Table of Contents
1. General Procedures
1.1 Vendor and Service Assistance
| Contractor | Client | ||
| a. | If deemed necessary by Contractor, obtain manufacturer's (vendor) assistance to ensure satisfactory installation of equipment | X | |
| b. | Obtain manufacturer's (vendor) assistance at Owner's expense if required requested by Owner for run in | X |
1.2 Inspection
| a. | Provide inspection of the plant to check conformity to flow diagrams, construction drawings, vendor prints and specifications | X | |
| b. | Arrange for any special pre-start-up inspections such as required by insurance or governmental agencies | X | |
| c. | Perform routine shop inspection | X | |
| d. | Witness shop inspection as desired | X | |
| e. | Verify completion of work and approve plant. Check any exceptions and note on a separate work order list (punch list) | X |
Note: Equipment which has been shop inspected will not be reopened for inspection in the field except as specifically noted herein.
1.3 Permits
| a. | Secure permits and certifications required in name of Contractor for design work or for erection work | X | |
| b. | Assist Owner at his expense in the procurement of all permits and certifications required to be secured in name of Owner for initial operation of the plant | X | |
| c. | Secure at Owner's expense all permits to be issued in name of Owner and required for installation, use, occupancy and operation of the plant | X |
1.4 Removal of Rust Preventatives
| a. | Remove rust preventatives and oils used to protect equipment during the construction period | X |
1.5 Maintenance and Spare Parts
| a. | Protect equipment from normal weather conditions, corrosion or damage prior to plant mechanical completion | X | |
| b. | Provide Company with spare parts lists as recommended by vendors | X | |
| c. | Provide spare parts and supplies | X | |
| d. | Provide maintenance for equipment, including such items as the cleaning of strainers and the repairing of steam traps, after plant mechanical completion | X |
1.6 Housekeeping
| a. | Provide construction clean up, including removal of excess materials, temporary facilities and scaffolding, rough sweeping or raking of job sites and trash pickup | X | |
| b. | Maintain housekeeping after mechanical completion as required for safe operation | X | X |
1.7 Instructions
| a. | Transmit to Owner any vendors' or manufacturers' instructions and drawings, as applicable | X | |
| b. | Provide Owner with any special instructions, such as requirements for drying liners | X | |
| c. | Maintain vendor instruction file for ready retrieval | X |
2. Specific Procedures
2.1 Electrical Power and Lighting Systems - Account E
| a. | Notify Owner of test schedule | X | |
| b. | Witness tests when notified and record test data if desired | X | |
| c. | Make insulation test of all wiring using a megohmmeter | X | |
| d. | Check lighting circuits and intensities | X | |
| e. | Make insulation tests of motor windings and of transformer windings from phase to phase, and phase to ground using a megohmmeter | X | |
| f. | Make grounding system tests to determine continuity of connections and value of resistance to ground | X | |
| g. | Arrange for breakdown tests by manufacturers on oil samples from oil-insulated transformers larger than 100 kVA. Check oil level of all transformers | X | |
| h. | Make trials and adjustments on all motor control and switchgear equipment | X | |
| i. | Test and set switchgear and motor control center relays for proper functioning | X | |
| j. | Obtain local inspector's/authority approval where required | X | |
| k. | Energize all substations after completion of all tests | X | |
| l. | Check phase sequence and polarity | X | |
| m. | Run electrical motors uncoupled | X | |
| n. | Check bearing, winding temperatures and vibration | X | |
| o. | Check installation of emergency and instrument power systems | X | |
| p. | Perform all necessary pre-start up checks on generators in accordance with vendors instruction | X | |
| q. | Assume responsibility for maintenance and operation of energized electrical facilities after acceptance | X | |
| r. | Provide Owner with record of work completed | X |
2.2 Instrument Systems - Account K
| a. | Make non-operating checks to ensure instrument operability, i.e. remove all shipping stops, check pointer travels and verify instrument capability to measure, operate and stroke in the direction and manner required by the process application | X | |
| b. | Field calibrate instruments with standard test equipment and make all required adjustments and control point settings | X | |
