Professional Documents
Culture Documents
COMMISSIONING
CAPTIVE POWER PLANT Sub Section A-3.14
BCPL PROJECT Page 1 of 45
1.0 SCOPE
To cater for the steam and power requirement of BCPL project, a combined cycle co-
generation power plant along with associated facilities and hook up with grid is proposed.
Details of the facilities coming under Captive Power Plant are described else where in the
bid document. The power plant shall comprise of following major equipment, hereinafter
called units for the purpose of mechanical completion, precommissioning and
commissioning activities:
GTG
STGs
UBs
HRSG
Auxiliary Equipments
- Bio datas of key personnel comprising the commissioning team. In case the member
of the commissioning team as mentioned in the offer is not available at the actual time
of commissioning then the EPCC CONTRACTOR shall ensure a replacement with
equivalent qualification and experience. The format of bio data is enclosed as
Annexure-I.
- Clause wise list of deviations, if any, in the format given in Annexure-II. In absence of
this it shall be taken that bidder has no deviation.
2.0 DEFINITIONS
Mechanical Completion of systems shall mean that all installation works of the system
including welding and radiography have been completed and hydro tested in accordance
with approved construction drawings, approved specification, applicable code as defined in
the bid package, accepted international good engineering practices and all the activities
have been completed in a comprehensive manner by the EPCC CONTRACTOR except
for minor mutually agreed leftover works of insulation and painting which may be
completed during pre-commissioning phase. EPCC CONTRACTOR shall ensure that
installation of in-line instruments like control valves, vortex meters, mass flow meters etc
shall be done after completion of line flushing and hydro testing activities. Suitable pipe
spool pieces of matching dimension shall be provided during initial phase of construction.
EPCC CONTRACTOR shall hydrostatically or pneumatically test all piping as required by
the drawings or specifications during mechanical construction stage. EPCC
CONTRACTOR shall notify OWNER of the hydro test schedule at least two days in
advance system by system. EPCC CONTRACTOR's competent representative shall
check the system / sub-system so that plant / unit/ system / sub-system meets the process
requirement and is constructed as per the approved drawings. Refer Annexure-VI for a
typical check list for mechanical completion. After liquidating the checklist generated by
EPCC CONTRACTOR as well as check list of OWNER (if any), EPCC CONTRACTOR
shall submit certificate as per FORMAT-I (attached in Annexure-III) stating unit / system /
sub-system, which is mechanically completed. Checklist generated by EPCC
CONTRACTOR and test certificates connected with the unit/ system / sub-system will form
a part of the FORMAT-I. All statutory approvals including IBR shall be obtained by EPCC
CONTRACTOR as part of mechanical completion milestone. Certificates of various
statutory bodies for relevant portion of the work completed shall be made available by the
EPCC CONTRACTOR as part of mechanical completion. OWNER / PMC shall check the
system along with EPCC CONTRACTORs representative and shall issue FORMAT-II (as
per format given in Annexure-III) which includes deficiencies / modifications required for
the portion of the work that is declared by the EPCC CONTRACTOR as mechanically
complete. However, certain pre-commissioning activities are also identified for achieving
mechanical completion. Indicative list of activities that need to be completed by the EPCC
CONTRACTOR to achieve unit / system / subsystem mechanical completion is presented
in Annexure-VI.
equipment for proper earthing, continuity, insulation resistance, conducting operability test
on individual equipment / system, charging of lubes & other chemicals. Fabrication and
supply of temporary facilities, for example, temporary bypasses, spools, blinds, jump
overs, vents, strainers, screens, centrifuges, external burners, alignment kits etc. which will
be required to carry out pre-commissioning activities shall be the in the scope of EPCC
CONTRACTOR. EPCC CONTRACTOR shall carry out all the pre-commissioning
activities. Before start-up of the pre-commissioning activities, safety audit shall be
conducted by EPCC CONTRACTOR and OWNER / PMC. Third party checklist points
such as those from OISD audit may also be furnished. All such checklist / deficiency
reports generated by safety audit team shall be corrected / rectified by EPCC
CONTRACTOR.
EPCC CONTRACTOR shall submit the list of systems and prepare list of pre-
commissioning activities to be performed for all applicable disciplines against each system
including flushing schemes for the piping sub-systems. The above details will be prepared
and submitted to OWNER at least 90 days before start of the pre-commissioning activities.
