Mechanical Completion Procedure [PDF]

Zitiervorschau

CRUX PIPELINE AND SUBSEA STRUCTURES

Pages: 1 of 113

Type of Document: Procedure

MECHANICAL COMPLETION EXECUTION PLAN

A

Issued For Bidding

14.Jan.20

Rev.

Purpose of Issue

Issue Date

MVB Prepared By

Reviewed By Sub-Contractor

Document No.: SUB-CONTRACTOR: PV SHIPYARD JSC

Approved By

Approved By Contractor

Title: MECHANICAL COMPLETION EXECUTION PLAN

REVISION RECORD SHEET

NO.

REV. NO.

1

A

CONTENT OF REVISION Issued for Bidding

DATE OF REVISION 14.Jan.2020

Title: MECHANICAL COMPLETION EXECUTION PLAN

TABLE OF CONTENTS

1.1

Project Background .......................................................................................5

1.2

Objective .......................................................................................................5

4.1

Definitions of Mechanical Completion .........................................................9

4.2

Definitions of Pre-Commissioning .............................................................10

5.1

Mechanical Completion Database Structure and Operation .......................11

5.2

Mechanical Completion Hierarchy .............................................................12 Systems .......................................................................................... 12 Sub-Systems .................................................................................. 12 Discipline Packages ....................................................................... 12 MC – ITR’s .................................................................................... 12

5.3

Boundary Documents ..................................................................................13

5.4

System / Sub-System Priorities ...................................................................13

6.1

SUBCONTRACTOR Construction/ Quality Control Team.......................13

6.2

CONTRACTOR Completions Team ..........................................................14

6.3

Mechanical Completion Team & Integrated Commissioning Team ..........14

7.1

Signatory Authority.....................................................................................16

7.2

Signature Matrix..........................................................................................22

7.3

Mechanical Completion Responsibility Matrix ..........................................22

8.1

The Mechanical Completion Inspection Test Records (MC-ITR) .............22

Title: MECHANICAL COMPLETION EXECUTION PLAN

MC-ITR Sign Off Authority .......................................................... 23 MC-ITR Completion Flowchart .................................................... 24 MC-ITR Queries ............................................................................ 24 8.2

The Mechanical Completion Discipline Acceptance Certificate (MC-DAC) 25

8.3

8.2.1

MC-DAC Sign Off Authority ........................................................ 25

8.2.2

Partial MC-DAC ............................................................................ 26

The Mechanical Completion Sub-System Acceptance Certificate (MC-

SSAC).....................................................................................................................26 8.3.1

MC-SSAC Sign Off Authority ...................................................... 27

8.4

Red-line Drawings ......................................................................................27

8.5

Construction As-Built Drawings .................................................................27

9.1

Execution Step ............................................................................................28

9.2

Ongoing activities post MC ........................................................................29

9.3

Exceptions to MC-SSAC Handover Acceptance ........................................30

9.4

Mechanical Completion Handover Dossiers...............................................30

9.5

Mechanical Completion Activities..............................................................31

15.1

Planning system ..........................................................................................36

15.2

Progress Measurement ................................................................................36

15.3

Monitoring and report .................................................................................37

Title: MECHANICAL COMPLETION EXECUTION PLAN

INTRODUCTION 1.1

Project Background

The Crux gas field is in the Australian Commonwealth waters, within permit AC/RL9 in the East Browse basin. The title is operated by COMPANY (82% equity) on behalf of the other joint venture participants SGH Energy (15%) and Osaka Gas (3%). The field lies in approximately 165m of water depth, 620km NNE of Broome (~300km from mainland Australia). The title is surrounded by COMPANY operated AC/P-41 title (COMPANY equity 75%) that incorporates the Libra gas field and is located approximately 160km NE of COMPANY operated Prelude Asset (Prelude FLNG). A Not Normally Manned (NNM) platform at the Crux field (Crux NNM platform) will be tied back to the Prelude Asset through an approximate 160km multiphase export pipeline. The export pipeline shall interface with the Prelude Asset through a 16” ID flexible riser. The subsea isolation valve on the associated riser base structure shall be controlled through a dedicated dynamic umbilical from the Prelude Asset. The Crux field location map is presented in Figure 1.

Figure 1: Crux AC/RL9 Field Location Map

Title: MECHANICAL COMPLETION EXECUTION PLAN

1.2

Objective

Crux Pipeline and Subsea Structures EPCI scope consists of the following: a. EPCI project management of the complete SCOPE. b. Engineering, detailed design, procurement, fabrication, testing and preservation of the following PERMANENT WORK: i. ii. iii. iv. v. vi. vii.

Crux 26” OD (24.5” ID controlled) export pipeline; Crux 26” OD (24.5” ID controlled) CRA rigid riser (excluding fabrication and onshore testing); Linepipes and bends external corrosion and concrete weight coatings/claddings; Crux 26” OD (24.5” ID controlled) pipeline end termination (PLET) structure and foundation Prelude 18” OD (16” ID controlled) pipeline end termination (PLET) structure and foundation Crux 26” OD (24.5” ID controlled) CRA rigid tie-in spool; and Crux Static Umbilical.

c. Load out and transportation of all MATERIALS and PERMANENT WORK; d. Engineering and execution of the following SCOPE: i. ii. iii. iv. v. vi.

Installation of pipeline, PLETs and foundations between Crux platform and Prelude FLNG; Flood, clean, gauge, hydrotest and preservation of pipeline PLET connector to PLET connector; Offshore metrology, fabrication and installation of Crux CRA rigid tie-in spool; Crux Static Umbilical pull-in, tie-in and test; Installation of Fibre Optic flying lead (at Crux) and test; Installation of 16” ID diverless connector on pre-installed flexible riser, tie-in of flexible riser to Prelude PLET and test; vii. Offshore tie-in of pre-installed wet parked Prelude dynamic umbilical to Prelude PLET and test; and viii. Topside Crux pig trap to topside Prelude pig trap system leak test, dewatering, drying and preservation.

Figure 2: Subsea & Pipeline System Schematic

DOCUMENT PURPOSE The purpose of this document is to provide a clear procedure, framework of responsibility and actions required by contractor and client for use during implementation and recording of

Title: MECHANICAL COMPLETION EXECUTION PLAN

Mechanical Completion (MC) of the scope of work awarded to SUBCONTRACTOR for completion at their fabrication yard in Vung Tau Vietnam. The document is intended to provide definition of the aspects of the MC process responsibilities, system breakdowns, certification levels, documentation type required to implement, record and validate MC activities associated with the awarded workscope. The document demonstrates discipline specific details and accountabilities for assessing fabrication craft, controlling MC documentation workflow through population and compilation of the associated certification and assuring construction quality and completeness. The document outlines inspection and quality assurance of workscope and certification sub- levels in the lead-up to final sign-off of Dossiers and handover for Pre-Commissioning of Mechanically Complete Sub-Systems within the SUBCONTRACTOR yard. ABBREVIATIONS CA

