMT’s properly qualified
appointed personnel (and with assistance of the Vendors / Licensors when required).

Performance Test Runs will be performed to ascertain whether the Plant can attain the process performance
guarantees as specified in the EPC Contract and the Owner’s Operations personnel/PMT shall witness these
tests.

Detailed performance test procedures shall be issued by NEPC and approved by Owner/PMT prior the execution
of the tests.

9. HANDING OVER OF THE PLANT TO OWNER

The Plant shall be handed over to Owner/PMT at the date of the Provisional or Final Turnover Completion (PTOC
or FTOC) date. At this stage, all the plant equipment, systems and components have been started-up and
successfully tested.

Owner/PMT operating personnel have been fully involved in the work since the pre-commissioning stage and
should be acquainted with all the commissioning procedures and normal operation of the Unit.

NEPC shall give the required handing over documents pertaining to their scope of supply. NEPC Commissioning
Manager shall compile all documentation pertaining to the commissioning operations in a specific hand over
dossier, arranged by systems/units, which will contain all the information required to demonstrate to the
Owner/PMT that the plant has reached the PTOC or FTOC date.

The dossier will include the following:

• Provisional or Final Acceptance Certificate, whichever is appropriate

• System “As Built” Drawings
• Commissioning Completion Reports
• Performance Test Report/Result
• Punch List or Outstanding Work and Deficiency List
• Noise Mapping Levels and Plant Emission Levels
• Plant Room Keys

All punch list items detected during all the phases from pre-commissioning throughout the test run activities shall
be duly-acted upon by NEPC subject to Owner/PMT approval/acceptance.

10. FOLLOW-UP OF OUTSTANDING ITEMS

All Plant defective items, process and/or engineering faults detected during all the phases of the work/preparation
will be repaired, replaced or remedied, as the case may be, as soon as the problems are identified and defined.

Such defect or faults should not be confused with improvement that Owner/PMT may request.

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 Plant improvements shall be treated separately and shall be considered exception from the Provisional or Final
Acceptance Certificate issued by Owner.

Throughout the Defects Liability Period (DLP), NEPC shall provide status updates regarding site and/or DMPC
Head Office follow-ups of the pending problems/issues listed in the punch list until satisfactory solutions have
been formulated and carried-out.

A system for the proper follow-up and closing of outstanding items is presented In Appendix VII - Punch List
Procedure. In this procedure, the database system and the method of follow-up of such outstanding items by
NEPC are explained in detail.

11. SAFETY

The avoidance of accidents involving injury to personnel or damage to equipment is to be a major objective in the
performance of the work.

NEPC shall appoint an experienced and qualified person as safety supervisor who will prepare all those
procedures to make the pre-commissioning, commissioning and start-up operations safe.

These procedures that are already being utilized by NEPC Construction Team are to be implemented keeping in
mind the fact that during the execution of pre-commissioning and commissioning activities, electrical power,
utilities and process fluids are present.

Other important argument to be highlighted in these procedures is the safeguarding of those sections where the
erection works are still in progress while parts of the Unit are already in operation. This involves the proper
implementation of the Permit to Work Procedure as described in Appendix VIII and definition of
“Commissioning Battery Limits” which is well explained in Appendix II - Turnover Procedure,.

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12. APPENDICES

Appendix I - Plant Commissioning Schedule

Appendix II - Turnover Procedure

Appendix III - Example of a Turnover Package

Appendix IV - Commissioning Staff Organization

and Job Descriptions

Appendix V - CV of key personnel

Appendix VI - Inspection and Test Program

Appendix VII - Procedure to Establish a System for Punch List

Appendix VIII - Permit to Work Procedure during Commissioning

Appendix IX - Procedure for Management of Test Instruments

Appendix X - List of Instruments, Tools and Consumables

During Commissioning

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 Appendix I

PLANT COMMISSIONING SCHEDULE

Page 26 of 139
(Attach the Commissioning Schedule in this page)

Page 27 of 139
 Appendix II

TURN OVER PROCEDURE

(A GUIDELINE FOR A SYSTEMATIC HANDING-OVER OF COMPLETED
SYSTEMS / PACKAGES FROM ERECTION TO COMMISSIONING)

Page 28 of 139
1. SCOPE

• Identify systems / turnover packages to be handed over from construction to commissioning.

• Outlines the boundary of responsibilities.
• Defines the procedure of handing over a system / packages.
• Defines the completeness of a system / package before handing-over to commissioning.

2. REFERENCES

The turn-over of completed systems from construction to commissioning are carried-out on the basis of the
following project-related documents, as applicable:

• P&I Diagrams
• Functional Control Drawings or Logic Diagrams
• Instrumentation Loops
• Single Line Diagrams
• Cabling and Interconnection Lists
• Layout Drawings
• Equipment List.
• Equipment Data Sheet
• Tie-in List.
• Punch List Procedure.
• Pre-commissioning and Commissioning Procedure.
• Inspection and Test Programs
• Contract and Technical Specifications
• Project Quality Plan
• List of Turnover Packages
• Commissioning Logic Diagram

A copy of the above listed documents shall be provided by NEPC Commissioning Team. .

3. DEFINITIONS AND ABBREVIATIONS

3.1 Erection Completion

Erection completion is achieved when all the equipment included in a package or system have been
installed according to the erection documents and all the checks that do not need main power, auxiliary
power, final fluids, compressed air, etc. have been successfully carried-out in accordance with speific
plant documents.

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 As a general rule, erection completion is achieved when the following conditions are fulfilled:

• System is fully operable

• All equipment set on foundation grouted and aligned
• Pumps, motors, valves, etc. are lubricated and ready for operation
• Piping erected, hydrotested and with the supports cold setting done
• Electrical and instruments calibrated, installed, connected and wired
• Insulation checks done (meggering, high voltage pressure test, etc.)
• Punch List consolidated and accepted by all parties
• Working area is clean and safe
• All components are labeled/tagged according to contractual requirements
• Final check is performed for completeness of components

3.2 Turn Over Packages

Turn Over Package (TOP) is defined as a systematic grouping of equipment and/or components
interconnected and interrelated in such a way that all together, it can perform an operation and/or specific
function (Example: to feed water to the Boiler).

From this view point, it is consequential that, to perform an operation function, the TOP should include
mechanical equipment, electrical equipment, I&C equipment and all the interconnections in between as
well as the Plant Operator interface.

One TOP can include a full system or a sub-system depending on the criticality and sequence of pre-
commissioning and commissioning activities.

That means that, when a TOP is accepted for pre-commissioning, all the equipment and components
related to that particular TOP are ready to work/operate.

3.3 Terminal Points

From the moment when a package is turned-over from the Erection Team to the Commissioning Team
for the execution of pre-commissioning and commissioning activities, it will be energized or charged with
fluids which involve risks if not properly monitored and controlled. For that reason, each TOP should be
contained within a boundary of isolation points (Terminal Points) in order to prevent any untoward
incident to the Erection Team who could still be working, outside this limit, on other TOPs.

Any erection work inside the boundary of the terminal points shall be handled in accordance with the
“Permit to Work Procedure”.

The terminal points should always be in the form of breakers, isolators, valves, removable links, blind
flanges, fuses, etc. which can isolate a system. All terminal points of any system not turned over must be
in a safe condition (e.g. breakers racked out, valves locked with proper locking device if available or with
chain and padlock).

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4. APPLICABILITY

This procedure is applicable to the 15MW DMTPP Project under NEPC‘s scope of work.

5. RESPONSIBILITY

5.1 General

Construction Team shall be responsible for all works related to any system prior to handing-over; that is
when erection completion is achieved (see definition in Section 3.1)

5.2 Responsibility of Construction Team After Handing-Over

Construction Team shall be responsible to support the Commissioning Team in undertaking the following
activities after hand-over:
• Temporary erection work for testing or flushing (e.g. piping for steam blow out or condensate system
flushing) including removal and restoration
• Correction of errors in construction (e.g. wire swap of motors)
• Final assembly (e.g. assembly of definitive components after testing and flushing)
• Execution of Punch List items

5.3 Responsibility of the Turn-Over Engineer

The main responsibility of the Turn Over Engineer shall be as follows:

• Identify the systems / packages to be handed over to commissioning and prioritize according to the
established sequence of commissioning
• Preparation of the necessary documentation for each system/package and coordinate the actions with
the Construction Team to achieve erection completion according to the requirements of
commissioning
• Categorization of Punch List
• Organize the “Final Inspection” to check and verify or approve for erection completion of each system
/ package

5.4 Responsibility of QA/QC Department

QA/QC shall guarantee that the work is done according to established quality standards by undertaking
the following activities according to approved QA/QC procedures:

• Inspections
• Documentation
• Non-conformance
• Review of Punch List

5.5 Responsibility of Safety Engineer

• Ensure strict compliance to health and safety environment procedure in the place of work
• Verify status of terminal points for each commissioning package
5.6 Ensure proper implementation of Permit to Work (PTW) Procedure

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 5.7 Responsibility of Commissioning Team

Commissioning Team shall execute the activities including but not limited to the following:

Pre-commissioning Checks:
• All I & C tests that needs DCS energized
• Oil flushing
• Water flushing / air blowing
• Steam blow-out
• Motor test-run (rotation, power)
• Calibration and adjustment of components
• Chemical cleaning
• Protection system for generators and transformers

Commissioning Start-up and Optimization:

• Functional tests
• Regulation adjustments
• System start-up

6. DOCUMENTATION AND IDENTIFICATION OF TURN-OVER PACKAGES

From the detailed commissioning sequence, the Turn-Over Engineer shall identify the Turn-Over Packages
(see Attachment B) of which the extent shall be mutually agreed between the Construction and
Commissioning Teams. For each one of these TOPs, the following documents shall be prepared:
• List of equipment included in the package
• List and status of the terminal points
• List of outstanding work (punch list) with category
• List of pre-requisites for erection completion
• Inspection and Test Program (ITP) for pre-commissioning and commissioning
• Marked-up P & IDs, mechanical Flow Diagrams, Single Line Diagrams (SLDs) and other applicable
documents/drawings

7. PROCEDURE TO ACHIEVE ERECTION COMPLETION FOR EACH T.O.P.

The procedure described herein is summarized in the attached flow diagram (Attachment A).

7.1 The documentation listed in Section 4 is prepared by the Turn Over Engineer long in advance and
distributed to the Erection Team. This documentation becomes the guide for the planning and
execution of all the erection completion activities and finishing works (pre-requisites for erection
completion) associated with the package.

7.2 The inspection forms related to each TOP are filed and collected by QA/QC.

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7.3 The checklist associated to a TOP are filled-in by the Discipline Supervisors; the completion of
outstanding works and remedial actions shall be verified by the Turn Over Engineer and Discipline
Supervisors during the inspection checks.

7.4 The punch list of the system or turn over package inspected is prepared by Construction, updated and
categorized by Turn Over Engineer and reviewed/verified by QA/QC.

7.5 When all the above documents are ready, the final inspection shall be performed and the relevant
Handing-Over Certificate for particular system or package shall be submitted to the Owner/PMT for
information (Attachment C).

ONCE THE SYSTEM IS HANDED OVER TO COMMISSIONING, ONLY THE COMMISSIONING

MANAGER OR HIS DEPUTY ARE AUTHORIZED TO TAG-OUT THE SYSTEM OR PART THEREOF IN
ACCORDANCE WITH THE PERMIT TO WORK PROCEDURE.

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Attachment A – Flow Chart for Erection Completion Activities

Resp.

Identify and prioritizeTurn Over Turn Over Engineer

Packages Construction Manager

Prepare documentation for each T.O.P. (marked up

dwgs and P&ID, Equipment List, status of terminal Turn Over Engineer
points, etc.)

Plan the completion of erection

activities
Construction Manager

Typical for all discipline

Execute the
RECTIFICATION completion of
erection activities
Discip. Supervisors
Correction of
Defects or
Making Good Punch List
Team Schedule &
Request for QA/QC
Inspection

T.O. Engr–QA/QC
Review
Perform Commissioning Mgr.
Deficiency Inspection
Inspection and Discip. Supervisors
Forms
Safety Audit QA/QC
Safety Engineer
Turn Over Engineer

Notification NO Commissioning
Accepted?
for Mgr.
Deficiency Cat. A
QA/QC registers
and file
YES (Cat. B / C)

Release of Handing
Over Certificate Turn Over Engineer registers and files
Consultant / CLIENT (for information)

Start Pre-
commissioning Commissioning Team
Activities

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Attachment B – Identification of Turn Over Packages

The following is the list of Turn Over Packages identified for the balance of plant of 15MW DMTPP Project and their
relevant system numbers for proper identification (these numbers shall be used in all documents related to the same
Turn-Over Package).

Seq. Code No System Description

1
2 PLEASE REFFER TO SEPARATE DOCUMENT : 15MW DMTPP T.O.P. LIST
3 - A. COAL HANDLING SYSTEM
4 - B. STEAM BOILER
5 - C. STEAM TURBINE
6 - D. ELECTRICAL
7 - E. POWER PLANT AUXILIARY SYSTEMS / PROCESS
8 - F. I & C AND AUTOMATION
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

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Attachment C – HANDING OVER CERTIFICATE

This is the form for Handing Over Certificate to be completed for each Turn Over Package.