Indicative list of activities that need to be completed by EPCC CONTRACTOR as part of
pre-commissioning is presented at Annexure-IV
The units shall be considered `Ready for Commissioning' when all the facilities have been
completed along with their auxiliaries and support facilities in every respect including
charging of lubes, chemicals, preparation of solution, any last minute modifications, if any,
as recommended by the OWNER / PMC. All temporary structures, scaffolding etc. used for
carrying out the pre-commissioning works shall be removed, all the blinds shall be put into
position as required by P&IDs and all pertinent units / systems shall be purged and
pressurised. All pre-commissioning and other documents including blinds list, set
pressures of PSVs and TSVs and their test certificates etc. shall be handed over to the
OWNER / PMC.
EPCC CONTRACTOR shall issue a certificate of ready for commissioning of process unit
for acceptance by the OWNER / PMC in standard format, FORMAT-IV (as per format
given in Annexure-III) with all exceptions resolved.
After the unit has been declared as `Ready for Commissioning', EPCC CONTRACTOR
shall not carry out any hot work in the plant without prior written permission of the
OWNER.
EPCC CONTRACTOR shall prepare plant specific draft-operating manual of the units. This
should include procedure related with Package Items if any and submit to OWNER / PMC
for review at least 120 days prior to mechanical completion. EPCC CONTRACTOR shall
submit editable soft copies of each draft operating manuals for review. In particular the
following information shall be covered as applicable.
- Start-up procedure.
- Normal operating procedure.
- Shutdown procedure (normal & emergency).
- Plant trouble shooting procedure.
- Vendor instructions for all equipment for start-up, shutdown, normal operation and
troubleshooting.
- Operating parameters and set points of alarms and trips.
- Operating conditions of different cases of operation.
- Effect of operating variables on the process.
- Functional description of all complex control schemes
- Details of interlock logic, trip etc.
- Functional description of safe shut down systems.
- List of emergencies and emergency handling procedures.
- Dosage rate of chemicals used and other related operating information.
- Initial requirement of chemicals for first start-up.
- Safe handling precautions for chemicals used.
- List of equipment and their major details.
- List of all instruments like control valve, safety valve etc.
- Relief valve schedule, tag numbers, location, set pressure, capacity basis, failure
scenarios considered etc.
- Motorised valve schedule (tag number, location, MOC etc.)
- List of blinds for shut down and start-up.
- Approved / final PFDs / P&IDs, drawings and equipment datasheets etc.
- Any other special conditions / instructions / information, etc.
- Summary of chemical consumption.
- Summary of utility consumption.
- Lubrication schedule (with equivalent lubricant available in India).
- Hydrocarbon detection and associated safety system.
- Use of life saving devices
- Fire and safety system
- Laboratory analysis requirement and procedure with sampling schedule.
- Procedure for preparation of equipment hand over
- Work permit procedure
- Chemical solution preparation procedure
- Safe handling of chemicals
- MSDS of chemicals
-
Review of operating manuals shall be done by OWNER / PMC within 30 days after receipt
of draft operating manuals. All the changes, additions, deletion required by OWNER / PMC
shall be discussed with EPCC CONTRACTOR and shall be incorporated in the final
operating manuals by EPCC CONTRACTOR. EPCC CONTRACTOR shall submit twenty
copies of final operating manual. The same shall also be forwarded in floppy discs / CD.
These manuals shall be furnished to OWNER at least 90 days prior to mechanical
completion. These operating manuals shall be followed during start-up and commissioning
of the process units. Operating manuals provided by equipment suppliers shall not form a
part of these operating manuals.
In case of any revisions due to any reason, the same shall be incorporated and submitted
as revised sheets during the start-up and commissioning stage along with updated copy of
editable compact disc. However, revised operating manual incorporating changes shall be
submitted as final operating manual within one month after the commissioning has been
completed.
For the purpose of execution of these pre-commissioning activities, the process units shall
be divided into system and sub-systems so that pre-commissioning activities of each
system/sub-system can be progressively carried out along with the construction activities.
The pre-commissioning document shall be submitted by EPCC CONTRACTOR at least
120 days prior to mechanical completion which will contain the following as a minimum:
EPCC CONTRACTOR shall arrange manpower, instruments and tools required for
carrying out pre-commissioning activities. At the end of pre-commissioning activities of the
unit / facility, EPCC CONTRACTOR will submit request to the OWNER for permission to
start up the unit.
Commissioning of the facilities will not be permitted till EPCC CONTRACTOR has
submitted all the documents to OWNER. Any delay in commissioning on this account shall
be considered as a delay in commissioning by the EPCC CONTRACTOR.
EPCC CONTRACTOR shall prepare and submit draft maintenance manual to OWNER /
PMC for their review at least three months prior to the mechanical completion. Final
maintenance manual incorporating all comments shall be submitted by EPCC
CONTRACTOR within one month after issue of comments.
