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TANGGUH EXPANSION PROJECT EXECUTE

LNG EPC

MATERIAL MANAGEMENT AT SITE PROCEDURE

Code Description
A Proceed - No comment
B Proceed - With comment
C Do Not Proceed - Revise & Resubmit
D Cancelled
E Received as information
Signature:

Issued for inquiry

Rev Reason for Issue Author Date Checked Date Approver Date

! This document is copyright and shall Document Number Contractor Doc Number
not be reproduced without the
- 870300-PTS-900-CST-PRO-02967
permission of BP

Document Class
BP p.l.c.
Security Classification: N/A
Tangguh Expansion Project LNG EPC
Material Management at site

Table of Contents
1. PURPOSE ............................................................................................................5
1.1 Project Background ................................................................................................. 5
2. INTRODUCTION ..................................................................................................5
2.1 Objectives of the Document ................................................................................... 5
2.2 Methods of Implementation .................................................................................... 6
3. REFERENCE DOCUMENTS ................................................................................6
3.1 Internal References ................................................................................................. 6
4. DEFINITION, ABBREVIATIONS AND ACRONYMS .............................................6
5. ACTIVITY DESCRIPTION ...................................................................................10
5.1 Document and Responsabilities ............................................................................ 10
6. OBJECTIVE .......................................................................................................10
6.1 Definition of warehouse organization structures ................................................... 10
6.2 Warehouse Organization and Responsibilities....................................................... 11
6.3 Receipt and inspection of materials....................................................................... 12
6.4 Non-Conforming material....................................................................................... 12
6.5 Material take-over for management ...................................................................... 13
6.6 Storage/Preservation of the material ..................................................................... 14
6.7 Materials to be stored inside the warehouse ........................................................ 14
6.8 Materials to be stored in open fenced area covered with tarpulin ........................ 15
6.9 Materials to be stored in uncovered area .............................................................. 15
6.10 Traceability and Identification of Materials ............................................................ 16
6.11 Use and application of rust preventives................................................................. 16
7. PRESSURE EQUIPMENT ..................................................................................16
8. VESSELS ...........................................................................................................17
9. ADDITIONAL INSTRUCTIONS FOR SHELL AND TUBE BUNDLE OF HEAT
EXCHANGERS ..........................................................................................................18
10. ADDITIONAL INSTRUCTIONS FOR AIR COOLERS ..........................................18
11. ADDITIONAL INSTRUCTIONS FOR SPECIAL PRESSURE EQUIPMENT ..........18
12. FIRED HEATERS, BOILERS AND STACKS .......................................................18
13. MACHINERY .....................................................................................................19
14. PIPES/SPOOLS .................................................................................................20
15. ADDITIONAL REQUIREMENTS FOR COATED PIPES ......................................21
16. FLANGES ..........................................................................................................21
17. FITTINGS ...........................................................................................................21
18. VALVES .............................................................................................................22
19. GASKETS AND BOLTING ..................................................................................22

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20. STAINLESS STEEL (INCLUDING AUSTENITIC).................................................22


21. STEEL STRUCTURES ........................................................................................22
22. ELECTRICAL AND INSTRUMENT MATERIAL ..................................................23
23. BATTERIES........................................................................................................23
24. LOW VOLTAGE EQUIPMENT ...........................................................................23
25. SWITCH-GEAR, STARTERS AND ELECTRICAL CONTROL EQUIPMENT ........23
26. INSTRUMENTS AND PROCESS CONTROL EQUIPMENT ................................24
27. MOTORS AND GENERATORS..........................................................................24
28. CABLES .............................................................................................................25
29. PAINTING ..........................................................................................................25
30. INSULATION .....................................................................................................25
31. MISCELLANEOUS AND OPERATING MATERIALS ..........................................25
32. CONSUMABLES ...............................................................................................26
33. CONSUMABLE MATERIAL STORAGE .............................................................26
34. HAZARDOUS MATERIALS................................................................................26
35. CONTROL OF OPERATING AND MAINTENANCE MANUALS .........................26
36. MAIN RECOMMENDATIONS ABOUT MATERIAL STORAGE, PROTECTION
AND PRESERVATION ..............................................................................................27
37. DELIVERY AND RETURN OF MATERIAL .........................................................31
38. STOCK-TAKING AND SPARE PARTS ................................................................31
39. MATERIAL RECONCILIATION ..........................................................................32
40. DOCUMENTS....................................................................................................32
41. MATERIAL RECEIPT REPORT (ATTACHMENT A, FOR REFERENCE ONLY) ...32
42. OVER/SHORT DAMAGE REPORT (ATTACHMENT B, FOR REFERENCE ONLY)
32
43. MATERIAL NON-CONFORMANCE REPORT (NCR)..........................................33
44. MATERIAL RETURN VOUCHER .......................................................................33
45. ATTACHMENTS ................................................................................................33