Certification Authority

CHEP

Commissioning & Handover Execution Plan

CMS

Completions Management System

COD

Change of Duty

COR

Certificate of Readiness

FAT

Factory Acceptance Test

HUC

Hook Up & Commissioning

ICP

Independent Competent Person

ICT

Integrated Commissioning Team

IDC

Inter-Discipline Check

ITP

Inspection and Test Plan

ITR

Inspection and Test Record

IVB

Independent Verification Body

LOTO

Lock Out / Tag Out

MC

Mechanical Completion

MC-ITR

Mechanical Completion Inspection & Test Record

MC-DAC

Mechanical Completion Discipline Acceptance Certificate

MC-SSAC

Mechanical Completion Subsystem Acceptance Certificate

OS&D

Overage, Shortage and Damage

P&ID

Piping & Instrument Diagram

Title: MECHANICAL COMPLETION EXECUTION PLAN

PC

Pre-commissioning

PCCC

Pre-commissioning Completion Certificate

PC-DAC

Pre-commissioning Discipline Acceptance Certificate

PC-ITR

Pre-commissioning Inspection & Test Record

PEP

Project Execution Plan

P/L

Punch List

PS

Performance Standards

PTW

Permit to Work

QA

Quality Assurance

QC

Quality Control

RFC

Ready for Commissioning

SAC

System Acceptance Certificate

SAT

Site Acceptance Test

SCE

Safety-Critical Element

SHC

System Handover Certificate

SHE

Safety, Health & Environment

SLD

Single Line Diagram

TRA

Task Risk Assessment

TQ

Technical Query

VR

Vietnam Register – Certifying Authority

VDRL

Vendor Data Requirement List

Title: MECHANICAL COMPLETION EXECUTION PLAN

DEFINITIONS 4.1

Definitions of Mechanical Completion Mechanical Completion (MC) as a term means bringing the plant and equipment, including switchboards, piping systems etc. to a state of completion whereby single discipline precommissioning can commence in accordance with project specifications.

The fabricator/

constructor / Vendor (in both onshore and offshore contexts) will demonstrate MC by inspection and testing of the installation and presentation of the information in check sheet format (MC-ITR Check sheets). Typical work which may be specified on the relevant Mechanical Completion Records will include, but not be limited to, checks and verification of completion of the following: 

Fabrication, assembly, dimensional checks and finishing of all structural steelwork.



Installation of platforms, including stairways, safety grills, etc.



Surface preparation, painting or galvanizing of all steelwork, pipework, equipment and facilities support steelwork.



Installation of all equipment described in the contract and designated for installation together with its associated piping, electrics, instrumentation and other services.



Fabrication, installation, connection and hydrostatic testing of all pipework.



Installation of all cable support systems, cable glands, penetrations, junction boxes, outlets, light fittings and grounding.



Installation, securing, terminating, marking, continuity and tightness checking, of all electrical, telecommunications and instrumentation cabling and wiring.



Installation of all switchgear, transformers etc., power supply and control panels.



Installation of HVAC ducting complete with all support steel, equipment, accessories, filters, instrumentation and controls. Carrying out an integrity test of the ducting and mechanical alignment / function tests of equipment.



Checking free rotation, alignment and correct orientation of all rotating equipment.



Installation of all floor coverings, partitions, wall linings and associated insulation, furniture, fittings and service systems.



Installation of all instruments, instrument control panels, associated piping and cabling loop checks and leak tests.

Title: MECHANICAL COMPLETION EXECUTION PLAN



Integrity testing of piping and continuity checking of cable.



Installation of all fire protection/detection, gas detection equipment and accessories including associated piping and wiring.



Installation of insulation and insulation fixing materials.



Installation and certifying of safety equipment including platform safety and hazardous area signs.

 4.2

Installation, certifying, testing of lifting equipment, runway beams and pad eyes.

Definitions of Pre-Commissioning Pre-Commissioning is the execution of single discipline checks carried out on individual items of equipment by commissioning personnel required to demonstrate unit or component functionality by the introduction of energy for operation under no load conditions. Pre-Commissioning activities are performed post Mechanical Completion to ensure functionality of the system/equipment is ready for commissioning. Presentation of Pre-Commissioning information is in check sheet format (PC-ITR Check sheets). Tests shall: 

Verify MC documentation is in place.



Be carried out on a single discipline basis.



Require individual equipment to be energized



Validate the functionality of equipment



Simulate process fluids for function testing.



Record any outstanding Punch List items.



Completion of Pre-Commissioning PC-ITR Check sheets.

Title: MECHANICAL COMPLETION EXECUTION PLAN

MECHANICAL COMPLETION PROCESS & BREAKDOWN 5.1

Mechanical Completion Database Structure and Operation With 02 locations of construction activity associated with the ZWP14 & ZWP15 Jacket Fabrication it is vital for the progress of MC at each site to be visible to Company Project Management Team (PMT). The overall MC schedule must be maintained, transparent and accurately managed throughout the various phases of the Project as planned. SUBCONTRACTOR Construction / Quality Control / MC Team shall: 

Maintain continual status indices and MC reports for all Sub-Systems.



Prepare accurate and fully populated hardcopy handover certification.



Clearly forecast and alert CONTRACTOR of upcoming ‘completion’ activity 24 hours in advance.



Verify MC-ITRs status, Punch list status and certification at handover of Sub-Systems.



Clear all deficiencies identified prior to re-submittal of handover documentation.



Participate in joint Multi-Discipline Sub-System walk-down with CONTRACTOR Site Commissioning Team.



Perform and record all required Preservation activities as detailed by Supplier documentation as a minimum.

CONTRACTOR Construction / Quality Control / MC Team shall: 

Monitor, Witness, Review, Reject, Approve offered MC-ITRs.



Monitor, Witness, Review, Reject, Approve offered MC-DACs.



Conduct discipline walk-downs as appropriate.



Assist with the review of MC-SSACs along with CONTRACTOR Commissioning Team.



Agree any deficiencies to be rectified by SUBCONTRACTORprior to re-submittals.



Participate

in

Multi-Discipline

Sub-System

walk-downs

with

CONTRACTOR

Commissioning Team. 

Approve SUBCONTRACTORConstruction Punch lists where acceptable along with CONTRACTOR Commissioning Team.

Title: MECHANICAL COMPLETION EXECUTION PLAN



Review and ensure Preservation activities are performed as scheduled during Construction and MC Phases and preservation database is maintained.

5.2

Mechanical Completion Hierarchy In order to achieve a correctly documented MC Handover from SUBCONTRACTOR Construction to ICT all Systems are divided to form Sub-Systems which further transcend to Discipline packages. Systems Defined Systems have been allocated a number by the Integrated Commissioning Team – Pre Execution personnel which transcends down to numbering of the Sub- Systems. Sub-Systems A Sub-System is the boundary of equipment which has been conveniently grouped for the purposes of dividing the larger systems into more manageable sections for MC and Pre- Commissioning. Each Sub System shall be allocated a number by SUBCONTRACTOR which shall relate to systems module. Every item of equipment within each Sub System e.g. piping, cables instruments etc. shall be referred to by its allocated unique project tag number. Discipline Packages Discipline packages within a Sub-System have been allocated to further divide the Sub- Systems and have been provided with individual Discipline identifications. When all the Discipline packages within a Sub-System are agreed by the ICT as mechanically complete, the larger SubSystem by definition is considered to be mechanically complete. MC – ITR’s The listing of equipment shall be further broken down into individual Mechanical Completion Records (MC-ITRs) which identify test and inspection requirements for each item of equipment.