Lubrication schedule
- Plant item
- Plant number
- Location
- Points of lubrication
- Methods of application
- Recommended applications types and grades.
- Frequency of application
- Frequency of sampling and oil change.
Valves types / specifications / materials for different service.
Inspection
- Recommended inspection frequencies and items requiring inspection.
- Inspection details and activities.
- Work planning and execution techniques.
- Inspection recording systems.
EPCC CONTRACTOR shall ensure that all safety devices like pressure safety valves
(PSV), emergency shut down valves are tested, witnessed and certified in the presence of
representatives of OWNER / PMC / other statutory agency like IBR (wherever required).
These certificates are to be handed over to OWNER / PMC prior to start-up of the plant
along with Ready for Commissioning certificate. EPCC CONTRACTOR shall submit the
master blind list and record of set pressures of all PSVs provided in the unit. EPCC
CONTRACTOR shall install `No Smoking' boards & boards for other instructions at
designated areas. EPCC CONTRACTOR is required to maintain and follow all safety
practices, equivalent or better than those being practised by OWNER for the complex
during pre-commissioning and commissioning.
i) All critical pumps i.e. hydrocarbon pumps, vacuum pumps, chemical injection pumps,
utility pumps etc.
ii) All blowers, centrifuges, vacuum filters, agitators, fans, air coolers etc.
iii) All package type items, such as chemical injection facilities, crystallizers, dryers etc.
iv) Stand alone / proprietary system packages, Analyzers, Machine monitoring system,
ESD system, Variable speed drives, mass flow meters, radar / ultrasonic / RF type
level transmitters etc.
v) Specialist for supervision of cooling water system passivation
vi) Gas (hydrocarbon and H2) detection system, fire detection systems and safety
equipment.
vii) Gas Turbine, Steam Turbine, Utility Boiler, HRSG
viii) Special software package suppliers
ix) Any other critical / proprietary equipment, for which it is felt necessary to call Vendor's
representative for proper commissioning.
6.1 Review of pre-commissioning documents and network (as detailed in section 3.2 and 3.3
above).
6.2 Review of operating manual (as detailed in section 3.1 above).
6.3 Check listing (system-wise)
a) Preliminary checklist on system completion.
b) Final checklist before start of pre-commissioning activities.
Activities Witness/Inspection
a) Installation of safety device Complete
b) Provision of temporary strainers and blind at critical locations Complete
c) Water flushing and air / steam blowing of pipelines Complete
d) Cleaning and internal flushing of vessels, Tightness / Leak Test Complete
e) Heater refractory dry out Complete
f) Instrumentation interlock checks Complete
g) Flushing of instrument air piping / tubing Complete
h) Leak testing of instrument air connections using liquid leak Complete
detectors
i) Installation of transmitters, control valves, shut down valves etc Complete
j) Installation of in line instruments Complete
k) Mechanical run test of all rotating equipment Complete
l) Operability test for a system/equipment Complete
m) Blind list as per start up requirement/normal operation Complete
n) Chemical cleaning of boiler tubes, feed water lines, economiser Complete
& lube oil circuit
Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved
PROJECT EXECUTION & ASSURANCE PLAN Part A, SECTION: A-3
COMMISSIONING
CAPTIVE POWER PLANT Sub Section A-3.14
BCPL PROJECT Page 10 of 45
Witness / inspection / approval of OWNER / PMC is not an obligation but a right with no
change in EPCC CONTRACTOR's liabilities.
At the discretion of OWNER / PMC, the extent of witness / inspection may be extended /
reduced as deemed fit.
OWNER / PMC / EPCC CONTRACTOR shall carry out a final inspection of the unit before
starting the commissioning activity..
Record of liquidation of checklist point, test record etc shall be submitted by EPCC
CONTRACTOR to OWNER / PMC. Any deficiency / changes required in the offered
system shall be liquidated by the EPCC CONTRACTOR.
9.0 COMMISSIONING
It shall be the responsibility of the EPCC CONTRACTOR to commission the plants under
the scope of the EPCC CONTRACTOR. Commissioning of the units will be carried out
under necessary guidance and overseeing of representatives of OWNER / PMC after
mechanical completion is over successfully, all pre-commissioning activities are carried out
and certificate of Ready for commissioning is accepted by OWNER. EPCC
CONTRACTORs representatives responsible for developing P&IDs, PFDs, Heat & Mass
Balance Diagrams shall provide necessary co-ordination during start up and they will
furnish technical clarification.
Commissioning of the units shall mean taking the feed and utilities, passing these through
the normal route; establishing the process control parameters first at turn down & then at
design value stipulated in the process package along with supplementary instructions, if
any, from OWNER.