System Code No.: System Description:

Construction Department
System construction is completed and ready for commissioning
Construction Manager Date Signature

QA/QC Department
System is inspected and found to be complying with Project Quality Plan.
QA/QC Manager Date Signature

Owner/ Engineer
System is accepted for hand over to Commissioning.
O/E Representative Date Signature

Commissioning Department
System is accepted for pre-commissioning and commissioning.
Commissioning Manager Date Signature

Remarks:

Page 36 of 139
 Appendix III

EXAMPLE OF A TURNOVER PACKAGE

Page 37 of 139
 Project Doc. Ident No Index Rev. Page Total

Project-Document-Number
Title

POWER PLANT
TURNOVER PACKAGE

Derived from Replaced by Replaces Format Lang. Off. resp. Ref. File name

En

Turnover Package: Chlorination Plant

Turnover Package Code No.

System: CHLORINATION PLANT

Issued: (Date / dept. / sign) Checked: (Date / dept. / sign) Standard checked: (Date / dept. / sign) Released: (Date / dept. / sign)
Date Date Date
Name Name Name

Page 38 of 139
 TABLE OF CONTENTS

i. System Outline

ii. Table of Contents

iii. Handing Over Certificate

1. List of Main Equipment

2. List of Applicable Documents (P&I D, SLD, Equipment Layout, etc.)

3. List and Status of Terminal Points

3.1 Terminal Points for Mechanical and Piping

3.2 Terminal Points for Electrical and I&C

4. Pre-requisites for Erection Completion

5. Punch List

6. Inspection and Test Program

7. Test Forms and Manufacturer’s Instructions

8. Special Procedures

9. List of Components by Type

10. Permit to Work

11. Special Instructions for Safety or Environmental Protection

Page 39 of 139
 HANDING OVER CERTIFICATE

System Code No.: System Description:

CHLORINATION PLANT

Construction Department
System construction is completed and ready for commissioning
Date Signature
Construction Manager

QA/QC Department
System is inspected and found to be complying with Project Quality Plan.
Date Signature
QA/QC Manager

Owner/ Engineer
System is accepted for hand over to Commissioning.
Date Signature
O/E Representative

Commissioning Department
System is accepted for pre-commissioning and commissioning.
Date Signature
Commissioning Manager
Remarks:

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1. EQUIPMENT LIST

No. Code No. DESCRIPTION

1 TRANSFORMER
2 TRANSFORMER
3 TRANSFORMER
4 TRANSFORMER
5 RECTIFIER
6 RECTIFIER
7 RECTIFIER
8 RECTIFIER
9 HYPOCHLORITE GENERATOR
10 HYPOCHLORITE GENERATOR
11 HYPOCHLORITE GENERATOR
12 HYPOCHLORITE GENERATOR
13 STRAINER
14 STRAINER
15 NaClO C.W. DOSING PUMP
16 NaClO C.W. DOSING PUMP
17 NaClO C.W. DOSING PUMP
18 NaClO C.W. DOSING PUMP
19 NaClO C.W. DOSING PUMP
20 NaClO POTABLE WATER DOSING PUMP
21 NaClO POTABLE WATER DOSING PUMP
22 NaClO WASTE WATER DOSING PUMP
23 NaClO WASTE WATER DOSING PUMP
24 HYDROCHLORIC ACID DOSING PUMP
25 HYDROCHLORIC ACID DOSING PUMP
26 BLOWER
27 BLOWER
28 MIXER
29 HYPOCHLORITE STORAGE TANK
30 HYPOCHLORITE STORAGE TANK
31 HYPOCHLORITE STORAGE TANK
32 HYPOCHLORITE STORAGE TANK

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No. Code No. DESCRIPTION
33 HYDROCHLORIC ACID TANK
34 NEUTRALIZATION TANK
35 FUME SCRUBBER
36 FLAME ARRESTOR
37 FLAME ARRESTOR
38 FLAME ARRESTOR
39 FLAME ARRESTOR
40 HCL TRANSFER EDUCTOR
41 NaOH TRANSFER EDUCTOR

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2. DOCUMENT LIST

No. Drawing No. Rev. Title

1 Chlorination Plant – P&I Diagram
2 Chlorination Plant – Process Flow Diagram
3 Chlorination Plant – System Description
4 Chlorination Plant – Equipment List
5 Chlorination Plant – Equipment Data Sheets
6 Chlorination Plant – Layout
7 Chlorination Plant – Line List
8 Chlorination Plant – Valve List
9 Chlorination Plant – User Electrical List
12 Chlorination Plant – Electrical Motor Data Sheets
13 Chlorination Plant – Single Line Diagram
14 Chlorination Plant – Instrument List
15 Chlorination Plant – Alarm and Interlock List
16 Chlorination Plant – I/O Measurement List
17 Chlorination Plant – I&C Setting and Alarm List
18 Chlorination Plant – Cable List
19 Chlorination Plant – Control System Logic Diagram
20 Chlorination Plant – Operating Manual

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3. LIST AND STATUS OF TERMINAL POINTS

3.1 Terminal Points – Mechanical and Piping

No. KKS No. Item Description Status Sign.

1 00PBN03AA001 Valve – to Generator Stage I, Ph. 2 Closed Operable
2 00PBN03AA003 Valve – fr. Generator Stage 1, Ph. 2 Closed Operable
3 00PBQ20AA001 Valve – to Dosing Pump Stg. 1, Ph. 2 Closed Operable
4 00PBQ24AA001 Valve – fr. Dosing Pump Stg. 1, Ph. 2 Closed Operable
5 00PBN10AA001 Drain Valve - Generator 00PBN10 Closed Operable
6 00PBN10AA001 Drain Valve - Generator 00PBN20 Closed Operable
7 00PBN10AA001 Drain Valve - Generator 00PBN30 Closed Operable
8 00PBN10AA001 Drain Valve - Generator 00PBN40 Closed Operable
9 00PBN10AA001 Samp. Conn. - Generator 00PNB10 Closed Operable

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3.2 Terminal Points – Electrical and I&C

No. KKS No. Item Description Status Sign.

1 00PBN10GT001 Board 00BCA00 – Transformer/Rectifier Operable
2 00PBN20GT001 Board 00BCB00 – Transformer/Rectifier Operable
3 00PBN30GT001 Board 00bCA00 – Transformer/Rectifier Operable
4 00PBN40GT001 Board 00BCB00 – Transformer/Rectifier Operable
5 00PBN10GT002 Board 00BCA00 – Rectifier Aux. & Control Operable
6 00PBN20GT002 Board 00BCB00 – Rectifier Aux. & Control Operable
7 00PBN30GT002 Board 00BCA00 – Rectifier Aux. & Control Operable
8 00PBN40GT002 Board 00BCB00 – Rectifier Aux. & Control Operable
9 00PBN11AT001 Sub-dist. board 00UBT10GS001 – Strainer Operable
10 00PBN12AT001 Sub-dist. board 00UBT10GS001 – Strainer Operable
11 00PBQ31AP001 MCC 00BCKC – NaClO C.W. Dosing Pump Operable
12 00PBQ32AP001 MCC 00BCKD – NaClO C.W. Dosing Pump Operable

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4. PRE-REQUISITES FOR ERECTION COMPLETION

Pre-requisite Description Checked

• Grounding system erection completed ________________

• Pumps installed ________________
• Eye wash and sinks working ________________
• Anti-acid coatings finished ________________
• Ventilation system available ________________
• 460 - 220 V AC power available ________________
• 110 V DC power available ________________
• Seawater supply available ________________
• Instrument air available ________________
• Service/potable water available ________________
• Chemicals available ________________
• Filters fitted ________________
• Drains completed and available ________________
• Piping, valves, supports and hangers fitted ________________
• Clean and safe area ________________
• Local panel and instruments completed, tested and calibrated ________________
• Hypochlorite storage tanks completed and available ________________
• Caustic/acid containers available ________________
• Neutralization basins available ________________
• Auxiliary cables connected and tested ________________
• Power cables connected and tested ________________
• Junction boxes installed and connected ________________
• Root valves and primary elements installed ________________

QA/QC Checks completed: Checked

• Local instrumentation ________________

• Piping hydraulic test ________________
• Piping insulation (if applicable) ________________
• Grounding System ________________
• Rotating machine alignment ________________
• Valves with free movement ________________
• Pumps/motor with free rotation ________________

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5. PUNCH LIST

Punch List Issued on _______________following inspection.

N° DESCRIPTION CATEG. AREA ACTION REQUIRED/ DUE DATE VERIFIED COMPLETE

INSPECTED BY:

NAME COMPANY SIGNATURE

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6. INSPECTION AND TEST PROGRAM

INSPECTION AND TEST PROGRAM: COMMISSIONING

PROCEDURE
Sheet
CHLORINATION SYSTEM 1/3
EQUIPMENT DESIGNATION: SYSTEM: P&I D

Test INSPECTION AND TEST DESCRIPTION TEST FORMS / WITNESSED DATE

No. QTY. DOCUMENTS BY:

1 CHLORINATION SYSTEM
1.1 Joint inspection for completion of erection (Prerequisites) P&ID

1.2 Valve stroking

Pneumatic operated valves at filter drain AT512
Pneumatic operated valves at generator inlet AT512
Pneumatic operated valves at hypochlorite to TBS AT522

1.3 Open / Closed Loop checks AT503X, Logic diagram

Control Cabinet AT524X
Switches AT621X, AT521X
Transmitter AT511X
Remote indicators AT510X
Analyzers AT517X
Thermocouple & RTD AT629X

1.4 Seawater Self-cleaning Filters O&M manuals

- Visual inspection
- Self-cleaning filters functional checks

1.5 Seawater Pumps

- Motor checks &motor bumping AT339AX
- Motor coupling AT119X
- Pumps operation checks and supply line flushing AT102X,AT339DX

1.6 Transformer/Rectifier Units O&M manual

- Visual inspection
- Electrical tests in no-load condition

1.7 Hypochlorite Generator O&M manual

- Visual inspection
- Free water flow no leaks
- Electrical test on load (water flow)

1.8 Hypochlorite Storage Tanks AT104BX

- Visual inspection (including flame arrestors)
- Filling with checks on level interlocks/releases

1.9 Hydrogen Dilution Fans

- Motor checks & motor bumping AT339BX
- Motor coupling AT119X
- Fans operational test AT114X

Page 48 of 139
INSPECTION AND TEST PROGRAM: COMMISSIONING
PROCEDURE
Sheet
CHLORINATION SYSTEM 2/ 3
EQUIPMENT DESIGNATION: SYSTEM: P&I D

Test INSPECTION AND TEST DESCRIPTION TEST FORMS / WITNESSED DATE

No. QTY. DOCUMENTS BY:

1.10 Neutralization Mixer AT115X

- Motor checks
- Operational test with water

1.11 Neutralization Tank AT104BX

- Visual inspection
- Filling with water

1.12 Acid Washing Solution Tank AT104BX

- Visual inspection (include fume scrubber)
- Filling with water

1.13 Acid Washing Pump

- Motor checks & bumping AT339BX
- Motor coupling AT119X
- Pump operation test (with water) AT102X

1.14 NaOH/HCl Transfer Ejector AT140X

- Visual inspection
- Vacuum test without acid or soda

1.15 Potable Water Dosing Pump

- Motor checks & motor bumping AT339BX
- Motor coupling AT119X
- Pump operation test (with stable seawater flow) AT102X

1.16 Waste Water Dosing Pump

- Motor checks & motor bumping AT339BX
- Motor coupling AT119X
- Pump operation test (with stable seawater flow) AT102X

1.17 Hypochlorite C.W. Dosing Pump

- Motor checks & motor bumping AT339BX
- Motor coupling AT119X
- Pump operation test (with stable seawater flow) AT102X

1.18 Local Control Panel AT503X

- Visual inspection
- Electrical test

1.19 Piping checks AT106X

1.20 Safety Shower & Eyes Washer checks

Page 49 of 139
INSPECTION AND TEST PROGRAM: COMMISSIONING
PROCEDURE
Sheet
CHLORINATION SYSTEM 3/ 3
EQUIPMENT DESIGNATION: SYSTEM: P&I D

Test INSPECTION AND TEST DESCRIPTION TEST FORMS / WITNESSED DATE

No. QTY. DOCUMENTS BY:

1.20 System Flushing & Initial Operation O&M manual

Sea Water System available
Potable Water System available
Service Air System available
Instrument Air System available
Flushing of Sea Water Supply pipes
Flushing of Hypochlorite pipes
Flushing of Acid circuits
Blowing of Dilution Air
Flushing of Safety Devices circuits
Filling of Acid Washing circuit with Potable Water
Oper. of Acid Washing Pump & close circuit test
On-load operational tests at continuous dosing and shock dosing

Page 50 of 139
7. TEST FORMS AND SUBSUPPLIER INSTRUCTIONS

Turnover Package: CHLORINATION PLANT

Turnover Package No.

