PROJECT EXECUTION & ASSURANCE PLAN Part – A, SECTION: A-3

COMMISSIONING
CAPTIVE POWER PLANT Sub Section – A-3.14
BCPL PROJECT Page 1 of 45

A-3 PROJECT EXECUTION &
ASSURANCE PLAN

A-3.14 PRE COMMISSIONING,
COMMISSIONING & TESTS

CAPTIVE POWER PLANT

PROJECT : BRAHMAPUTRA PETROCHEMICAL COMPLEX

OWNER : BRAHMAPUTRA CRACKER AND POLYMER LTD.
(BCPL)

PMC : ENGINEERS INDIA LTD.

JOB NO. : 6907

0 17-07-2009 ISSUED FOR BIDS KS PKS NS
Rev. Prepared Checked Approved
Date Purpose
No by by by
Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved
PROJECT EXECUTION & ASSURANCE PLAN Part – A, SECTION: A-3
COMMISSIONING
CAPTIVE POWER PLAN Sub Section – A-3.14
BCPL PROJECT, Page 2 of 45

PRE-COMMISSIONING, COMMISSIONING AND PERFORMANCE TEST RUN

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

EPCC CONTRACTOR shall be responsible to carry out pre-commissioning,
commissioning and performance test run of Power plant in association with Owner’s
operating personnel. EPCC CONTRACTOR’s scope covers supply and fill all initial
lubricants, chemicals, consumable, spares required for start-up. Free issue of materials
shall be limited to items as brought out elsewhere in contract. The scope also includes
providing technical experts/ technician for critical equipment and equipment supplier(s)
representative(s) for commissioning supervision and is to be indicated along with the bid.
Operation of units from DCS during synchronisation and performance test runs is also in
EPCC CONTRACTOR’s scope.

A procedure for detailed mechanical completion, precommissioning, commissioning, start
up (unit as well as individual equipment) and performance test shall be developed by
EPCC CONTRACTOR based on the guideline provided in the document and this shall be
approved by OWNER / PMC. EPCC CONTRACTOR has to prepare the operating manual
based on the guideline provided in the document.

1.1 FOLLOWING SHALL BE ENCLOSED BY BIDDER IN HIS OFFER

- An organisation chart of bidder's proposed commissioning team indicating the positions
with the required qualifications and experience.
It shall also indicate the position that the bidder proposes to fill from personnel engaged
from back up agency, whenever bidder proposes to engage such an agency. A
proposed ORGANOGRAM for commissioning team is attached as per Annexure-V.
Adequate manpower (skilled and unskilled for control room and field) should be
provided in each shift to carry out pre-commissioning / startup / commissioning activities
un interrupted.

- Bio data’s 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.

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 3 of 45

- Track record of bidder related to commissioning experiences of similar plants.

- 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

2.1 MECHANICAL COMPLETION

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 CONTRACTOR’s 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.

2.2 PRE-COMMISSIONING ACTIVITIES

Pre-commissioning activities (as detailed in Annexure-IV) are defined as those activities,
which are required to be performed after completion / installation, inspection, hydro testing
etc. of an equipment / system to make it ready for commissioning. EPCC CONTRACTOR
shall raise FORMAT – III (as per format given in Annexure-III) which certifies that all
checklist points are liquidated and the plant / unit / system / sub-system is ready for pre-
commissioning. EPCC CONTRACTOR will start pre-commissioning activities after
acceptance of FORMAT-III by PMC / OWNER. This shall include but shall not be limited to
activities such as system checking as per P&IDs / Drawings, site modifications, internal
inspection of equipment / vessels, flushing / steam blowing, air blowing of pipelines
including gasket blowing, purging of system using inert gas, leak test both for low / high
pressure systems, chemical cleaning, calibration of instruments, checking of the electrical
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 4 of 45

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

2.3 READY FOR COMMISSIONING

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.

3.0 DOCUMENTS FOR PRE-COMMISSIONING / COMMISSIONING

3.1 OPERATING MANUAL

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.

- Design basis of unit.
- Chemistry of the process.
- Detailed process / plant description.
- Pre-start checks.
- Pre-commissioning procedures
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 PROJEC Page 5 of 45

- 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.

3.2 PRE-COMMISSIONING AND COMMISSIONING NETWORK

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 6 of 45

EPCC CONTRACTOR shall submit the pre-commissioning and commissioning schedule in
the form of network detailing therein the sequence of all the pre-commissioning and
commissioning activities and time taken by each individual activity to be carried out in each
equipment / sub-system of the units. This shall be submitted to OWNER prior to start of
pre-commissioning activities. EPCC CONTRACTOR shall submit weekly progress report
and the status of pre-commissioning and commissioning activities, likely slippage and
action being taken by the EPCC CONTRACTOR to contain this slippage.

3.3 PRE-COMMISSIONING DOCUMENTS

It shall be the responsibility of the EPCC CONTRACTOR to prepare detailed checklist of
pre-commissioning and commissioning activities for each equipment, subsystem, system
and unit / plant as a whole. EPCC CONTRACTOR shall submit the said format for
approval to the OWNER / PMC. This checklist shall indicate the checks / test to be carried
out on each equipment / system and shall also indicate the sequence and schedule of the
activities.

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:

i) Process system identifications on P&IDs.
ii) Flushing systems including general guidelines, medium of flushing
iii) Pre-commissioning and start-up schedule
iv) Detailed procedure for the various pre-commissioning activities i.e. flushing,
blowing, purging, leak checking, system tightness, equipment operability test with
forms to record the observation of each of the activities carried out.
v) Procedure and forms for operability tests of equipment and system as a whole,
wherever applicable.
vi) Pressure testing loops and pressure limits, guidelines of pressurisation and
depressurisation
vii) Lube schedule indicating manufacturer (Indian equivalent to lubes, quality, initial fill
recommended, and frequency of changing the lube oil).
viii) Detailed procedure for chemical cleaning if any.
ix) Detailed procedure for carrying out passivation of cooling water system /
compressor circuit (wherever applicable) shall be approved before implementation.
Requirement of tanks, pumps, chemical dosing arrangement and apparatus for
chemical analysis shall be detailed out by EPCC CONTRACTOR and shall be in
EPCC CONTRACTOR's scope.
x) Detailed heater refractory dry out procedure / passivation of heater tubes ( if
applicable).