Revision History
Amendment Revision Amender Amendment
Date Number Name

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OMS references
OMS section ref OMS section title Relevant section of this
document

Related documents
Document Document name Description of Content
number

Stakeholders
Name Date Reviewed

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1. PURPOSE
1.1 Project Background

BP Berau Ltd., hereafter known as COMPANY, is the operator of Tangguh LNG, a two train natural gas (NG)
liquefaction facility in Bintuni Bay, Papua, Indonesia. The facility includes associated onshore infrastructure,
two offshore platforms, pipelines and twelve wells. These facilities are the Trains 1 and 2 development at
Tangguh.
COMPANY has initiated the Tangguh Expansion Project to commercialise the incremental resource into high
margin gas markets based on a single LNG (liquefied natural gas) train expansion (Train 3).
Tangguh Expansion Project will consist of new offshore facilities, including wellhead platforms and
pipelines, and onshore development on the existing Tangguh brownfield site. The new onshore facilities
will include one additional natural gas liquefaction train of a similar design and capacity to the existing trains,
an onshore receiving facility (ORF), new LNG and condensate loading berth, additional boil off gas (BOG)
recovery, utilities, flares and the infrastructure to support logistics and the associated increase in the
temporary and permanent workforce.
The Tangguh Expansion Project comprises of the following new facilities:
Onshore Receiving Facility (ORF)
LNG Train 3
Condensate Stabilization Train 3
Interconnection Plant Utility Facilities
LNG Loading System
Condensate Loading System
Integrated Control and Safety System (ICSS)
Telecommunication System
Trestle Jetty Structure
Onshore Infrastructure
Hazardous and Non-hazardous Waste Management System
Waste Water Treatment
New Dry, Wet and Tankage Flares

2. INTRODUCTION
2.1 Objectives of the Document
This document defines responsibilities, documentation and reporting requirements for receipt, storage,
withdrawal, tracking and preservation of equipment and materials during fabrication, transportation and
installation/construction phases.

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2.2 Methods of Implementation

This document describes the minimum requirements that shall be applied during the execution of the works
for the construction progress measurement management, in accordance with Project specification and Client
requirements. This procedure is intended to be fully inclusive and shall not be used to modify or supplement
the work contract or any part thereof.

The objective of this work process is intended to achieve are as follows:


Standardize the working methods to speed-up the work progress;
Formulate the subcontract periodical payment methods.
Create the set of rules to issue the accounting documents;
Ensure to issue the all accounting documents, including full supporting information needed for the work
process;
Define the responsibilities of all staff involved in the work process;
Schedule set up to issue the accounting documents;
Promptly supply UTs with all significant information resulting from analyses of accounts;
Be ready for any internal/external audit.

3. REFERENCE DOCUMENTS
3.1 Internal References

The reference document will be informed later.


CONTRACTOR will produce additional Project specific work practices and procedures as the project
develops, including to strengthen or update this procedure, and Subcontractors to implement accordingly.

4. DEFINITION, ABBREVIATIONS AND ACRONYMS

Abbreviations Description
COMPANY BP Berau ltd.
CONTRACTOR CSTS (Chiyoda, Contractor, Tripatra, SAE)
EDMS Engineering Document Management System

SUBCONTRACTOR An organization appointed by the Contractor to perform activities that


make up the scope of the active Subcontract.