Page 51 of 139
 7. 1 ELECTRICAL TEST FORMS

Company Name Signature Date

Performed By :

Witnessed By :

Witnessed By :

Witnessed By :

Page 52 of 139
Equipment Description : M.V. & L.V. A.C. MOTOR OVER OR EQUAL TEST SHEET NO. AT339 AX
TO 100 kW sh. 1 of 5

Description :

Item : IDPID :

Test : 1) Visual Inspection

2) Insulation Resistance Measurement
3) Operational Tests
Note : Test Procedure from sheet 3
______________________________________________________________________________

TEST RESULTS

1) Visual Inspection
1.1) Name plate data : rated power _______ kW; P.F. ______
rated voltage ________ V; _________Ph
rated current ________ A; freq. _______Hz
rated speed ________rpm; Isol. cl _______
wind. connect. _________________________

1.2) Completeness and damages

1.3) Stator bolted
1.4) Frame grounded
1.5) Rotor alignment done
1.6) Coupling protection installed (if any)
1.7) Proper and tightness connections
1.8) Bearing lubrication
1.9) Motor cooling
1.10) Temperature detectors connection (when provided)

Page 53 of 139
Equipment Description : M.V. & L.V. A.C. MOTOR OVER OR EQUAL TEST SHEET NO. AT339 AX
TO 100 kW sh. 2 of 5

2) Insulation Tests (Test 2.2 for M.V. motors only)

Test 2.1) Insulation Resistance 2.2) Dielectric Strength Note

Nr. Phase before After Volt Time Leaking Current
connections Hi-pot test Hi-pot test (kV- (sec) initial final
A B C dc) (mA) (mA)
0 0 0
t g g
0 0 0
t g g
0 0 0
t g g

Note: g = grounded; t = tested. Ambient temperature : _______0 C

2.3) Polarization Index (for M.V. motors only)

Mohm (10’)
------------------------------------------------------ = _____
Mohm (1’)

Ambient Temperature : _______ 0 C

2.4) Shaft Voltage Measurement (for insulated bearings M.V. motors only)

Test Date Reading (mV A.C.) Voltmeter Resistance (kohm / V) Note

No.
1
2
3
4
5
6

3) Operating Tests
3.1) Control circuit tested

Page 54 of 139
Equipment Description : M.V. & L.V. A.C. MOTOR OVER OR EQUAL TEST SHEET NO. AT339 AX
TO 100 kW sh. 3 of 5

3.2) Protection tested (Test Form attached, if necessary) :

Protection type Magnetic Thermal Test Cert. No.

Range Set Range Set

3.3) Hand motor rotation (if feasible)

3.4) Rotation direction
3.5) Starting current _____ A
3.6) Starting time ____ sec.
3.7) Running test (if required - see separate Test Form)

Motor released for operation ___/___/_____

TEST PROCEDURE

The test shall be made on equipment completely mounted in usual service conditions, in dry and
clean conditions.

1) Visual Inspection
Visual Inspection shall be made to verify :
1.1) Equipment nameplate data
1.2) Equipment completeness without damages
1.3) Frame securely bolted
1.4) Frame grounded at least at one point
1.5) Rotor alignment checked
1.6) Coupling protection installed (if required)
1.7) Proper connections and tightness of bolted connections in terminal boxes
1.8) Bearing lubrication
1.9) Motor cooling system
1.10) Temperature detectors connection (if provided)

Page 55 of 139
Equipment Description : M.V. & L.V. A.C. MOTOR OVER OR EQUAL TEST SHEET NO. AT339 AX
TO 100 kW sh. 4 of 5

2) Insulation Tests

2.1) Insulation Resistance Measurement

- Insulation resistance measurement shall be performed for each winding against the others
connected to ground.
- Stator winding shall be tested applying the voltage of 1000 Vdc.
- If necessary heat the windings to improve their insulation resistance; records of the insulation
resistance of the windings are to be taken during heating every 24 hours, until satisfactory
value is obtained.
- The tests shall be carried out before and after the applied voltage test.
- Attention shall be made to connect to ground the winding already tested at the end of the test
and before dismounting the circuit.
- During test, RTDs shall be short circuited & earthed.

2.2) Dielectric Strength (for M.V. equipment only)

The test shall be carried out to check insulation conditions of windings.

- The test shall be carried out according to BS Standards 2613 by applying for 60 sec.
alternatively between each phase and the others connected to the frame and earthed, the
voltage of :
a) for motors above 2 kV up to 6 kV :
2,5 x rated voltage x 1,6 x 0,8 = ________ kV d.c.
b) for motors above 6 kV up to 17 kV :
(2 x rated voltage + 3 kV x 1,6 x 0,8 = _____ kV d.c.

- The test voltage must not be applied suddenly but gradually at the gradient rate of 1,5
kV/sec, starting from zero. Similarly the voltage shall be gradually reduced when the test is
finished.

- Attention shall be made to connect to ground the winding at the end of the test and before
dismounting the circuit.

Note :

Applied voltage test must not be run if result of insulation measurement gives a value lower
than the recommended minimum value (Rm) at 400 C, estimated by the formulae :
Rm = kV + 1 = Mohm (kV : motor nominal voltage in kV)
If this happens, reason of the low insulation resistance should be removed and test repeated.
If the insulation test performed after the dielectric test gives a value lower than 80 % of the
value found before testing, the cause of the fact shall be investigated and removed.

Page 56 of 139
Equipment Description : M.V. & L.V. A.C. MOTOR OVER OR EQUAL TEST SHEET NO. AT339 AX
TO 100 kW sh. 5 of 5

2.3) Polarization Index (for M.V equipment only)

The test shall be carried out according to IEEE Standards, Publications 43 and 115.

- The voltage of 1000 Vdc shall be applied between the winding and the ground; readings of
the insulation resistance shall be made after one minute and ten minute voltage application;
the index is given by formula :

Ten minutes resis. insulation readings (Mohms)

Index = ------------------------------------------------------------------
One minute resis. insulation readings (Mohms)

- The value obtained shall not be lower than 2. Otherwise warm up the machine until this
minimum value is obtained.

2.4) Shaft Voltage Measurement

The shaft voltage measurement shall be made for M.V. bearing insulated motors.

A voltmeter having very high internal resistance (over 40.000 ohm per Volt an electronic one
is advisable) (i.e. once a year), using the same instrument.

A reading of some millivolt shall be obtained (normally 5 to 10 mV approx. but no more than
50 millivolt).

Measure can be easily taken by removing the motor bottom cover (joint opposite side) and,
with the motor running at nominal speed, measuring the voltage between the shaft center point
(axle) and the ground.

3) Operating Tests

3.1) Control, signalling, alarm circuit are tested.

3.2) Protections are tested.

3.3) Make hand turning by the motor coupling and check that motor is rotating freely (if feasible).

3.4) Bumping operation shall be made on the motor to check proper rotating direction.

If no abnormal condition is found, the motor shall be restarted to check (in normal operating
condition) :

3.5) Starting current (*)

3.6) Starting time (*)

(*) Monitored values are indicative.

Page 57 of 139
Equipment Description : SMALL L.V. A.C. MOTOR < 100 kW TEST SHEET NO. AT339 BX
Sh. 1 of 2

Description :

Item : IDPID :

Test : 1) Visual Inspection

2) Insulation Resistance Measurement
3) Operational Tests
Note: Test Procedure from sheet 2
______________________________________________________________________________

TEST RESULTS

1) Visual Inspection
1.1) Name plate data: Rated power _______ kW; P.F. ______ Wind. Con. ___
Rated volt./curr./freq.: _____ V/____A/ _____Hz
Rated speed __________ rpm; Isol. cl _____
1.2) Completeness and damages
1.3) Stator bolted
1.4) Frame grounded
1.5) Rotor alignment done (if applicable)
1.6) Coupling protection installed (if any)
1.7) Proper and tightened connections, supply cable checked
1.8) Overload range _______ A, setting at ________ A vis. check
Magnetic protection set at ______ A visually checked

2) Insulation Tests
2.1) Windings to ground: RYB / ground = ________ Mohm ________
Amb. Temp. + ________0 C

3) Operating Tests
3.1) Control circuit tested
3.2) Hand motor rotation (if feasible)
3.3) Rotation direction _______________
3.4) On-load current _______ A (only if ammeter equipped)
3.5) Bearings temperature (if applicable) _______ 0 C

Page 58 of 139
Equipment Description : SMALL L.V. A.C. MOTOR < 100 kW TEST SHEET NO. AT339 BX
Sh. 2 of 2

TEST PROCEDURE

The test shall be made on equipment completely mounted in usual service conditions, in dry and
clean conditions.

1) Visual Inspection
Visual Inspection shall be made to verify :

1.1) Equipment nameplate data

1.2) Equipment completeness without damages
1.3) Frame securely bolted
1.4) Frame grounded at least at one point
1.5) Rotor alignment checked
1.6) Coupling protection installed (if required)
1.7) Proper connections and tightness of bolted connections in terminal boxes
1.8) Magnetic / Overload protections setting values visual checks (Recommended overload
setting between 5 to 10% approx. more than motor nominal current).

2) Insulation Resistance Measurement

- Insulation resistance measurement shall be performed for each winding against the
others connected to ground by meggering at 500/1000 Vdc for 1 minute.
- If necessary heat the windings to improve their insulation resistance; records of the
insulation resistance of the windings are to be taken during heating every 2 hours, until
satisfactory value is reached.
- Attention shall be made to connect to ground the winding already tested at the end of the
test and before dismounting the circuit.

3) Operating Tests

3.1) Control, signaling, alarm circuit are tested.

3.2) Make hand turning by the motor coupling and check that motor is rotated freely (if feasible).
3.3) Bumping operation shall be made on the motor to check proper rotating direction.

If no abnormal condition is found, the motor shall be restarted to check (in normal operating
conditions):

3.4) On-load current (only when equipped with ammeter).

3.5) Bearings temperature (only when thermowells are built-in).

Page 59 of 139
 Equipment Description : MOTOR RUNNING TEST (> 100 kW) TEST SHEET NO. AT339 DX
sh. 1 of 2

Description :

Item : IDPID :

Test : 1) Running Test

2) Vibrations Monitoring
______________________________________________________________________________

TEST RESULTS
1) Running Test
Bearing Temperature: A = Coupling side, B = Opposite
Winding point (description) 1) ______________ 2) ___________________
3) ______________ 4) ___________________

No. Reading Time Motor Temperature (0 C) Ambient Note

time hours Volt Curr. Bearing Windings
.(V) (A)
A B 1 2 3 4
1 start
2 10’
3 20’
4 30’
5 45’
6 60’
7 75’
8 90’
9 105’
10 120’

2) Vibrations (1/1000 mm Peak to Peak) (if required)

Direction Point A Point B Frame ___________ Note

Horizontal

Vertical

Axial

Page 60 of 139
Equipment Description : MOTOR RUNNING TEST (> 100 kW) TEST SHEET NO. AT339 DX
sh. 2 of 2

TEST METHOD

1) Running Test

Running Test is normally required only for motors which have temperature monitoring facilities
built-in by the Manufacturer. It is not applicable for STARTING MOTORS. In both cases only
on-load (*) current shall be recorded. Running test shall be made to check bearings / windings
temperatures until normalization, normally reached within two hours with motors in normal
operating conditions. Readings shall be taken each 10’ minutes for the first half-hour and then
each 15’ minutes, and recorded in the attached table.

2) Vibrations Monitoring

During Running Test, Vibrations shall be observed, especially on Fans’ motors and, if required,
monitored. If any vibration should be found abnormal, the cause shall be investigated and
removed.

(*) Monitored values are indicative.

Page 61 of 139
 Turnover Package: CHLORINATION PLANT

Turnover Package No.

7. 2 INSTRUMENTATION & CONTROL TEST FORMS

Company Name Signature Date

Performed By :

Witnessed By :

Witnessed By :

Witnessed By :

Page 62 of 139
Equipment Description : LOGIC CONTROL TEST SHEET NO. AT503 X
Sh. 1 of 1

DESCRIPTION:

ITEM:

FCD IDENT.:

P & ID IDENT.:

TEST: Control Logic Blank Checks

_____________________________________________________________________________

SYSTEM INVOLVED: ________________________________

The control logic functions have been checked according to listed documents where
available:

- Block diagram or Flow chart

- Logic or Schematic diagram

- Specification (if any)

- _________________

- _________________

- _________________

- _________________

Logic control circuit checked date ___/___/_____

Page 63 of 139
Equipment Description : CONTROL CABINET TEST SHEET NO. AT524 X
Sh. 1 of 2

DESCRIPTION: ITEM:

P & ID IDENT.:

DATA SHEET:

TEST: 1) Pre-Operational Checks

2) Operational Test
_____________________________________________________________________________

1) Pre-operational Checks

1.1) No visual damages to panel and apparatus

1.2) Cleanliness condition satisfactory

1.3) Lock and Key

1.4) Clearance between alive electrical parts

1.5) Fuses and / or M.C. Breakers ratings checked

1.6) Preformed connectors & cables properly fitted and tight

1.7) Earth bar properly grounded

1.8) Correct A.C. power supply

1.9) Correct D.C. power supply / polarity

1.10) Auto / manual station and / or alarm visualizer properly connected

1.11) Internal light (if provided)

1.12) Internal heater and thermostat setting (if provided)

1.13) Internal fan and thermostat setting (if applicable)

Page 64 of 139
Equipment Description : CONTROL CABINET TEST SHEET NO. AT524 X
Sh. 2 of 2

2) Operational test

Note: Operational tests are intended to check common parts only, as Logic/Analog
tests are performed under separate Test Forms.

2.1) Internal P.S.U. and / or power supply voltage / polarity checked for all and each section of
system (A.C. / D.C.).