A unit shall be considered to be commissioned successfully when the complete unit, with
instrumentation / control systems, process, utilities and support systems have been on
uninterrupted stable operation for not less that 72 hours. Any interruption of duration upto
30 minutes during the commissioning run of 72 hours shall be ignored. However, for
interruptions greater than 30 minutes, the commissioning run period shall be extended by
the time equal to interruption time plus the time taken to stabilise the unit back to the
normal operating conditions. Whether the 72 hours operation has been successful or not,
shall be decided by the OWNER based on observations recorded during 72 hours. The
countdown for 72 hours operation shall start only after unit has been on stable operation
with all controls and safety system in normal operation for a period of not less than 48
hours. OWNER will issue acceptance certificate (Format-V) accordingly.
Bidder in his offer shall submit the organisation chart of commissioning team and the bio-
data of key persons who shall be present at the time of commissioning. Bidder shall also
specify the planned duration of stay of these personnel.
Upon successful commissioning of various units of CPP, the same shall be taken over by
the OWNER for day to day operation and maintenance only. Final takeover shall be
subject to compliance to all the contractual obligations by the EPCC CONTRACTOR.
Once the plant is successfully commissioned, EPCC CONTRACTOR will issue FORMAT-
V (as per format given in Annexure-III) to OWNER for take over of the unit from EPCC
CONTRACTOR.
10.1 After the units have been completed, put into operation and steady state operation is
established, performance test of units shall be conducted. Before carrying out of the
performance test of units, EPCC CONTRACTOR shall develop a procedure / protocol and
schedule in consultation with the OWNER and submit to OWNER for their approval. Among
other things the procedure shall broadly include the following.
- Test conditions
- Log sheet for recording operating data
- Sampling methods
- Analytical methods
- Methods of calculations
- Pre-test run period, if any
- Methodology for interpretation and measurement of tests
- Methodology for taking operating data and its frequency
10.2 EPCC CONTRACTOR shall provide the services of his commissioning engineer who was
associated with the commissioning of the process units at site during this performance test
run period.
EPCC CONTRACTOR shall be held responsible for any defects noted during performance
test run and attributable to him and shall be dealt as per the relevant provision of the
contract.
10.3 The performance test shall be carried out by operating the units continuously for a
minimum period as specified in performance guarantee test procedure stipulated in sec A-
2-2 of bid document. The results obtained during that period will form the basis of
comparison between the actual performance and guarantees offered by EPCC
CONTRACTOR in bid.
10.4 Measuring methods, tolerances, instructions for analysis and calculations shall be as per
accepted practices and shall be mutually agreed upon before the start of performance test.
10.5 If a performance test of units has been carried out successfully for a period as specified
and plant guarantees as per EPCC CONTRACTORs bid are met, then the performance
test shall be deemed to have been successfully completed.
10.6 After completion of a performance test, all relevant operating and production figures shall
be recorded in a protocol to be signed by authorised representatives from EPCC
CONTRACTOR and OWNER / PMC.
10.7 EPCC CONTRACTOR shall prepare test report and submit to OWNER/PMC within 15
(fifteen) days after the completion of each performance test. A guarantee shall be deemed
to have been met if OWNER/PMC indicates that the performance test was successful and if
OWNER / PMC within 20 (twenty) days after notification of the results of such performance
test, do not specify in writing to EPCC CONTRACTOR in what respect, in OWNERs /
PMC's opinion, such guarantee has not been met.
a. Functional Tests.
b. Operability Test
c. Commissioning Test
d. Reliability Test.
e. Capability Test
f. Performance Guarantee Tests
The Functional Tests shall demonstrate that the safety and controls of the plant operate
satisfactorily. The Functional Tests shall be part of EPCC CONTRACTORs commissioning
program. These tests shall be performed prior to offering the plant for Reliability Test and
Performance Guarantee Tests. The Plant shall be ready in all respects prior to
commencement of the Functional Tests. The individual Functional Tests to be
demonstrated by the EPCC CONTRACTOR and witnessed by the OWNER / PMC for each
plant / system under this package shall be mutually agreed upon during detail engineering
phase.
Functional Tests shall broadly cover, but not be limited to, the demonstration of satisfactory
functioning of the following:
11.1.1 General Functional Tests (applicable for all plants/systems under this package)
a. STG Governor controls in islanded and synchronized operation of the CPP, with
changes in plant electrical and process steam load.
b. Sustenance of the CPP at the maximum sustainable electrical load throw-off.
c. Gas Turbine fuel switching from 100% start up fuel to 100% normal and alternate
fuels, as well as prolonged operation of the GTG on dual fuel at various
combinations.
d. Full load throw-off of each GTG without over-speeding.
e. Full load throw-off of each STG without over-speeding..
f. Black Starting of GTG
This test shall require the EPCC CONTRACTOR to run Sub-System & Individual
equipment to be tested for 72 hours each for satisfactory outage free operation. However,
this will not include GTG, HRSG, UBs & STGs.
