3. GENERAL ACTIVITIES The following table broadly identifies the activities to be performed for the Project during each of the periods defined above and shown in the table below until Ready for Start-Up and designates which Party is responsible for each such activity. Commis sioning Onshore Contracto r Owner Onshore Contracto r Owner Onshore Contracto r Owner Activity Description Mechanical Completion PreErection Comm. 3.1. Manufacturer or Vendor Service Assistance Where responsibility is not indicated in Section 4: a. Obtain the assistance of the manufacturer or vendor, when necessary, to make a satisfactory installation as agreed ContractorContractor and Employer between Onshore and Owner b. Obtain the assistance of the manufacturer or vendor, as required, for technical assistance, for informational and operational purposes until Final Acceptance c. Contact, control, coordinate, and supervise vendors’ engineers and representatives as necessary to fulfil the requirements. d.- Furnish names and telephone numbers, including contacts, of manufacturers’ and vendors’ technical service representatives Employer for use by Owner. e.- Advise Employer Owner of requirements for licensors’ representative’s attendance as necessary, including licensors’ attendance during Mechanical Completion, Pre-commissioning, Commissioning, start-up and Performance Tests. 3.2. Permits a.- Obtaining all necessary licenses, permits and authorizations required to be obtained in the name of Onshore Contractor or any Subcontractor. (see 27.viii, “LOI and EPC terms”). b.- Provision of assistance to Employer Owner in obtaining all necessary licenses and permits required to be obtained in the name of Employer, without assuming the responsibility for obtaining Owner, such licenses and permits. (see 27.ix, “LOI and EPC terms”). 3.3. Instructions or documentation a.- Maintain adequate vendor equipment file so that information may be readily retrieved through Commissioning and Ready for Start-Up. b.- Transmit to Employer Owner all applicable vendor’s or manufacturer’s instructions and drawings, and related data X X X X X X X X X X X X X X X X X X X X X X Mechanical Completion PreErection Comm. Commis sioning Onshore Contracto r Owner Onshore Contracto r Owner Onshore Contracto r Owner Activity Description c.- Provide Employer Owner with any special instructions, such as the required procedures for drying liners. 3.4. Removal of Rust Preventives a.- Remove all rust preventives and oils used to protect the equipment during the construction period whenever these protective materials will be detrimental to operation. b.- Dispose of solvents and test fluid in an environmentally responsible manner in accordance with the local environmental code. c.- Provide Employer Owner with a record of work completed. 3.5. X X X X X X X X X X c.- Provide all lubricants for first fill in quantity and quality required as per vendors list. d.- Flush systems and install initial charge of all lubricants. Dispose of all flushing oil in accordance with the applicable regulations. e.- Maintain lubrication after initial charge until handover X X X Packing and Seals a.- Install mechanical seals and accessories, as required X b.- Install packing and accessories, as required X c.- Adjust and replace mechanical seals, packing and accessories, a 3.7. X Lubricants a.- Provide a list of manufacturer’s recommended lubricants for use in the Facility b.- Provide filters for flushing 3.6. X X Removal of Temporary Bracing a. Remove all temporary supports, bracing, or other foreign objects that were installed in vessels, ducts, piping, transformers, machinery, or other equipment to prevent damage during shipping, storage, and erection and repair any damage sustained b. Check that grouting of base plate meets the Project’s technical specifications 3.8. Rotation and Alignment a. Check rotating machinery for correct direction of rotation and for freedom of moving parts before connecting the driver X X X Commis sioning Onshore Contracto r Owner Onshore Contracto r Owner Onshore Contracto r Owner Activity Description Mechanical Completion PreErection Comm. b. Perform cold alignment to the manufacturer’s tolerances and record c. Perform hot alignment d.- Obtain the services of a factory representative to witness installation of equipment, as required 3.9. Tie-ins at Unit Limits 3.10. X X X a.- Identify and prepare all systems for safe tie-ins. X b.- Obtain approval and make the necessary tie-ins at the unit limits, as required by the specifications and as directed by Employer Owner c.- Install and remove blinds, car seals, and so forth, as required. X X System definition a.- Define systems and sub-systems for effective turn over plan of the unit(s) per the requirements. b.- Provide a joint integrating plan for Pre-Commissioning and Commissioning activities, in each case split/segregated by Unit/systems. c.- Perform equipment and system test as specified. X X X d.- Provide test procedures and checklist for System acceptance. c.