2.2) (Automatic) change over between power supply units as well power failure alarm checked
(if applicable) and check effects on supplied systems.

2.3) Inter-panel supply voltage polarity and zero voltage bars checked (if applicable).

2.4) Test lamp checked (if provided).

2.5) Common alarm section (if provided) checked as per ________ sequence.

2.6) Internal light working

2.7) Internal heater running

2.8) Internal fan lamp signaling running

2.9) Inside temperature during operation, checked

Control cabinet released for operation.

Page 65 of 139
Equipment Description : REMOTE INDICATOR TEST SHEET NO. AT510 X
Sh. 1 of 1

DESCRIPTION:

P & ID IDENT.: ITEM:

DATA SHEET:

TEST: 1) Pre-operational Checks

2) Functional Checks
_____________________________________________________________________________

1) Pre-operational Checks

1.1) Signal / air supply

1.2) Input range
1.3) Indication range / class

2) Function checks
* In case of direct temperature measurement, 0% reading will be done at ambient
temperature.

% Signal Input Measured Value

(_________) ( __________ )

increase decrease

0+/ -5%

25+/ - 5%

50+/ - 5%

75+/ - 5%

100+/ - 5%

Page 66 of 139
Equipment Description : TRANSMITTER TEST SHEET NO. AT511 X
sh. 1 of 1

DESCRIPTION :

P & ID IDEN : ITEM :

DATA SHEET

TEST : 1) Pre-operational Checks

2) Functional Checks
_____________________________________________________________________________

1) Pre-operational Checks

1.1) Signal / air supply

1.2) Power supply (if applicable)
1.2) Input range
1.3) Output range

2) Function checks

% Signal Input Measured Value

(_________) ( __________ )

increase decrease

0+/ -5%

25+/ - 5%

50+/ - 5%

75+/ - 5%

100+/ - 5%

* In case of direct temperature measurement, 0% reading will be done at ambient

temperature.

Page 67 of 139
Equipment Description : PNEUMATIC PISTON ACTUATOR TEST SHEET NO. AT512 X
OR OPERATED VALVE sh. 1 of 2

DESCRIPTION : ITEM :

P & ID IDEN : SHEET :

DATA SHEET

TEST : 1) Pre-Start Up Checks

2) Operational Checks
_____________________________________________________________________________

1) Pre-Start Up Checks

1.1) Stem lubrication (if provided)

1.2) Signal to positioner

1.3) Cam type ( if applicable)

1.4) Actuator air supply dripfeed oiler

(if provided)

1.5) Air supply (after pressure regulating valve)

1.6) Limit switches positioning (%)

(if provided)

Page 68 of 139
 Equipment Description : PNEUMATIC PISTON ACTUATOR TEST SHEET NO. AT512 X
OR OPERATED VALVE sh. 2 of 2

2) Operational Checks

2.1) Actuator manual operation

(if provided)
2.2) Actuator travel :

% Signal to positioner Piston Position Measured Position

+/ - (psi / mA) Theoretical-Cam type Transmitter
3%
Increase decrease 1 2 3 incr. decr. incr. decr.

0 0 0 0

25 25 6, 25 50

50 50 25 70, 71

75 75 56, 25 86, 66

100 100 100 100

2.3) Air failure check :

Driven unit position open ______ close ______ locked ______

2.4) Signal failure :

Driven unit position open ______ close ______

2.5) Limit switches operation

(if provided)

2.6) Local indication

(if provided)

2.7) Position transmitter remote indication

(when is provided)

Page 69 of 139
Equipment Description : FLOW METER TEST SHEET NO. AT519 AX
Sh. 1 of 1

DESCRIPTION: ITEM:

P & ID IDENT.:

DATA SHEET:

TEST: 1) Visual Inspection

2) Operational test
_____________________________________________________________________________

DESCRIPTION

Mark the type under test:

Flow element type - Turbine

Magnetic
Others (specify)

1) Visual inspection

1.1) Fluid flow according arrow indicating direction

1.4) Performance data ( ____________ )

Flow Rate Max. Min. Norm.

Frequency range
Fluid temperature
Fluid pressure
Output signal

1.5) Pulse totalizer (if appl. )

1.6) Integrator totalizer (if appl. )
1.7) Pre-determining computing (if appl.)
1.8) Remote flow rate indicator (if appl.)

2) Operational test

2.1) No leakage at the flanges

2.2) Other operational checks, (if required) give details.

Page 70 of 139
Equipment Description : pH ANALYZER TEST SHEET NO. AT517 AX
Sh. 1 of 2

DESCRIPTION: ITEM:

P & ID IDENT.:

DATA SHEET:

TEST: 1) Pre-operational Checks

2) Operational test
_____________________________________________________________________________

1) Pre-operational checks

1.1) Visual inspection

1.2) Electric power supply available

1.3) Maximum pressure and temperature

1.4) Temperature compensation (if applicable)

2) Operational test

2.1) Functional check method:

2.2) Reference sample ________ other ________

2.3) Electrode type

2.4) Acceptable fluid temperature range

( _____/_____ 0 C)

2.5) Range of measure

Page 71 of 139
Equipment Description : pH ANALYZER TEST SHEET NO. AT517 AX
Sh. 2 of 2

2.6) Function check table (* suggested)

Reference Sample Analyzer

% concentr. temp. readout output Notes
0
(pH) C (pH) (m __)

0 *

50 *

100 *

Alarms (if any): 1st step _______________; 2nd step ________________

2.7) Remote alarm, control

signal, recording and
monitoring checked

Analyzer in service date ____/_____/_____

Page 72 of 139
Equipment Description : WATER ANALYZER TEST SHEET NO. AT517 BX
sh. 1 of 2

DESCRIPTION : ITEM :

P & ID IDEN :

DATA SHEET

TEST : 1) Pre-operational Checks

2) Operational test
_____________________________________________________________________________

Use this form for : Silica Si02

(delete analysis not used) Sodium Hydrox NaOH

If other solution is analyzed give detail : ___________________

1) Pre-operational checks

1.1) Visual inspection

1.2) Electric power supply available

1.3) Cation & anion exchanger available (if any)

1.4) Chemical reagents

SPECIFICATIONS

1.5) Number of sample streams

1 2 3 4 5 6

1.6) Sampling time

1.10) Concentration range

Page 73 of 139
Equipment Description : WATER ANALYZER TEST SHEET NO. AT517 BX
sh. 2 of 2

1.11) Output signals

1.12) Temperature compensation (if applicable)

For further calibration data see manufacturer instructions book

2) Operational test

2.1) All pre-checks satisfactory

2.2) Energize the apparatus

2.3) Set function switch in Man.

2.4) Allow 30 minutes for the analyzer to stabilize

2.5) Switch on push button “calibration” and follow the procedure

2.6) All reference parameters of inspection procedure are satisfactory

2.7) Alarms (if any) : 1st step : ______ ; 2nd step ______

2.8) Remote alarm, control signal, recording & monitoring checked

Analyzer in service date : ____/____/____

Page 74 of 139
Equipment Description : GAS ANALYZER TEST SHEET NO. AT517 CX
sh. 1 of 2

DESCRIPTION : ITEM :

P & ID IDEN :

DATA SHEET

TEST : 1) Pre-operational Checks

2) Operational test
_____________________________________________________________________________

Use this form for : O2

(delete gases not analyzed CO2
H2
Cl2
SO2

If other gas is analyzed give details :

1) Pre-operational checks

1.1) Visual inspection

1.2) Electric power supply available

1.3) Air supply available

1.4) Cooling water available (if any)

1.5) Filter or strainer available

(if any)

1.6) Gas reference (Zero, Span) available

1.7) Temperature compensation (if appl. )

Page 75 of 139
Equipment Description : GAS ANALYZER TEST SHEET NO. AT517 CX
sh. 2 of 2

SPECIFICATION

1.10) Sample flow

1.11) Maximum press. & temp.

1.12) Measuring range

1.13) Output signals

For further calibration data see manufacturer instructions book

2) Operational test

2.1) All pre-checks satisfactory

2.2) Energize the apparatus

2.3) Switch on heater (if provided)

2.4) Allow 30 minutes for the analyzer to stabilize

2.5) Switch on push button “calibration” and follow the procedure

2.6) All reference parameters of inspection procedure are satisfactory

2.7) Alarms (if any) : 1st step : ______ ; 2nd step ______

2.8) Remote alarm, control signal, recording & monitoring checked

Analyzer in service date : ____/____/_____

Page 76 of 139
Equipment Description : SWITCHING DEVICE TEST SHEET NO. AT521 X
sh. 1 of 1

DESCRIPTION : ITEM :

P & ID IDEN :

DATA SHEET

TEST : 1) Visual insp. Range

2) Functional Checks
_____________________________________________________________________________

This form applies to : PS PIS PDS PDIS TS TIS TS TDIS AS AIS

Underline as necessary :

1) Visual Inspection
1.1) Installation check

2) Function checks
2.1) Switching Device

Contact Setting ( _____ ) Resetting ( ______) Differential Contact Note

N. Increase decrease increase decrease status
Sett. pos

2.2) Indicator (if provided)

Process Variable Indication In case of direct temp.

% ( __________ ) Increase Decrease measurement 0 %
0 + / -5% reading will be done at
25 + / -5% ambient temperature
50 + / -5%
75 + / -5%
100 + / -5%

Page 77 of 139
Equipment Description : GENERIC SWITCHING DEVICE TEST SHEET NO. AT621 X
sh. 1 of 1

DESCRIPTION : ITEM :

P & ID IDEN :

DATA SHEET

TEST : 1) Visual Inspection Range

2) Functional Checks
_____________________________________________________________________________

This form applies to : LS LIS FS ZS

Underline as necessary :

1) Visual Inspection

1.1) Installation check

2) Function checks

2.1) Switching Device

A) Increasing level / flow / position contact

B) Decreasing level / flow / position contact

2.2) Indicator (if provided)

Process Variable Indication

% ( ____ ) increase decrease
25 _____________ ______ _______
50 _____________ ______ _______
75 _____________ ______ _______
100 _____________ ______ _______

* no check is possible for flow indicator

Page 78 of 139
 Equipment Description : THERMOCOUPLE & R.T.D. TEST SHEET NO. AT629 X
sh. 1 of 2

DESCRIPTION : ITEM :

P & ID IDEN :

DATA SHEET

TEST : 1)
Continuity & Insulation Checks
Thermoelement relevant to :
_____________________________________________________________________________

Nr Pos. Syst. & Step Item Sensor ** Thermoel Note

Continuity .
length
Type ** (*)
Insulation
01

02

03

04

05

(*) Note : Thermoelement length suitable to thermowell deep

(Not applicable for factory built-in thermoelements).

(**) : Test done with tester.

Page 79 of 139
 Equipment Description : THERMOCOUPLE & R.T.D. TEST SHEET NO. AT629 X
sh. 2 of 2

Nr Pos. Syst. & Step Item Sensor ** Continuity Thermoel. Note

length
Type ** Insulation (*)

(*) Note : Thermoelement length suitable to thermowell deep

(Not applicable for factory built-in thermoelements).

Page 80 of 139
 Turnover Package: CHLORINATION PLANT

Turnover Package No.

7.3 MECHANICAL TEST FORMS

Company Name Signature Date

Performed By :

Witnessed By :

Witnessed By :

Witnessed By :

Page 81 of 139
Equipment Description : ATMOSPHERIC TANKS TEST SHEET NO. AT104 BX
sh. 1 of 3

Item :

Description :

P & ID Iden. : Sheet :

Test: 1) Pre-start up checks

2) Operational checks
3) Floating roof checks
_____________________________________________________________________________

Tank service : __________________________________________________

Tank capacity : m3 _______________________________________________

Tank type : floating or cone roof-open top-drum-batching tank - etc

_______________________________________________

Test / Inspection carried out on : ___________________________________________

By (Operator) ______________________ | Signature _________________________

Page 82 of 139
Equipment Description : ATMOSPHERIC TANKS TEST SHEET NO. AT104 BX
sh. 2 of 3

1) Pre-start up checks tick

1.1) Hydraulic test done (if required) _________

1.2) Internal cleaning complete _________

1.3) Internal protective coating (if any) _________

1.4) Valves fitted and operational _________

1.5) Tank vent, drain, draw-off and overflow

unclogged _________

1.6) Manhole / opening inspected and secured _________

1.7) Level gauge / indicator, measuring and

control instruments fitted and calibrated _________

1.8) Mixer (if installed) checked _________

1.9) Tank foundation & grouting completed.

