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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

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APPENDIX D

CHECKLIST FOR MECHANICAL COMPLETION

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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

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CONTENTS

D.1

PURPOSE...................................................................................................................................................3

D.2

GENERAL PROCEDURES.....................................................................................................................4

D.2.1
D.2.2
D.2.3
D.2.4
D.2.5
D.2.6
D.2.7
D.2.8
D.2.9
D.2.10
D.2.11
D.2.12
D.2.13
D.2.14
D.2.15
D.3

SPECIFIC PROCEDURES....................................................................................................................10

D.3.1
D.3.2
D.3.3
D.3.4
D.3.5
D.3.6
D.3.7
D.4

REMOVAL OF RUST PREVENTIVES................................................................................................... 4

LUBRICANTS................................................................................................................................. 4
PACKING AND SEALS..................................................................................................................... 4
REMOVAL OF TEMPORARY BRACING............................................................................................... 5
ROTATING AND ALIGNMENT.......................................................................................................... 5
TIE-INS AT BATTERY LIMITS........................................................................................................... 5
LEAK AND PRESSURE TESTS.......................................................................................................... 6
INSPECTION.................................................................................................................................. 7
SAFETY DEVICES........................................................................................................................... 7
FLUSHING AND CHEMICAL/MECHANICAL CLEANING........................................................................7
TEMPORARY SCREENS, STRAINERS AND BLINDS............................................................................8
PURGING/INERTING....................................................................................................................... 8
HOUSEKEEPING............................................................................................................................. 8
SAFETY........................................................................................................................................ 9
EQUIPMENT STORAGE................................................................................................................... 9
PIPING........................................................................................................................................ 10
ROTATING EQUIPMENT................................................................................................................. 10
ELECTRIC POWER........................................................................................................................ 10
INSTRUMENTATION...................................................................................................................... 10
WATER SYSTEMS ( FIRE WATER, RAW WATER SYSTEM)...................................................................11
WASTE DISPOSAL........................................................................................................................ 11
MISCELLANEOUS......................................................................................................................... 11

SPLITTING OF PRECOMMISSIONING AND COMMISSIONING ACTIVITIES......................12

D.4.1
D.4.2
D.4.3
D.4.4
D.4.5
D.4.6
D.4.7

VESSELS..................................................................................................................................... 12
SHELL AND TUBE HEAT EXCHANGERS..........................................................................................13
ROTATING EQUIPMENT (PUMPS AND COMPRESSORS)......................................................................14
PIPING SYSTEM........................................................................................................................... 14
ELECTRIC POWER DISTRIBUTION AND LIGHTING...........................................................................15
INSTRUMENTATION...................................................................................................................... 16
MECHANICAL AND LOADING EQUIPMENT....................................................................................17

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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

D.1

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PURPOSE

The checklists of general and specific procedures are intended to define the operations and
tests to be performed by the CONTRACTOR as the construction of the WORK or of part
thereof is being completed.
These lists are intended to show the operations and tests required to demonstrate that the
WORK has been provided and constructed in accordance with the drawings, specifications
and applicable codes and generally with all terms and conditions of the CONTRACT which are
applicable at the considered stage of progress of work.
The performance to the satisfaction of the ENGINEER of the said operations and tests is one
of the conditions for issuance by the ENGINEER of the certificate of MECHANICAL
COMPLETION of the entire WORK and/or of the interim statement of MECHANICAL
COMPLETION of any part of the WORK.
CONTRACTOR will have to finalize detailed check lists which have to be approved by ANCAP.
Such checklists shall cover all the procedures to be developed on the basis outlined in D2
and in D3 hereafter when applicable.