EPCC CONTRACTOR shall submit the draft of above mentioned pre-commissioning
documents 120 days before the activities are to be carried out. The document shall be
reviewed by the OWNER / PMC. EPCC CONTRACTOR shall submit 30 days prior starting
of activities, a revised document after incorporating OWNER / PMC's comments. The
documents shall be followed till the project is completed and handed over to OWNER.

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.

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 7 of 45

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.

3.4 MAINTENANCE MANUAL

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.

Maintenance manual shall contain the following chapters as a minimum:

i) Introduction to the plant / unit maintenance
ii) Equipment / facilities register
- Location and list of all plant equipment.
iii) Equipment record card
- Equipment No. and name.
- Equipment serial No. and manufacturer details
- Brief description including details of parameters.
iv) Maintenance guidelines
- Maintenance philosophy.
- Check list of routine inspection of equipment
- Maintenance procedures of individual equipment and system.
- Maintenance procedure for Gas Turbine Generator
- Maintenance procedure for Steam Turbine Generator
- Maintenance procedure for Utility Boiler
- Maintenance procedure for Heat Recovery Steam Generator
- Preventive and predictive maintenance schedules.
- Procedures and precautions to be taken for handing over of equipment for
shutdown maintenance, viz., tanks, vessels, exchangers, boilers, burners,
heaters, blowers, turbines, pumps, agitators, dryers, centrifuges, filters,
gear boxes, couplings, motors, valves etc.
- Details of preventive maintenance and predictive maintenance.
- Gasket details with respect to pressure ratings and temperature.
- Coupling details, like, type of coupling and coupling bolts with make, serial
No. and dimensional details.
Method for alignment including optical, if required.
- Tightening torque with respect to critical services and sizing of bolts / studs.
Exchanger maintenance
- Tube extraction/tube bundle pull out procedures.
Centrifugal/screw/gear pumps
- Shaft dimensions
- End float dimensions and checking procedure.
- Diametrical clearances.
- Clearance checking in screw pumps.
- Setting of timing gears in screw compressors.
- Mechanical seal maintenance
- Dimensional details including manufacturer catalogue.
- Methods to evaluate the surface finish of the mating surfaces of mechanical
seals.
Vibration
- Normal and critical values.
- Trip conditions including values.
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 8 of 45

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.

v) Maintenance trouble shooting
- Trouble shooting guide for critical equipment like compressors, turbines,
blowers, screw pumps, heaters, boilers, centrifuges, conveyors, filters etc.

vi) Maintenance store
- Identification and classification of spares and consumables.
- Stock levels to be maintained
- Spare parts requirement for at least 2 years of trouble free operation and
insurance spares.
- General tools and tackles including special tools, if any.
- Inspection gadgets including tension device for bolts tightening
requirement.

vii) Information storage and retrieval system
- Pressure vessels records including as built drawings, data sheets, licenses,
approvals etc.
- Piping - as built drawings, test records etc.
- Details of piping support system including type, size, specification and
make of spring supports clearly shown on the drawings.
- Lifting tackles / equipment details.
- Lifting equipment - test programme and schedule.
- Safety relief valve - test records & schedule including set values.

viii) Maintenance training
- Training needs and areas identified.

4.0 OTHER REQUIREMENTS

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.

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 9 of 45

5.0 MANUFACTURER'S REPRESENTATIVE

It shall be the responsibility of the EPCC CONTRACTOR to arrange for services of
manufacturer's installation / commissioning engineer at site during mechanical completion
/ pre-commissioning & commissioning of all the major equipment and systems listed as
under:

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.

6.0 REVIEW / CHECKLISTING / INSPECTION CO-ORDINATION

A general guideline on OWNER / PMC interaction with respect to plant pre-start up
activities is given below. However, OWNER / PMC reserve right to witness all works at
any stage.

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.

7.0 A TYPICAL APPROACH TO WITNESS / INSPECTION OF PRE-COMMISSIONING
ACTIVITY BY PMC / OWNER

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

o) Alkali boil out of steam generation systems Complete
p) Steam Blowing Complete

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.

8.0 FINAL INSPECTION BEFORE START OF COMMISSIONING

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
CONTRACTOR’s 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.

It will be the responsibility of the EPCC CONTRACTOR to provide commissioning
assistance to OWNER's operating crew by way of manpower, tools and tackles,
consumable etc for carrying out the commissioning activities.

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.

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 PROJE Page 11 of 45

Three months in advance of starting the commissioning, EPCC CONTRACTOR shall
submit proposal to the OWNER’s representative giving details of the programme to be
followed during commissioning. This shall be reviewed by OWNER’s representative. EPCC
CONTRACTOR shall arrange trained operation team comprising of commissioning
manager, shift in charge, control room operators (DCS and local panels), field operators,
mechanical, electrical and instrument engineers / foreman etc. to carry out plant start-up
and commissioning and for process operations and maintenance. OWNER shall depute
operating team consisting of field and control room operators and supervisors during
commissioning.

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.

EPCC CONTRACTOR is also required to provide on the job training to OWNER’s
operation personnel by associating them in all the day to day pre-commissioning,
commissioning and maintenance activities and unit operations. However, responsibility for
adequate manning the plant shall be that of EPCC CONTRACTOR. After successful
commissioning of the plant as above the same shall be handed over to the OWNER for
operation. In case of any constraint in achieving the desired process parameters in the
unit, the EPCC CONTRACTOR shall communicate the same to the OWNER in writing.
This will be reviewed jointly by OWNER / PMC to arrive at a decision on whether the
constraint is on account of reasons attributable to the EPCC CONTRACTOR or not. The
action in either case will be according to the relevant provisions provided elsewhere in the
contract.

EPCC CONTRACTOR in some cases may be required to do part commissioning of the
mechanically completed sections of the plant as per directives from the OWNER.

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.

10.0 PERFORMANCE TEST RUN

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

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 12 of 45

- Methodology for evaluating the performance of the unit, fuel/utilities/energy
consumption, steam and power generation at CPP battery limits etc

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 CONTRACTOR’s 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 OWNER’s /
PMC's opinion, such guarantee has not been met.