Check fixed and sliding feet _________

1.10) Thermal insulation fitted (if applicable) _________

1.11) Tank fire detection and fire fighting

installation completed (if applicable) _________

1.12) Tank grounding connection (if any) _________

Page 83 of 139
Equipment Description : ATMOSPHERIC TANKS TEST SHEET NO. AT104 BX
sh. 3 of 3

2) Operational checks tick

2.1) All pre-start up checks completed _________

2.2) Instruments and control device checked _________

2.3) Check for leakage _________

2.4) Drain and vent lines clear _________

2.5) Mixer, heating / cooling equipment in

service (if installed) _________

3) Floating Roof Checks

3.1) For floating roof tank only inspect the

following installations :

- floating roof rain water disposal _________

- floating roof / shell seals _________

- rolling roof ladder with track _________

- floating roof anti-rotational device _________

- pontoon buoyant floats inside _________

- pontoon removable or fixed supports _________

Atmospheric tank released for operation _____/____/_______

Page 84 of 139
Equipment Description : FANS (BLOWERS) TEST SHEET NO. AT114 X
Sh. 1 of 1

Item :

Description :

P & ID Ident. : Sheet :

Test: 1) Pre-start up checks

2) Operational Checks

___________________________________________________________________________

Service: _________________________

1) Pre-start up checks tick

1.1) Frame bolts tightness _________

1.2) Alignment with drive checked or check

‘V’ belts tension _________

1.3) Free rotation by hand (if applicable) _________

1.4) Drive motor checked _________

1.5) Lubrication _________

2) Operational checks

2.1) Start the fan motor _________

2.2) Check fan if it is running properly

Fan released for operation ____/__/_____

Test / Inspection carried out on : ___________________________________________

By (Operator) ______________________ | Signature _________________________

Page 85 of 139
Equipment Description : PUMPS TEST SHEET NO. AT102 X
Sh. 1 of 3

Item :

Description :

P & ID Ident. : Sheet :

Test: 1) Pre-start up checks

2) Operational checks

_____________________________________________________________________________

1) Pre-Start up Checks tick

1.1) Lubrication:
- Cleaning and flushing completed (if applicable) ___________

- Lubricant level ___________

- Lubricant cooling available (if applicable) ___________

1.2) Foundation bolts tightened ___________

1.3) Alignment to drive motor checked

(See separated Test Form if any) ___________

1.4) Pump free rotation by hand (if feasible) ___________

1.5) Coupling protection fitted (if appl.) ___________

1.6) Shaft seals sealing and / or purging available (if any) ___________

1.7) Suction filters fitted (if applicable) ___________

1.8) Suction and discharge valves operational ___________

1.9) Minimum flow protection (if any) ___________

1.10) Measuring instruments fitted ___________

Test / Inspection carried out on: _____________________________________________

By (Operator) ___________________________ | Signature ______________________

Page 86 of 139
Equipment Description : PUMPS TEST SHEET NO. AT102 X
Sh. 2 of 3

tick

1.11) Alarm, control, interlocks checks completed ___________

1.12) Drive motor checks completed

1.13) Pump body vent & drain (if applicable) ____________

For LIQUID SEAL VACUUM PUMP ONLY :

1.14) Liquid seal equipment available ____________

1.15) Vacuum suction piping available ____________

For METERING / DOSING PUMP only :

1.16) Batching tank available and mixer available

(if applicable) ____________

Page 87 of 139
Equipment Description : PUMPS TEST SHEET NO. AT102 X
Sh. 3 of 3

2) Operational Checks tick

2.1) All pre-start up checks completed ________

2.2) Shaft seals and glands operation ________

2.3) Suction pressure / temperature ______ / _______

2.4) Discharge pressure / temperature ______ / _______

2.5) Minimum flow protection : (if any) _________

2.6) Bearing metal / oil temperature (*) _________

2.7) Bearing vibrations (*) _________

2.8) Check for leakage _________

For LIQUID SEAL VACUUM PUMP only :

2.9) Set liquid seal flow and verify discharge outlet __________

Equipment released for operation ______/__/_____

(*) To be recorded only when specifically required and normally for power 40 kW
(50 HP) and over.

Page 88 of 139
Equipment Description : ATMOSPHERIC TANKS TEST SHEET NO. AT104 BX
Sh. 1 of 3

Item :

Description :

P & ID Ident. : Sheet :

Test: 1) Pre-start up checks

2) Operational checks
3) Floating roof checks
_____________________________________________________________________________

Tank service : __________________________________________________

Tank capacity : m3 _______________________________________________

Tank type : floating or cone roof-open top-drum-batching tank - etc

_______________________________________________

Test / Inspection carried out on: ___________________________________________

By (Operator) ______________________ | Signature _________________________

Page 89 of 139
Equipment Description : ATMOSPHERIC TANKS TEST SHEET NO. AT104 BX
Sh. 2 of 3

1) Pre-start up checks tick

1.1) Hydraulic test done (if required) _________

1.2) Internal cleaning complete _________

1.3) Internal protective coating (if any) _________

1.4) Valves fitted and operational _________

1.5) Tank vent, drain, draw-off and overflow

unclogged _________

1.6) Manhole / opening inspected and secured _________

1.7) Level gauge / indicator, measuring and

control instruments fitted and calibrated _________

1.8) Mixer (if installed) checked _________

1.9) Tank foundation & grouting completed.

Check fixed and sliding feet _________

1.10) Thermal insulation fitted (if applicable) _________

1.11) Tank fire detection and fire fighting

installation completed (if applicable) _________

1.12) Tank grounding connection (if any) _________

Page 90 of 139
Equipment Description : ATMOSPHERIC TANKS TEST SHEET NO. AT104 BX
Sh. 3 of 3

2) Operational checks tick

2.1) All pre-start up checks completed _________

2.2) Instruments and control device checked _________

2.3) Check for leakage _________

2.4) Drain and vent lines clear _________

2.5) Mixer, heating / cooling equipment in

service (if installed) _________

Atmospheric tank released for operation _____/____/_______

Page 91 of 139
Equipment Description : PIPEWORK TEST SHEET NO. AT106 X
sh. 1 of 1

Item :

From :

To : Diam. :

P & ID Iden. : Sheet :

Test: 1) Pre-start up checks

2) Operational checks
___________________________________________________________________________

1) Pre-start check tick

1.1) Pipework pressure test certificate No. _________

1.2) Valves, fittings, expansion joints, strainer /

fitter, specially items fitted _________

1.6) Supports installed (stop pins removed and

cold position checked) _________

1.7) Measuring devices fitted, accessible and

calibrated _________

1.8) Vents and drains _________

2) Operational checks

2.2) Absence of interferences with other pipes

or structures _________

2.3) Vents, drains operational

(if provided) _________

Pipework released for operation _____/___/____

Test / Inspection carried out on : ___________________________________________

By (Operator) ______________________ | Signature _________________________

Page 92 of 139
Equipment Description : FANS (BLOWERS) TEST SHEET NO. AT114 X
sh. 1 of 1

Item :

Description :

P & ID Iden. : Sheet :

Test: 1) Pre-start up checks

2) Operational Checks

___________________________________________________________________________

Service : _________________________

1) Pre-start up checks tick

1.1) Frame bolts tightness _________

1.2) Alignment with drive checked or check

‘V’ belts tension _________

1.3) Free rotation by hand (if applicable) _________

1.4) Drive motor checked _________

1.5) Lubrication _________

2) Operational checks

2.1) Start the fan motor _________

2.2) Check fan if it is running properly

Fan released for operation ____/__/_____

Test / Inspection carried out on : ___________________________________________

By (Operator) ______________________ | Signature _________________________

Page 93 of 139
Equipment Description : MIXERS TEST SHEET NO. AT115 X
sh. 1 of 1

Item :

Description :

P & ID Iden. : Sheet :

Test: 1) Pre-start up checks

2) Operational Checks

___________________________________________________________________________

Service : _______________________________

1) Pre-start up Checks tick

1.1) Anchoring bolts tightness _________

1.2) Drive motor checked _________

2) Operational checks

2.1) Start the mixer _________

2.2) Observe for proper running _________

CAUTON : Do not start the mixer in the empty tank

Mixer released for operation ______/___/___

Test / Inspection carried out on : ___________________________________________

By (Operator) ______________________ | Signature _________________________

Page 94 of 139
Equipment Description : ROTATING EQUIPMENT TEST SHEET NO. AT119 X
sh. 1 of 1

Item :

Description :

P & ID Iden. : Sheet :

Test: 1) Alignment check

___________________________________________________________________________

- Looking from drive side and rotating clockwise

- Tolerance :

___________________________________________________________

Radial Axial

1 1

4 ------------------------------- 2 4 ------------------------------- 2

3 3

POSITION 1 (mm) 2 (mm) 3 (mm) 4 (mm) NOTE

RADIAL

AXIAL

Test / Inspection carried out on : ___________________________________________

By (Operator) ______________________ | Signature _________________________

Page 95 of 139
Equipment Description : EJECTORS TEST SHEET NO. AT140 X
Sh. 1 of 2

Item :

Description :

P & ID Ident. : Sheet :

Test: 1) Pre-start up checks

2) Operational checks

___________________________________________________________________________

1) Pre-start up checks (Ref Dwg. _____________) tick

1.1) Piping, condenser (if any) properly supported and

insulated _________

1.2) Drains and vents installed as required _________

1.3) Motive fluid piping blown out _________

1.4) Control instruments fitted and checked _________

1.5) All motorized valve commissioned (if any) _________

1.6) All relevant manual valves greased and operating _________

1.7) Condensate level control (if any) dry adjusted _________

1.8) All logic blank checks on the ejectors system performed

(if any) _________

1.9) Motive fluid filters installed (if any) _________

Test / Inspection carried out on: _________________________________________

By (Operator) ______________________ | Signature: ______________________

Page 96 of 139
Equipment Description : EJECTORS TEST SHEET NO. AT140 X
Sh. 2 of 2

2) Operational checks

2.1) Pre-start up checks complete _________

2.2) No leakage _________

2.3) No abnormal pipes vibration _________

2.4) Condensate level control operation (if any) _________

Equipment released for operation ____/___/_____

Page 97 of 139
8. SPECIAL PROCEDURES (acid cleaning, blowing off, etc.)

N.A.

Page 98 of 139
9. LIST OF COMPONENTS BY TYPE

9.1 Electrical Equipment

No. Code No. Description

1 Transformers
2 Rectifiers
3 Hypochlorite Generators

9.2 Rotating Equipment

No. Code No. Description

1 Strainers
2 NaClO C.W. Dosing Pumps
3 NaClO Potable Water Dosing Pumps
4 Hydrochloric Acid Pumps
5 Blowers
6 Mixers

9.3 Static Equipment

No. Code No. Description

1 Hypochlorite storage tanks
6 Hydrochloric acid tank
7 Neutralization tank
8 Fume scrubber
9 Flame arrestors
10 HCL transfer eductor
14 NaOH transfer eductor

9.4 Line List

No. Code No. Description

1 Sea Water Lines
2 Sodium Hypochlorite Lines
3 Dilution Air Lines
4 Service Water Lines
5 NaOH Line

Page 99 of 139
9.3 Control Loops

No. Code No. Description

1 Low-air flow rate - Hypochlorite TK40
2 Very high H2 level - H2 Analyzer
3 Very high H2 level - Cl2 Analyzer
4 Low level - Hypochlorite tank
5 Mixer actuator - Neutralization Mixer
6 Cl2 Residual analyzer
7 Common Trip - Rectifier
8 Low-air flow rate - Blower
9 Valve actuator - Sea water to Gen10
10 Current - Rectifier10
11 Total Voltage - Rectifier10
12 Remote set point - Rectifier10
13 Common Alarm - Rectifier
14 Common Trip - Rectifier10
15 ON/OFF - Rectifier10
16 Ready to Start - Rectifier10
17 Low flow rate - Sea water to Gen10
18 Very low flow rate - Sea water to Gen10
19 Very low level - Hypochlorite TK10
20 Low level - Hypochlorite TK10
21 Very high level - Hypochlorite TK10
22 High temp.- Hypochlorite from Gen10
23 Very high temp.- Hypochlorite from Gen10
24 Valve actuator - Sea water FLTR11
25 Filter actuator - Sea water FLTR11
26 Low-air flow rate - Hypochlorite TK30
27 Very High DP - Sea water FLTR11
28 Valve actuator - Sea water FLTR12
29 Filter actuator - Sea water FLTR12
30 Low-air flow rate - Hypochlorite TK20
31 Very High DP - Sea water FLTR12
32 Low-air flow rate - Hypochlorite TK10
33 Valve actuator - Sea water to Gen20
34 Current - Rectifier20
35 Total Voltage - Rectifier20

Page 100 of 139

No. Code No. Description
36 Remote set point - Rectifier20
37 Common Alarm – Rectifier
38 Common Trip - Rectifier20
39 ON/OFF - Rectifier20
40 Ready to Start - Rectifier20
41 Low flow rate - Sea water to Gen20
42 Very low flow rate - Sea water to Gen20
43 Vere low level - Hypochlorite TK20
44 Low level - Hypochlorite TK20
45 Very high level - Hypochlorite TK20
46 High temp.- Hypochlorite from Gen20
47 Very high temp.- Hypochlorite from Gen20
48 Valve actuator - Sea water to Gen30
49 Current - Rectifier30
50 Total Voltage - Rectifier30
51 Remote set point - Rectifier30
52 Common Alarm - Rectifier
53 Common Trip - Rectifier30
54 ON/OFF - Rectifier30
55 Ready to Start - Rectifier30
56 Low flow rate - Sea water to Gen30
57 Very low flow rate - Sea water to Gen30
58 Very low level - Hypochlorite TK30
59 Low level - Hypochlorite TK30
60 Very high level - Hypochlorite TK30
61 High temp. - Hypochlorite from Gen30
62 Very high temp. - Hypochlorite from Gen30
63 Valve actuator - Sea water to Gen40
64 Current - Rectifier40
65 Total Voltage - Rectifier40
66 Remote set point - Rectifier40
67 Common Alarm - Rectifier
69 ON/OFF - Rectifier40
70 Ready to Start - Rectifier40
71 Low flow rate - Sea water to Gen40
72 Very low flow rate - Sea water to Gen40
73 Very low level - Hypchlorite TK40

Page 101 of 139

 74 Low level - Hypochlorite TK40
75 Very high level - Hypochlorite TK40
76 High temp. - Hypochlorite from Gen40
77 Very high temp.- Hypochlorite from Gen 40
78 Pump actuator - Acid washing pump 41
79 Pump actuator - Acid washing pump 42
80 Low level - Hydrochloric acid tank
81 Pump actuator - Hydrogen dilution fan
82 Pump actuator - Hydrogen dilution fan
83 Pump actuator - Hypo. Dosing pump 11
84 Pump actuator - Hypo. Dosing pump 12
85 Valve actuator - Hypo to Travelling Screen
86 Pump actuator - Hypo Dosing pumps
87 Pump actuator - NaOH C.W. dosing pumps

10. PERMIT TO WORK (see sample PTW form in Appendix VIII, Attachment D)

11. SPECIAL INSTRUCTIONS FOR SAFETY AND ENVIRONMENT PROTECTION

11.1 Fire Protection

It is imperative that all possible means of fire prevention be practiced continuously. Quick and
efficient action by site personnel in the first few minutes of fire outbreak, can save hours of
harzardous fire fighting and reduce the risk of damage to equipment and physical injury to personnel.
If a small fire has been extinguished by the operator, the competent authority must be informed.