| c. | Fully pressurize and energize the transmitting and control signal system, open process connections at primary sensors and final regulators and make control mode settings for automatic operation of equipment as the plant is brought on stream | X | |
| d. | Install and connect all system components and verify their conformance with specifications and design criteria for function and range using dummy transmitted signals as needed | X | |
| e. | Clean all transmission and control tubing by blowing with cooled and filtered clean air prior to connecting to instrument components | X | |
| f. | Clean all air supply headers by blowing with clean air and check for tightness | X | |
| g. | Leak test pneumatic control circuits in accordance with ISA Recommended Practice RP 7,1 | X | |
| h. | Check process lead piping for tightness | X | |
| i. | Check all electrical signals and alarm wiring for continuity, correct sources of power and polarity | X | |
| j. | Check thermocouples for proper joining of wires, position of elements in wells, proper polarity and continuity of receiving instruments | X | |
| k. | Identify orifice plates by tagging and deliver to Owner | X | |
| l. | Isolate, or remove, if necessary, inline components such as control valves, positive displacement meters, turbine meters, etc. for pressure testing and reinstall such items | X | |
| m. | Check bores of orifice plates | X | |
| n. | Install such plates after completion of flushing operations | X | |
| o. | Isolate or remove in-line components for flushing operations and reinstall them on the completion of such operations | X | |
| p. | Fill air line lubricators with oil supplied by Owner | X | |
| q. | Check designation and function of each isolator and fuse in electric systems | X | |
| r. | Check operation of automatic transfer systems, reset mechanisms, etc. | X | |
| s. | Loop check all instrumentation from field to control room. | X | |
| t. | Witness all loop checks | X | |
| u. | Clean gauge glasses and check illuminators | X | |
| v. | Stroke all control valves, on/off valves, lubricate as required | X | |
| w. | Check all analyzers, clean and flush lines to/from arrange for vendor representation for calibration of analyzers if required (e.g. chromatographs) | X | |
| x. | Test and adjust all safety devices and seals where necessary use vendor if required | X | |
| y. | Install all safety devices e.g. pressure relief valves after testing | X | |
| z. | Assume responsibility for maintenance and operation of all instrument facilities after acceptance | X |
2.3 Piping - Account C
| a. | Hydrostatically or pneumatically test all piping as required by the drawings or specifications | X | |
| b. | Notify Owner of test schedule | X | |
| c. | Witness field pressure tests when notified by Contractor | X | |
| d. | Provide at owners expense any special media for test purposes and facilities for their disposal | X | |
| e. | Check pipehangers, supports, guides and pipe specialities for the removal of all shipping and erection stops, and for the correctness of cold settings for the design service. In addition, provide Owner with instructions for hot settings | X | |
| f. | Check pipehangers, supports, guides and pipe specialities for hot settings and make minor adjustments as necessary | X | |
| g. | Install carseals on valves where necessary | X | |
| h. | Check and record position of all carsealed valves | X | |
| i. | Check steam tracing for tightness and continuity (use steam when available) and check proper tagging of supply and returns | X | |
| j. | Install all strainers (temporary and permanent) spades and spectacle blinds as called for on drawings. | X | |
| k. | Waterflush and/or air-blow small bore piping | X | |
| l. | Carry out chemical cleaning as required per job specification | X | |
| m. | Operate steam and water systems for flushing, cleaning and tracing | X | |
| n. | Blowdown/clean steam lines with steam e.g. turbine inlets | X | |
| o. | Witness flushing and cleaning | X | |
| p. | Clean strainers after flushing and remove if warranted | X | |
| q. | Maintain records of blinds installed | X | |
| r. | Obtain Owner's approval and permits and make tie ins as required by applicable specification | X | |
| s. | Isolate all systems to allow tie ins to be made | X | |
| t. | Remove blinds as required during start up | X |
2.4 Towers - Account A
2.4.1 Shop-fabricated:
| a. | Install all internals not already installed in fabricating shop, including trays, caps, grids, demisters, internal piping, packing and linings | X | |
| b. | Inspect all internals | X | |