This test shall require GTG, HRSG, STGs & UBs will run continuously for 72 hours for each
type of fuel. During this period, cumulative outage of 4 hours with each outage not
exceeding hours will only be allowed.
Reliability Test shall require the EPCC CONTRACTOR to operate the Cogeneration Plant
for 14 days continuously to demonstrate the reliability of the Plant. During this period,
cumulative outage of 35 hours with continuous outage not exceeding six (6) hours will only
be allowed. The detailed procedure for conducting the Reliability Test of the Facility (plant/
systems) under the Package shall be submitted by the EPCC CONTRACTOR for the
approval of the OWNER / PMC during the detail engineering phase, prior to the conduction
of the test. The general guidelines for the detailed test procedure are as below:
Prior to the Reliability Test being conducted, EPCC CONTRACTOR may perform process
adjustments and cleaning procedures of the equipments, such as opening of the equipment
for cleaning and polishing, adjust clearances, replace filters or other defective components
etc.
EPCC CONTRACTOR shall formally notify OWNER in writing that the facility provided by
him is ready for the 14 days Reliability Test.
During the 14 days Reliability Test all facility (plants/ systems) under the package shall
operate meeting the following condition:
The entire Facility under the package shall be operated throughout the duration
at a load not lower than Normal Operating conditions.
The Facility may operate at any load as required over and above the Normal
operating conditions.
During this period, cumulative outage of 35 hours with continuous outage not
exceeding six (6) hours will only be allowed.
In case of Steam Generators (HRSG and UBs) Rated capacity shall be
generated keeping one burner stand by i.e. with one burner less rated capacity
shall be generated.
In the event that one or more of the above operating conditions are not met for reasons
attributable to the EPCC CONTRACTOR, the Reliability Test shall be repeated.
If during the Reliability Test the Facility is out of service or operated at partial load for
reasons not attributable to the EPCC CONTRACTOR for a certain period, the Test shall be
extended for the same period after the reasons for interruption is passed in order to
complete the 14 days Reliability Test.
On successful reliability test, OWNER will operate the plant under supervision of EPCC
CONTRACTORs supervisor until successful completion of Performance Guarantee test.
After all the units have been commissioned, put into operation, steady state operation is
established and all foregoing tests (listed in 11.1 to 11.5) have been successfully
conducted, performance guarantee test of each unit and captive power plant as a whole on
normal (guarantee) fuel shall be conducted. The performance test is to be carried out as
soon as practicable after the commissioning not later than 12 months.
Performance Guarantee tests shall be conducted in the presence of the OWNER / PMC to
demonstrate compliance with the performance guarantees as set herein and as quoted by
the EPCC CONTRACTOR in its Bid offer.
All PG test results shall be corrected to rated Guarantee Point Design Conditions, for which
performance correction curves / data shall have to be submitted by EPCC CONTRACTOR
for approval of the OWNER / PMC prior to the conduction of the test. EPCC
CONTRACTOR shall submit correction curves for variation in any other special conditions
applying to a particular guarantee for OWNERs approval during detail engineering phase,
prior to the conduction of the test. No corrections for ageing shall be allowed for the
Performance Tests that are to be conducted by the EPCC CONTRACTOR. However EPCC
CONTRACTOR shall furnish the relevant ageing curves for the use of OWNER for future
performance tests that may be conducted during the course of Plant operating life.
EPCC CONTRACTOR shall submit the Detailed Performance Guarantee Test Procedure
for all the Performance Tests for the approval of the OWNER / PMC during detail
engineering phase, prior to actual conduction of the tests.
EPCC CONTRACTOR at his cost shall arrange all special / test instruments required as
per codes for the demonstration of the guaranteed parameters.
EPCC CONTRACTOR shall be held responsible for any defects attributed to him and shall
be dealt as per relevant provision of contract. The cost of fuel shall be borne by EPCC
CONTRACTOR in case of unsuccessful test. The entire unsuccessful test shall be
repeated after EPCC CONTRACTOR carries out necessary modification / repair
a. Tests wherein the Plant / Equipment shall be accepted with penalty / reduction in
price for shortfall in performance parameter from that guaranteed by the EPCC
CONTRACTOR to a certain specified extent, over which it shall be liable for
rejection. For details, refer Sec A-2.2 Special Conditions of Contract.
a. Fuel Consumption (in Million kcal/hr) for CPP package in Peak operating conditions.
b. Fuel Consumption (in Million kcal/hr) for CPP package in normal operating
conditions
c. Cogeneration Cycle Efficiency of the CPP running at Peak operating conditions.
d. Cogeneration Cycle Efficiency of the CPP running at normal operating conditions.