11.0 PERFORMANCE TESTS

The Plant Performance Tests shall broadly consist of:

a. Functional Tests.
b. Operability Test
c. Commissioning Test
d. Reliability Test.
e. Capability Test
f. Performance Guarantee Tests

11.1 FUNCTIONAL TESTS

The Functional Tests shall demonstrate that the safety and controls of the plant operate
satisfactorily. The Functional Tests shall be part of EPCC CONTRACTOR’s 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

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 13 of 45

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. Hydraulic guarantee test
b. Alarm, trip, remote/ manual operation, process and safety interlocks, emergency
shutdown of the systems / equipments in CPP, and black start DG set included in
this package.
c. Automatic operation of all system controls, bumpless changeover of Auto/ manual
controls and proper maintenance of the controlled variables within the desired band.
d. Normal start up & shutdown sequence of the Plant.
e. Over speed Trip tests for the GTG/ STG.
f. Fail safe shutdown in the event of total power failure.
g. Plant Turndown

11.1.2 Special Functional Tests for CPP

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

11.2 OPERABILITY TEST

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.

11.3 COMMISSIONING TEST

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 ½ hours will only be allowed.

11.4 RELIABILITY TEST

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.

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 14 of 45

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
CONTRACTOR’s supervisor until successful completion of Performance Guarantee test.

11.5 CAPABILITY TEST

EPCC CONTRACTOR shall demonstrate following tests as part of capability tests.

a. Capability test at Peak operating condition
EPCC CONTRACTOR shall demonstrate Peak Net Power Output, Net BFW
Export and Net HP / MP / LP Steam Export at CPP Battery Limit. The Plant shall
be kept operating with Peak total power and steam requirements during these
tests. For Peak condition steam & power requirements, refer Power Plant Design
Basis enclosed elsewhere. For the above capability test, normal fuels shall be
used for the Gas Turbine, HRSG and UBs in CPP.
b. Capability on alternate fuel
Clause (a) is also to be demonstrated with alternate fuel.
c. Demonstration of Guaranteed Auxiliary Power consumption of CPP at
normal operating condition.
EPCC CONTRACTOR shall demonstrate the guaranteed Auxiliary Power
consumption under normal operating condition with normal fuels used in GT,
HRSG and UBs.
Bidder shall also furnish with the bid, complete item wise break up of auxiliary
power consumption for arriving guaranteed auxiliary power consumption figure
d. Demonstration of Guaranteed Noise levels for each GTG and each STG.
EPCC CONTRACTOR shall demonstrate the Guaranteed Noise Levels for each
STG and GTG.
e. Demonstration of Guaranteed NOx levels for each Gas turbine running on
simple cycle at base load
EPCC CONTRACTOR shall demonstrate the Guaranteed NOx emission for Gas
Turbine running on simple cycle at base load when firing Diesel range material,
with NOx control measures in operation. NOx emission with and without NOx
control medium has to be demonstrated.
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 15 of 45

f. Demonstration of Guaranteed Peak Output of GTG on 100% Normal fuel.
EPCC CONTRACTOR shall demonstrate the Guaranteed Peak Output of GTG
on 100%normal fuel.
g. Demonstration of sustaining 1 utility boiler on steam driven auxiliaries.
EPCC CONTRACTOR shall demonstrate that under normal operating conditions,
one utility boiler can be run exclusively with steam driven auxiliaries. Intent of this
test is to ensure that at least one utility boiler continues to run in the event of
electrical black out in CPP for supplying emergency steam requirement to the
process units and starting of a STG. Test procedure shall clearly indicate
limitation on output capacity and duration for which UB operation can be
sustained under electrical black out condition.

11.6 PERFORMANCE GUARANTEE TEST

Performance Guarantee Tests shall constitute of tests to demonstrate the guaranteed
parameters, failing which penalties shall apply and / or the Plant shall be liable for rejection.

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 OWNER’s 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

Performance Guarantee Tests shall consist of:

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.

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 16 of 45

b. Tests wherein it shall be mandatory to meet the performance guarantees, failing
which the Plant / Equipment is liable for rejection such as, but not limited to,
guarantees on emission.

Further, following minimum parameters shall be demonstrated during performance
guarantee test.

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.

e. Heat Rate of Gas Turbine at base load on normal fuel.
f. Heat Rate of Gas Turbine at peak load on normal fuel.
g. DM Water / Steam injection quantity for base and peak load of GTG.
h. MCR of VHP Steam production of HRSG with normal fuel firing and with GTG at
Base Load.

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.

12.0 SPARES AND CONSUMABLES

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

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 17 of 45

shall submit catalogues for all the lubricants and chemicals being charged for
commissioning.

13.0 SPECIAL REQUIREMENT

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”.

15.0 POST COMMISSIONING

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.

16.0 PLANT STAFFING

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.

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 18 of 45

ANNEXURE - I

FORMAT FOR BIODATA OF KEY PERSONNEL FOR COMMISSIONING

1. PRPOSED POSITION IN ORGANISATION CHART:

2. NAME:

3. QUALIFICATION:

4. TOTAL YEAR OF EXPERIENCE
IN PLANT OPERATION / COMMISSIONING:

5. DETAILS OF COMMISSIONING EXPERIENCE:

SL PROJECT PLANT LICENSOR OWNER YEAR OF DURATION OF
NO. DESCRIPTION CAPACITY COMMISS. STAY AT SITE

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 19 of 45

ANNEXURE-II

QUESTIONAIRE

CLAUSE DESCRIPTION OF CLAUSE AGREED NOT REMARK
NO. AGREED

1.0 SCOPE

2.0 DEFINITIONS

3.0 DOCUMENT FOR PRE-
COMMISSIONING AND
COMMISSIONING

4.0 OTHERS REQUIREMENTS

5.0 MANUFACTURER
REPRESENTATIVE

6.0 REVIEW / CHECKLISTING /
INSPECTION /
CO-ORDINATION

7.0 A TYPICAL APPROACH TO
WITNESS/ INSPECTION

8.0 FINAL INSPECTION

9.0 COMMISSIONING

10.0 PERFORMANCE TEST RUN

11.0 SPARE AND
CONSUMABLES

12.0 SPECIAL REQUIREMENTS

13.0 SAFETY

14.0 PROCESS UNIT STAFFING

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 20 of 45

ANNEXURE-III

FORMAT TO BE USED DURING PRE-COMMISSIONING AND COMMISSIONING

(TOTAL 5 FORMATS)

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 21 of 45

FORMAT-I

INTIMATION REGARDING SYSTEM COMPLETION

PROJECT:__________________ CUSTOMER:__________
UNIT:________________

Following system / sub-system has been mechanically completed in all respects
with exceptions noted below. The system / sub-system can be taken up for
checking and preparation of checklist.

SYSTEM NO.