- Maintain System completion and test records, as required. 3.11. X X X X X X Leak and Pressure Tests a.- Notify Employer Owner of the schedule for non-operating field leak tests or field pressure test on piping and field fabricated Employer. equipment, unless otherwise directed by Owner. b.- Provide media for test purposes and facilities for their disposal. c.- Conduct all tests in accordance with applicable codes, Employer's instructions. specifications, regulations, and Owner’s instructions. d.- Witness test. X X X X X X e.- Maintain records, as required. X f.- Provide a joint integrity plan including torque and tensioning requirements and procedures for specific flanges identified in the system and Pre-commissioning plans. X X X Commis sioning Onshore Contracto r Owner Onshore Contracto r Owner Onshore Contracto r Owner Activity Description Mechanical Completion PreErection Comm. 3.12. Inspection a.- Provide inspection of the plant equipment to verify that erected facilities conform to “Issued for Construction” diagrams, vendor prints and specifications. b.- Verify that specified Materials have been installed in the Facility and document verification to the extent required. c.- Verify the checklists for the various disciplines, e.g. Process, Electrical, Piping, Civil etc., have been completed and any defects noted have been added to the Punch List. d.- Perform specified inspections and performance tests and prepare certified reports of all shop inspection and witness tests. e.- Witness final shop inspections, as specified. Note: Shop inspected equipment will not be reopened for inspection in the field except as specified by Employer Owner or as specifically noted in 4.1 f.- Verify and approve the plant inspection. Note any exceptions on the Punch List. g.- Provide for special inspections, such as those required by insurance or governmental agencies. 3.13. Pressure/Vacuum Safety Relief Devices a.- Provide Employer Owner with a list of proper pressure settings. b.- Transfer relief devices to and from the specified testing facility. c.- Test, adjust and tag all safety devices and seal wherever necessary or desirable. 3.14. Flushing and Chemical/Mechanical Cleaning X X X X X X X X X X a. Except as specifically noted in the next section: 1. Conduct all flushing, blowing, and mechanical (by hand tools) cleaning operations where such operations can be accomplished without using permanently installed equipment and providing temporary equipment as necessary. 2. Conduct air blowing on steam interconnecting and distribution piping. 3. Conduct steam blowing on steam interconnecting and distribution piping, when steam is available. X X X Commis sioning Onshore Contracto r Owner Onshore Contracto r Owner Onshore Contracto r Owner Activity Description Mechanical Completion PreErection Comm. b. Conduct chemical and special mechanical (e.g. hydro-jetting) cleaning, providing and disposing of all fluids used during execution. c.- Turn systems over to Employer Owner free of trash and construction debris to be demonstrated by visual inspection during joint walkthrough. d.- Conduct all operational tightness and joint integrity test. Note: The following equipment, if pressure tested in the fabricator’s shop, will not require retesting in the field, unless specified by Employer. Owner. Such individual items of equipment shall be included in the testing of attendant Employer. piping systems whenever practical and approved by Owner. 1. Vessels 2. Shell and tube exchangers 3. Air cooled exchangers e.- Maintain records, as required. 3.15. X X X X Temporary Screens, Strainers and Blinds a. Provide and install all required temporary strainers. X b. Clean strainers, as required, during circulation. c. Provide, install and remove all temporary blinds required for flushing. d. Provide, install and remove all temporary blinds required for isolation. f.- Maintain records, as required. 3.16. X X X X X X X Purging / Inerting a.- Install purge/inerting connections. X b.- Provide purge / inerting materials. c.- Conduct necessary purging / inerting operations. 3.17. X X Drying Out a.- Dry out facilities, as requested, to prevent contamination of catalysts, operating materials and/or product b.- Dry out systems, refractory and linings when this drying operation is to be accomplished with temporary facilities. c.- Dry out systems, refractory and linings by means of permanently installed equipment. X X X Commis sioning Onshore Contracto r Owner Onshore Contracto r Owner Onshore Contracto r Owner Activity Description Mechanical Completion PreErection Comm. d.- Provide dry out procedures and technical assistance during performance of the Work for equipment supplied by a specific vendor/Licensor. 3.18. Vessel Packing and Fixed Beds X a. Install all inert materials such as sand, gravel, balls, rings and saddles. b. Inspect the vessel interior before any inert material loading to ensure proper installation. c. Install all materials such as chemicals, catalyst, resins and desiccants. d. Inspect the vessel interior after any inert material loading to ensure proper installation. e.