Title: MECHANICAL COMPLETION EXECUTION PLAN

5.3

Boundary Documents The boundary limits of Sub Systems shall initially be identified by SUBCONTRACTOR Commissioning Team on marked up P&ID's, Layout Drawings, Instrument Block Diagram and Electrical Single Line Drawings. The boundary limits shall be reviewed and agreed with CONTRACTOR Completions Team prior to final approval. On completion of approved System/Sub System boundaries all equipment within the established Sub System limits shall be listed including in line and remote instruments, associated power and control cables by type and number.

5.4

System / Sub-System Priorities Sub-System priorities for completion have been identified by the ICT. At the correct point in time SUBCONTRACTOR will define Systems and Sub-Systems within the Work Breakdown Structure of their Level 03 Construction Execution Schedule and present proposed MC Handover dates and MC ‘skyline’ charts to ICT for approval. These documents will reflect the handover priorities requested by the ICT and will establish a progressive handover flow in a sequence supporting the defined System / Sub- System priorities. ORGANISATION RESPONSIBILITIES

6.1

SUBCONTRACTOR Construction/ Quality Control Team The primary responsible function of the SUBCONTRACTOR Construction/ Quality Control Team is to fabricate, outfit and Mechanically Complete works including handover to CONTRACTOR Construction/ QC/ Completions Team.

Title: MECHANICAL COMPLETION EXECUTION PLAN

SUBCONTRACTOR Construction/ QC Team will: 

Develop an integrated fabrication fit-out and MC schedule taking due consideration of System and Sub-System completion requirements as identified in the Commissioning programs.



Be responsible for all verifications of testing and inspection activities carry out by SUBCONTRACTOR. They shall take full responsibility for the management, execution of MC and for completion of associated certification offered for acceptance (MC-ITRs and MCDACs) to CONTRACTOR Construction/ QC Team.



Maintain certification and database records of test activities as detailed on MC-ITRs and MCDACs.



Punch-out and rectify items as necessary prior to the joint Sub-System walk-down.



Prepare all supporting document for MC-DACs and MC-SSACs approval and handover to Pre-commissioning/ Commissioning Team.

 6.2

Participate in joint Sub-System walk-down/ punch-out activities.

CONTRACTOR Completions Team CONTRACTOR Completions Team, which consists of CONTRACTOR Site Construction / Quality / Commissioning Teams has accountability for the management of MC works, for quality standard and acceptance of associated certification offered for acceptance by SUBCONTRACTOR Construction/ QC Team. The primary functions of CONTRACTOR Completions Team are: 

Verify and Accept inspections, approval certification and database records of test activities as detailed on MC-ITRs, MC-DACs. They will review the MC-DAC’s which will either be rejected or approved by CONTRACTOR Commissioning.



Punch-out, as necessary, prior to the joint Sub-System walk-down.



Review handover documentation for completed Systems / Sub-Systems ready to be offered to the Pre-Commissioning/ Commissioning Team.

 6.3

Participate in joint Sub-System walk-down/punch-out activities.

Mechanical Completion Team & Integrated Commissioning Team This team operates as an integrated team of: 

CONTRACTOR Completions Team

Title: MECHANICAL COMPLETION EXECUTION PLAN



SUBCONTRACTOR Commissioning Team



SUBCONTRACTOR Mechanical Completion Team

During Mechanical Completion phase the Mechanical Completion Team shall be responsible for the acceptance and verification of Mechanical Completion. During the MC phase the MC Team will: 

Control issue of sub-system folders to Construction team



Coordinate activities with QA/QC manager and Construction Managers to ensure earliest transfer of area to sub-system, discipline sub-system completion (DAC), sub-system acceptance (SSAC).



Monitor MC progress, check completeness of ITR’s, check punch-list status.



Preparation and maintenance for MC schedule



Participate in joint Sub-System walk-down/ punch-out activities.



Receive handover from Construction Team and take each Sub-System to a state of Ready to Pre-Commissioning in accordance with the Commissioning schedule.

During the MC phase the Commissioning Team will: 

Mark-up boundary clearly for each system/ sub-system.

The SUBCONTRACTOR

Commissioning Team will prepare and submit to CONTRACTOR Commissioning Team for review and agreement. 

Prepare check-sheet templates for all MC works (MC-ITRs, MC-DACs, MC-SSACs). SUBCONTRACTOR Commissioning Team will prepare and submit to CONTRACTOR Commissioning Team for review and agreement.



Participate in joint Sub-System walk-down/ punch-out activities.



Verify and approve for Discipline Acceptance Certificate (MC-DAC) and Sub-System Acceptance Certificate (MC-SSAC).



Receive handover from Construction Team and take each Sub-System to a state of Ready to Pre-Commissioning in accordance with the Commissioning schedule.

During Pre-commissioning & Commissioning phases the ICT is responsible for preparation, management, execution of Pre-Commissioning and dynamic Commissioning of systems in accordance with approved procedures. They are also responsible for specific mechanical completion activities of Contractors supplied Vendor packages.

Title: MECHANICAL COMPLETION EXECUTION PLAN

MC HANDOVER DOCUMENTATION RESPONSIBILITY SPLIT The MC Flow Chart (Figure 3) demonstrates the progression and signatory responsibilities of MCITR’s from issue through to MC-ITR completion. Once all the MC-ITR’s within a Sub-system / Discipline are completed the MC-DACs are generated for acceptance and sign off. The MC-DACs are then accumulated appropriately and the MC-SSACs are generated for acceptance and sign off by the Integrated Commissioning Team (ICT). 7.1

Signatory Authority As shown on the MC Flow Chart in Figure 3 a hierarchical arrangement of SUBCONTRACTORConstruction / QC / MC personnel positions and CONTRACTOR Completions personnel positions are accountable for signing-off the sub-level hierarchy of MC certification. In general, all MC documentation will be countersigned by both SUBCONTRACTORand CONTRACTOR. An exception may be made for MC-ITRs where the MC-ITR is not called for as a CONTRACTOR hold/witness/inspect point by QC ITPs. In that instance MC-ITRs may be both completed and accepted by Contractor only. Identification of these MC-ITRs will be provided by CONTRACTOR. The following signatory authority tables cross-reference those positions within the structured arrangement of accountabilities for ensuring compliance with workmanship quality, documentation accuracy, completeness and co-ordination of certification flow through to full MC of the Jacket. On signing certification, the SUBCONTRACTORConstruction / QA / MC signatory authority is stating they have personally monitored, witnessed, reviewed the workmanship and dossier contents involved with the specific scope and that all are of an acceptable standard. CONTRACTOR Completions team will sign as a verification / acceptance function. Throughout the full construction and mechanical completion process of Jacket both SUBCONTRACTOR and CONTRACTOR will work on the basis that: “Whoever has undertaken the work will have signed the documentation and is fully responsible for the scope it covers”