SYSTEM DESCRIPTION:

EXCEPTIONS:

_____________________________ ________________
SIGNATURE DATE
EPCC CONTRACTOR’S CONSTRUCTION:
CO-ORDINATOR
_______________________________________________________________

The system is ready / not ready for Check listing

_____________________________ ________________
SIGNATURE DATE
OWNER/PMC:

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 22 of 45

F O R M A T - II

CHECKLIST

PROJECT:______________CUSTOMER:_____________UINT:___________

SYSTEM/SUB-SYSTEM___________________________________________

CHECKLIST TYPE PRELIMINARY/FINAL

SL.NO. CHECKLIST ITEMS REMARKS

SIGNATURE DATE

PMC: ________________ ____________

OWNER: ________________ ____________

LICENSOR: ________________ ____________

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 23 of 45

F O R M A T - III

READY FOR PRE-COMMISSIONING CERTIFICATE

PROJECT:_______________CUSTOMER:______________
UNIT:______________

SYSTEM/SUB-SYSTEM__________________________________________

This is to certify that the following plant/system/sub- system as detailed below is
completely installed and all the Checklist points are carried out except for minor
details as given in the attached list.

DESCRIPTION OF PLANT / SECTION / SUB-SECTION
_________________________________________________________________

SIGNATURE DATE

EPCC CONTRACTOR’S CONSTRUCTION
CO-ORDINATOR: ______________ ___________

EPCC CONTRACTOR’S COMMISSIONING
CO-ORDINATOR ______________ ___________
_______________________________________________________________
The system is ready/ not ready for pre-commissioning

PMC: ______________ ___________

OWNER: ______________ ___________

LICENSOR: ______________ ___________

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 24 of 45

F O R M A T - IV

READY FOR COMMISSIONING CERTIFICATE

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 CONTRACTOR’S COMMISSIONING
CO-ORDINATOR
_______________________________________________________________

SIGNATURE DATE

PMC: ______________ ___________

OWNER: ______________ ___________

LICENSOR: ______________ ___________

:

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 25 of 45

FORMAT-V

COMPLETION OF COMMISSIONING CERTIFICATE

PROJECT:___________CUSTOMER:_____________
UNIT:__________________

SYSTEM/SUB-SYSTEM____________________________________________

This is to certify that the system/sub-system as detailed below has been
successfully commissioned and is under operational control of Client's Production
department. The minor items, which will not effect the normal operation of the
system/sub-system, are given in the attached list.

DESCRIPTION OF SYSTEM/SUB-SYSTEM___________________________

SIGNATURE DATE

EPCC CONTRACTOR’S COMMISSIONING
CO-ORDINATOR: ______________ ___________

_______________________________________________________________

PMC’S COMMISSIONING
CO-ORDINATOR: ______________ ___________

OWNER'S COMMISSIONING
CO-ORDINATOR: ______________ ___________

LICENSOR: ______________ ___________

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 26 of 45

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.

Manufacturer's / Vendor’s instructions for pre-commissioning checks, testing must
also be followed for all equipment.

A. GENERAL PROCEDURE FOR PRE-COMMISSIONING

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.

A-1 Installation of Seals and Packing

¾ Install mechanical seals, permanent packing and accessories,
wherever required.
¾ Adjust and replace mechanical seals, packing and accessories, as
necessary during pre-commissioning / commissioning period.

A-2 Removal of Temporary Bracing

¾ Remove all temporary supports, bracing, or other foreign objects that
were installed in vessels, transformers, piping, rotating machinery or
other equipment to prevent damage during shipping, storage and
erection.

A-3 Rotation and Alignment

¾ Check rotating machinery for correct direction of rotation and for
freedom of moving parts before connecting driver.
¾ Make cold alignment to the manufacturer's tolerances along with
OWNER / OWNER's Representative. Provide all the alignment
readings records to OWNER.
¾ Check all lubricants and their quality, fill etc. before operating the
equipment.
¾ Carry out no load run of motors and turbines etc.
¾ Check bearing temperatures, vibration, over speed trips function of
different safety device and other relevant tests. Carry out adjustments
as required.
¾ Make hot alignments and any adjustments required after equipment
has been put in operation.
¾ Arrange for manufacturer representative for equipment as required
during installation and/or pre-commissioning and commissioning.

A-4 Tie-ins at Unit Battery Limits

¾ 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

approval of OWNER / PMC for the safety measures to be taken by
him before any tie-in work is taken-up.

A-5 System Check / Inspection

¾ Provide inspection facilities to the OWNER / PMC to check that
created facilities conform to the approved process and
instrumentation drawings, construction drawings, vendor drawings
and specifications approved for construction, verify and approve the
facility check. Note exceptions, if any.

A-6 Site Modifications

¾ Carry out site modifications as found necessary during system check
/ inspection from view point of operability, maintenance and safety of
the plant.

A-7 Flushing and Blowing

¾ Flushing schemes for various systems / subsystems / equipment
should be prepared well in advance and to be submitted to
OWNER/PMC for approval.
¾ Perform flushing using fresh treated water and blowing using air of
all above ground and underground piping to remove dirt, welding
slag, etc. after hydrotesting (along with gasket / sheet blasting).
¾ Perform flushing of steam lines using steam as flushing medium.
Necessary cycles of heating and cooling should be maintained during
steam flusing. Achieve target plate requirements for steam system
connected with rotating equipment.
¾ Arrange for cleaning media for carrying out flushing / blowing and
disposal of the cleaning media in accordance with procedures to be
adopted by the EPCC CONTRACTOR and approved by OWNER /
PMC.
Following rates of cleaning media to be maintained:
Air - 8-9 ft/sec.
Water - 3-4 ft/sec.
¾ Adequate arrangements to handled flushed streams to be created by
EPCC CONTRACTOR without causing flooding of existing facilities.
¾ System flushed with water shall be followed by blowing with air for
removal of free water. System requires to be kept under inert
pressure as recommended by licensor / vendor is to be kept under
inert pressure.
¾ Instrument piping and tubing shall be flushed.
¾ Dryout all equipment and piping in general by water draining from all
low points and blowing air / nitrogen as applicable.

A-8 Temporary Spools, Strainers, Screens and Blinds

¾ Provide and install all strainers, both temporary and permanent.
¾ Clean strainers as required during pre-commissioning and
commissioning.
¾ Provide, install and remove all blinds required for flushing or
operation. (Install and dismantle temporary pipe pools as and when
required for pre-commissioning and commissioning).

