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Manufacturers Data Report (MDR) - Plant Projects EP-08-030-37

This is a Controlled Document that complies with CSBP Limited formatting and Quality Control guidelines. Please check that this is the latest available version before use. Title:

MANUFACTURERS DATA REPORT (MDR) - PLANT PROJECTS

Number:

EP-08-030-37

Owner:

David Zacher

Authoriser:

David Zacher

Version Details:

Owner/Authoriser changed - was Phil Talbot. No changes to document.

TABLE OF CONTENTS 1.

INTRODUCTION..................................................................................................................... 2

2.

PURPOSE .................................................................................................................................. 2

3.

RELATED STANDARDS AND GUIDES .............................................................................. 2

4.

MDR PREPARATION AND SUBMISSION ......................................................................... 3

5.

MDR FORMAT ........................................................................................................................ 4

6.

MDR CONTENTS .................................................................................................................... 4 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

SCOPE OF WORK ............................................................................................................... 5 SECTION 1 - DESIGN ......................................................................................................... 5 SECTION 2 - OFF SITE FABRICATION............................................................................ 5 SECTION 3 - SITE CONSTRUCTION AND INSTALLATION ........................................ 6 SECTION 4 - COMMISSIONING ....................................................................................... 7 SECTION 5 - EQUIPMENT TECHNICAL DATA ............................................................. 7 SECTION 6 - DRAWINGS .................................................................................................. 8 SECTION 7 - STATUTORY APPROVALS, REGISTRATION AND CERTIFICATES ... 8

APPENDIX 1 - MDR CONTENTS CHECK LIST ........................................................................... 9 SCOPE OF WORK............................................................................................................................ 9 SECTION 1 - DESIGN...................................................................................................................... 9 SECTION 2 - OFF SITE FABRICATION ........................................................................................ 9 SECTION 3 - ON SITE CONSTRUCTION AND INSTALLATION ............................................ 10 SECTION 4 - COMMISSIONING .................................................................................................. 11 SECTION 5 - EQUIPMENT TECHNICAL DATA........................................................................ 11 SECTION 6 - DRAWINGS ............................................................................................................. 12 SECTION 7 - STATUTORY APPROVALS, REGISTRATION & CERTIFICATES ................... 12

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Manufacturers Data Report (MDR) - Plant Projects EP-08-030-37

1.

INTRODUCTION

The Manufacturer’s Data Report (MDR) is the compilation of all the technical details and records of activities performed by a contractor as part of an engineering construction or modification project. This may include any of the following activities. a.

Design

b.

Supply of materials, proprietary plant and equipment

c.

Off site fabrication, surface treatment, assembly

d.

On site construction, assembly, erection and installation of plant and equipment

e.

Inspection, testing, and commissioning.

The MDR is provided by a Contractor to the Superintendent on completion of the Work under the Contract, usually as a precondition to the issue of the Certificate of Practical Completion. The primary purpose of the MDR is to provide CSBP with the information required to safely operate the plant and equipment provided under the contract and to service and maintain the equipment to achieve reliable operation over its expected life. The MDR also serves as a historical record and can be useful in helping to identify the cause of problems with quality, performance or reliability of the plant and equipment later in its life.

2.

PURPOSE

The purpose of this procedure is to define the requirements for preparation and submission of a MDR, and to provide a contents checklist for typical engineering projects. This document is focussed primarily to mechanical engineering contracts which include design, supply of equipment, off site fabrication, site installation and commissioning of mechanical equipment and piping. It is also relevant to civil, structural, electrical and instrumentation works, and should be used as a guide to format the MDR for these works. Note:

3.

It is usual for special equipment items such as pumps, control valves, and relief valves to be purchased by CSBP's Project Responsible Officer and free-issued to the contractor for installation. The technical data for these free-issued items will be assembled by the CSBP Responsible Officer and passed on to Reliability Support and to the CSBP Customer in the form of an MDR as described in this document.

RELATED STANDARDS AND GUIDES

The following CSBP documents shall form the basis of MDR requirements. a.

Technical Data Requirements for Plant and Equipment (GM-05-043-01)

b.

Equipment Numbering System (ES-14-101-06)

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Manufacturers Data Report (MDR) - Plant Projects EP-08-030-37

c.