Title: MECHANICAL COMPLETION EXECUTION PLAN

MC-ITR Signatory Authority Check Sheet by Discipline MC-ITR Signatory Authority

Discipline

A - Architectural

E - Electrical

H - HVAC

I - Instrumentation

IN - Insulation

M - Mechanical

P - Piping

S - Safety

St - Structural

Completed by SUBCONTRACTOR

Verified/Approved by SUBCONTRACTOR

Witnessed/Reviewed by CONTRACTOR

Construction Team

QA/QC Team

Completions Team

 Discipline Supervisor

 Discipline Supervisor

 Discipline Supervisor

 Discipline Supervisor

 Discipline Supervisor

 Discipline Supervisor

 Discipline Supervisor

 Discipline Supervisor

 Discipline Supervisor

 Discipline Inspector  Lead discipline Inspector  Discipline Inspector  Lead discipline Inspector  Discipline Inspector  Lead discipline Inspector  Discipline Inspector  Lead discipline Inspector  Discipline Inspector  Lead discipline Inspector  Discipline Inspector  Lead discipline Inspector  Discipline Inspector  Lead discipline Inspector  Discipline Inspector  Lead discipline Inspector  Discipline Inspector  Lead discipline Inspector

 Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector

Title: MECHANICAL COMPLETION EXECUTION PLAN

T - Telecoms

X – Surface Protection

 Discipline Inspector

 Discipline Supervisor

 Lead discipline Inspector  Discipline Inspector

 Discipline Supervisor

 Lead discipline Inspector

 Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector

Table 1: MC-ITR Positional Sign-off Authority MC-ITR Signatory Authority Check Sheet by Discipline Jacket MC-ITR Signatory Authority

Discipline

E - Electrical

I - Instrumentation

M - Mechanical

P - Piping

St - Structural

Completed by VSP Team

 Discipline Supervisor

 Discipline Supervisor

 Discipline Supervisor

 Discipline Supervisor

 Discipline Supervisor

Verified/Approved by SUBCONTRACTOR QA/QC Team  Discipline Inspector  Lead discipline Inspector

 Discipline Inspector  Lead discipline Inspector

 Discipline Inspector  Lead discipline Inspector

 Discipline Inspector  Lead discipline Inspector

 Discipline Inspector  Lead discipline Inspector

Witnessed/Reviewed by CONTRACTOR Completions Team  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector  Construction Discipline Engineer  QC Discipline Inspector

Table 2: Jacket MC-ITR Positional Sign-off Authority

Title: MECHANICAL COMPLETION EXECUTION PLAN

MC-DAC Signatory Authority Acceptance Certification by Discipline MC-DAC Signatory Authority Accepted by Completed by Discipline

SUBCONTRACTOR Construction Team

SUBCONTRACTOR MC & Commissioning Team, or Verified by SUBCONTRACTOR QA/QC Team

A - Architectural

 Discipline Superintendent

E - Electrical

 Discipline Superintendent

H- HVAC

 Discipline Superintendent

I - Instrumentation

 Discipline Superintendent

IN -Insulation

 Discipline Superintendent

M - Mechanical

 Discipline Superintendent

P - Piping

 Discipline Superintendent

 QC Lead Discipline Inspector

 Discipline Superintendent

 Discipline Superintendent

Commissioning Team, Completion team & Operation Team

 Completion team  Commissioning

Discipline Engineer

Discipline Engineer

 Commissioning

 Commissioning

Discipline Engineer

Discipline Engineer

 Commissioning

 Commissioning

Discipline Engineer

Discipline Engineer

 QC Lead Discipline Inspector

 Completion team

 Commissioning

 Commissioning

Discipline Engineer

Discipline Engineer

 Commissioning

 Commissioning

Discipline Engineer

Discipline Engineer

Inspector / Commissioning Discipline Engineer

St - Structural

CONTRACTOR

 Commissioning

 QC Lead Discipline S - Safety

Reviewed by

 QC Lead Discipline Inspector

 Completion / Operations / Commissioning Discipline Engineer  Completion team

Title: MECHANICAL COMPLETION EXECUTION PLAN

T - Telecoms X – Surface Protection

 Discipline Superintendent

 Discipline Superintendent

 Commissioning

 Commissioning

Discipline Engineer

Discipline Engineer

 QC Lead Discipline Inspector

 Completion team

Table 3: MC-DAC Positional Sign-off Authority MC-DAC Signatory Authority for Jacket Acceptance Certification by Discipline Jacket MC-DAC Signatory Authority

Accepted by SUBCONTRACTOR Discipline

Completed by VSP Team

MC & Commissioning Team, or Verified by SUBCONTRACTOR QA/QC Team

E - Electrical

 Discipline Superintendent

I - Instrumentation

 Discipline Superintendent

M - Mechanical

 Discipline Superintendent

P - Piping

 Discipline Superintendent

St - Structural

 Discipline Superintendent

Reviewed by CONTRACTOR Commissioning Team, Completion & Operation Team

 Commissioning

 Commissioning

Discipline Engineer

Discipline Engineer

 Commissioning

 Commissioning

Discipline Engineer

Discipline Engineer

 Commissioning

 Commissioning

Discipline Engineer

Discipline Engineer

 Commissioning

 Commissioning

Discipline Engineer

Discipline Engineer

 QC Lead Discipline Inspector

 Completion team

Title: MECHANICAL COMPLETION EXECUTION PLAN

Table 4: Jacket MC-DAC Positional Sign-off Authority MC-SSAC Signatory Authority Acceptance Certification by Sub-System MC-SSAC Signatory Authority Reviewed by

Accepted by Completed by Discipline

CONTRACTOR

SUBCONTRACTOR

SUBCONTRACTOR Construction Team

Commissioning Team,

MC/Commissioning Team

Completion team &

& QC Team (Non

Operation Team (Non

Commissionable Sub

Commissionable Sub

Systems)  MC or Commissioning

All Associated Disciplines and

 Construction

Manager

Information for the

Manager

 QC Manager (Non

SSAC and Dossier

Commissionable Sub System)

Systems)  Commissioning Supervisor  Completion/Operation team (Non Commissionable Sub System)

Table 5: MC-SSAC Positional Sign-off Authority MC-SSAC Signatory Authority for Jacket

Acceptance Certification by Sub-System Jacket MC-SSAC Signatory Authority Accepted by Completed by Discipline

VSP Construction Team

SUBCONTRACTOR MC/Commissioning Team & QC Team (Non Commissionable Sub Systems)

All Associated

 Construction

 MC & Commissioning

Disciplines and

Manager

Manager

Reviewed by CONTRACTOR Commissioning Team, Completion team & Operation Team (Non Commissionable Sub Systems)  Commissioning Supervisor

Title: MECHANICAL COMPLETION EXECUTION PLAN

Information for the

 QC Manager (Non

 Completion/Operation

SSAC and Dossier

Commissionable Sub System)

team (Non Commissionable Sub System)

Table 6: Jacket MC-SSAC Positional Sign-off Authority 7.2

Signature Matrix An Authorised Signature Matrix for these positions will be maintained by SUBCONTRACTOR Construction / QC / MC Team, CONTRACTOR Completions Team and ICT.

