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TABLE OF CONTENTS
1.0 SCOPE........................................................................................................................................ 3
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Factory Test Guideline 1400-20-CO-RP-8008
BP – Gulf of Mexico Deepwater Development Program Revision 0
1.0 SCOPE
This guideline covers the range of testing activities performed on project equipment at vendor
factories.
Project equipment will include vendor-packaged equipment, skidded equipment and systems.
The extent of testing of each equipment item at vendor factory will be determined by the
project, in accordance with that projects’ requirements. Document 1400-20-CO-RP-8006
“Topsides Hook-Up and Commissioning Guideline” (in particular the flowchart in section 4.5
‘Early Commissioning Workscope and Prioritization’) provides guidance on how this testing
workscope can be determined in each case.
Each project will develop a factory testing program, covering the extent of testing to be
performed on each equipment item. The basis of this information is contained in the purchase
order placed with equipment vendors. The factory testing program will also detail project
inspection activities, and will list required project and Operations participants.
In general, factory testing activities will be structured to maximize the likelihood of a trouble-free
offshore start-up, through uncovering problems sufficiently early in the project cycle that they
are resolved without impacting overall schedule.
This document is intended to help each project maximize the value of their factory testing
through having agreed objectives and deliverables for each test, consistent conduct by all
projects at each vendor factory, and appropriate preparation and participation in the testing
activity.
This document describes the approach to be taken to factory testing, in terms of:
timing
objectives
participation
structure
The document recognizes the program-environment, in which:
several projects will procure similar pieces of equipment from the same manufacturer, and
therefore have the opportunity to
rationalize testing workscope across projects (so the maximum assurance of equipment
function is gained through the minimum aggregate testing across the projects)
combine attendance at factory tests (so the maximum familiarity and competence can
be gained through cross-project participation in a rationalized workscope)
several key contracts have already been structured in a cross-project fashion, including
engineering design fabrication, and installation; providing the opportunity to
share cost and benefit of provision of (for example) temporary utilities and connections
at fabrication site to facilitate onshore commissioning, thereby providing a mitigation for
factory test workscope which is not completed prior to equipment shipment to
fabrication site
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Factory Test Guideline 1400-20-CO-RP-8008
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Factory Test Guideline 1400-20-CO-RP-8008
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Factory Test Guideline 1400-20-CO-RP-8008
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Factory Test Guideline 1400-20-CO-RP-8008
BP – Gulf of Mexico Deepwater Development Program Revision 0
THE OBJECTIVE OF THE PUNCHLIST IS TO IDENTIFY REMEDIAL WORKS NECESSARY FOR EQUIPMENT TO BE OF FIT-FOR-PURPOSE
STANDARD OF CONSTRUCTION, AND TO BE SAFELY OPERABLE (INCLUDING CONSISTENCY OF PAPERWORK).
Liaise with other Completions Team members to arrange time for punchlisting.
Obtain latest revisions of system P&ID’s (as-builts if possible), line drawings, & electrical diagrams.
Check area on PDMS model, if necessary/available.
Inform the area authority (if appropriate) that you will be in the area.
Check local permit boards for ongoing work, and maintain good housekeeping in the area
Ensure that the safety of yourself and others in the area is not compromised by the actions you carry
out
Walk through the system and note any remedials arising from the following checks:
1) Check all documentation is correct and available (e.g. instrument calibrations and general readiness of
equipment).
2) Check equipment is clean.
3) Check tagging/setting of equipment is correct and that it corresponds to nameplate and drawings.
4) Check all indication is of correct color protocol.
5) Check access/egress provision (allow for temporary factory set-up).
6) Check that all shipping stops, bracing and packaging materials have been removed and that all sliding feet are
free.
7) Check equipment for damage to painting or coating, check condition of insulation.
8) Check all threads and faces (e.g. mechanical fasteners, JB’s, TX lids) are adequately lubricated to prevent
corrosion.
9) Check pipework orientation does not facilitate corrosion (dead-legs, etc.).
10) Ensure all interlocks and mechanical locking/isolating devices are functioning.
11) Check mechanical operation of all push buttons.
12) Check for internal damage to equipment.
13) Check bolts and gaskets are installed at all joints, and that studbolts are correct spec, length and tightness.
14) Check jointing is to correct spec and all flanges are correctly aligned.
15) Check that temporary equipment, e.g. strainer, is installed and identified as temporary, and meets all system
specifications
16) Check pipework for adequate supports and brackets.
17) Check operability and accessibility of valves.
18) Check orientation of NRV’s, control valves, and flow orifices.
19) Check local PI’s and TI’s are in place and are of the required range and rating.
20) Check all instrumentation for correct connection to process, electrical, pneumatic and hydraulic supplies.
21) Check control, electrical and earthing cables are terminated.
22) Check integrity of all Ex. equipment.
23) Check terminations and connections are secure.
24) Check all electrical supplies/temporary supplies are correctly fused and rated.
25) Check integrity of earthing system.
26) Check operation of stop/start stations.
27) Check there are no exposed contacts/terminals inside cubicles, which remain accessible when live.
28) Check gaskets and seals are not damaged.
29) Check all test equipment is in good working order, and correctly calibrated.
30) Check use of correct glands and glandplates: check tightness of glands.
31) Check all cables are in good condition and correctly fixed and identified.
32) Check mechanical-handling equipment is in place and adequate.
33) Confirm rotating equipment alignments are complete, and suitable adjustment is achievable in field (shim packs,
etc).
34) Confirm lubrication and seal systems are flushed to correct specification prior to equipment use.
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Factory Test Guideline 1400-20-CO-RP-8008
BP – Gulf of Mexico Deepwater Development Program Revision 0
CATEGORIZE EACH DEFECT AS LISTED BELOW. MARK UP P&ID’s WITH ALL DEFECTS, LABEL IN FIELD.
Category A: Items to be repaired/completed/corrected before the equipment can be safely powered-up and
commissioned.
Category B: Items that can be repaired/completed/corrected at a later date and which do not stop the
equipment from being safely commissioned/operated.
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Factory Test Guideline 1400-20-CO-RP-8008
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