Technical Data Sheets - Mechanical, Electrical and Instrumentation (ES-14-101-12). (These sheets should be provided to the Contractor early in the project to ensure standardisation of presentation of information)

d.

Fabrication and Installation of Piping (ES-14-602-01)

e.

Inspection and Testing of Piping Systems (ES-14-602-02)

f.

CSBP Stage 1 Commissioning Inspection Report and Stage 2 Commissioning Test Report forms. Note: These forms are available in Dom.doc in Business Support - Engineering Engineering Forms - Commissioning Reports

g.

Repairs and Minor Alterations to Existing Pressure Equipment, Piping and Tanks (DP-05095-06)

h.

Major Alterations and Replacement to Existing Pressure Equipment, Piping and Tanks (DP-05-095-08)

i.

Testing and Commissioning of Electrical and Instrumentation Installations (ES-14-902-02).

4.

MDR PREPARATION AND SUBMISSION

The Contractor shall compile an MDR for the contract work in the format detailed in 5. below. For large complex projects, the MDR may be submitted in several parts, for example, MDR for off-site manufacture and supplied equipment, MDR for on-site installation, erection and pre-commissioning; MDR for commissioning; For larger, multi discipline projects, separate MDRs may be produced for each discipline eg MDR for Civil Works, MDR for equipment supply/fabrication/assembly, MDR for mechanical installation, MDR for Electrical Installation. The Contractor and the Superintendent will review the check list provided in Appendix 1 at an early stage of the contract to agree the content of the MDR. The MDR shall be progressively compiled during the course of the work and kept up to date as the work progresses so that delivery of the MDR is not delayed at the completion of the work. Presentation of the required number of copies of a full and comprehensive MDR at the conclusion of construction is a contractual requirement under all CSBP engineering contracts and, unless specifically stated otherwise in the contract, is a precondition for the issue of the Certificate of Practical Completion to the Contractor. The MDR shall be presented to the Superintendent for review upon request to ensure compliance to the Contract requirements and to ensure that progressive compilation is being maintained. Initially, a single draft copy shall be submitted for review and approval by the Superintendent. MDRs covering fabrication, welding, heat treatment and testing of pressure piping or pressure equipment shall be submitted to and approved by the CSBP Senior Inspector before final acceptance by the Superintendent.

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On approval of the draft copy of the MDR, two final copies of the MDR shall be prepared and submitted by the contractor. An additional copy of Sections 5, 6 and 7, as described in 6.6, 6.7 and 6.8 shall also be supplied by the Contractor. The final copies of the MDR shall be distributed by the CSBP Responsible Officer as follows. - One complete copy to CSBP Customer - One complete copy retained in the CSBP Project File - Copy of Sections 5, 6 and 7 to Reliability Support

5.

MDR FORMAT

The MDR shall be prepared by the Contractor in one or more hard cover, A4 size, loose leaf, lever arch binders, with file separators clearly segregating each section. The MDR shall have a detailed table of contents at the front of each of the binders. The outside front cover and spine of the binders shall be identified with: •

The name of the Project

•

Manufacturer's Data Report for Manufacture (or installation, etc, as applicable)

•

The description of the subject work

•

The CSBP Contract or Purchase Order number

All documents for inclusion in MDR shall be written in the English language, in SI units, shall be complete and shall be originals or clearly legible copies. Documents and drawings larger than A4 size, which cannot be reduced clearly, shall be folded into A4 plastic pockets. MDRs shall be divided into the sections described below, as appropriate, and each section shall be divided by tabbed separator sheets. All of the separator sheet tabs shall carry the applicable section number and the title of the section. If a particular section is not applicable, the section may be omitted.

6.

MDR CONTENTS

The MDR shall be divided into the sections described below, as appropriate to the scope of the contract. The check list attached as Appendix 1 should be reviewed to check that all relevant documents for each aspect of the work have been included in the relevant section of the MDR as detailed below and in Appendix 1. If not already covered in this procedure, MDRs shall also contain those documents identified in the approved Inspection and Test Plan / Inspection and Test Program for the subject work as well as those identified in Contract/Order and in the applicable codes, Standards and legislation.

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6.1

SCOPE OF WORK

Insert as the front of MDR a brief description of the contract Scope of Work applicable to the MDR.