7.3

Mechanical Completion Responsibility Matrix For full clarity scope responsibility within the Site Teams and specific division of construction tasks between SUBCONTRACTOR and CONTRACTOR within Mechanical Completion scope of SV CPP are defined within a detailed MC Responsibility Matrix table. MC DOCUMENTATION, SIGNATORIES & HANDOVER CRITERIA In general, all MC documentation will be countersigned by both SUBCONTRACTOR and CONTRACTOR. On signing certification, the signatory authority is stating they have monitored, witnessed and reviewed the workmanship and dossier contents involved with the specific scope and that all are of an acceptable standard.

8.1

The Mechanical Completion Inspection Test Records (MC-ITR) The Project Mechanical Completion Record MC-ITR is a standard form tailored to suit a particular item or type of equipment. It identifies the specific checks and tests to be carried out required to achieve compliance with design, specification, regulations, quality control and certification of the installation as being Mechanically Complete. The MC-ITR pro format shall be prepared by SUBCONTRACTOR Commissioning Team and agreed with CONTRACTOR Completions Team prior to being loaded in the MC database. MC-ITRs are divided into the following disciplines within CMS: Discipline Architectural

Code A

Title: MECHANICAL COMPLETION EXECUTION PLAN

Electrical

E

HVAC

H

Instrumentation

I

Insulation

IN

Mechanical

M

Piping

P

Safety

S

Structural

St

Telecoms

T

Surface Protection

X

For MC of facilities the MC-ITR form is the standard employed at the first level of certification and has been tailored to suit each particular item or type of equipment. The MC-ITR identifies specific checks and tests to be completed, and frameworks the hardcopy records to be controlled in order to achieve verification of compliance with design, specification, regulations, quality control and certification of the specific component being Mechanically Complete. Each MC-ITR has sign off for approval by authorised signatories and shall not be deemed complete until approval signatures have been obtained.

MC-ITR Sign Off Authority As shown on the MC-ITR Signatory Authority Table (Refer to Section 9.1), signatures for the MC-ITRs will be as follows Work carried out at SUBCONTRACTORSite Completed By

SUBCONTRACTOR Construction

Verified/Approved By

SUBCONTRACTOR QA/QC Department

Witnessed/Reviewed By

CONTRACTOR Completions Team

Work carried out at Sub-Contractors Site

Title: MECHANICAL COMPLETION EXECUTION PLAN

Completed By

Sub-contractors Construction Team

Verified/Approved

SUBCONTRACTOR QA/QC Department

Witnessed/Reviewed By

CONTRACTOR Completions Team

During and after completion review of the specific Construction scope it is necessary that each inspection line item on the particular MC-ITR is addressed with either "OK” or "P/L" or "N/A" comment. While completing the MC-ITR any item necessitating a "P/L" must be then identified on a Punchlist Form. MC Note: Idemitsu Completions Team shall only sign off on MC-ITR’s where they have been in attendance and witnessed the inspections / testing as identified on the MC-ITR. Any MC-ITRs not signed by Idemitsu Completions Team within that Sub-system shall be reviewed during the MCDAC and MC-SSAC dossier review with relevant comments added if required. This process has been discussed and agreed with the Idemitsu Commissioning and Operations Teams. MC-ITR Completion Flowchart The flowchart in Figure 4 is intended to demonstrate the process related to satisfactory completion of MC-ITRs from start to finish and includes requirements for P/Ls and signatory approvals. For Construction quality of work craft and standard of MC-ITR paperwork the process should enforce completeness and value while accurately capturing any scope that does not conform to specification and cannot be immediately remedied. MC-ITR Queries SUBCONTRACTOR Construction/ QC Team MC-ITR queries regarding the check necessary for any particular item of equipment, shall be referred to the Integrated Commissioning Team. Any future additions, deletions or amendments to MC-ITRs shall require approval by the Integrated Commissioning Team who shall maintain responsibility for issuing and recording MCITR alterations. Note: Although MC-ITRs are necessary evidence of work completion, they are not intended to supersede, modify or vary contractual agreements. The MC-ITR for pumps, motors, vessels etc. shall list the checks that are normally performed upon that type of equipment but may not be specifically written for each particular item of equipment. Where additional information is required to be included for the equipment the comments section of the ITR should be used.

Title: MECHANICAL COMPLETION EXECUTION PLAN

All inspection and test equipment used for measurement shall be calibrated to a national standard with a full list of test equipment and current calibration details submitted to CONTRACTOR Quality Control Team and maintained by SUBCONTRACTORQuality Control Team. 8.2

The Mechanical Completion Discipline Acceptance Certificate (MC-DAC) On completion of all MC-ITRs within a discipline package within a Sub-System the Discipline Acceptance Certificate (MC-DAC) will be issued for SUBCONTRACTOR Construction / QC offer to Integrated Commissioning Team for acceptance. The CA’s / CONTRACTOR Commissioning representative will be invited to participate in all MC activities at site including all MC walk downs and final MC inspections. SUBCONTRACTOR Construction/ QC Team and Integrated Commissioning Team will carry out a joint physical review of the offered Discipline package. Attendance at the review by these groups is mandatory. Where SUBCONTRACTOR Construction/ QC Team and Integrated Commissioning Team review of the MC-DAC offering reveals that the requirements of the associated MC-ITRs, Design Specifications or Drawings have not been achieved SUBCONTRACTOR Construction shall rectify the work and shall re-submit that item(s) of work/ MC-ITR(s) for approval and for the consortium to review again. Only when all associated Discipline package MC-ITRs have been completed shall a MC-DAC be considered 'Mechanically Complete' and accepted by the CONTRACTOR.

8.2.1

MC-DAC Sign Off Authority As shown on the MC-DAC Signatory Authority Tables, signatories for the MC-DACs shall be completed by SUBCONTRACTOR Construction Team and accepted by SUBCONTRACTOR Commissioning Team & CONTRACTOR Commissioning Team. For the Non-Commissionable Systems, MC-DACs shall be completed by SUBCONTRACTOR Construction Team, verified by SUBCONTRACTOR QC Team and accepted by CONTRACTOR Completion Team. When, if material shortage or outstanding design changes prevent completion of certain MC- ITRs within the Sub-System MC-DAC, then a punchlist can be raised and agreed between SUBCONTRACTOR Construction/ QC Teams, SUBCONTRACTOR Commissioning Team and CONTRACTOR Commissioning Team or nominated persons. The Integrated Commissioning

Title: MECHANICAL COMPLETION EXECUTION PLAN

Team will ensure all/any outstanding / rectification work accepted for carry-forward is accurate and detailed on the P/L associated with the MC-DAC. In general MC-DAC Punchlists shall contain only ‘B’ items and will be kept to an absolute minimum. 8.2.2

Partial MC-DAC During the Mechanical Completion phase there may be instances where a partial handover of a Sub-System Discipline (MC-DAC) is required, albeit by exception and not as the norm. This would typically be related to Lighting & Small Power Circuits, PAGA Speaker Loops etc. where the entire limit of the full Sub-System handover may not be available. On condition that all individual components and associated MC-ITRs identified for that particular part of the Sub-System to be handed over have been completed then a partial MC-DAC shall be raised and approved. This partial MC-DAC will clearly identify with marked up revised boundary documents identifying the limits of the proposed handover of the “partial Sub-System”. Also attached will be a CMS Status Report listing the components which have successfully passed the inspection & testing requirements to facilitate handover and energization of the equipment using the project approved procedures. The partial MC-DAC will be processed and signed by all personnel as would be a full MC-DAC, upon completion of all remaining components within the Sub-System then a full MC-DAC will be raised and signed.