In case a serious fire matter occurrs, shut down the chlorination unit by local push button (if possible)
and inform immediately the fire brigade.

No matches or cigarettes lighters have to be carried into the chlorination unit.

Smoking in the chlorination area is strictly prohibited.

11.2 Explosion Hazard

The hydrogen production in sea water electrolysis plant is about 0.03 kg H2/kg CL2. The hydrogen
gas disengages from the liquid phase in the upper part of the storage tanks and it is discharge to the
atmosphere in a safe area, after that an air injection for hydrogen dilution is provided to avoid
explosion hazard.

The prevention of explosive mixture formation is efficiently made by frequent checking that all the

Page 102 of 139

 operating parameters, controls, alarms and interlocks are efficient.

During the performance of commissioning activities and normal operation the safety prescription of
cell room and storage tanks area, no smoking and no use of free flames, are to be kept in mind.
Before allowing any work (repair or maintenance) to be done in these areas, be sure that hydrogen
has been previously and completely removed from the area and the permit to work system has been
strictly implemented.

Whenever possible, leave the air fans in operation.

11.3 Electrical Hazard

Since the electrolytic cells in operation are supplied with DC voltage, the commissioning and operation
personnel must wear rubber shoes and rubber gloves for safety even in case of a hand touch. The
energized parts shall not be touched. Therefore, unauthorized personnel shall not be allowed to enter
the cell room or other electrical equipment room. During the operation of the electrochlorination plant,
no work except for switching, valve handling and sampling shall be carried out. If metal tools or other
conductive tools must be used near the electrolytic cells for repair or maintenance purposes, the
supply power of the electrolytic cells shall be stopped in advance to prevent short-circuit trouble, and
the permit to work system shall be strictly implemented.

Page 103 of 139

 Appendix IV

COMMISSIONING STAFF ORGANIZATION

AND JOB DESCRIPTION
1.0 SCOPE

This procedure describes the composition, deployment and job descriptions of Contactor commissioning key
personnel, who will manage, supervise and perform the commissioning, operation and maintenance of 15MW
DMTPP Project from handing-over of completed systems up to the Owner/PMT’s acceptance of the Unit.

In order to ensure continuity in the commissioning processes, since the pre-commissioning and commissioning
activities are mostly sequential and for certain aspects overlapping, NEPC commissioning organization outlined
in this procedure is structured to manage both phases.

2.0 APPLICABILITY

This procedure is applicable to the commissioning of 15MW DMTPP Project under NEPC scope of work.

3.0 EFFECTIVE DATE

This procedure is effective as on the issue date.

4.0 JOB DESCRIPTION OF KEY POSITIONS

With reference to the attached organization chart (Attachment 1), the positions outlined are described here
below:

4.01 Commissioning Manager

4.02 Turn Over Engineer
4.03 Tubine Commissioning Engineer
Boiler Commissioning Engineer
Process/Operation Commissioning Engineer
4.04 Electrical Commissioning Engineer
4.05 I & C Commissioning Engineer
4.06 Chemist
4.07 Mechanical Maintenance Engineer
4.08 Electrical Commissioning Technician
4.09 I & C Commissioning Technician
4.10 Operators
4.11 Plant Attendants
4.12 Rotating Equipment Mechanic
4.13 Pipe Fitter
4.14 Lubricator

Page 104 of 139

4.01 Commissioning Manager

4.01.1 Position: Commissioning Manager

4.01.2 Job Holder:
4.01.3 Deputy: Process/Operation Commissioning Engineer

4.01.4 Line of Report:

4.01.4.1 The Commissioning Manager reports directly to the NEPC Site Project Manager on
the overall organization, administrative, quality and customer-related matters.
4.01.4.2 On technical issues regarding commissioning of plant, the Commissioning Manager
has the lead and reports directly to the Site Project Manager
4.01.4.3 During commissioning and trial operation of the plant, NEPC commissioning staff,
sub-contractor personnel and all assisting personnel will work under the direction of
the Commissioning Manager and his organization (from handing over of the
completed systems to commissioning organization).
4.01.5 Tasks:
4.01.5.1 Main Tasks are direction, supervision and coordination of the various
commissioning teams and specialists involved during commissioning, trial phase
and acceptance tests in order to achieve Owner/PMT’s acceptance in accordance
with the established schedule and contractual obligations.
4.01.5.2 Detailed Tasks:
4.01.5.2.1 Overall planning of the commissioning activities within the range of the established
project milestones.
4.01.5.2.2 Allocation of necessary personnel, tools, instruments, consumables, and spare parts
during commissioning.

4.01.5.2.4 Organize and supervise the operation during all phases of commissioning and
testing in cooperation with partners and customers.
4.01.5.2.5 Planning of short-term schedules of site activities and allocation of the required
number of commissioning personnel and vendor specialists.
4.01.5.2.6 Issue of non-conformity reports according to established procedure and make sure
that the non-conformance is resolved.
4.01.5.2.7 Sporadic check of Operation and Maintenance Manuals (if complete and adequate).
4.01.5.2.8 Definition of the operating procedure.
4.01.5.2.9 Organize and supervise the updating and completion of the technical documentation
within the limits of the scope of supply as required by the contract in time for
Owner/PMT’s acceptance.
4.01.5.2.10 Issue monthly and weekly progress report to the NEPC Site Project Manager.

4.01.6 Responsibility
4.01.6.1 Overall responsability of the execution of the Commissioning in accordance with the
Technical requirement and the time schedule including implementation of the safety
procedure.
4.01.6.2 Technical and operational interface between NEPC operating structure and the
operating structure of the Owner/PMT.
4.01.6.3 Implementation of the Permit to Work procedure for the activities to be performed on
the systems already handed over to commissioning.
4.01.6.4 Implementation of the project quality plan dedicated to the commissioning phase.
4.01.6.5 Authorize solution to non-conformance pertaining the whole power plant.

Page 105 of 139

 4.01.6.6 Monitoring of concession request especially needed for commissioning activities.
4.01.6.7 Updating of commissioning inspection & test program.
4.01.6.8 Implementation of environmental protection requirement.
4.01.6.9 Review and follow up the status of the commissioning schedule.

4.02 Turn Over Engineer

4.02.1 Position: Turn Over Engineer

4.02.2 Job Holder:
4.02.3 Deputy: n.a.
4.02.4 Reporting to: Commissioning Manager

4.02.5 Tasks:
4.02.5.1 Identification of the systems / turn over packages.
4.02.5.2 Identification of terminal points for each system or turn over package.
4.02.5.3 Preparation of the documents required for checking the erection completion of the
systems / turn over packages.
4.02.5.4 Review and follow up the status of erection completion of each system or package in
accordance with the established schedule for handing over; review the status of
punch list and follow up the timely clearance of the punch points.
4.02.5.5 Categorization of punch list points.
4.02.5.6 Organization of the final inspection with the concerned parties to check the erection
completion of the systems / packages.

4.03 -Process / Operation Commissioning Engineer

-Boiler Commissioning Engineer
-Turbine and Thermal Cycle Commissioning Engineer

4.03.1 Position: Process/Operation, Boiler and Turbine Commissioning Engineer

4.03.2 Job Holder:
4.03.3 Deputy: Chemist
4.03.4 Reporting to: Commissioning Manager

4.03.5 Tasks:
4.03.5.1 Overall organization, coordination and supervision of the commissioning activities of
Steam Boiler/ Turbine and thermal cycle/operation and process systems for whole PP
(including manpower, documentation, tools and relevant forms).
4.03.5.2 Overall supervision of engineers and technicians; Owner/PMT’s personnel on training;
and plant operation personnel during commissioning.
4.03.5.3 Determine the needs and the duration of the presence of vendor’s specialist in the
commissioning of process systems.
4.03.5.4 Coordination and support to all vendor specialists involved during commissioning of
process systems.
4.03.5.5 Coordination and supervision of on-the-job training program for the operation
personnel.
4.03.5.6 Responsible for the implementation of safety rules for systems handed over to
commissioning.

Page 106 of 139

 4.03.5.7 Responsible for the Testing and troubleshooting of mechanical, hydraulic and
pneumatic equipment and auxiliaries including flushing of piping and equipment, as
well as steam blow-out.
4.03.5.8 Responsible for the start-up, testing and operation of the process systems.
4.03.5.9 Verification that all contractual and technical requirements are met at the end of
commissioning of the completed process systems.
4.03.5.10 Preparation of weekly and monthly programs of the commissioning activities of the
process systems under his responsibility.
4.03.5.11 Preparation of weekly and monthly progress report for his scope of work.

4.04 Electrical Commissioning Engineer

4.04.1 Position: Electrical Commissioning Engineer

4.04.2 Job Holder:
4.04.3 Deputy: n. a.
4.04.4 Reporting to: Commissioning Manager

4.04.5 Tasks:
4.04.5.1 Overall organization, coordination and supervision of the commissioning of all
electrical systems (including manpower, documentation, tools and relevant forms).
4.04.5.2 Overall supervision of electrical commissioning technicians, Owner/PMT’s personnel
on training and plant operation personnel assigned under his scope of responsibility.
4.04.5.3 Determine the needs and the duration of the presence of vendor’s specialist in the
commissioning of electrical systems.
4.04.5.4 Coordination and support to all vendor specialists involved during commissioning of
electrical systems.
4.04.5.5 Check if the established safety procedure is implemented for the systems within his
scope and responsibility that are handed over for commissioning.
4.04.5.6 Responsible for the start-up, testing and operation of electrical systems.
4.04.5.7 Verification that all contractual and technical requirements are met at the end of
commissioning of the completed electrical systems,
4.04.5.8 Preparation of weekly and monthly programs of the commissioning activities of the
systems under his responsibility.
4.04.5.9 Preparation of weekly and monthly progress report for his scope of work.

Page 107 of 139

4.05 I & C Commissioning Engineer

4.05.1 Position: I&C Commissioning Engineer

4.05.2 Job Holder:
4.05.3 Deputy: n. a.
4.05.4 Reporting to: Commissioning Manager

4.05.5 Tasks:
4.05.5.1 Overall organization, coordination and supervision of the commissioning of all
process control systems, DCS interfaces and instrumentation (including manpower,
documentation, tools and relevant forms).
4.05.5.2 Overall supervision of I&C commissioning technicians, Owner/PMT’s personnel on
training and plant operation personnel assigned under his scope of responsibility.
4.05.5.3 Determine the needs and the duration of the presence of vendor’s specialist in the
commissioning of l&C systems.
4.05.5.4 Coordination and support to all vendor specialists involved during commissioning of
I&C systems.
4.05.5.6 Responsible for the start-up, testing and operation of I&C systems and process
controls.
4.05.5.5 Verification that all contractual and technical requirements are met at the end of
commissioning of the completed I&C systems,
4.05.5.6 Preparation of weekly and monthly programs of the commissioning activities of the
systems under his responsibility.
4.05.5.7 Preparation of weekly and monthly progress report for his scope of work.

4.06 Chemist

4.06.1 Position: Chemist

4.06.2 Job Holder:
4.06.3 Deputy: n.a.
4.06.4 Reporting to: Operation Commissioning Engineer/Commissioning Manager

4.06.5 Tasks:
4.06.5.1 Commissioning, supervision, control and trouble shooting related to the chemical
process systems under the area of responsibility.
• Sampling systems water/steam/flue gas.
• Steam boiler, thermal cycle and steam turbine.
• Chemical injection/dosing systems of boiler, thermal cycle and ash handling.
• Water demineralization plant
• Chlorination Plant
• Sewage water, Oily Water, Coaly water treatment plants
• Potable water system

Page 108 of 139

4.07 Mechanical Maintenance Engineer

4.07.1 Position: Mechanical Maintenance Engineer

4.07.2 Job Holder:
4.07.3 Deputy: n.a.
4.07.4 Reporting to: Commissioning Manager

4.07.5 Tasks:
4.07.5.1 Organization, coordination and supervision of the preparation works for the
mechanical equipment of systems handed over for tests and first operation.
4.07.5.2 Organization, coordination and supervision of erection and dismantling of temporary
equipment and piping necessary for pre-commissioning activities.
4.07.5.3 Overall responsibility for routine maintenance (lubrication, greasing, cleaning, etc.) of
systems handed over to commissioning.
4.07.5.4 Recording of information relevant to maintenance to the equipment card and
lubrication card.
4.07.5.5 Overall supervision of all personnel assigned to maintenance.
4.07.5.6 Coordination and support to all mechanical vendor specialists during commissioning.
4.07.5.7 Scheduling of daily and weekly maintenance and preservation activities to the plant
equipment.