6.2

SECTION 1 - DESIGN

This section shall include all design calculations required to be submitted under the contract including design criteria, assumptions made and any references for design method selected. Calculations shall be sufficiently detailed to enable independent verification. Copies of all technical queries and their replies shall be included. Details of any authorised deviations from the contract specifications and the reasons for the deviations shall be included. Lists of all equipment, valves, pipelines and vessels provided by the contractor shall be included for reference.

6.3

SECTION 2 - OFF SITE FABRICATION

This section shall contain records of all activities associated with off site fabrication and assembly of materials and equipment to be incorporated into the works. The extent of the information to be included in the MDR will depend on the requirements of the contract. 6.3.1

Material Certificates and Test Reports

Where material traceability is required under the contract, this section shall contain an indexed list identifying material certificates and material test reports referenced to the locations of the materials used by their part, piece or item number and the applicable drawing(s). The material certificates and traceability shall include welding consumables. A copy of the certificates and reports shall be included in this section of the MDR indicating the certificate or report number, Heat, lot, plate number, etc, and the name of Mill. For clarity, the section shall also contain a drawing of the equipment or piping marked up to show the certificate number and heat number for the materials used at each location. 6.3.2

Weld Records

Details of all welding procedures and qualifications relevant to the subject work, including evidence of CSBP's approval, shall be included in this section. If more than one welder is used, then traceability sheets and / or marked up drawings, sketches or maps shall be included to identify the welder responsible for each weld, and what WPS was used. 6.3.3

Non Destructive Examination (NDE)

This section shall include a list of all NDE carried out on the subject works. The listing shall include for each test location, the type of NDE, the NDE procedure, the NDE report number and the result of the examination. The listing may be incorporated into the welding control and record sheets. The section shall include a marked up drawing, sketch or map to identify the NDE report

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numbers relevant to each test location together with a copy of all NDE certificates/reports in the order in which they are included in the above list. The section shall also include a list of all non-destructive testing personnel employed on the subject work and evidence of their qualifications. 6.3.4

Heat Treatment

If applicable, certificates and properly scaled furnace charts for all heat treatment performed shall be included. Charts shall include the complete heat treatment cycle including heating, soak period and cooling. The charts shall clearly show the calibrated temperature and time scales and provide a reference to the heat treatment procedure and to the specific item or weld that was heat treated. The charts shall be dated and signed by the person responsible for verifying the correctness of the heating cycle. Traceability sheets and / or marked up drawings, sketches or maps shall be included to identify the heat treatment charts relevant to each weld or item being heat treated. 6.3.5

Hydrostatic Testing

Where required by the contract, records of hydrostatic testing performed offsite, along with supporting documentation such as NATA test certificates for test gauges, shall be included in this section of the MDR. Stage 1 Commissioning inspection report forms should be completed prior to the commencement of such tests, and be included in this section of the MDR, whether included in the ITP or not. 6.3.6

Combination of Traceability Information

The traceability sheets and drawings, sketches or maps for material certificates, welder identification, NDT and heat treatment may be combined partially, or fully, in a format to be approved by the Superintendent.

6.4

SECTION 3 - SITE CONSTRUCTION AND INSTALLATION

This section shall contain records of all activities associated with site fabrication, assembly, installation and construction and Stage 1 commissioning of materials, plant and equipment incorporated into the works. Material traceability information, weld records, non destructive examination records, heat treatments records, etc, as detailed in 6.2 above and in Appendix 1, when applicable to the work done on site, shall be included in this section of the MDR. This section shall contain a copy of the approved ITP with evidence that the Contractor has complied with the ITP. Evidence of compliance shall be by signature of the persons responsible for verifying satisfactory performance of the identified inspections and tests in the relevant spaces provided in the ITP. Where applicable, this shall include the Superintendent and the Owner's inspector.

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Manufacturers Data Report (MDR) - Plant Projects EP-08-030-37

This section shall contain all those inspection and test records required by the ITP except for those that are identified for inclusion in other sections of the MDR. Where a standard CSBP Stage 1 Commissioning Inspection Report form is available for a particular item of equipment, the form shall be completed and included in this section of the MDR, whether indicated in the ITP or not. The records shall be filed in this section in the order in which they are identified on the ITP, or in some other logical order, clearly referenced to the particular inspection or test stage identified on the ITP.