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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

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D.2 GENERAL PROCEDURES

The general procedures listed below outline the work to be performed by the CONTRACTOR.
Procedures applicable to specific systems or items of equipment are covered separately in
paragraph D.3. and D.4. thereafter.
Items hereafter have to be considered only if applicable.
Responsibility of
work
ContracANCAP
tor

D.2.1 REMOVAL

OF RUST PREVENTIVES

Remove all rust preventives and oils used to

protect the equipment during the construction
period whenever these protective materials
will be detrimental to operation.
Provide

Category
of work
Precom- Commis
miss'g
sioning

ANCAP with
completed.

record

of

work

D.2.2 LUBRICANTS
a/ Provide
lubricants

a list of

b/ Install
lubricants

initial

all

necessary

charge

of

all

X
c/ Maintain
charge.
D.2.3 PACKING
a/

b/

lubrication

after

initial

AND SEALS

Install
mechanical
permanent
packing
accessories when required

seals,
and

Adjust and replace mechanical

seals, packing and accessories,
as necessary.

X
X

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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

Responsibility of
work
Contrac- ANCAP
tor
D.2.4 REMOVAL

Category
of work
Precom- Commismiss'g
sioning

OF TEMPORARY BRACING

Remove all temporary supports, bracing, or other

foreign objects that were installed in vessels,
transformers,
rotating
machinery,
or
other
equipment to prevent damage during shipping,
storage, erection and repair any damage sustained
D.2.5 ROTATING

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AND ALIGNMENT

a/

Check rotating machinery for correct direction

of rotation and for freedom of moving parts
before connecting driver.

b/

Make cold alignment to the manufacturer's

tolerances and record data.

c/

Operate equipment and check vibration, trip,

governor and safety device.

doweling

a/

Prepare all systems for safe tie-ins and

observe the systems while tie-ins are being
made.

b/

Obtain ANCAP's approval to make the

necessary tie-ins at the battery limits as
required by the specifications.

All checks, and any other operating tests and

adjustments as required.
d/

Make

hot alignment
required.

D.2.6 TIE-INS

and

any

AT BATTERY LIMITS

X
c/

Make the tie-ins at B.L.

X
d/

Remove blinds, car seals and so forth, as

required.

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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

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Responsibility of
Category
work
of work
Contra ANCAP Precom Commi
cstor
miss'g sioning
D.2.7 LEAK

AND

PRESSURE TESTS

a/

Notify ANCAP of the test schedule.

b/

Make non-operating field leak tests or field

pressure tests on piping and field fabricated
equipment. Conduct all tests in accordance
with applicable codes and specifications.
Dispose of the test media according with
ANCAPs instructions.

c/

Provide test record for ANCAP.

d/

Provide any special media for test purposes

and provide facilities for disposal.

e/

Conduct all operational tightness testing.

f/

Proceed with hydraulic pressure tests of shell

ant tube heat exchangers when installed and
connected to piping. Nozzles on shell and tube
sides shall be closed by blinds. Test shall be
conducted
on
shell
and
tube
sides
successively. Checking will be made by
pressure gauge and by visual inspection.

g/

Proceed with hydraulic pressure tests of

vessels and air coolers

D.2.8 INSPECTION
a/

b/

D.2.9
a/

Provide inspection of the WORK to check that

erected facilities conform to flow diagrams,
construction drawings, vendor prints and
specifications.
Provide for special inspection such as those
required by insurance or governmental
agencies.
SAFETY

DEVICES

Test and adjust all safety devices and seal

wherever necessary or desirable.
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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

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b/

Install all safety devices (including pressurerelief valves) after testing and adjustment.

c/

Provide format for safety records

X
X

d/

Maintain the necessary records on safety

devices on ANCAPs format.

D.2.10

FLUSHING
CLEANING

a/

b/

AND

CHEMICAL/MECHANICAL

Conduct
all
flushing,
blowing
and
chemical/mechanical cleaning operations
and provide required circulating media and
chemicals. ANCAP designated priorities to
be followed.
Dispose of wastes and cleaning media
according to ANCAPs instructions.