8.3

The Mechanical Completion Sub-System Acceptance Certificate (MC-SSAC) When all MC-DACs are complete within a Sub-System the MC-SSAC will be issued for SUBCONTRACTOR Construction/ QC Team to offer the Mechanically Complete Sub-System to the Integrated Commissioning Team for review and acceptance. For the Non- Commissionable Sub-Systems, MC-SSACs shall be completed by SUBCONTRACTOR Construction Team, verified

by

SUBCONTRACTOR

QC

Team

and

accepted

by

CONTRACTOR

Completion/Operation team. The Dossier complementing the MC-SSAC will be complete with a computer printed list detailing all Sub-System associated completed MC-ITRs and MC-DACs with any outstanding punch-list items and modified ‘Red-Line’ drawings. SUBCONTRACTOR and CONTRACTOR Construction / QC Team will carry out a joint review of the offered Sub-System and documentation alongside the Integrated Commissioning Team.

Title: MECHANICAL COMPLETION EXECUTION PLAN

Where the Integrated Commissioning Team review of the MC-SSAC dossier reveals that the requirements of the associated MC-ITRs, Design Specifications or Drawings have not been achieved, SUBCONTRACTOR Construction shall rectify the work and shall re-submit that item of work(s) / MC-ITR(s) for approval and the consortium to review again. Only when all Sub-System MC-ITRs and MC-DACs have been completed shall a MC-SSAC be considered 'Mechanically Complete' and accepted by CONTRACTOR. 8.3.1

MC-SSAC Sign Off Authority As shown on the MC-SSAC Signatory Authority Tables, signatories for the MC-SSACs will be from SUBCONTRACTOR Construction Team on the ‘Completed By’ level, with two signatories on the ‘Accepted by’ level by SUBCONTRACTOR Commissioning Manager and CONTRACTOR Commissioning Supervisor. For the Non- Commissionable Sub-Systems, MCSSACs shall be completed by SUBCONTRACTOR Construction Team, verified by SUBCONTRACTOR QC Team and accepted by CONTRACTOR Completion/Operation team. Upon acceptance of a Sub-System by the Integrated Commissioning Team, the Handover documentation shall be entered into the CMS database and the Sub-System recognized as Mechanically Complete. In general, Sub-System Acceptance Punch Lists shall contain only ‘B’ items and will be kept to an absolute minimum. Acceptance of a Sub-System by the Integrated Commissioning Team signifies the formal handover of ownership of all equipment defined (with exceptions) in the submission. Following acceptance of a Sub-System by the Integrated Commissioning Team the Pre-com / Commissioning Permit to Work, LOTO and LUN (Livening Up Notification) systems shall be applied. Further requirement for access to any of the accepted equipment after this stage will require the SUBCONTRACTOR Construction / QA/QC teams to have an approved PTW.

8.4

Red-line Drawings Engineering drawings contained within the accepted MC Handover Dossier which have been redlined to record construction changes to scope at site will be processed through the defined As-Built Procedure.

8.5

Construction As-Built Drawings

Title: MECHANICAL COMPLETION EXECUTION PLAN

A Construction As-Built Stamp that will be used by Construction team on the latest revision of drawings. This stamp indicates that the drawing is verified by Construction team and that all contents inside the drawing are correct to the actual installation. In instances where the drawing has many pages / sheets and if all drawings are verified as correct then Construction will stamp on the first page only. MC WORKFLOW The Mechanical Completion Flowchart (Appendix 4) demonstrates the flow of activities from material arrival onsite through to installation, MC-ITR completion leading to the handover process in the form of MC-DAC and MC-SSAC. Once the MC-SSAC has been accepted the Sub System is deemed Mechanically Complete and the ownership now lies with SUBCONTRACTOR Commissioning Team. 9.1

Execution Step The list of equipment for each discipline will be prepared by SUBCONTRACTOR Commissioning Team at the early stage of the Construction phase to monitor the completion of all installed equipment. This will not include Vendor Packaged equipment and Future installation equipment. Vendor Package equipment with on-site project interfaces should be included as they will generally require MC-ITRs allocating. Check sheet Overview will be imported into the Mechanical Completion Database by MC-ITR Type No, Discipline, System, Sub System and Tag number. The template of MC-ITR forms by type will be held in the database. Any changes in the Check sheet Overview of each discipline in the database shall be informed to Construction team by Commissioning Team via email. This data will be downloaded from a Computer Hardware Operating system and verified jointly by SUBCONTRACTOR and CONTRACTOR. SUBCONTRACTOR shall issue MC-ITRs in Discipline and Sub System packs direct from the CMS database. SUBCONTRACTOR shall then proceed to carry out the checks as required by the MC-ITR sheets. Updating of database status will be carried out and reported on a daily basis. Upon completion of each MC-ITR Check Sheet and approval by the authorized signatory of all MC-ITR’s within a Discipline Package the SUBCONTRACTOR will generate a Discipline

Title: MECHANICAL COMPLETION EXECUTION PLAN

Acceptance Certificate (MC-DAC). Prior to submission of the MC-DAC for approval all Punch list 'A' must be cleared. In general Sub System Acceptance Punch Lists shall contain only ' B' items. Exceptions can be made with approval from Integrated Commissioning Team (see Exceptions) The SUBCONTRACTOR Construction and Integrated Commissioning Team shall carry out a joint physical review of the offered Sub System at the MC-DAC phase and accept with a jointly agreed punch list or return the Sub System to SUBCONTRACTOR Construction for completion. The single discipline DAC where required can commence the Livening Up Notice (LUN) and issue the Permit To Work for Pre-commissioning activities.

When all MC-DACs are completed within a Sub System a Sub-System Acceptance certificate (MC-SSAC) will be generated for SUBCONTRACTOR to offer up the Mechanically Complete Sub-System to the Integrated Commissioning Team for approval. The MC-SSAC will have attached an MC Status Report and Sub-system Punchlist Report detailing the completed MC-ITRs and any outstanding punch-list items. Acceptance of a Sub System by Integrated Commissioning Team signifies the formal handover of ownership of all equipment defined (with exceptions) in the Submission. 9.2

Ongoing activities post MC In some instances (particularly relating to Switchboard, Lighting & Small Distribution Boards, ICSS RIO Cabinets, Marshalling Panels, and Instrument Control Panels) there will be a requirement to continue with glanding/terminating/testing activities of field cabling after completion of the MC-ITRs and acceptance of the MC-DAC for that particular Discipline within a Sub-System. Although the MC-DAC has been accepted and the equipment now belongs to ICT it will still be possible for SUBCONTRACTOR Construction to work on this equipment whilst de-energised with the appropriate Pre-Com / Commissioning PTW. The ICT will closely monitor this outstanding Construction work in other Sub-systems. At such times when the majority of the glanding/terminating/testing activities have been completed or energization of the equipment is schedule driven a joint decision may be made between all parties to energize the equipment and restrict access to construction.