For the above test, normal fuels shall be used for the Gas Turbine, HRSG and UBs in CPP.
For normal and peak condition steam & power requirements, refer Power Plant Design
Basis elsewhere in the bid document. Peak conditions referred in this document are same
as max. requirement in the design basis document.
The above parameters shall be derived with BFW heating and Condensate Preheating load
on the HRSG.
i. NOx emission at HRSG outlet for the above mentioned MCR operation of HRSG
and GT running at Base Load with NOx control.
j. Steam Temperature control of HRSG over the bidder specified load range.
k. Maximum Electrical Output of STG with Normal extraction loads, considering no
flow through the PRDS stations between various pressure level steam headers.
l. Utility Boiler Efficiency based on LHV for each UB at MCR, utilising only IFO as fuel.
m. MCR of VHP Steam production in each UB firing normal fuel.
n. Steam Temperature control of each UB over the bidder specified load range
o. Flue gas exit temperature at UB stack with CPP in normal operating conditions and
UBs running on IFO.
p. Flue gas exit temperature at UB stack with CPP in peak operating conditions and
UBs running on IFO.
q. Sustenance of CPP at Maximum Sustainable Electrical Load throw-off.
EPCC CONTRACTOR shall be responsible for the supply of all spares and consumables
for start-up, pre-commissioning and commissioning. Excess spares shall be handed over
by EPCC CONTRACTOR to the OWNER after commissioning. EPCC CONTRACTOR shall
be also responsible for supply of lubes, chemicals and other consumables in addition to
commissioning and start-up requirement for six months normal operation after
commissioning.
OWNER shall provide to the EPCC CONTRACTOR utilities like air, nitrogen, power, water,
steam to the extent of normal consumption for operation of unit during pre-commissioning /
commissioning at the battery limit of CPP. However, EPCC CONTRACTOR shall specify
such requirement along with schedule dates with the bid. It shall be EPCC
CONTRACTOR's responsibility to repair any damage to the system occurred during
storage, installation, pre-commissioning and commissioning stage. EPCC CONTRACTOR
shall submit catalogues for all the lubricants and chemicals being charged for
commissioning.
All the utilities like air, cooling water, raw water, steam, power, instrument air etc. shall be
provided at the conditions and locations given in the package and drawings. Any upgrade,
if required, either for pre-commissioning or commissioning shall be carried out by the EPCC
CONTRACTOR at his own cost. Hook-ups required between various EPCC
CONTRACTORs will be provided by the EPCC CONTRACTOR wherever it is shown in his
scope.
14.0 SAFETY
EPCC CONTRACTOR shall follow OWNER's safety practices during execution of pre-
commissioning / commissioning works. EPCC CONTRACTOR is required to maintain and
follow all safety practices equivalent or better than those being practised by OWNER for the
complex during pre-commissioning and commissioning. Necessary hot / cold work permit
shall be obtained to carryout jobs once declared mechanically complete.
The scope covers assistance in operation, maintenance and running of the plant for a
period of 4 weeks reckoned from the date of successful commissioning for stabilising the
plant, performance guarantee runs, handing over the plant to Owner. EPCC
CONTRACTOR shall depute sufficient supervisory personnel having requisite qualification
and as per Man Power Chart AGREED BY OWNER / PMC.
EPCC CONTRACTOR shall identify and submit manning requirement (category) and the
plant operation organisation structure to OWNER / PMC for effective operation and
maintenance of the unit. The proposed manning requirement and organisation structure to
take into account the Indian condition.
ANNEXURE - I
2. NAME:
3. QUALIFICATION:
ANNEXURE-II
QUESTIONAIRE
1.0 SCOPE
2.0 DEFINITIONS
5.0 MANUFACTURER
REPRESENTATIVE
9.0 COMMISSIONING
13.0 SAFETY
ANNEXURE-III
(TOTAL 5 FORMATS)
FORMAT-I
PROJECT:__________________ CUSTOMER:__________
UNIT:________________
SYSTEM NO.