| c. | Make necessary corrections to internals, remove all debris and heavy dirt | X | |
| d. | Do chemical cleaning, if required | X | |
| e. | Do final flushing and make tightness tests | X | |
| f. | Perform necessary leakage tests on trays | X | |
| g. | Carry out final inspection and formally accept vessel, issue permit to close | X | |
| h. | Final close vessel | X |
2.4.2 Field-Erected:
| a. | Supervise construction, code testing and installation of internals | X | |
| b. | Inspect all internals | X | |
| c. | Make final mechanical clean out | X | |
| d. | Perform necessary leakage tests on trays | X | |
| e. | Do chemical cleaning, if required | X | |
| f. | Do final flushing and tightness test | X | |
| g. | Carry out final inspection and formal accept vessel, issue permit to close | X | |
| h. | Final close vessel | X |
2.5 Vessels - Account MR
| a. | Open after erection to place any internals requiring field installation and inspect at time of installation. Open external manways on vessels for inspection by Owner | X | |
| b. | Clean out debris, etc. | X | |
| c. | Witness inspections to the extent desired | X | |
| d. | Open after dry out and chemical cleaning and charge materials as chemicals, resins, desiccants and catalysts (procurement by Owner) | X | |
| e. | Hot bolt vessels after heat up | X | |
| f. | Final inspection, and formally accept vessel, issue permit to close if applicable | X |
Note: When vessels have been subjected to a shop test, they will not be further tested in the field but may be included as part of a piping system test.
2.6 Tanks - Account M
| a. | Clean out debris, etc. | X | |
| b. | Carry out chemical cleaning as required by job specifications | X | |
| c. | Cure and dry out any special cement or protective linings in accordance with manufacturers' specifications and instructions | X | |
| d. | Test in accordance with applicable specs | X | |
| e. | Purge systems and charge chemicals as required | X | |
| f. | Final inspection, and formally accept vessel, issue permit to close if applicable | X | |
| g. | Close vessel | X |
2.7 Shell and Tube Exchangers - Account T
| a. | If desired, field inspect exchangers which have been shop inspected | X | |
| b. | If desired, field test exchangers which have been subjected to a shop test | X | |
| c. | Hot bolt equipment after heat up | X |
2.8 Air-cooled Exchangers - Account T
| a. | Inspect to ensure that temporary shipping supports and erection material have been removed. Check for damage | X | |
| b. | If desired, field test exchangers which have been subjected to a shop test | X | |
| c. | Couple fan to motor after motor has been run uncoupled | X | |
| d. | Test and balance fans as required. Check blade setting | X | |
| e. | Test louvers and controls of same | X | |
| f. | Final inspection and formally accept air cooler | X |
2.9 Fired heaters - Account H
| a. | Pressure test in accordance with applicable code, as required | X | |
| b. | Provide all non-operating prefiring checks in accordance with specifications and manufacturers' instructions | X | |
| c. | Blow fuel lines, check for cleanliness, and connect burner piping | X | |
| d. | Check proper functioning of registers and dampers, and verify position of indicators | X | |
| e. | Dry refractories during initial firing by following manufacturer's temperature cycles | X | |
| f. | Conduct boilout and chemical cleaning and flushing operations as required | X | |
| g. | Obtain and charge liquid heat transfer media, if required | X | |
| h. | Conduct light off, drying and purging operations | X |
2.10 Pumps, Compressors and Turbine Drivers - Account P-PC
| a. | Level baseplates and sole plates and grout all bearing surfaces, cold align units and furnish record of alignment | X | |
| b. | Check for and remove any excess piping stresses which may be imposed on the equipment | X | |
| c. | Chemically clean the installation of any seal and lube oil system, if specified | X | |
| d. | Provide all lubricants required | X | |
| e. | Charge the lube and seal oil systems | X | |
| f. | Circulate for cleaning purposes any seal oil, lube oil and cooling systems | X | |
| g. | Make vibration tests when driver is coupled. Check temperatures | X | |
| h. | Install mechanical seals, permanent packing and accessories if required | X | |
| i. | Hot align pumps, and turbines etc., and dowel if required | X | |
| j. | Couple units to drivers after motors have been test run | X | |
| k. | Install temporary strainers in suction piping | X | |
| l. | Arrange for manufactures representatives to supervise erection and perform test on large compressors, turbines | X | |