Title: MECHANICAL COMPLETION EXECUTION PLAN

Energization of the equipment will be processed through the MC-DAC / MC-SSAC / LUN / LOTO / PTW Systems resulting in the requirement of a PTW for access to work on the equipment. This will be coordinated through the PTW/JSA Systems and carefully managed by the PTCS Commissioning Team and CONTRACTOR Completion System Responsible Engineer(s). To minimize exposure to working in close proximity to “LIVE” equipment during dayshift unrestricted access may be granted on a nightshift where the equipment can be safely de-energized after dayshift activities have been completed and LOTO applied and with the appropriate Pre-Com / Commissioning PTW. 9.3

Exceptions to MC-SSAC Handover Acceptance By exception the Integrated Commissioning Team can agree to accept a Sub-System with ‘A’ Punch List Items if these items can be effectively isolated from the Sub-System on a temporary basis so as to allow the commencement of Pre-Commissioning in an efficient and safe manner. Further exceptions can be agreed between SUBCONTRACTOR Construction and Integrated Commissioning Team for the handover of Discipline packages prior to a Sub-System being complete to allow Pre-Commissioning to commence on a Discipline basis providing this can be carried out safely and efficiently. Clearing these exceptions still remains the responsibility of SUBCONTRACTOR Fabrication and Construction teams as applicable.

9.4

Mechanical Completion Handover Dossiers Final acceptance of a Sub system will take place upon the submission by SUBCONTRACTOR of the MC Handover Dossier which shall contain as a minimum: 

MC Dossier Completion Status Sheet



MC Sub-system Acceptance Certificate (MC-SSAC)



MC Discipline Acceptance Certificates (MC-DAC's)



Boundary Documents



Mechanical Completion Punchlist



Technical Queries & Work / Site Instructions



Construction As-Built / Red Line Drawings



Any other associated correspondence

Title: MECHANICAL COMPLETION EXECUTION PLAN



Vendor As Built information (Red Line drawings at site if applicable)



Status Indices & MC Inspection Test Records

Specifically, for the Vendor data section the following is considered as minimum requirements where applicable for inclusion into the Sub-System dossiers (refer to VDRL for more detail) 

FAT Reports



Vendor Release notes



Outstanding Vendor Punch lists and OS&D Punch lists



Vendor As built information (red line drawings at site if applicable)



Supplier Document Register

E-mail hard copies are not acceptable as official approval or notification of design changes, agreed deviations or technical clarifications, however in exceptional cases an e-mail signed as accepted by the relevant discipline Technical Authority and enclosed in the Associated Engineering Queries section, shall be deemed acceptable for clarification purposes. 9.5

Mechanical Completion Activities Mechanical Completion will be completed by respective workforces according to each Discipline. All the inspection and test results are recorded into MC-ITR’s as described in Appendix 09. PUNCH LIST On completion of an MC-ITR by SUBCONTRACTOR any item which does not meet the required standards should be signified by ticking the “P/L” box next to the item on the MC-ITR. At this point it is important to note that the Punchlist will be a list of items which describes how and where “completed works” are non-conforming in relation to project specification or scope. Outstanding / Incomplete works shall not be tracked on the completions Punchlist. In relation to a “P/L” reference, a ‘Punchlist Raise Form’ will accompany the MC-ITR. The Punchlist Raise Form contains several categories to identify and isolate Punchlist items within CMS: 

Sub-System (Identifies Sub-System Number that the non-conforming scope is associated with)



Description (Sub-System title)



Punchlist Number (generated automatically from CMS)

Title: MECHANICAL COMPLETION EXECUTION PLAN



Tag Number (Identifies Tag Number that the non-conforming scope is associated with)



Drawing Number (Generally will reference the discipline drawing: Iso, SLD, etc)



Punchlist Description (Written description accurately describing P/L Item)



Category ‘A’ or’ B’ (Indicates the safety implication for operation of the Item)



Materials Required (If material is needed for P/L resolution a PO Number must be input if available)



Target Completion Date (A forecast date for closing out the P/L will be inserted)



Responsible (Indicates who is responsible for the non-conforming scope, categories stated on P/L form)

Supporting information may also be referenced and attached with the Punchlist Form to further clarify non-conforming scope. Accepted Punchlist details will be entered in the CMS database, which will format individual items on a discipline basis for each Sub-System (or in any format relevant to the input categories). All subsequent clearances of Punch List items will be recorded in the database. a) Outstanding Punchlists compiled by SUBCONTRACTOR and agreed by the Integrated Commissioning Team will be submitted with the completed MC-DAC in discipline format, and will be agreed and categorised by SUBCONTRACTOR and CONTRACTOR Completions Team before being issued and recorded in the consolidated Punchlist database. b) All punchlist items of both ‘A’ and ‘B’ categories are to coincide with the relevant discipline tag number where the “P/L” reference has been used. c) Items will also be supported by relevant paperwork; order numbers, damage reports, material shortage reports, photographs, etc. d) Any item considered to be a design change will be raised in the form of a design change proposal with supporting information, follow Project Management Change Procedure. e) Punchlists items will always be correctly categorised into ‘A’ or ‘B’ status

Title: MECHANICAL COMPLETION EXECUTION PLAN

Figure 5: MC Punchlist Flowchart

Title: MECHANICAL COMPLETION EXECUTION PLAN

Category ‘A’ Punchlists Any punchlist item that is categorised as 'A' will indicate that the relevant Sub-System is considered unsafe to operate or cannot be operated effectively. It will be rejected and returned in its entirety to SUBCONTRACTOR Construction / Quality Control / MC Team as applicable. The returned Sub-System shall be accompanied by the MC-DAC & MC-SSAC which will be noted, rejected, signed and dated. Cat A P/L items should be identified at the MC-DAC phase and unless agreed and accepted by all parties as being acceptable the S/S should not reach the MC-SSAC stage. Any Safety Critical or Operation Critical items that must be repaired or corrected before the equipment can be safely Pre-Commissioned, Commissioned or Operated. Such items may include but not be limited to missing valve / instruments, faulty equipment, leaks that could cause damage to plant, personnel and the environment. The MC-DAC and MC-SSAC will be re-submitted by SUBCONTRACTORConstruction / Quality Control / MC Team on completion/resolution of punchlist ‘A’ items. As previously described in special circumstances Integrated Commissioning Team will sanction handover of Sub-Systems with ‘A’ Punchlist items included, Typically this would be where a P/L item can be rendered safe and is not critical to the progress of Pre-Commissioning / Commissioning. Prior to acceptance of such Sub-Systems a thorough review of all safety aspects relating to operation of the equipment will be carried out between all relevant parties. Category ‘B’ Punchlists Any items that can be repaired completed or corrected at a later date and which will allow the commencement of Pre-Commissioning/Commissioning activities without endangering personnel, plant, environment or operational integrity. Such items may include but not be limited to missing valve handles, missing identification tags or plates, broken gauge glass, paint touch-up. The raising of such items for acceptance should be kept to an absolute minimum as a high number of such P/L items may result in a rejection of the MC-DAC and/or MC-SSAC. Punchlist Clearance CMS will produce punchlist line item reports by Sub-System, Discipline and Tag Number. In order to clear a punchlist line item(s) a Punchlist Clearance report shall be printed and marked up. As a punch item is cleared in the field the appropriate sections against the punchlist line item on the report table will be wet signature signed and dated.