- Maintain records, as required. 3.19. X X X X X Housekeeping a. At completion of construction, 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. b. After mechanical completion maintain adequate housekeeping practices as required for safe operation. 3.20. Maintenance, Spare Parts, and Special Tools a. Before and during Pre-Commissioning, protect equipment from normal weather conditions, corrosion or damage. b. After Pre-Commissioning in complete, provide adequate maintenance for equipment until hand over, including the cleaning of strainers and the repairing of steam traps c. Provide Employer Owner with spare parts lists, as recommended by the manufacturers. d After Pre-Commissioning, maintain adequate spare parts and supplies for commissioning and start-up 3.21. Noise Survey X X X X X X X X X X a. Conduct individual equipment noise surveys, as required X b. Document all survey data X 4. SPECIFIC ACTIVITIES In addition to the work described in the previous section, the detailed list of activities outlined below further defines the main works for specific systems and items of equipment. 4.1. Vessels, Towers, reactors and drums a.- Open each vessel and execute inspection of internals after installation. b.- Open both internal and external man ways and execute final inspection of the vessel, unless otherwise specified. c.- Mechanically clean the vessel internally, as required. X X X d.- Cure and dry out any special protective linings in accordance with the manufacturers’ specifications and instructions. e.- Dry out, if required, open vessel; and install materials. X X f.- Close after final inspection. 4.2 X Shell and Tube Exchangers a.-Perform field inspection of exchangers, if required. 4.3 X Air-Fin Exchangers a.- Inspect exchangers to ensure that temporary shipping supports and erection materials have been removed. b.- Adjust fan assemblies to obtain specified tip clearance and test. c.- Perform uncoupled motor test run. Check bearing operation and direction of rotation. d.- Install and adjust tensioning of belts. 4.4 a b X X X X e.- Check operation of louvers and operating linkage; adjust and lubricate all fittings as necessary. f.- Run-in, with belt installed, air fin exchanger and check bearing temperature and vibration. Fired Heaters Perform the pressure test in accordance with the applicable codes, specifications, and Employer's Owner’s instructions, if required. Provide quality assurance and quality control data as required by specifications, duly certified by third-party inspectors, where applicable. Include material certifications, regulatory reports as required. X X X X Owner Comm. Onshore Contractor Owner PreComm. Onshore Contractor Onshore Contracto r Owner Erection c d e f g h i j k l m n o p q r 4.5 a b Provide records of all progressive non-destructive tests made during fabrication (e.g. progressive dimensional checks and vacuum testing and welding examinations). Obtain service engineer for technical assistance during erection, Commissioning or Start-Up, where required. Inspect for completeness and correctness of installation and make other non-operating pre-firing checks. Blow fuel lines, check them for cleanliness and connect burner piping. Carry out final installation of burners, checking operability. X X X X X X X X X X X X X Conduct chemical cleaning, and flushing operations, as required. Dispose of waste and cleaning media in Employer's instructions and in accordance accordance with Owner’s with the requirements set forth in the Safety Program Manual. Charge liquid heat transfer media, if required. X X Conduct all operational tests and obtain the required certification. After drying-out, clean stack and duct, open manholes and other openings for inspection. Check operation of dampers. Close stack and duct after inspection. Pumps, Compressors, Blowers, Turbines, Fans X X X X Owner Onshore Contractor Owner Comm. X Check air preheaters, registers, dampers, soot blowers and other equipment for proper operation and burners nozzles for correct positioning. Verify burner piping and burner tips are free of rust and debris. Check out instruments, controls and safety systems on heaters. Dry refractory during initial firing by following the manufacturer’s temperature cycles. De-couple drivers (if applicable). Run-in fan drivers check for rotation and smooth operation. Re-couple fans to drivers. Fit guards in place. (if applicable). Start fans and drivers to check vibration (if applicable). Provide all quality control data, duly certified by thirdparty inspectors, where applicable. Alleviate any excess piping stresses that may be imposed on pumps, compressors and drivers. PreComm. Onshore Contractor Onshore Contracto r Owner Erection c d e f g h i Level baseplates and soleplates and grout all bearing surfaces. Check equipment piping and clean as necessary. o p Re-install mechanical seals or permanent packing. q Conduct solo