| m. | Loop check auxiliaries on large equipment with vendor representatives | X | |
| n. | Witness all tests, checks and test-runs of large compressors and turbines. | X |
2.11 Special Equipment - Account G
(Agitators, mixers, rotary filters, weigh scales, materials handling equipment, vacuum equipment)
| a. | Fully assemble rotary filters except for final filter media (cloth or screens) | X | |
| b. | Install all final filter media (cloth, precoat, etc.) | X | |
| c. | Level and calibrate weigh scales with assistance of the manufacturer's representative and set tare weights where possible | X | |
| d. | Manually check materials handling equipment for freedom and direction of movement | X | |
| e. | Make all final adjustments during run in and any performance tests required | X | |
| f. | Obtain vendor's service engineer for start up | X | |
| g. | Test vacuum equipment, check all joints for leaks | X |
2.12 Boilers - Account H
| a. | Make hydrostatic pressure test in accordance with applicable codes, if required by specifications | X | |
| b. | Inspect installation for completeness and correctness of installation and make other non-operating pre-firing checks in accordance with specifications and manufacturer's instructions | X | |
| c. | Check proper functioning of registers and dampers and verify position of indicators | X | |
| d. | Blow fuel lines, check for cleanliness and connect burner piping | X | |
| e. | Dry refractories during initial firing by following manufacturer's temperature cycles | X | |
| f. | Purge, flush and drain steam mains as necessary | X | |
| g. | Obtain and charge treated water (per specifications) for boil out and initial operation as required | X | |
| h. | Commission auxiliaries as detailed elsewhere under the appropriate equipment type | X | |
| i. | Conduct boil out and chemical cleaning and flushing operations as required | X | |
| j. | Conduct initial light off with associated checks and adjustments | X | |
| k. | Conduct all operating tests and obtain required certification | X |
2.13 Water Treating Plants
| a. | Inspect for completeness and correctness of installation and make any non-operating checks which may be required | X | |
| b. | Install initial charge of ion exchange resins and inert bed material (supply by Owner) | X | |
| c. | Make the necessary operating tests and adjustments to water treatment systems | X | |
| d. | Provide all water treatment chemicals | X | |
| e. | Obtain services of water consultant to advise and monitor | X |
2.14 Water Systems
(Service wells, cooling towers, fire water, seawater systems, etc.)
| a. | Inspect for completeness and correctness of installations and make any non-operating checks required | X | |
| b. | Initially clean cooling tower basin and install screens in suction pit prior to water circulation | X | |
| c. | Test well delivery and flush well piping if wells are furnished by Contractor | X | |
| d. | Flush, drain and clean cooling water basins | X | |
| e. | Clean intake screens | X | |
| f. | Operate fire pumps to check output of systems | X | |
| g. | Fill reservoirs, head towers, etc. | X | |
| h. | Arrange for insurance company inspection of fire system as required | X | |
| i. | Obtain and install all fire fighting chemicals as required and portable equipment such as hoses, fire extinguishers and related equipment | X | |
| j. | Establish water treating program | X |
2.15 Waste Disposal
| a. | Inspect facilities for completeness and correctness of installation and make any non-operating checks to ensure conformance with specifications | X | |
| b. | Operate all equipment and supply all chemicals, agents, etc. related to waste treatment | X |
2.16 Buildings and Accessories
| a. | Check installation of any buildings and accessories including all heating, ventilating and air conditioning equipment to ensure completeness and conformance with specifications | X | |
| b. | Obtain certification that all plumbing, wiring and elevator installation are in compliance with local governmental regulation | X | |
| c. | Test heating, ventilating and air-conditioning units and make all performance tests, if weather permits, otherwise by Owner | X | |
| d. | Obtain certificate for occupancy and use, if required | X |
2.17 Insulation and Painting - Accounts N and R
| a. | Inspect and accept all materials and field workmanship | X | |
| b. | Complete all insulation work as specified | X* | |
| c. | Complete all painting as specified, weather permitting | X* | |
| * | This work may extend beyond the date of start up. |