X
c/

X
X

Maintain records, as required

D.2.11 TEMPORARY

SCREENS, STRAINERS AND

BLINDS

a/

Provide and Install all required temporary

strainers.

b/

Clean
strainers
as
required
during
circulation and remove strainers when
adequately cleaned

c/

Provide, install and remove all

required for flushing or operation.

d/

blinds

Maintain the required records on ANCAPs

format.

D.2.12 PURGING/INERTING
a/

Install purge/inerting connections

b/

Conduct necessary purge operations.

X
X

X
X

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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

D.2.13
a/

b/

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HOUSEKEEPING
At completion of construction provide cleanup of the WORK area. Remove excess
materials,
temporary
facilities
and
scaffolding; rough sweep or rake the area;
and pick up trash.
Perform washing or
further clean-up as required.
After completion of construction maintain
adequate
housekeeping
practices,
as
required for safe operation.

Responsibility of
work
Contractor

ANCAP

Category
of work
Precom- Commismiss'g
sioning

D.2.14 SAFETY
During precommissioning activities, CONTRACTOR
shall ensure all safety regulations and practices
imposed by ANCAP are strictly followed.
D.2.15

EQUIPMENT STORAGE

Protect equipment against weather, corrosion,

and/or any other damage up to commissioning

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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

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D.3 SPECIFIC PROCEDURES

In addition to the work to be performed in accordance with paragraph D.2., the detailed
procedures outlined below further define the work to be performed by the CONTRACTOR for
specific systems and items of equipment, when applicable.
ANCAP witnessing and
verification are required.
PIPING
See construction and commissioning requirements in Appendix L.
ROTATING

EQUIPMENT

a/

Pumps run-in during six consecutive hours (at commissioning stage)

b/

Statement of engine intensity, bearing temperature, vibrations and noise (at

commissioning stage)

c/

Engines alignment with their drivers, in the hot state, during 4 weeks. (The cold
alignment and one hot alignment verification during the period)

ELECTRIC

POWER

a/

All equipment installed according to drawings

b/

Insulation resistance of all electrical equipment, power & control cables

c/

Earth connections continuity and grounding system resistance measurement

d/

Illumination levels measurements (at commissioning stage)

e/

Conformity with diagrams

f/

Phase rotation for all electric device and checking of motor rotation direction(at
commissioning stage)

g/

For every high voltage feeder: high voltage test (at commissioning stage)

h/

Protective relays testing and setting according to discrimination studies (at

commissioning stage)

i/

Checking of conformity with applicable codes and regulations

j/

Checking of proper installation of equipment, cables etc

k/

Checking of instruments power supply system (at commissioning stage)

INSTRUMENTATION
a/

Cable insulation ( wire to wire and wire to earth)

b/

Conformity with diagrams

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c/

Mechanical installation and leak tests for all instruments

d/

Range setting for all instruments and valves in conformity with specifications

e/

Instrument air piping installation and tightness tests

f/

Electrical power supply functional test (at commissioning stage)

g/

Alarms & interlocks testing

h/

Control loops functional tests

i/

Seal pots filling

j/

Check inside diameter & and flow direction for calibrated orifices after line
cleaning

k/

Setting of pressure relief valves at test bench

D.3.5 WATER
a/

SYSTEMS

FIRE WATER, RAW WATER SYSTEM)

Check completeness & correctness of installation, make non operating checks

as necessary

b/ Operate fire pumps, if needed, to check output of system ( at commissioning

stage)
c/

Provide insurance company inspection of fire system, as required.

d/

Install all required fire fighting chemicals and portable equipment such as
hoses, fire extinguishers and related equipment.

WASTE

DISPOSAL

Inspect facilities for completeness and correctness of installation and make any nonoperating checks to ensure their conformance to specifications.

MISCELLANEOUS
Civil engineering

Conformity with drawings, appearance, anchorage,

equipment drain, paving slope, expansion joints, etc...

skirt

Steel structure

Conformity with drawings, welds appearance, rain water drains,

safe thermal expansion, etc...

Earthwork, roads

Conformity with drawings, rain water drain, dikes, etc..