run of steam turbine drivers. r Run Machine on stream. s Prepare and follow non-running care and maintenance field schedule until Ready for Start-Up. Check noise levels. j k l m n t u v Obtain the assistance of manufacture’s service engineer for technical advice during installation or/and start-up, if desired. Maintain records, as required. X X X X X X X X X X X X X X X X X X X X X X X Owner Onshore Contractor Owner Comm. X Clean and flush auxiliary systems, lube oil and seal oil as required by specifications. Dispose of waste and cleaning media in accordance with the requirements set forth in the Safety Program Manual. Charge the lube oil, seal oil, and oil cooling systems with flushing oil and circulate for cleaning purposes. Dispose of Employer's instructions any flushing oil in accordance with Owner’s Cold align equipment and driver and install coupling between driven and driver machines. Install temporary strainers in suction piping. Charge the lube oil, seal oil and oil cooling systems with the operating oil recommended by the manufacturer. Commission any lube oil, seal system, instrument and auxiliary systems. Couple pumps to drivers after the motor has been checked for rotation and smooth operation and install all guards. Execute no load run-in, of driver and monitor bearing temperature, vibration, trip, governor, oil levels and pressure and safety device. Execute run-in of coupled equipment / driver and monitor bearing temperature, vibration, trip, governor, oil levels and pressure and safety device. Check control circuits and safety trip devices to the extent possible prior to Ready for Start-Up. Grout all mounting surfaces. PreComm. Onshore Contractor Onshore Contracto r Owner Erection 4.6 Tanks a c Provide quality assurance and quality control data as required by specifications, duly certified by third-party inspectors, where applicable. Include material certification, regulatory reports as required. Provide records of all progressive non-destructive tests made during construction (e.g. progressive dimensional checks and vacuum testing and welding examinations). Inspect tanks interior for cleanliness. d After erection and installation, install any internals. X e Inspect installation of internals X f h Hydro-test tank and internals, as required. Dispose of test water in accordance with Employer's Owner’s instructions. Conduct chemical cleaning or flushing operations, as required. Dispose of waste and cleaning media in accordance with the requirements set forth in the Safety Program Manual. Complete painting and insulation. 4.7 Piping Systems a Provide evidence of positive material identification for piping, fittings and valves, including mill certificates for bulk piping in accordance with the project specification. Check piping for conformity with the piping and instrumentation (P&ID’s) diagrams and isometrics. Notify Employer Owner of test schedule. b g b c d e f g h Hydrostatically or pneumatically test all piping, as required instructions. by codes, specifications, and Employer's owner instructions. Witness field pressure test, when notified. Remove temporary blanks, control valves, etc and break flanges as necessary to permit piping to be flushed clear of debris. Provide suitable temporary hose connections, spools, and gaskets. Flush or blow system and install orifice plates. Drain system, remove blinds and perform gross leak tests, as required. X X X X X X X X X X X X X X Owner Comm. Onshore Contractor Owner PreComm. Onshore Contractor Onshore Contracto r Owner Erection i j k l m n o p All welded joints (longitudinal, girth and nozzle) in underground piping that have not been shop tested shall be left exposed (free of paint, dope, and wrap) until the specified testing have been completed. After final testing of these joints, cover the system. Reinstall orifice plates, control valves, strainers, etc. after line flushing. Check pipe hangers, supports, guides, expansion joints and other pipe specialties for the removal of all shipping and erection stops and the correctness of cold settings. Check pipe hangers, supports, guides, and pipe specialties for hot settings and make minor adjustments, as necessary. Check pipe anchors and guides for proper operations. X X X X X Check that all strainers are installed with start-up mesh, where specified. Install permanent filter elements, as required. X X u Verify that specified valve packing has been provided in valves installed in the Facility. Install car seals on valves, where necessary and check and record the positions of all car-sealed valves; paint or identify valves, as required. Correct support, vibration and thermal expansion problems detected during commissioning. Perform bolt torquing/tensioning. Re-torque all hot and cold service bolting during commissioning and start-up, as required. Install corrosion probes. v Service test steam and electric tracing, before insulating. X w Charge refrigerant fluids. X x y Complete painting, identification and insulation. Maintain records