Title: MECHANICAL COMPLETION EXECUTION PLAN

At this point the CMS Operator will update the status of punch item(s) into CMS based on the information from the report table. PRESERVATION Preservation and De-Preservation throughout the Mechanical Completion phases shall be the responsibility of SUBCONTRACTOR Construction / Quality Control / MC Team / Commissioning Team and will be carried out in accordance with approved preservation procedures and Vendor recommended preservation requirements. EX INSPECTION Every piece of Ex Equipment, either Vendor or SUBCONTRACTOR installed, is required to have a detailed Ex inspection carried out. All tagged Ex equipment should be uploaded into CMS and allocated an MC-E30-A for completion during the early Vendor works scope or at site during the Mechanical Completion Phase of the Project. In addition to being entered into CMS every Ex tag needs to be included in the Project Master Ex Register. Ex Leader is responsible for managing / updating and issuing the Project Master Ex Register.” VENDOR MANAGEMENT RELATED MC WORK SUBCONTRACTOR Commissioning Manager shall be responsible for the coordination and final approval of all Construction and Commissioning Vendor site visits. Any Vendor onsite requirements during the Fabrication / Construction / Integration phases will be identified and coordinated by SUBCONTRACTOR Construction Team. The initial issue of SUBCONTRACTOR Construction schedules shall be reviewed and where possible rationalized and coordinated to avoid duplication of effort or resources. SAFETY MANAGEMENT RELATED MC WORK & PERMIT TO WORK The safety objective during the execution of Construction and Mechanical Completion activities is to prevent unsafe actions and working conditions which may cause injuries, health risks and damage to property. All personnel involved shall comply with Project Safety Health and Working Environment requirements and also safety requirements contained in Site Manuals and procedures. SUBCONTRACTOR shall implement a Permit to Work System which shall remain in force throughout onshore Mechanical Completion.

Title: MECHANICAL COMPLETION EXECUTION PLAN

The CONTRACTOR Permit to Work system shall be implemented after systems handover to CONTRACTOR operations. PLANNING AND MONITORING SYSTEM 15.1

Planning system Planning of Mechanical Completion shall be driven by Commissioning Sequences which determines the precedence of priority for each System. Utility Systems such as Diesel, Instrument Air, Drains and Electrical Power are required to provide services for all other Platform Systems and therefore shall be prioritized for Mechanical Completion. Approved dates for Mechanical Completion of each Sub-System shall be loaded into CMS. CONTRACTOR may elect to implement Mechanical Completion Milestones ahead of baseline schedule in order to progress critical commissioning activities early. Mechanical Completion SubSystem Milestones shall be determined by: 

Site testing required following Factory Acceptance Testing.



Equipment Delivery dates.



Planned duration of SUBCONTRACTORConstruction and MC activities.



Definition of work scope.



Required MC Handover dates to meet critical start dates of Pre-Commissioning and Dynamic System Commissioning in order to achieve overall Project Completion Milestones.

15.2

Progress Measurement The Mechanical Completion progress will be measured on the completion of the MC-ITRs and will be submitted by the Construction Team to the MC Team for uploading into CMS. The SUBCONTRACTOR Completions Management System (CMS) is capable of tracking and reporting progress of MC-ITR completion by Tag, Discipline, Sub System and System. These reports will be compiled by the CMS Coordinator as and when required by Project Management in both native format and pdf. The level of detail can be selected by using simple drop down boxes within CMS to give the required information. Such “Live” CMS data can be passed from the CMS Coordinator to the Project planning department for uploading into Primavera. As a follow on from tracking and reporting the MC-ITR completion status CMS can track and report against Handover Documentation such as MC-DAC and MC-SSAC completion in the same way as for ITR completion. CMS will track completion of agreed MC Handover dates by Sub

Title: MECHANICAL COMPLETION EXECUTION PLAN

System / System to meet critical start dates of Pre-commissioning and Dynamic System Commissioning. 15.3

Monitoring and report Mechanical Completion Progress measurement system will be updated on a weekly report on MCITRs progress and percentage completion. The reporting cut-off will be COB Friday each week. The progress figures are included in the weekly progress report which will be submitted to CONTRACTOR on Tuesday of the following week. QUALITY ASSURANCE AND CERTIFICATION INTERFACES The Project MC and Commissioning groups interact with the QA/QC group in many ways, primary interaction is through the preparation, issuance and implementation of the project procedures. The quality assurance group shall also conduct periodic internal audits to ensure that the MC and Commissioning groups are functioning in line with the procedures and guidelines that have been developed specifically for the Project. It is the responsibility of the quality group to ensure the requirements for ‘CERTIFICATION AUTHORITY’ certification are identified and provided for throughout the design, procurement, equipment manufacturing, construction, integration, commissioning and start up phases of the project. For Mechanical Completion and Commissioning phases the certification requirements will primarily be the inspection of completions certification and witnessing of specific testing activities by ‘CERTIFICATION AUTHORITY’ which will be coordinated by the Quality Group. SUBCONTRACTOR shall be responsible for the accuracy and integrity of the CMS database and MC implementation including physical records of MC Inspection Test Records (MC-ITRs) with built in quality control activities to verify the achieved quality standard throughout the MC phase. SUBCONTRACTOR will be responsible for ensuring the accuracy and integrity of the CMS database including physical records of MC and PC Inspection Test Records (MC-ITRs & PCITRs), status indices and project certification used in the handover between the responsible parties in each phase. The SUBCONTRACTOR Coordinator shall be responsible for ensuring: 

Tests and checks carried out are executed, witnessed as required and recorded in accordance with this procedure.

Title: MECHANICAL COMPLETION EXECUTION PLAN



Validation of MC status and acceptance certification when Discipline packages and Subsystems have been mechanically completed.



Accuracy of Punch list records to include all deviations errors or incomplete work within the sub system that cannot be rectified prior to acceptance

Quality assurance of site test equipment SUBCONTRACTOR shall maintain a comprehensive list of all test equipment to be used. This list shall prove that all test equipment has a standard of accuracy equal to, or better than, that of the manufacturer's stated accuracy for the instrument / equipment being tested. Acceptable evidence of satisfactory condition of test equipment (e.g. copies of up to date Test Certification) shall be provided in accordance with the SUBCONTRACTOR approved calibration procedure. All test equipment shall be frequently checked throughout the MC period for deterioration. Where test equipment requires an electrical or air supply, SUBCONTRACTOR shall ensure accuracy of voltage and frequency / pressure and quality.