Вы находитесь на странице: 1из 38

CRUX PIPELINE AND SUBSEA STRUCTURES

Type of Document: Procedure Pages: 1 of 113

MECHANICAL COMPLETION EXECUTION PLAN

A Issued For Bidding 14.Jan.20 MVB

Prepared By Reviewed By Approved By Approved


Rev. Purpose of Issue Issue Date By
Sub-Contractor Contractor

Document No.:

SUB-CONTRACTOR: PV SHIPYARD JSC


Title: MECHANICAL COMPLETION EXECUTION PLAN

REVISION RECORD SHEET

NO. REV. NO. CONTENT OF REVISION DATE OF REVISION

1 A Issued for Bidding 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
8.2.1 MC-DAC Sign Off Authority ........................................................ 25
8.2.2 Partial MC-DAC ............................................................................ 26
8.3 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. Crux 26” OD (24.5” ID controlled) export pipeline;
ii. Crux 26” OD (24.5” ID controlled) CRA rigid riser (excluding fabrication and onshore testing);
iii. Linepipes and bends external corrosion and concrete weight coatings/claddings;
iv. Crux 26” OD (24.5” ID controlled) pipeline end termination (PLET) structure and foundation
v. Prelude 18” OD (16” ID controlled) pipeline end termination (PLET) structure and foundation
vi. Crux 26” OD (24.5” ID controlled) CRA rigid tie-in spool; and
vii. Crux Static Umbilical.
c. Load out and transportation of all MATERIALS and PERMANENT WORK;
d. Engineering and execution of the following SCOPE:
i. Installation of pipeline, PLETs and foundations between Crux platform and Prelude FLNG;
ii. Flood, clean, gauge, hydrotest and preservation of pipeline PLET connector to PLET connector;
iii. Offshore metrology, fabrication and installation of Crux CRA rigid tie-in spool;
iv. Crux Static Umbilical pull-in, tie-in and test;
v. Installation of Fibre Optic flying lead (at Crux) and test;
vi. 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 pre-
commissioning 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.

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

4.2 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 Sub-
System 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 MC-
DACs) to CONTRACTOR Construction/ QC Team.

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

 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.

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

6.2 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.

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

6.3 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 MC-
ITR’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
Completed by Verified/Approved by Witnessed/Reviewed by
Discipline SUBCONTRACTOR SUBCONTRACTOR CONTRACTOR
Construction Team QA/QC Team Completions Team
 Construction Discipline
 Discipline Inspector
A - Architectural  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector
 Construction Discipline
 Discipline Inspector
E - Electrical  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector
 Construction Discipline
 Discipline Inspector
H - HVAC  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector
 Construction Discipline
 Discipline Inspector
I - Instrumentation  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector
 Construction Discipline
 Discipline Inspector
IN - Insulation  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector
 Construction Discipline
 Discipline Inspector
M - Mechanical  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector
 Construction Discipline
 Discipline Inspector
P - Piping  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector
 Construction Discipline
 Discipline Inspector
S - Safety  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector
 Construction Discipline
 Discipline Inspector
St - Structural  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector
Title: MECHANICAL COMPLETION EXECUTION PLAN

 Construction Discipline
 Discipline Inspector
T - Telecoms  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector
 Construction Discipline
X – Surface  Discipline Inspector
 Discipline Supervisor Engineer
Protection  Lead discipline Inspector
 QC Discipline Inspector

Table 1: MC-ITR Positional Sign-off Authority

MC-ITR Signatory Authority

Check Sheet by Discipline


Jacket MC-ITR
Signatory Authority
Verified/Approved by Witnessed/Reviewed by
Completed by
Discipline SUBCONTRACTOR CONTRACTOR
VSP Team
QA/QC Team Completions Team
 Construction Discipline
 Discipline Inspector
E - Electrical  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector

 Construction Discipline
 Discipline Inspector
I - Instrumentation  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector

 Construction Discipline
 Discipline Inspector
M - Mechanical  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector

 Construction Discipline
 Discipline Inspector
P - Piping  Discipline Supervisor Engineer
 Lead discipline Inspector
 QC Discipline Inspector

 Construction Discipline
 Discipline Inspector
St - Structural  Discipline Supervisor Engineer
 Lead discipline Inspector
 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
Reviewed by
SUBCONTRACTOR
Completed by CONTRACTOR
MC & Commissioning
Discipline SUBCONTRACTOR Commissioning Team,
Team, or Verified by
Construction Team Completion team &
SUBCONTRACTOR
Operation Team
QA/QC Team

 QC Lead Discipline
A - Architectural  Discipline Superintendent  Completion team
Inspector

 Commissioning  Commissioning
E - Electrical  Discipline Superintendent
Discipline Engineer Discipline Engineer

 Commissioning  Commissioning
H- HVAC  Discipline Superintendent
Discipline Engineer Discipline Engineer

 Commissioning  Commissioning
I - Instrumentation  Discipline Superintendent
Discipline Engineer Discipline Engineer

 QC Lead Discipline
IN -Insulation  Discipline Superintendent  Completion team
Inspector

 Commissioning  Commissioning
M - Mechanical  Discipline Superintendent
Discipline Engineer Discipline Engineer

 Commissioning  Commissioning
P - Piping  Discipline Superintendent
Discipline Engineer Discipline Engineer

 Completion /
 QC Lead Discipline
Operations /
S - Safety  Discipline Superintendent Inspector / Commissioning
Commissioning Discipline
Discipline Engineer
Engineer

 QC Lead Discipline
St - Structural  Discipline Superintendent  Completion team
Inspector
Title: MECHANICAL COMPLETION EXECUTION PLAN

 Commissioning  Commissioning
T - Telecoms  Discipline Superintendent
Discipline Engineer Discipline Engineer

X – Surface  QC Lead Discipline


 Discipline Superintendent  Completion team
Protection Inspector

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
Reviewed by
SUBCONTRACTOR
CONTRACTOR
Completed by MC & Commissioning
Discipline Commissioning Team,
VSP Team Team, or Verified by
Completion &
SUBCONTRACTOR
Operation Team
QA/QC Team

 Commissioning  Commissioning
E - Electrical  Discipline Superintendent
Discipline Engineer Discipline Engineer

 Commissioning  Commissioning
I - Instrumentation  Discipline Superintendent
Discipline Engineer Discipline Engineer

 Commissioning  Commissioning
M - Mechanical  Discipline Superintendent
Discipline Engineer Discipline Engineer

 Commissioning  Commissioning
P - Piping  Discipline Superintendent
Discipline Engineer Discipline Engineer

 QC Lead Discipline
St - Structural  Discipline Superintendent  Completion team
Inspector
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
CONTRACTOR
SUBCONTRACTOR
Completed by Commissioning Team,
MC/Commissioning Team
Discipline SUBCONTRACTOR Completion team &
& QC Team (Non
Construction Team Operation Team (Non
Commissionable Sub
Commissionable Sub
Systems)
Systems)
 Commissioning Supervisor
All Associated  MC or Commissioning
Disciplines and  Construction Manager
 Completion/Operation
Information for the Manager  QC Manager (Non
team (Non Commissionable
SSAC and Dossier Commissionable Sub System)
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
Reviewed by
Accepted by
CONTRACTOR
SUBCONTRACTOR
Completed by Commissioning Team,
MC/Commissioning Team
Discipline VSP Construction Completion team &
& QC Team (Non
Team Operation Team (Non
Commissionable Sub
Commissionable Sub
Systems)
Systems)
All Associated  Construction  MC & Commissioning
 Commissioning Supervisor
Disciplines and Manager Manager
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 Code

Architectural 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 MC-
DAC 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 MC-
ITR 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, MC-
SSACs 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 red-
lined 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 Sub-
System 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 MC-
ITRs 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 & PC-
ITRs), 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 Sub-
systems 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.