as required, including ASME stamping of piping systems welded at the Site as required by code for Section I, Div. 1, where applicable. q r s t 4.8 a X X X X X X X X X b Electrical Power and Lighting Systems Perform all necessary pre-start-up checks on emergency generators in accordance with vendor instructions and Ready for Start-Up procedures. Commission and run in emergency generators. c Notify Employer Owner of test schedules. X X Owner Comm. Onshore Contractor Owner PreComm. Onshore Contractor Onshore Contracto r Owner Erection d e f g h i j k l m n o p q r s t 4.9 a Witness tests when notified and record test data, as required. Using a megohmeter, make insulation tests on all wiring except lighting wiring. Using a megohmeter, make insulation tests on motor and transformer windings from phase to phase and phase to ground. Dry-out electrical equipment if necessary to achieve required insulation resistance level. Make grounding system tests to determine the continuity of connections and the value of resistance to ground. Arrange for breakdown tests on oil samples from oil insulated transformers larger than 100 kilovolts absolute. Check condition of grease in grease lubricated motor and generator bearing as specified. Obtain local electrical inspector’s approval where required (see 26 .vi, “LOI and EPC terms”). Charge electrical gear with oil and/or other media, as required. Perform trials and adjustments on all switchgear, motor control equipment and generators. Test and set switchgear and circuit breaker relays for proper coordination. Set protective relays and time delays on all switchgear in accordance with tabulated data. Test relay characteristics at points on the relay calibration curves as indicated in the tabulated data. Energize all substations with approval of Employer Owner after completion of all tests. Check phase sequence, polarity, and motor rotation. Conduct performance tests, Check trip alarm, safeguard and synchronizing systems as per the Project specification in accordance with procedure approved by Employer, Owner, where applicable. Check installation of emergency power and lighting systems, including light intensity. Commission and Energize all power supply system as required. Instrument Systems Provide all quality control data, for all materials manufactured by vendors. X X X X X X X X X X X X X X X X X X X Owner Comm. Onshore Contractor Owner PreComm. Onshore Contractor Onshore Contracto r Owner Erection b c d e f g h i j k l m n o p q r Conduct any non-operating checks to ensure instrument operability, 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. As dictated by Employer's Owner’s practice, bench or field calibrate instruments with standard test equipment and make all required adjustments and control point settings. Clean all transmission and control tubing by blowing with dry clean air before connecting to instrument components. Clean all air-supply headers by blowing with clean air and check them for tightness. Leak test pneumatic control circuits. Check piping from instruments to process piping for tightness. Check the accessibility of all instruments and components for field adjustment, routine maintenance and removal for overhaul. Relocate if necessary. For each instrument loop verify conformance to specifications and design criteria for function and range using dummy transmission signals, as needed. Check all electrical signals and alarm wiring for continuity, correct source of power, and polarity. Check thermocouples for proper joining of wires, position of elements in wells, proper polarity, and continuity of receiving instruments. Check and record bores of orifice plates. Isolate or remove, if necessary, in line components such as control valves, positive displacement meters, and turbine meters for pressure testing. Isolate or remove components for flushing operations and reinstall them on the completion of these operations. Install any sealing fluids, as required. Perform instrument loop checks. Perform functional checks on process control system (PCS) including sequence, action and reset functions. Provide a schedule of recorder charts. 4.10 Boilers X X X X X X X X X X X X X X X X X X Owner Comm. Onshore Contractor Owner PreComm. Onshore Contractor Onshore Contracto r Owner Erection a k Provide QA/QC data as required by specifications, duly certified by third-party inspectors, where applicable. Include material certifications and regulatory reports as required. Provide records of all progressive NDT examinations made during fabrication (e.g. progressive dimensional checks and vacuum testing and welding examinations). Schedule and confirm the assistance of manufacturer’s service engineer during boiler Mechanical Completion, Pre-commissioning, and Commissioning . Make a non-operating boiler pressure test in accordance with applicable codes, specifications, and Employer's Owner’s instructions, if required. Inspect the boiler for completeness and correctness of installation, and make other