6.5

SECTION 4 - COMMISSIONING

This section shall contain records of all activities associated with Stage 2 and Stage 3 commissioning. Where a standard CSBP Stage 2 Commissioning Test Report form is available for a particular item of equipment, the form shall be completed and included in this section of the MDR, whether indicated in the ITP or not. The records shall be filed in this section of the MDR in the order in which they are identified on the ITP, or in some other logical order, clearly referenced to the particular inspection or test stage identified on the ITP.

6.6

SECTION 5 - EQUIPMENT TECHNICAL DATA

This section shall contain technical information for all items of equipment supplied under the contract to allow ongoing operation, servicing and maintenance to be carried out. Information shall be included in sufficient detail to enable CSBP to identify and purchase individual parts of equipment supplied and to enable those parts to be installed. A drawing shall be supplied for each item of equipment, showing a complete breakdown of all parts. Each drawing shall be accompanied by a complete parts list, indicating the quantity of each part required and the manufacturer's part number. Any specific overhaul / repair kit must also have a part number and identify the items comprising the kit. Dimensional details of all non-proprietary items shall be provided by the Contractor, to allow CSBP to source replacements at a competitive price e.g. bearings, gaskets, oil-seals, packing materials, etc. Detailed drawings for all purpose-built items, unavailable “off-the-shelf”, shall be included in this section, specifying materials and all dimensions required to manufacture a replacement. E.g. gaskets for heat exchanger end covers, non-standard pipework components, etc. Nozzle drawings, showing flange details, should also be included in this section, to assist in linking gaskets to items of equipment. Completed Data Sheets on the applicable CSBP standard form shall be provided for each equipment item. Technical data in this section should address service conditions and operating parameters, e.g. temperatures, pressures, etc.

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This information should contain sufficient detail to enable purchase of a replacement item able to perform the same function even if from another manufacturer. Name plate details for tanks, vessels, heat exchangers, etc., should also be included in this section of the MDR. Commissioning, Operating and Maintenance Manuals shall be included for all items provided under the contract in sufficient detail to enable CSBP to safely and reliably commission, start up, operate, service, maintain and overhaul the items supplied by the contractor.

6.7

SECTION 6 - DRAWINGS

6.7.1

Drawing List

A complete list of all drawings including revision numbers produced by the Contractor for construction purposes, and which have been passed to CSBP’s drawing office for electronic storage, shall be included in this section of the MDR. 6.7.2

Vendor Drawings

Paper copies of Vendor drawings including assembly and sectional drawings showing details of overall width, height, base-to-shaft centres, base plate holes, etc, shall be provided with the MDR. 6.7.3

As-built Drawings

As-built drawings shall be provided with the MDR. As-built details shall be marked up with a red pen onto a paper copy of the contract drawing to clearly show changes that were made during manufacture or construction and to record any particular details not included in the original drawings. In particular, the exact location of buried pipework or buried other services shall be accurately recorded.

6.8

SECTION 7 - STATUTORY APPROVALS, REGISTRATION AND CERTIFICATES

This section shall list the various parts, equipment, materials and activities which require statutory approval and registration. Evidence of the required approval and compliance for each item shall be included in this Section.

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Manufacturers Data Report (MDR) - Plant Projects EP-08-030-37

APPENDIX 1 - MDR CONTENTS CHECK LIST SCOPE OF WORK Insert a brief description of the contract Scope of Work applicable to the MDR at the front of MDR.

SECTION 1 - DESIGN a.

Design calculations

b.

Technical Queries

c.

Authorised Deviations

d.

Equipment lists

e.

Valve List

f.

Pipeline lists

g.

Pressure Vessel List

h.

Instrument List

i.

Motor List

SECTION 2 - OFF SITE FABRICATION Fabrication and Welding of Pressure Vessels, Pipe Spools and Steelwork a.

Signed off ITPs for each stage of the work

b.

Material Certificates, including all items directly welded to piping or pressure vessels

c.

Material and consumable map for traceability

d.

Consumables Certificates

e.

Weld Procedure Records (WPR)

f.

Weld Procedure Qualification Records (WPQR)

g.

Welder Qualification Records (WQR)

h.

Material Heat Traceability Records

i.

Inspection and Non Destructive Testing (NDT) Records

j.

Weld maps identifying NDT records against location

k.

Weld maps identifying welders and WPS used for each weld

l.