A-9 Leak, Vacuum and Pressure Tests, Purging

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 28 of 45

¾ Make non-operating leak tests and pressure tests on piping and all
equipment, including field fabricated equipment.
¾ 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/cm²g of gas.
¾ 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.
¾ 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.
¾ 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.
¾ Provide 4 copies of all the test records to the OWNER.
¾ Provide any special media for test purpose and provide facilities for
disposal.
¾ Conduct all operational tightness testing.
¾ 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.
¾ Pneumatic testing of instrument air piping / tubing.
¾ Pneumatic testing DP testing of instrument air lines.
¾ Hydrostatic testing of all impulse piping and tubing.
¾ Testing of instrument tube fittings / connections using halogen free
liquid leak detection solution.
¾ Hot bolting to be done wherever required.
¾ 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.

A-10 Safety Devices

¾ Provide a list of proper settings for safety devices to the OWNER.
¾ Install all safety devices (including pressure relief valves) on the
equipment after calibration test and adjust all safety device and seals
wherever necessary or desirable.
¾ Install all shut down valves, trip instruments, partial stroke testing
setups / software etc.

A-11 Drying Out

¾ Undertake system drying out operation as per approved operating
procedure and guidelines for carrying out drying of heaters and major
equipment, wherever dryout is necessary.
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 29 of 45

A-12 House Keeping

¾ Provide continuous clean-up of the construction and operational area.
¾ Remove excess materials, temporary facilities and scaffolding and
pick-up trash.
¾ Perform washing for clean-up as required.

A-13 Equipment Protection and Spare Parts

¾ Protect equipment from normal weather conditions, corrosion, or
damage before commissioning. This shall also include binding of
monsoon tapes to all instruments, applying anti seize compound to all
threaded covers, applying sealant compound to all cable gland
entries etc.

A-14 Removal of Rust Preventives

¾ 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-15 Chemical Cleaning / Pickling

¾ Perform special chemical cleaning or pickling of the piping as
required by specification.

A-16 Miscellaneous

¾ Carry out any other check / test as required by OWNER / PMC and
provide all test certificates as required by the OWNER / PMC.

A-17 Operability Test for a System / Equipment

¾ Each system / equipment shall be given operability test for sufficient
duration (not less than 4 hours) to demonstrate worthiness of the
system for normal operation.
¾ EPCC CONTRACTOR shall provide his proposal / procedures for
carrying out the operability test of each equipment / system to prove
that the equipment system installed meet the design specification.
This shall also include the supply of log sheets wherein the operating
parameters shall be recorded hourly. The operability test shall be
carried out by the EPCC CONTRACTOR in presence of OWNER’s /
PMC's Representative and the Vendor representative wherever
applicable.
¾ EPCC CONTRACTOR shall make necessary checks, adjustments,
repairs required for normal operation of the system / equipment.
¾ All the safety devices shall be tried for their proper operation.
¾ Upon completion of the operability test the log sheet with all
observations shall be signed by the EPCC CONTRACTOR, Vendor,
OWNER's / PMC’s Representative. The performance shall be
evaluated based on the data and observations made during the
operability test.

B. SPECIFIC PROCEDURES

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 30 of 45

In addition to the work to be performed in accordance with the above,
the detailed procedures outlined below further define the work
responsibilities of the EPCC CONTRACTOR for specific systems and
items of equipment.

B-1 Tanks and Vessels

¾ Vessel / Tanks after erection and put in place have internals requiring
field installations. These internals shall be inspected before and after
installation.
¾ Open both internal and external manways for inspection of vessel for
OWNER / PMC inspection.
¾ Test tanks and internals as required. Dispose of test water as per
OWNER’s instructions.
¾ Conduct chemical cleaning / flushing operation, as required. Dispose
of wastes and cleaning media as per OWNER’s instructions.
¾ 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.

B-2 Shell and Tube Heat Exchangers

¾ Perform internal inspection / testing as required by specifications or
drawings.
¾ Perform separate field testing, if desired by OWNER, of exchangers
that have been shop tested.
¾ Cross leakage for exchangers may be tested at OWNER's discretion.

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.

B-3 Steam Turbine Generators, Gas Turbine Generator, Utility Boilers

¾ Perform all precommissioning activities as per manufacturer’s
recommendation and submit test reports to OWNER / PMC.
B-4 Pumps and Drivers

¾ 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.
¾ 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

¾ Charge the lube oil, seal oil and oil cooling system with operating oil
recommended by the manufacturer.
¾ Obtain service engineer for technical assistance during installation
and / or pre-commissioning and commissioning as specified.

B-5 Piping System

¾ Piping system shall be thoroughly flushed and cleaned to the
satisfaction of the OWNER / OWNER's Representative.
¾ Orifice plates, control valves and any other online instruments
should not be installed before testing and flushing. If installed, they
shall be removed and necessary spool pieces shall be provided in
their place wherever required during flushing to avoid damage.
¾ After testing, drain and dispose of the test media as per the
OWNER's instructions.
¾ All the piping will be dried using air and boxed up.
¾ Check pipe hangers, supports, guides and pipe specialities for hot
settings and make minor adjustments as necessary.
¾ Install seals on valves where necessary. Replacing dry up graphite
seals with fresh ones shall be in EPCC CONTRACTOR's scope of
work.
¾ Correct support, vibration and thermal expansion problems detected
during commissioning.

B-6 Instrument System

¾ EPCC CONTRACTOR shall make all non-operating checks that will
ensure instrument operability i.e. 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.
¾ Clean all impulse lines (etc.) by blowing with cooled and filtered
clean air compatible with instrument components.
¾ Clean all air supply headers by blowing with clean air and check them
for tightness.
¾ Leak test pneumatic control circuits.
¾ Functional check of all instrument and controllers.
¾ Check all loops for proper functioning.
¾ Checking and recording positions of all valves.
¾ Check piping from instruments to process piping for tightness.
¾ Install and connect all system components and verify their
conformance to specifications and design criteria for functional and
range using dummy transmission signals as needed.
¾ Check all electrical signals and alarm wiring for continuity, correct
source of power and polarity.
¾ Check thermocouple for proper joining of wires, position of elements
in wells, proper polarity and continuity of receiving instruments.
¾ Identify orifice plates by tagging and check for proper installation of
upstream side of plates.
¾ Isolate or remove if necessary, the components such as control
valves, positive displacement meters, and turbine meters for pressure
testing. Reinstall these items after testing the system.
¾ Check bores of orifice plates and install these plates after completion
of flushing operations.
¾ As dictated by OWNER’s specifications, calibrate instruments with
standard test equipment and make all required adjustments and
control point settings. Fully pressurize and energize the transmitting
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 32 of 45