non-operating pre-firing checks. Inspect internal surfaces of drums and boiler internals. Check operation of air preheaters, dampers, soot blowers, and other equipment for proper positioning and travel. Ensure relief valves are installed in correct positions and set for the conditions specified. Check boiler burner control and safety systems. De-couple drivers. Run-in fan drivers; check for rotation and smooth operation. Re-couple fans to drivers. Fit guards in place. l Start fans and drivers and check for vibrations. m n Blow fuel lines, check for cleanliness. Dry refractories during initial firing by following the manufacturer’s temperature cycles. Purge, flush, and drain steam mains, as necessary. Obtain treated water for boil-out and initial operation, as required. Commission auxiliaries as detailed elsewhere under the appropriate equipment type. Conduct boil-out, chemical cleaning, and flushing operation, as required. Dispose of waste and cleaning media in accordance with the requirements set forth in the Safety Program Manual. Conduct initial light-off, making the associates checks and adjustments. b c d e f g h i j o p q r s X X X X X X X X X X X X X X X X X X X X X Owner Comm. Onshore Contractor Owner PreComm. Onshore Contractor Onshore Contracto r Owner Erection t Conduct all operating tests and obtain the required certification. X u Recheck and set pressure-relief valves. X 4.11 Water Treatment Plants a. Inspect for completeness and correctness of installations and make any non-operating checks that may be required. b. Provide and install the initial charge of ion-exchange resins and inert bed material. c. Provide all water treatment chemicals (see 26 .xvi, “LOI and EPC terms”). d. Make the necessary operational tests and adjustments to water treatment systems. e. Obtain the services of a water consultant to advise and monitor the water treatment operation, as required. e. Purify potable water systems. 4.12 Water Systems (Service Wells, Cooling Towers, Fire Water Systems, and Sea Water Systems) a Inspect for completeness and correctness of installations and make any non-operating checks that may be required. b Clean the cooling tower basin and install screens in the suction pit before water circulation. c Check fans for vibration and operation of vibration monitoring system. d Flush, drain, and clean the cooling tower basins. e f g h i j k Clean intake screens. Adjust cooling tower fans to obtain specified tip clearance and test. Operate fire pumps to check performance of systems. Head up reservoirs vessels tanks, and other water system equipment, as required, fill with water, check for leaks, and flush to clean. Provide insurance company inspection of the fire systems, as required. Obtain and install all required fire fighting chemicals and portable equipment, such as hoses, fire extinguishers, and related equipment. Carry out specific tests as required by local Authorities. Owner Comm. Onshore Contractor Owner PreComm. Onshore Contractor Onshore Contracto r Owner Erection X X X X X X X X X X X X X X X X X 4.13 Waste Disposal a Inspect facilities for completeness and correctness of installation and make any non-operating checks to ensure their conformance to specifications. b Obtain the services of a waste treatment consultant to advise and monitor the system operation, as required. 4.14 Buildings and Accessories a Check installation of buildings and accessories. including all heating, ventilating and air conditioning equipment, to ensure their completeness and conformance to specifications. b As required, obtain certification that all plumbing, electrical, fire protection, elevator, and special materials handling installations comply with local government regulations. c Operate heating, ventilating and air conditioning units and make all performance tests. d Check fire fighting equipment has been installed and is ready for use. e Obtain certificate for occupancy and use, if required. f Owner Onshore Contractor Owner Comm. X X X X X X X Maintain Building & Facilities until Ready for Start-Up. 4.15 Miscellaneous Equipment (Agitators, Mixers, Rotary Filters, Weigh Scales, and Materials Handling Equipment) a Provide all quality control documentation data, duly certified by third-party inspectors, where applicable. b Fully assemble rotary filters except for final filter media (cloth, precoat, or screen). c Install all final filter media. d Level and calibrate weigh scales with the assistance of the manufacturer's representative and set tare weights wherever possible. e Manually check materials handling equipment for freedom and direction of movement. f Check clearances on materials handling equipment. g Obtain a service engineer for technical assistance during installation or start-up, if required. h As required, obtain certification that all lifting and materials handling installations and other items of equipment comply with government regulations. PreComm. Onshore Contractor Onshore Contracto r Owner Erection X X X X X X X X X X X X