Hardness Test Records (to be included in NDT traceability)

m.

Heat Treatment Records

n.

Map for identifying heat treatment records against welds and/or location

o.

Pressure Test Records

p.

Pressure Test instrument calibration records (NATA)

q.

Stage 1 Pre-commissioning Inspection Reports completed prior to pressure tests

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r.

Non-conformances, concessions and technical queries

a.

Test Certificates

b.

Material Certificates

Valves

Surface Treatment and Protective Coatings a.

Surface preparation Records

b.

Coating application and thickness records

SECTION 3 - ON SITE CONSTRUCTION AND INSTALLATION Inspection and Test Plans (ITPs) a.

Signed off ITPs for each stage of the work

Civil Works a.

b.

c.

Earthworks 1.

Survey and set out records

2.

Backfill Checklist

3.

Compaction Checklist

Concrete Works 1.

Formwork Inspection and Pre-Pour Records

2.

Concrete Placing Records

3.

Concrete Delivery Dockets

4.

Reinforcing Schedule

5.

Coating record sheets

Concrete Testing 1.

Compressive Strength Testing

Structural Steel Erection a.

Installation record sheets

Mechanical Equipment Installation a.

Pre-commissioning Inspection Reports

b.

Pump alignment records

a.

Approved repair procedure as per DP-05-095-06 for welded tie-ins to existing piping and equipment

b.

Welding Procedure Specifications / WPQR

c.

Welder Qualifications Records

d.

Material Heat Number Index

e.

Material Certificates

Piping

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f.

Material and consumable map for traceability

g.

Weld Maps for welder, WPS and NDT traceability

h.

Weld & Material Heat Number Traceability Records

i.

Non Destructive Testing (NDT) Records

j.

Post Weld Heat Treatment (PWHT) Records

k.

PWHT traceability maps

l.

Hardness Test Records (include in NDT traceability)

m.

Pressure Testing Records and test packs, including NATA calibration certificates for test instruments

n.

Completed Punch-lists

o.

Non-conformances, concessions and technical queries

p.

Stage 1 Pre-commissioning Inspection Reports

Insulation / Cladding Records Refractory Inspection and Test Records Electrical and Instrument installation records a.

Commissioning Test Reports as detailed in CSBP Engineering Standard ES-14-90202 Testing and Commissioning of Electrical and Instrumentation Installations

b.

Cable Test Result Sheets

c.

Instrument Calibration Record Sheets

d.

Loop Check Sheets

e.

Hazardous Area Check Sheets

f.

Trip Settings Record Sheets

Miscellaneous Records a.

Test equipment certificates

SECTION 4 - COMMISSIONING a.

Approved commissioning procedure

b.

Stage 2 Dry Commissioning Test Reports

c.

Stage 3 Wet Commissioning records

d.

Completed punchlists resulting from b and c.

SECTION 5 - EQUIPMENT TECHNICAL DATA Vendor details a.

Equipment number and description

b.

Vendor and Order number

c.

Vendor contact details (address, telephone number, fax number, email address, contact name)

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Technical Data a.

Technical Data Sheets

b.

Name Plate Details

c.

Test certificates

d.

Calibration certificates

Operating and Maintenance Information a.

General Information

b.

Safety Precautions

c.

Assembly and Installation Instructions

d.

Start-up Procedures

e.

Maintenance and inspection requirements, intervals, checks, etc

f.

Lubrication schedules including grease and oil types, quantities

g.

Repair / Overhaul Procedures

h.

Assembly Torque settings

i.

Storage instructions

j.

Test Certificates

k.

Recommended Spare Parts Lists

l.

Calibration procedures

SECTION 6 - DRAWINGS a.

Drawing List including revision number

b.

General arrangement drawings

c.

Layout drawings

d.

Marking plans

e.

Vendor drawings

f.

Assembly drawings

g.

As-Built Drawings 1.

Piping isometrics and details

2.

Buried pipe and services

3.

Red pen markups to contract drawings

SECTION 7 - STATUTORY APPROVALS, REGISTRATION & CERTIFICATES a.

Pressure Vessel Design Registration details

b.

Lifting equipment certification

c.

Development approval and Building license

d.

Gas and electrical installation certificates

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e.

Electrical equipment hazardous area rating certification

f.

Test certificates for pressure safety valves and bursting disks

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