4.09 Electrical Commissioning Engineer

Tasks:

Lead the Electrical Technicians under his responsibility in performing the following commissioning activities:

• Testing, energizing and trouble shooting of electrical equipment.

• Electrical wiring checks (identification and trouble shooting).
• Testing and adjustments of electrical protections.
• Testing and checking of MV & LV distribution systems.
• Testing and checking of grounding systems.
• Testing of alarm and trip circuits

4.10 I & C Commissioning Engineer for DCS and PLC

Tasks:

Lead the I&C Technicians under his responsibility in performing the following commissioning activities:

• Testing, energizing and troubleshooting DCS and PLCs.

• Testing and optimizing of interfaces between DCS and PLCs
• Testing of open-loop circuits
• Testing and optimizing of closed-loop circuits
• Testing of drives
• Testing of functional group logic
• Testing of alarm and trip circuits

Page 109 of 139

4.11 Electrical Commissioning Technician

Tasks:

• Checking and trouble shooting of connections to marshalling kiosks, distribution panels, PC/MCC boards.
• Checking of indication signals from/to switchgears
• Checking and adjusting of settings of various electrical devices
• Checking of grounding systems.
• Assist in testing, energizing and trouble shooting of electrical equipment
• Assist in testing and adjustments of electrical protections.
• Assist in testing of alarm and trip circuits

4.12 I & C Commissioning Technician

Tasks:

• Perform wiring loop checks (identification and trouble shooting).

• Check and trouble shooting of connections to marshalling kiosks.
• Check of process signal from / to local control buses.
• Checking and adjusting of settings of various I&C devices.
• Assist in testing, energizing and troubleshooting DCS and PLCs
• Assist in testing and optimizing of interfaces with DCS
• Assist in testing of alarm and trip circuits

4.13 Operator

Tasks:

• Adjustment of operations of the plant from the control room

• Continuous supervision of processes
• Taking periodical readings
• Supporting commissioning tests

4.14 Plant Attendant

Tasks:

• Assist in testing and trouble shooting of mechanical, hydraulic and pneumatic auxiliaries.
• Taking readings of data for plant systems
• Checking of temperatures, levels, pressures, noise, vibrations, etc.; of balance of plant systems
• Perform routine checks for equipment

4.15 Rotating Equipment Mechanic

Tasks:

Page 110 of 139

 • General maintenance, dismantling, troubleshooting, and re-assembling and alignment of gears, pumps,
motors, valves, actuators and mechanical equipment in general.
• Perform routine checks and preventive maintenance on all rotating equipment for balance of plant.

4.16 Pipe Fitter

Tasks:

• Erection and dismantling of temporary lines.

• Dismantling, cleaning and re-installation of filters.
• External and internal cleaning of equipment.
• Perform routine checks and preventive maintenance on all pipe works

4.17 Lubricator

Tasks:

• Performing all minor and major lubrication works for plant equipment
• Re-filling or replacement of lubricants
• Supervising of lubricant consumption
• Perform routine checks of lubricants
• Perform lubrication purification

Page 111 of 139

 Appendix V

CURRICULUM VITAE OF KEY PERSONNEL

Page 112 of 139

 CURRICULUM VITAE

POSITION: COMMISSIONING MANAGER

(INCLUDE CURRICULUM VITAE OF OTHER KEY PERSONNEL AS DESCRIBED ABOVE)

Page 113 of 139

 Appendix VI

INSPECTION AND TEST PROGRAM

Page 114 of 139

 INSPECTION AND TEST PROGRAM - INDEX
Form Code No. of Shts. System
COAL HANDLING SYSTEM
EAA-SUN-001 Ship unloading
EAC-CBS-001 Coal conveying before storage yard
EBA-CAS-001 Coal conveying after storage yard
SAM-SYS-001 Coal sampling system
EAT-EBT-001 Scales and calibration device
EBE-MDM-001 Metal detector and magnetic separator
SDS-WSS-001 Water spray and sewage water pumps
CHM-MHC-001 Coal handling maintenance hoist and cranes
SGC-DSS-001 Dust suppression system

STEAM BOILER
ERB-LFO-001 Light fuel oil system
MID-LPC-001 Limestone power conveying system
HFB-CCF-001 Coal feeding system
ENF-SBC-001 Start-up material conveying (Bed of sand)
HAD-FWS-001 Boiler feed water supply system
HJA-FSB-001 Start up burner and ignition system
HLB-FDF-001 PAF – SAF – IDF -& dumpers
HDB-FSS-001 HP fluidizer and sealing air system
HNA-FGS-001 Flue gas system
HLA-SAS-001 Boiler SH&RH live steam
HDE-ESP-001 Electrostatic precipitator ESP
HDA-BAH-001 Bottom ash handling
HDA-FAH-001 Fly ash handling
HAN-DBD-001 Boiler vent, blow-down and drain system
HCB-SBS-001 Sootblower system
QCC-PHI-001 Chemical dosing and injection system
QUW-SWS-001 Steam and water sampling & analyzer system
HAJ-SVF-001 Boiler safety valves
HNY-CEM-001 Exaust gas emission control system –CEMS-
HAH-ELE-001 Boiler elevator

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 STANDARD INSPECTION AND TEST PROGRAM - INDEX
Form Code No. of Shts. System
SMA-CAH-001 Boiler crane and hoist
HAB-VAC-001 Vacuum cleaning system for boiler

STEAM TURBINE
LBA-SHS-001 Main live steam – SH & RH
LBG-AUS-001 Auxiliary and start-up steam
MAW-GST-001 Shaft sealing (Gland steam)
MAL-VAD-001 Turbine vent, drain and exaust system

LBQ-LBS-001 Steam extraction system

MAV-LOS-001 Lube oil system

MAV-EHO-001 EH oil (Jacking oil system)

MAA-MAB-001 Turbine alarms interlocks,protection and FG logic system

LAB-FWS-001 Feed water HP,IP & Lp system and deareator

LCC-HPH-001 HP , LP Heaters vents and drainages

PAH-SPB-001 Condenser tube cleaning device

MAJ-CVE-001 Condenser vacuum extraction

LBC-CAM-001 Condensate and make up system

PGA-CCS-001 Closed cooling system CCWS

SMA-TUR-001 Turbine cranes and hoists for maintenance.

ELECTRICAL
AEA-GIS-001 230 KV GIS Substation
BAT-BCT-001 Power transformer GSTU – UAT - SAT
BFT-AUT-001 Auxiliary transformer
BAA-BAB-001 IPBD MV
BBA-MVS-001 MV Switchgear
BFA-LVS-001 LV Switchgear
BFB-LVS-001 LV Subdistribution boards
BTA-BTB-001 Battery charger and DC system
BRU-UPS-001 UPS System and distribution boards

Page 116 of 139

 STANDARD INSPECTION AND TEST PROGRAM - INDEX
Form Code No. of Shts. System
EAS-GRS-001 Earthing and lightining system
LIG-SYS-001 Lighting system
POC-HVM-001 Power cables MV-LV
EMO-MLV-001 Electrical motors MV - LV
XJA-EDG-001 Emergency diesel generator
INT-PAG-001 Comunication system,telephone,CCTV, pagging,interphone.
CAT-PRO-001 Cathodic protection for CW underground pipe
MKC-EXC-001 Generator excitation and protection system

POWER PLANT AUXILIARY SYSTEM

PAC-SVI-001 Sea water intake and CW system

GCB-DES-001 Sea water desalination
GCK-DWP-001 Demi water production, storage and distribution
GRK-GRC-001 Service water, sewage, drainage and treatment system
CWW-CWS-001 Coaly waste water drainage and treatment system
JOG-DRS-001 Oily waste water drainage and treatment system
RWS-TRD-001 Rain water drainage system
PBN-CHL-001 Chlorination production and distribution system
QEA-CAP-001 Service and instrument air system
QJA-SAD-001 Nitrogen system
SMA-BOP-001 Crane and hoist
HVA-CCR-001 Plant air conditioning and ventilation (HVAC)

FIRE FIGHTING PROTECTION AND DETECTION

FFP-NET-001 Fire fighting pumping station and distribution network
WSD-SYS-001 Water spray deluge system
FOA-SYS-001 Foam system
ADS-FFS-001 Alarm and detection system
CLA-FMO-001 FF clean agent system (FM 200)

Page 117 of 139

 STANDARD INSPECTION AND TEST PROGRAM - INDEX
Form Code No. of Shts. System
ENVIROMENTAL
WWE-CWS-001 Waste water effluent control system
PNM-OPP-001 Plant noise measurement
OMS-OPP-001 Outdoor meteorological device

Page 118 of 139

INSPECTION AND TEST PROGRAM: COMMISSIONING
PROCEDURE
Sheet
1/2
EQUIPMENT DESIGNATION: UNIT: KKS NO

Test INSPECTION AND TEST DESCRIPTION TEST FORMS / WITNESSED DATE

No. QTY. DOCUMENTS BY:

IN ORDER TO COMPLETE THE

COMMISSIONING MANUAL, IT IS NECESSARY
TO COPY AND PASTE IN HERE ALL THE
INSPECTION AND TEST PROGRAM (ITP)
FORMS THAT ARE INSIDE EACH TURN OVER
PACKAGE (REFER TO ABOVE ITP INDEX)

Page 119 of 139

INSPECTION AND TEST PROGRAM: COMMISSIONING
PROCEDURE
Sheet

EQUIPMENT DESIGNATION: UNIT: KKS NO

Test INSPECTION AND TEST DESCRIPTION TEST FORMS / WITNESSED DATE

No. QTY. DOCUMENTS BY:

Page 120 of 139

 Appendix VII

PUNCH LIST PROCEDURE

(A GUIDELINE FOR THE MANAGEMENT OF OUTSTANDING WORKS

AND NON-CONFORMANCES DURING COMMISSIONING)

Page 121 of 139

 TABLE OF CONTENTS

1. SCOPE

2. RESPONSIBILITY
2.1 QA/QC Department
2.2 Turn Over Engineer
2.3 Punch List Coordinator
2.4 Technical Office
2.5 Procurement Office

3. CATEGORY OF PUNCH POINTS

4. PROCEDURE FOR THE MANAGEMENT OF PUNCH LIST

4.1 General
4.2 Generation of Punch List
4.3 Clearing of Punch List
4.4 Structure of Punch List Database

Page 122 of 139

1. SCOPE

During the construction and commissioning phase of the Unit up to the Provisional or Final Acceptance by
the Owner/PMT, the deficiency in the construction or shortfall in equipment, materials or systems that need
to be made good are classified as punch list.

This procedure defines the methods adopted for the management of such punch list and the relevant
corrective actions necessary to address and close this punch list items.

2. RESPONSIBILITY

The responsibility of each section internal to NEPC site organization with respect to the management of
punch list are described here below:

2.1 QA/QC Department

• Ensure Punch List items are at a minimum
• Review the correctness and acceptability of each item identified in the Punch List
• Participate in the final inspection of the systems or packages to verify their erection completion and
acceptability
• “Sign Off” the Master Punch List on the same time the item is cleared
• Provide updated information to the Turn Over Engineer

2.2 Turn Over Engineer

• Categorize the Punch List items in accordance with Item 3 below
• Identify the person responsible for each Punch List item
• Define the type of deficiency
• Obtain commitment from the person responsible for the punch point to be made good on the
expected date of clearance
• Give technical and commercial assistance to the field personnel assigned to clear the Punch List
• Verify in coordination with the QA/QC Team the constant updating of the Punch List master file
• Provide the information necessary to the Punch List Coordinator in due time in order to keep
updated the Punch List database

2.3 Punch List Coordinator

• Develop and maintain Punch List database
• Update the database on a regular basis
• Produce reports according to the requirements of the Contract and the requirements of the
Owner/PMT for proper monitoring of the Punch List

2.4 Technical Office

• Provide technical support to the Construction for the solution of Punch List
• Issue MR to purchase the materials that are required to clear the Punch List

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 2.5 Procurement Office
• Procure the materials specified in the MR issued by the technical office within the time frame
required to clear the Punch List
• Provide information to the concerned parties regarding the expected date of material arrival at site,
inspection date (if required) and availability of Vendor documents or certifications relevant to the
material procured

3. CATEGORY OF PUNCH POINTS

The categories for the classification of punch points are defined as follows:
• Category A – punch point that manifests unsafe conditions which may put to risks the personnel and
equipment (for punch point under this category, it will not be possible to turnover a system or package to
the Commissioning Team)
• Category B – punch point which may affect the safe operation of the system (normally cleared before the
start of hot commissioning)
• Category C – punch point of minor importance (normally cleared before the Provisional or Final
Acceptance of the Unit)

4. PROCEDURE FOR THE MANAGEMENT OF PUNCH LIST

4.1 General
The Punch List shall be developed to cover the outstanding works from erection completion up to the
Provisional or Final Acceptance of the Unit..