and control signal system by opening process connections at primary
sensors and final regulators and by making control mode settings for
automatic operation of equipment as the process unit is charged and
brought onstream.
¾ Check setting of all alarm and shutdown switches.
¾ Check all shutdown systems before commissioning.
¾ EPCC CONTRACTOR shall arrange for testing and recalibration of
all the safety valves settings at site. Ensure that safety valve isolation
valves are locked open as per drawing.
¾ Check each field bus segment for compliance with respect to design
guidelines like availability of minimum voltage at each instrument
end, communication with hand held terminal, measuring noise level,
checking configuration of each device etc.
¾ Wet leg / dry leg calibration of all DP type instruments including zero
level suppression.
¾ Calibration / setting of radar / RF type level instruments installed on
tank / vessel.
¾ Installation and proving of partial stroke testing circuitry of shutdown
valves.
¾ Check that orifice plate is installed with proper tightness before going
ahead with welding / installation of pre fabricated hookups.
¾ Check that all dampers used for control are operating both in manual
mode (winch operation mode) and automatic mode ( pneumatic
mode)
¾ Check that opening / closing time of dampers are within stipulated
period as required by design conditions.
¾ Check that all skin type thermocouples are installed as per installation
drawings

B-8 Buildings and Accessories

¾ Check buildings and accessories including all heating, ventilating,
and air conditioning equipment to ensure their completeness and
conformance to approved drawings.
¾ Obtain all statutory approvals for plumbing, electrical, fire protection,
elevators, cranes, occupancy and use

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 33 of 45

ANNEXURE-V

Proposed ORGANOGRAM for EPCC CONTRACTOR’s Commissioning team

EPCC CONTRACTOR’s Site In
charge

Overall Commissioning
Incharge

Mechanical Electrical Instrument Operation Co- Safety
Co-ordinator Co-ordinator Co-ordinator ordinator Supervisor

Mechanical Electrical Instrument
Technicians Technicians Technicians

Technicians shall include Technicians and semi-skilled personnel.

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 34 of 45

ANNEXURE-VI

CHECK LIST FOR MECHANICAL COMPLETION

ACTIVITIES FOR MECHANICAL COMPLETION

SECTION-1

1.0 GENERAL PROCEDURES

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

Where responsibility is not indicated in Section 2.

1. Obtain the assistance of the manufacturer or vendor, when
necessary, to make a satisfactory installation as agreed on ■ □ □
by the EPCC CONTRACTOR and the Owner

2. Obtain the assistance of the manufacturer or vendor, as
required, for technical assistance during run-in by the □ ■ □
Owner’s operating and maintenance personnel, for training
or for informational and operating purposes

3. Furnish names and telephone numbers including
emergency contact of manufacturers, and vendors, □ ■ □
technical service representatives for use by the Owner.

1.2 Permits

1. Procuring all necessary permits and certifications required
to be secured by the Owner for initial use of the plant. ■ □ □
2. Make applications for all necessary permits issued in the
Owner’s name that are required for plant use, occupancy ■ □ □
and operation.

1.3 Instructions

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 35 of 45

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.

2. Transmit to the Owner all applicable vendor’s or ■ □ □
manufacturer’s instructions and drawings.
3. Provide the Owner with any special instructions such as the
required procedures for drying liners ■ □ □
1.4 Removal of Rust Preventives

1. Remove all rust preventives and oils used to protect the
equipment during the construction period whenever these ■ □ □
protective materials will be detrimental to operation

2. Provide the Owner with a record of work completed.
■ □ □
1.5 Lubricants

1. Provide a list of the manufacturer’s recommended
lubricants for use in the plant ■ □ □
2. Approve the lubricant list
□ □ ■
3. Provide all lubricants
■ □ □
4. Flush systems and install initial charge of the lubricants.
Dispose of all flushing oil in accordance with the Owner’s ■ □ □
instructions

5. Maintain Lubrication after initial charge
■ □ ■
1.6 Packing and Seals

1. Install mechanical seals and accessories, as required.
■ □ □
2. Install permanent packing and accessories as required.
■ □ □
3. Adjust and replace mechanical seals, packing and
accessories as necessary during commissioning period. □ ■ □
1.7 Removal of Temporary Bracing

1. 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.

1.8 Rotation and Alignment

1. Check rotating machinery for correct direction of rotation
and for freedom of moving parts before connecting the ■ □ □
driver.

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 36 of 45

Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
2. Perform cold alignment to the manufacturer’s tolerances ■ □ □
and record data.
3. Perform any doweling required.
■ □ □
4. Perform Hot alignment □ ■ □

5.. Obtain the services of a factory representative to witness
installation of equipment as required. ■ □ □
1.9 Tie-Ins at Unit Limits

1. Prepare all systems for safe tie-ins
■ □ □
2. Obtain approval and make the necessary tie-ins at the unit
limits, as required by the specifications and as directed by ■ □ □
the Owner.

3. Remove blinds, car seals and so forth as required.
□ ■ □
1.10 Leak and Pressure Tests

1. Notify the Owner of the schedule for non-operating field
leak tests or field pressure tests on piping and field ■ □ □
fabricated equipment, unless otherwise directed by the
Owner.

2. Provide any special media for test purposes.
■ □ □
3. Conduct all tests in accordance with applicable codes,
specifications, regulations and the Owner’s instructions. ■ □ □
4. Witness Tests. ■ ■ ■

5. Maintain records as required.
■ □ □
6. Dispose of all test media in accordance with the Owner’s
instructions. ■ □ □
7. Conduct all operational tightness tests.
□ ■ □
1.11 Inspection

1. Provide inspection of the plant to verify that erected
facilities conform to flow diagrams, construction drawings, ■ □ □
vendor prints and specifications.

2. Verify that specified materials have been installed in the ■ □ ■
plant and document verification to the extent required by
the Owner.