SYSTEM DESCRIPTION:
EXCEPTIONS:
_____________________________ ________________
SIGNATURE DATE
EPCC CONTRACTORS CONSTRUCTION:
CO-ORDINATOR
_______________________________________________________________
_____________________________ ________________
SIGNATURE DATE
OWNER/PMC:
F O R M A T - II
CHECKLIST
PROJECT:______________CUSTOMER:_____________UINT:___________
SYSTEM/SUB-SYSTEM___________________________________________
SIGNATURE DATE
F O R M A T - III
PROJECT:_______________CUSTOMER:______________
UNIT:______________
SYSTEM/SUB-SYSTEM__________________________________________
SIGNATURE DATE
F O R M A T - IV
PROJECT:________________CUSTOMER:_________________
UNIT:___________
SYSTEM/SUB-SYSTEM___________________________________________
This is to certify that all the necessary pre-commissioning activities for the
system/sub-system as detailed below have been completed and the
system/sub-system is ready for commissioning except for the minor details as
given below which will not affect the commissioning trial runs.
DESCRIPTION OF SYSTEM/SUB-SYSTEM___________________________
_____________________________ ________________
SIGNATURE DATE
EPCC CONTRACTORS COMMISSIONING
CO-ORDINATOR
_______________________________________________________________
SIGNATURE DATE
FORMAT-V
PROJECT:___________CUSTOMER:_____________
UNIT:__________________
SYSTEM/SUB-SYSTEM____________________________________________
DESCRIPTION OF SYSTEM/SUB-SYSTEM___________________________
SIGNATURE DATE
_______________________________________________________________
PMCS COMMISSIONING
CO-ORDINATOR: ______________ ___________
OWNER'S COMMISSIONING
CO-ORDINATOR: ______________ ___________
ANNEXURE-IV
PRE-COMMISSIONING ACTIVITIES
The checklist represents the absolute minimum work, which has to be performed
by the EPCC CONTRACTOR prior to commissioning of the facilities. It is NOT
intended to be a complete list of activities required to be carried out by the EPCC
CONTRACTOR.
The general work procedures listed below outline the work to be performed
by the EPCC CONTRACTOR. Procedures applicable to specific system or
items of equipment are covered separately.
Prepare all systems for safe tie-ins with utilities and auxiliary system.
EPCC CONTRACTOR shall prepare the existing operating systems
for tie-Ins in consultation with OWNER and will be responsible for
safety during tie-ins is being made. EPCC CONTRACTOR shall take
Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved
PROJECT EXECUTION & ASSURANCE PLAN Part A, SECTION: A-3
COMMISSIONING
CAPTIVE POWER PLANT Sub Section A-3.14
BCPL PROJECT Page 27 of 45
Make non-operating leak tests and pressure tests on piping and all
equipment, including field fabricated equipment.
Conduct all tests in accordance with applicable statutory/safety/ other
applicable design codes and specifications. Leak tests upto 5
kg/cm2.g pressure to be carried out after purging /flushing. Further
leak test at higher pressure shall be carried out in steps of 5/10
kg/cmg of gas.
Detailed procedure for leak and pressure tests on piping and field
fabricated equipment shall be submitted by EPCC CONTRACTOR to
the OWNER / PMC for approval. Disposal of test media should be
done as per the OWNER instructions.
The system which operates under vacuum will be pressurised upto
1.5 kg/cm2.g for leak testing. Once leak testing is over Vacuum test is
to be carried out. Pull maximum possible vacuum with the ejector or
vacuum pump. Isolate the system and observe the rate of drop in
pressure. Generally for most of the systems pressure drop of 50
Torr/hr is acceptable. Systems which are required to be vacuum
tested and the detailed vacuum test procedure shall be submitted by
EPCC CONTRACTOR to the OWNER / PMC for approval.
Notify the OWNER of test schedule at least two days in advance. All
the tests are to be witnessed and the test record on satisfactory
completion of the test to be signed by OWNER / OWNER's
Representative.
Provide 4 copies of all the test records to the OWNER.
Provide any special media for test purpose and provide facilities for
disposal.
Conduct all operational tightness testing.
If testing is required by nitrogen for any system more than the N2
supply header pressure, EPCC CONTRACTOR shall make suitable
arrangement for the same.
Pneumatic testing of instrument air piping / tubing.
Pneumatic testing DP testing of instrument air lines.
Hydrostatic testing of all impulse piping and tubing.
Testing of instrument tube fittings / connections using halogen free
liquid leak detection solution.
Hot bolting to be done wherever required.
Install necessary purge connections including installation of
temporary purge piping or hoses to equipment connection and carry
out system purging Purge all the systems as required with inert gas
or steam out to remove oxygen from the system. Detailed procedure
to be developed by EPCC CONTRACTOR for each system / sub
system.