Sewer system

Slope, tightness, flow at the flooding value, holiday checking,

etc..

Insulation

Conformity with specifications, thickness material, tightness,

plate overlap, etc..
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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

Painting

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Conformity with specifications, sand blasting,

adhesiveness checking, coats number, etc..

thickness,

Notes

D.4

1/

All the damaged equipment shall be retested (if required, competent Authorities
shall be present during such tests).

2/

All the equipment, built completely or partially on the site shall be hydraulically
tested (if required, competent Authorities shall be present during such tests).

SPLITTING OF PRECOMMISSIONING AND COMMISSIONING ACTIVITIES

Based on and in addition to the specific procedures as defined in D3, is presented hereafter
a breakdown of activities into precommissioning and commissioning. For each activity the
involvement of Contractor and ANCAP is indicated.
Responsibility of
Category
work
of work
Contra ANCAP Precom Commi
cstor
miss'g sioning
D.4.1 VESSELS
a/

Open vessels after mounting on their

foundations. Open access and nozzles for
inspection by ANCAP.

b/

Dry internal parts as necessary.

c/

Close vessel.

D.4.2 SHELL

AND TUBE HEAT EXCHANGERS

a/

Proceed with inspection and

which might be necessary
installation at site.

b/

Proceed
with
pressure
described in D.2.7.f.

tests

tests
after

as

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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

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Responsibility of
work
Contractor
D.4.3 ROTATING

EQUIPMENT
COMPRESSORS)

(PUMPS

Install and grout equipment on their

foundations.

b/

Correct
any
abnormal
effort
equipment due to piping connections
Proceed with cold line-up

d/

Proceed with hot line-up

e/

Proceed with initial filling of lubricants

D.4.4 PIPING

Precom- Commismiss'g
sioning

AND

a/

c/

ANCAP

Category
of work

on

SYSTEM

a/

Proceed with all pressure tests

b/

Install insulation only after pressure tests

c/

Proceed with all line flushing (without

orifice plates or meters)

d/

Install orifice plates or meters after

pressure tests and lines flushing under
the supervision of ANCAP.

e/

Check and adjust pipe supports and

guides in hot conditions

f/

Correct any problem of support, vibration,

thermal expansion

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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

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Responsibility of
work
Contractor
D.4.5 ELECTRIC

ANCAP

Category
of work
Precom- Commismiss'g
sioning

POWER DISTRIBUTION AND LIGHTING

a/

Check continuity of electric connections

b/

Check insulation of all the cable system

c/

Check insulation of equipments (electric

motors,
transformers,
accessories,
lighting devices, etc.)

d/

Check earthing system (continuity and

resistance)

e/

Calibrate the relays and protection

system to obtain a good selectivity

f/

Check phase sequences, correct rotation

of motors, polarity

g/

Check UPS systems

h/

Connect electric power to substation after

finalization of tests and with participation
of ANCAP

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APPENDIX D CHECKLIST FOR MECHANICAL COMPLETION

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Responsibility of
work
Contractor

ANCAP

Category
of work
Precom- Commismiss'g
sioning

D.4.6 INSTRUMENTATION

a/

Cleaning and pressure test of hook-up

lines

b/

Cleaning and pressure test of instrument

air headers

c/

Check
continuity
of
connections, polarity, etc.

instrument

d/

Check thermocouples
correct connection, etc.

continuity,

e/

Identifying and marking the orifice plates

and meters

Remove, if necessary, the control valves,

the positive displacement turbine meters
during pressure tests of piping line and
re-install them after tests.

Disconnect hook-up lines during pressure

test of piping

Calibration of instruments and control of

control loop continuity

f/

g/

h/

i/

j/

for

Pressure and energize the control

system, open hook-up line after oil-in,
proceed with fine tuning of control loops
after oil in.
Check and adjust set point of relief
valves

D.4.7 MECHANICAL

AND

LOADING EQUIPMENT

a/ Cleaning and pressure test

b/ Check assembly and readiness for operation

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