3. Verify and approve the plant inspection. Note any □ □ ■
exceptions on a separate work order list (punch list).

4. Provide for special inspections such as those required by ■ □ □
insurance or governmental agencies.

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 37 of 45

Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
5. Perform and report routine shop inspection. ■ □ □

6. Perform shop inspection and witness tests as desired. ■ □ □

7. Witness final shop inspections, as specified. ■ □ ■

1.12 Pressure / Vacuum Safety Relief devices

1. Provide the Owner with a list of proper pressure settings. ■ □ □

2. Transfer relief devices to and from the specified facility ■ □ □

3. Test and adjust all devices to and from the specified facility ■ □ □

4. Install all devices after testing, adjusting and tagging. ■ □ □

5. Maintain records as required. ■ □ □

1.13 Flushing and Chemical/Mechnical Cleaning.

I. Conduct all flushing, blowing and chemical/mechanical
cleaning operations where such operation can be ■ □ □
accomplished without using permanently installed
equipment.

2. Conduct all flushing and blowing operations where
permanently installed equipment must be used to obtain □ ■ □
proper line velocities.

3. Provide any special media for flushing and blowing ■
operations where permanently installed equipment must be □ □
used to obtain proper line velocities.
4. Dispose of all media in accordance with the Owner’s
instructions. ■ ■ □
5. Turn systems over to the Owner free of trash and
construction debris (not necessarily free of welding slag) ■ ■ □
6. Maintain records, as required. ■ ■ □

1.14 Temporary Screens, Strainers spools and Blinds.

1. Provide and install all required temporary strainers. ■ ■ □

2. Clean strainers, as required during circulation. ■ ■ □

3. Remove strainers when system is adequately cleaned. ■ ■ □

4. Provide install and remove all blinds, spools required for ■ ■ □
flushing and isolation.

5. Maintain records as required. ■ ■ □

1.15 Purging/Inerting

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 38 of 45

Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
1. Install purge/inerting connections. ■ □ □

2. Provide purge materials and conduct necessary purge ■ ■ □
operations.

3. Provide inerting materials and introduce where specified. ■ ■ □

1.16 Vessel Packing and Fixed Beds

1. Install all inert materials such as sand, gravel balls rings ■ □ □
and saddles.

2. Install all materials other than the materials specifically ■ ■ □
noted in Section 2, such as chemicals, resins, desiccants
and catalysts.

3. Install all mixed beds involving combinations of material, ■ ■ □
covered by 1 and 2 above.

4. Inspect the vessel interior before and during loading to ■ ■ □
ensure proper installation.

5. Maintain records, as required. ■ ■ □

1.17 House-Keeping

1. After completion of construction, remove excess material, ■ □ □
temporary facilities and scaffolding, rough sweep or rake
the area and pick up trash, perform washing or further
cleanup, as required.

2. After completion of construction, maintain adequate □ ■ □
housekeeping practices, as required for safe operation.

1.18 Maintenance, Spare Parts and Special tools

1. After pre-commissioning is complete, protect equipment □ ■ □
from normal weather conditions, corrosion or damage

2. After pre-commissioning is complete provide adequate □ ■ □
maintenance for equipment including the cleaning of
strainers and the repairing of steam traps.

3. Provide the Owner with spare parts list as recommended ■ □ □
by the manufacturers.

4. After pre-commissioning is complete, maintain adequate □ ■ □
spare parts and supplies required during commissioning &
performance test run.

1.19 Noise Survey

1. Conduct individual equipment noise surveys, as required ■ ■ □
by the Occupational Safety & Health administration on the
Owner’s specifications.

2. Document all survey data ■ ■ □
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 39 of 45

SECTION-2

2.0 SPECIFIC PROCEDURES
In addition to the work responsibility described in Section 1.0 the detailed procedures
Outlined below further define the work responsibility of the EPCC CONTRACTOR
and the Owner for specific systems and items of equipment.

Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
2.1 Vessels

1. Open the vessel after erection and put in place any ■ □ □
internals requiring field installation. These internals will be
inspected before and after installation

2. Open both internal and external manways for inspection of ■ □ ■
the vessel by the Owner, unless otherwise specified.

3. Withness inspections to the extent desired. □ □

4. Dry out if required, upon vessel and install materials that ■ □ □
are designated in 1.16

5. Close after proper execution of closure permits. ■ □ □

2.2 Shell and Tube Exchangers

1. Perfrom field inspection, if required of exchangers that ■ □ □
have previously been shop inspected.

2. Carry out hydro test at Site. ■ □ □

2.3 Air-Cooled Exchangers

1. Inspect exchangers to ensure that temporary shipping ■ □ □
supports and erection materials have been removed.

2. Adjust fan assemblies to obtain specified tip clearance and ■ □ □
test.

3. Check operation of louvers and operating linkage ■ □ □

2.4 Fired Heaters

1. Perform the pressure test in accordance with the applicable ■ □ □
codes, specifications and the Owner’s instructions if
required.

2. Provide all non-operating preferring checks in accordance ■ □ □
with the manufacturer’s instructions.

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 40 of 45

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.

5. Check operation of air preheaters, blowers and soot □ ■ □
blowers

6. Dry refractory during initial firing by following manufactures □ ■ □
temperature cycle.
7. Conduct Boilout, chemical cleaning, and flushing □ ■ □
operations, Conduct lightoff, drying, and purging
operations. as required .Dispose of wasted, cleaning
media, in accordance with Owners, instruction
8. Obtain and charge liquid heat transfer heat media , if □ ■ □
required.
9. Conduct lightoff, drying, and purging operations. □ ■ □
10. Obtain the assistance of a service engineer for technical ■ ■ □
advice during installation for start up if desired.

2.5 Pumps, Compressors and Drivers

1. Level base plates and sole plates and grout all bearing ■ □ □
surfaces.

2. Alleviate any excess piping stresses that may be imposed ■ □ □
on pumps, compressors and drivers.

3. Chemically clean any completed lube and seal oil system ■ □ □
when specified. Dispose of wastes and cleaning media in
accordance with the Owner’s instructions.

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 Owner’s instructions.

5. Charge the lube oil, seal oil and oil cooling systems with ■ □ □
the operating oil recommended by the manufacturer.

6. Operate equipment and make vibration trip governor and ■ ■ □
safety device checks and any operating tests and
adjustments as required.

7. Obtain the assistance of service engineer for technical ■ ■ □
advice during installation or start up if desired.

8.. Maintain records as required. ■ □ □

2.6 Tanks

1. After erection and installation, install any internals, which ■ □ □
require field installation.

2. Test tank and internals as required. Dispose of test water ■ □ □
in accordance with the Owner’s instructions.

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 41 of 45

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 Owner’s instructions.

4. Witness test and inspections to the extent desired. □ □ ■

5. Close after proper execution of closure permits. ■ □ □

2.7 Piping System

1. Notify the Owner of test schedule. ■ □ □

2. Hydrotestically or pneumatically test all piping as required ■ □ □
by codes, specifications and the Owner’s instructions.