The scope of the Punch List is to establish a unique document where the concerned parties
(construction and commissioning) agree to carry-out the outstanding activities necessary for the
completion of the Unit.

The list shall include the activities relevant to all the disciplines, i. e. civil, mechanical, electrical and
instrumentation & control.

The list shall be implemented starting from the erection completion stage of the systems.

The Punch List status shall be constantly updated and the relevant reports shall be distributed
periodically to the concerned parties; the contents and the structure of the reports shall be progressively
defined accordingly to the needs of the interested parties.

All correspondence regarding existing Punch List items should refer to the Punch List registration
number.

4.2 Generation of Punch List

The Punch List is generated for each system of the Unit during the inspection checks performed during
erection completion and prior the turnover of the system from Construction Team to the Commissioning
Team.

Page 124 of 139

 Additional punch points could be generated during the commissioning phase by Owner/PMT or by a
third party in case the tests to be performed by Commissioning Team are foreseen to be witnessed by
them; in which case, these punch points shall be managed as follows:
- The punch points must be notified to the QA/QC department who shall verify correctness and
acceptability, and inform the Turn Over Engineer for further action as defined in this procedure.
- All information relevant to the punch points raised shall be integrated to the Punch List database.
- An update of the Punch List shall be transmitted to Owner/PMT periodically.

4.3 Clearing of Punch List

For each punch point cleared and accepted, there must be a document to prove the agreement
between the individuals involved who must put their respective signatures on such document to attest
their acceptance/concurrence to close the particular punch point.

4.4 Structure of the Punch List Database

The Punch List of construction and commissioning shall organized in a common database where, for
each punch point, the following information shall be registered:

Field No. Field Name Contents Description

1 Registration Number A unique number to identify the punch point
2 System Number Identify the system number of the plant in which the punch point is
referred to. (for the list of systems of the Plant, see the relevant
procedure).
3 Discipline Defines the discipline in which the punch point belongs.
C – Civil
E – Electrical
M – Mechanical
I – I&C
H – LIGHTING & SOCKET System
F – Fire Fighting System
P – Painting
L – Insulation
4 Equipment Identification Code Equipment or component identification number by KKS
5 Drawing Number The reference drawings related to the equipment or component to
be made good.
6 Equipment Description Brief description of the equipment or component to be made good.
7 Punch Point Description Brief description of the defect, deficiency, etc.
8 Punch Point Category Classification of deficiencies (A, B, C)
9 Registration Date The date on which the deficiency is registered in the database.

10 Inspected by Identification of the person who raised the defect (it is presumed
that the same person verifies and accepts the item to clear the
punch point, Field No. 16)
11 Reference Document It is the document that is made in reference for the determination of
the defect (letters, contract, technical specifications).
12 Workability Indication of the prerequisites for making good:
1. There are no particular requirements.
2. Technical assistance is required.
3. Materials/spare parts are required.
4. Shutdown of the system or plant is required.
13 Responsibility Field Supervisor who is given the responsibility of making good.
14 Expected date of clearing Date expected when the punch point is to be made good and
cleared.
15 Actual date of clearing Date of actual clearing of the punch point.

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16 Responsible for the clearing of Punch Identification of the person who accepts and signs off the punch
List item point. (generally the same as Field No. 10).
17 Subcontractor Identification of the subcontractor responsible for the job and/or the
repair.
18 Additional Notes Additional information that may be relevant for controlling the punch
point.

Page 126 of 139

 Appendix VIII

PERMIT TO WORK PROCEDURE

(DURING COMMISSIONING)

Page 127 of 139

 INDEX

1.0 SCOPE

2.0 DEFINITIONS

3.0 SAFETY CONDITIONS

4.0 RESPONSIBILITY

5.0 REMARKS

6.0 PROCEDURE

Attachments:

Attachment A

Attachment B

Attachment C

Attachment D

Page 128 of 139

1.0 SCOPE

This procedure applies only to the installation or maintenance work on systems or packages handed-over from
Construction Team to the Commissioning Team within the boundaries of the construction area.

For some systems or packages having interfaces with the existing installation of Owner, the Permit to Work
system of Owner shall be applied.

2.0 DEFINITIONS

Permit to Work (PTW)

The Permit to Work (PTW) is a written and signed document that authorizes the work supervisor to carry out
installation or maintenance activities on a turned-over system to commissioning.

The PTW referred hereto is the one issued by NEPC Commissioning Manager within the construction area to
their personnel to perform during the commissioning stage of the Unit.

Main Control Room (MCR)

The Shift Charge Engineer keeps all the keys related to the PTW in a safety box located in the MCR.

The Shift Charge Engineer is the person authorized to issue PTW.

3.0 SAFETY CONDITIONS

The basic safety conditions classified by systems are summarized as follows:

A. Electrical System

Breaker racked out (if possible locked out) or isolator opened and locked out. Earth switch inserted if work
is being performed on electrical parts. Feeders grounded if work is being performed on bus bars.

B. Process System

Isolation valves upstream and downstream of section under PtW locked close, vents open, drains open to
allow the system to be cooled, depressurized and emptied.

C. Chemical and Fire Risk Systems

The same as B), but in addition, the section should be purged and washed under supervision of a Safety
Engineer.

D. Works in Restricted Area: Furnace, Ducts, Pipes, Condensers, etc.

In addition to C), any fire source or forced fluid has to be under safety conditions. Continuous purging or

Page 129 of 139

 ventilation shall be provided according to the type of risk involved; the team shall be at least two persons
and the manholes must be prevented to close to allow open access to the area where the work is being
performed.

4.0 RESPONSIBILITY

The Work Supervisor is responsible to identify correctly the activity and the equipment described in the PTW
and to carry out the work within the isolation points according to the indication listed in PTW form, Attachment C.
He is also responsible that the works are done according to the work safety rules.

The Shift Charge Engineer is responsible to implement the safety conditions in the portion of the Plant under
PtW, and to maintain the same conditions during the performance of the works foreseen (see Attachment D).
Finally, upon completion of the works and when he receives back the area from the Work Supervisor, it is
always the Shift Charge Engineer who is authorized to remove those safety conditions.

5.0 REMARKS

For systems or packages having interfaces with the existing installation of the Owner, the Permit to Work system
of Owner shall be applied.

In each isolation point of the system or part thereof under PTW, the Shift Charge Engineer provides tags printed
clearly with “CAUTION – WORK IN PROGRESS” (see Attachment A). Only him can remove these tags after
the work is completed, inspected and the work permit is signed off for resumption of activities on taking over by
operation.

6.0 PROCEDURE

The procedure for PTW system is illustrated in the attached flow chart (see Attachment B). By issuing a Permit
to Work, the Shift Charge Engineer guarantees the safe conditions at the work place and for the whole duration
of the work. He is also responsible that the work place does not become a danger source for other parts of the
plant.

Examples of the form for the authorization of a PTW and the register of PTW issued are attached in this
procedure (see Attachment C and D).

During the commissioning phase of the plant, safety rules to be implemented inherent to
safety at work shall be the same rules applied during the construction phase.

Page 130 of 139

 Attachment A

ATTENTION

WORK

IN

PROGRESS

P.T.W. No.______

Page 131 of 139

 Attachment B
FLOW CHART – PTW Procedure

CONSTRUCTION MAINTENANCE
WORKS WORKS

Identification of equipment and

work description

Construction
Supervisor
The equipment is handed over to NO responsible to
commissioning? authorize the
work (PTW not
YES required).
The Shift Charge Engineer implements
the safety conditions (Sect. 3.0)

The Shift Charge Engineer declares that the equipment is

under safety conditions and “opens” the “PTW” in the logbook.

The work supervisor accepts the

equipment

THE WORK CAN START

WORK EXECUTION

THE WORK ENDS

The Work Supervisor returns the equipment back to

the commissioning team

The Shift Charge Engineer removes the safety

conditions and “closes” the PTW in the logbook.

The equipment is available for Operation

Page 132 of 139

 Attachment C

Register of Permit to Work

The compilation of the PTW Register is the responsibility of Shift Charge Engineer.

PtW No. System Work Description Date/Time Start Date/Time

No. Completion

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ______ ____________________________ __________ __________

______ ____________________________ __________ __________

Page 133 of 139

 Attachment D

Permit to work standard form

Page 134 of 139

 Appendix IX

PROCEDURE FOR THE MANAGEMENT

OF TEST INSTRUMENTS

Page 135 of 139

1. ACTIVITIES RELATED TO COMMISSIONING TEST EQUIPMENT

The activities that necessarily require the use of the test equipment during commissioning are:

Laboratory activities:
Calibration of transmitters and controller and trouble shooting on cards and apparatus.
High-quality instruments are required for these activities.

Field activities:
Functional checks on equipment.
These activities do not need special quality instruments.

Performance and acceptance tests:

To be done with instruments calibrated in accordance with the ASME Standard or as per Owner/PMT
specifications.

2. QA - PLAN FOR COMMISSIONING TEST INSTRUMENT

This plan covers the following instruments, which shall be utilized in the temporary commissioning laboratory:

• Pressure gauges
• Laboratory multi-meters
• Thermometers associated with test oven or oil bath

For the above instruments, following information or documentation must be filled:

• Original calibration sheets made by the manufacturer or a qualified laboratory

• Routine re-calibration check, according to the company standard, of instrument on approved laboratory
• All these instruments should be tagged for proper identification and traceability.
• There should be a calibration logbook through which it is possible to trace each project instruments, test
instruments and its calibration status.
• For special use of the test instruments in the field, there should be a record sheet explaining who use it,
where it will be used, the condition when it is taken out and the condition when the test instrument is
returned.

3. RESPONSIBILITY

The person in-charge of the temporary laboratory is responsible for all QA-activities.

The QA/QC Engineer on site is responsible for:

• Approval of the calibration laboratory

• Supervision of the QA related activities in the calibration & test laboratory
• Auditing the QA-activities in the test laboratory

Page 136 of 139

 Appendix X

LIST OF INSTRUMENTS, TOOLS AND CONSUMABLES

DURING COMMISSIONING

Page 137 of 139

1. INSTRUMENTS

1.1. Stabilized Power Supply Unit 0 to 30 V, 0.1 to 5 A

1.2. Multi-meter (analog/digital)
1.3. DECABOX at 7 Switches
1.4. Temperature Signals Calibrator
1.5. Hydraulic Jacket for Pressure Signals Generation
1.6. Dead Weight Tester
1.7. Gauges for Pressure – Vacuum
1.8. Pressure and Temperature Meter with Microprocessor and Probes
1.9. Thermometer with Various Ranges
1.10. Portable Signal Generator (mA, mV, V)
1.11. Digital Pressure Signals Generator at Various Ranges
1.12. Manual Pressure Signals Generator at Various Ranges
1.13. Manual Vacuum Pump with Meter
1.14. Vacuum Pump with Meter
1.15. Recorder (Multi-signal)
1.16. Atmospheric Conditions Recorder
1.17. Digital PH Meter
1.18. RPM Meter (optic, mechanical)
1.19. Conductivity Meter
1.20. Noise Level Meter
1.21. Vibration Detector
1.22. Continuity Buzzer
1.23. Meteo Conditions Meter
1.24. Frequency Meter
1.25. Primary Injection Current Set
1.26. Secondary Injection Current Set
1.27. Grounding System Tester (step voltage, contact voltage)
1.28. Relays Testing Units
1.29. Low Resistance Meter
1.30. Phase Angle Meter
1.31. Phasing Stick
1.32. Digital Earthing Tester
1.33. Insulation and Continuity Tester
1.34. Transformer Resistance Tester (Kelvin – Weatstone Bridge)
1.35. Multi-signals Recorder (8 channels)
1.36. LUX Meter
1.37. Phase Rotation Detector
1.38. Analog/Digital Multi-meter

Page 138 of 139

 1.39. Clamp Meters
1.40. Mini Clamps for Protection Circuits
1.41. Hi Pot Tester (AC/DC)
1.42. VARIAC Single and Three Phase
1.43. Potential Transformers High Accuracy
1.44. Shunt for DC Current (A/mV)
1.45. Low Current Injector
1.46. Torque Key

2. TOOLS

2.1. - Tool Boxes:

- for Mechanics with standard set of keys
- for Instrument Technicians with standard set of keys, multi-meters, signals, generators.
- for Electrical Technicians with standard set of keys, multi-meters, clamp meters, phase rotation detector.

3. CONSUMABLES

3.1. PadLocks (various size)

3.2. Chains (various size)
3.3. Fast Hose Connections (various size)
3.4 Collars for Hoses
3.4. Klingerite Sheets (various thickness)
3.5 Gaskets for Oil and Acid
3.6 Teflon Sheets (various thickness)
3.7 Neoprene Sheets (various thickness)
3.8 Liquid Sealant
3.9 Graphite Boxes
3.10 Spanish Paper (various thickness)
3.11 Various Fittings
3.12 Various Hoses
3.13 Plastic Gaskets
3.14 Metallic Nets for Temporary Strainers (various mesh wires)

Page 139 of 139