Remove all rust preventives and oils used to protect the equipment
during the construction period whenever these protective materials
will be detrimental to operation
A-16 Miscellaneous
Carry out any other check / test as required by OWNER / PMC and
provide all test certificates as required by the OWNER / PMC.
B. SPECIFIC PROCEDURES
Vessel / Tanks after erection and put in place have internals requiring
field installations. These internals shall be inspected before and after
installation.
Open both internal and external manways for inspection of vessel for
OWNER / PMC inspection.
Test tanks and internals as required. Dispose of test water as per
OWNERs instructions.
Conduct chemical cleaning / flushing operation, as required. Dispose
of wastes and cleaning media as per OWNERs instructions.
Head up after proper execution of closure permits.
NOTE :
Vessels that have been pressure tested in the shop may require retesting if
felt necessary by the OWNER. They shall, however, be included in the
testing of attendant piping systems whenever practical and approved by
the OWNER / PMC.
NOTE :
Shell and tube exchangers that have been pressure tested in the shop may
required retest if felt necessary by OWNER. They shall, however, be
included in the testing of attendant piping systems whenever practical and
approved by the OWNER / PMC. If a shell and tube exchanger is taken in
piping system test and the exchanger is designed for differential pressure,
proper care shall be taken to ensure that differential pressure between
shell and tube side is not exceeding beyond the maximum recommended
differential pressure during the testing.
Level base plates and sole plates. Alleviate any excess piping
stresses that may be imposed on pumps and drivers. Chemically
clean complete lube and seal oil system when specified. Dispose of
waste and cleaning media as per OWNER instructions.
Charge the lube oil, seal oil and cooling systems with flushing oil and
circulate for cleaning purposes. Dispose of any flushing oil in
accordance with the OWNER's approved procedure.
Format No. EIL-1641-1924 Rev.1 Copyright EIL All rights reserved
PROJECT EXECUTION & ASSURANCE PLAN Part A, SECTION: A-3
COMMISSIONING
CAPTIVE POWER PLANT Sub Section A-3.14
BCPLPROJECT Page 31 of 45
Charge the lube oil, seal oil and oil cooling system with operating oil
recommended by the manufacturer.
Obtain service engineer for technical assistance during installation
and / or pre-commissioning and commissioning as specified.
ANNEXURE-V
Overall Commissioning
Incharge
ANNEXURE-VI
SECTION-1
The Dark box in the First Column pertains to the activities to be performed by the EPCC
CONTRACTOR to achieve mechanical Completion as per Contract. The activities
indicated in the Second Column are also to be performed by the EPCC CONTRACTOR.
However the same shall not be reckoned for Mechanical Completion with regard to
Contracts. For activities where dark box is placed in both first and second column, the
activity needs to be completed by EPCC CONTRACTOR to the extent possible for
mechanical completion i.e. the reason for non completion should not be attributable to the
EPCC CONTRACTOR. Items not applicable for CPP package are to be ignored.
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
1.1 Manufacturer OR Vendor Service Assistance
1.2 Permits
1.3 Instructions
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
1. Maintain an adequate vendor instruction file so that
information may be readily retrieved through plant
commissioning.
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
2. Perform cold alignment to the manufacturers tolerances
and record data.
3. Perform any doweling required.
4. Perform Hot alignment
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
5. Perform and report routine shop inspection.
3. Test and adjust all devices to and from the specified facility
1.15 Purging/Inerting
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
1. Install purge/inerting connections.
1.17 House-Keeping
SECTION-2
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
2.1 Vessels
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
3. Blow fuel lines, check them for cleanliness and connect
burner piping.
4. Check operation of registers and dampers and verify
position of indicators.
1. Level base plates and sole plates and grout all bearing
surfaces.
4. Charge the lube oil, seal oil and oil cooling systems with
flushing oil and circulate for cleaning purpose. Dispose of
any flushing oil in accordance with Owners instructions.
5. Charge the lube oil, seal oil and oil cooling systems with
the operating oil recommended by the manufacturer.
2.6 Tanks
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
3. Conduct chemical cleaning or flushing operations as
required. Dispose of wastes and cleaning media in
accordance with the Owners instructions.
13. Check and record the positions of all car sealed valves
paint of identify valves as required.
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
15. Re-torque all hot and cold service bolting during
commissioning and startup as required.
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
3. Clean all transmission and control tuning by blowing with
cooled and filtered clean air before connecting to
instrument components.
10. Check and record bores or orifice plates and install after
completion of flushing operations.
2.10 Boilers/Heaters
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
2. Inspect the boiler for completeness and correctness of
installation and make other non-operating preferring
checks.
Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
8. As required obtain certification that all lifting and materials
handling installations and other items of equipment comply
with government regulations.