3. Witness field pressure tests, when notified. □ □ ■

4. Flush and drain system and install orifice plates. Orifice □ ■ □
plates shall not be installed before hydrostatic testing. (see
2.9 for the removal or isolation of other inline components).

5. Drain system, remove blinds and perform tightness tests as □ ■ □
required.

6. Insulate or paint flanges, threaded joints or field welds after ■ ■ □
the specified testing of each system a has been completed.
Unless instructed otherwise by Owner.

7. 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 has been completed. After final testing of
these joints cover the system.

8. Check pipehangers, supports, guides, expansion joints and ■ □ □
other pipe specialities for the removal of all shipping and
erection stops and for the correctness of cold settings for
the design service. Also provide the Owner with
instructions for hot settings.

9. Check pipehangers, supports guides and pipe specialities □ ■ □
for hot settings and make minor adjustments as necessary.

10. Install permanent filter elements as required. □ ■ □

11. Verify, to the extent required by the Owner that specified ■ □ □
valve packing has been provided in valves installed in the
plant.

12. Install car seals on valves whether necessary. □ ■ □

13. Check and record the positions of all car sealed valves □ ■ □
paint of identify valves as required.

14. Correct support, vibration and thermal expansion problems □ ■ □
detected during commissioning.

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 42 of 45

Work Responsibility
EPCC CONTRACTOR OWNER
1 2 3
15. Re-torque all hot and cold service bolting during □ ■ □
commissioning and startup as required.

2.8 Electrical Power and Lighting Systems

1. Notify the Owner of the test schedule. ■ ■ □

2. Witness tests when notified and record test data as □ □ ■
required.

3. Using a megohmmeter, make insulation tests on all wing ■ □ □
except lighting wiring.

4. Using a megohmmeter, make insulation tests on motor and ■ □ □
transformer winding from phase to phase and phase go
ground.

5. Make grounding system tests to determine the continuity of ■ □ □
connections and the value of resistance to ground.

6. Arrange for breakdown tests on oil sample from oil ■ □ □
insulated transformers larger than 100 kilovolts absolute.

7. Charge electrical gear with oil and / or other media as ■ □ □
required.

8. Perform trails and adjustments on all switchgear, motor ■ ■ □
control equipments and generators.

9. Test and set switchgear and circuit breaker relays for □ ■ □
proper coordination.

10. Obtain local inspector’s approval, where required. ■ ■ □

11. Energize all substations with approval of the Owner after ■ ■ □
completion of all tests.

12. Check phase sequence polanty and motor rotation. ■ ■ □

13. Check installation of emergency power and lighting ■ ■ □
systems.

14. Provide the Owner with a record of work complete. ■ ■ □

2.9 Instrument System

1. Conduct any non-operating checks to ensure instrument ■ ■ □
operability, that is 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.

2. As dictated by the Owner’s practice, bench or field calibrate ■ □ □
instruments with standard test equipments and make all
required adjustments and control point settings.

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 43 of 45

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.

4. Clean all air-supply headers by blowing with clean air and □ ■ □
check them for tightness.

5. Leak test pneumatic control circuits in accordance with ■ ■ □
clean the latest edition of ISA Recommended Practice 7.1.
Pneumatic control circuit pressure test.

6. Install and connect all system components and verify their □ ■ □
conformance to specification and design criteria for function
and range suing dummy transmission signals as need.

7. Check all electrical signals and alarm wiring for continuity, □ ■ □
correct source of power and polarity.

8. Check thermocouples for proper joining of wires, position of □ ■ □
elements in wells proper polarity and continuity of receiving
instruments.

9. Identify orifice plates by tagging. ■ ■ □

10. Check and record bores or orifice plates and install after □ ■ □
completion of flushing operations.

11. Isolate or remove, if necessary, in line components such as ■ ■ □
control valves, positive displacement meters and turbine
meters for pressure testing. Reinstall these items after
testing the system with the components removed or
isolated.

12. Isolate or remove components for flushing operations and ■ ■ □
reinstall them on the completion of these operations.

13. Install any sealing fluids as required. □ ■ □

14. Fully pressurize and energize the transmitting and control □ ■ □
signal system(s) by opening process connections at
primary sensors and final regulations and by making
control mode settings for automatic operation of equipment
as the process unit is charged and brought on stream.

15. Provide a schedule of recorder charts. ■ ■ □

16 Checking piping from instruments to process piping for ■ ■ □
tightness'

2.10 Boilers/Heaters

1. Make a non-operating boiler pressure test in accordance ■ □ □
with applicable codes, specifications and the Owner’s
instructions, if required.

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 44 of 45

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.

3. Check operation of air pre-heaters, dampers soot blowers ■ ■ □
and other equipment for proper positioning and travel.

4. Dry refractories during initial firing by following the ■ ■ □
manufacturers temperature cycles.

5. Purge, flush and drain steam mains as necessary. ■ ■ □

6. Obtain and charge treated water of bailout and initial □ ■ □
operation as required.

7. Commission auxiliaries as detailed elsewhere under the □ ■ □
appropriate equipment type.

8. Conduct Boilout, chemical cleaning, and flushing □ ■ □
operations, as required .Dispose of wastes, cleaning
media, in accordance with Owners, instruction

9. Conduct initial lightoff, making associated checks and □ ■ □
adjustments
8. Obtain the assistance of service engineer for technical ■ ■ □
advice during installation of start up if desired.

10. Conduct all operating tests and obtain the required □ ■ ■
certifications.

11. Check and set pressure relief valves. □ ■ □

2.11 Miscellaneous Equipment (Agitators, Mixers, Rotary Filters,
Weigh Scales and Materials Handling Equipments).

1. Fully assemble rotary filters except for final filter media ■ □ □
(cloth, precoat or screen).

2. Install all final filter media. □ ■ □

3. Level and calibrate weigh scales with the assistance of the ■ □ □
manufacturers representation and set tare weights
wherever possible.

4. Manually check materials handling equipment for freedom ■ □ □
and direction of movement.

5. Check clearance on materials handling equipment as □ ■ □
directed by the Owner.

6. Make all final adjustments during run in and conduct any □ ■ □
required performance test.

7. Obtain a service engineer for technical assistance during ■ ■ □
installation of startup, if required.

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 45 of 45

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.

Format No. EIL-1641-1924 Rev.1 Copyright EIL – All rights reserved