QCP Quality Control Plan

TPI Third Party Inspection


PMIS Project Management Information System

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AREA/SUB-AREA Project physical area related to WBS level.
Construction basic activities used to measure progress and organized into
ELEMENTARY ACTIVITY
construction compositions
BILL ITEM Unique code of the price list and/or bill of quantities.
PMIS tool used for project magnitude estimation in terms of construction
quantities, hours and costs. The tool is used for
BOFF
the gathering of engineering estimated bill item quantities by WBS during
bid and executive phase.
Bill of Quantities - Document containing the work quantities associated to
BOQ the relevant bill items and submitted to Subcontractors during the bidding
phase for cost estimation purpose.
Construction Item List PMIS tool used for management of construction
CITEL
items.
Construction Management Class - Aggregates multiple Sub-CMCs, and
CMC
represents a homogeneous work activities.
Construction Program PMI Stool used for the management of
COPR
Construction activities planning.
Accounting Contractor _ PMIS tool used for the management of
COLAV
Subcontracts accounting activities.
Set of construction elementary activities used to measure physical progress
COMPOSITION
at ITEM level.
Construction Personnel PMI Stool used for gathering of site hours
COPE
(equipment and manpower).
Homogeneous construction work class that aggregates several CMC, Sub-
DISCIPLINE
CMC and BILL ITEMS.
UT Engineering Technical Unit.
EXPECTED MAN HOURS
Standard man hours multiplied per K1 factor.
(EMH)
GENANAG PMIS tool used for general libraries data bank.
IFC Issued for construction
Unique code, defined by the engineering department, that identifies the item
CONSTRUCTION ITEM
to be procured, constructed or installed and/or subject to a control cycle.
ITP Inspection test plan.
K1 K factor used to estimate the expecte man hours (SMH * K1 = EMH).

Productivity factor obtained from construction actual direct hours (AMH /


K2
SMH = K2).
MAGA PMIS tool used for project materials management.
NDT Non Destructive Tests.

Project Completion System PMIStool used for quality RFI and


PCOS
CERTIFICATEs management.

PRICE LIST Contractual bill items under the work contract.

PRIMAVERA (P6) Oracle tool used for planning activities.

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Contractor_Project Management Information System - Is a suite composed
CONTRACTOR_PMIS by different tool and applications used for the management and control of
bid and executive projects.

Sub Construction Management Class - Homogeneous construction work


SCMC
class that aggregates several BILL ITEMS.

Quantity performed in the UNIT of TIME (quantities/hour) under optimal


STANDARD EFFICIENCY conditions. It is associated to each bill item and it is used to define the
Standard Man Hours (SMH).
Direct man hours (foreman + labor including indirect construction, lifting,
STANDARD MAN HOURS
scaffolding, cleaning, on-site handling labor) required to complete an
(SMH)
activity under standard conditions.
A subsystem is a further subdivision of a system, which performs a partial
SUBSYSTEM operational function of the system, main packages are typical examples of
subsystem. Can be commissioned independently.
A system is a major subdivision of an installation, being either process or
utility, which performs a major function of the plant. The system includes all
SYSTEM
equipment that allow it to operate. Examples: Fire water system, Potable
water system.
Unique code, defined by the engineering department, that identifies the item
TAG ITEM
to be procured, constructed or installed and/or subject to a control cycle.
Grouping of objects with similar functions, characteristics and cycles of
TYPE OF ITEM
installation and controls.
Hierarchical breakdown of project activities into uniform and easily
WBS managed elements. Each descending level represents an increase in the
definition of the detail of the scope of work.

SI Site Instruction

ACRONYMS ROLES

PD Project Direct
PM Project Manager
TM Technical Manager
CM Construction Manager
PSL Project Specialist Leader
MSQM Management Systems and Quantity Manager
MASC Project Management Systems Coordinator
MISC Project Mechanical Information System Coordinator
QSC Quantity Survey Coordinator
QS Quantity Surveyor
PQM Project Quality Manager
PCM Project Control Manager
SCC System Completion Coordinator

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CONM Project Contract Manager
COM Commissioning Manager
DS Discipline Superintendent
FEM Field Engineering Manager
FSE Field Specialist Engineer
MM Material Manager
LDE Lead Discipline Engineer
PEP Project Engineering Plan

ACRONYMS DEPARTMENTS

OMIF ONSHORE PLANT MANAGEMENT INFORMATION SYSTEMS AND FEASIBILITY


ENG INGEGNERIA, TECNOLOGIE E COMMISSIONING
OCF ONSHORE PLANT CONSTRUCTION AND FABRICATION
TND TENDERING E&C
COMOP COMMISSIONING, PLANT OPERAT. AND MAINTENANCE ENGINEERING
OPQM ONSHORE AND OFFSHORE PROJECT QUALITY MANAGEMENT
PCON PROJECT CONTROL

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5. ACTIVITY DESCRIPTION
5.1 Document and Responsabilities

CONTRACTOR will be responsible for material/equipment storage and preservation for material under its
Scope of Supply until delivery to SUBCONTRACTOR.
After such delivery, SUBCONTRACTOR will be responsible of material/equipment storage and preservation
until issuance of Final Acceptance Certificate by CONTRACTOR. CONTRACTOR will not be alleviated from
any responsibility towards the COMPANY.
SUBCONTRACTOR shall take into consideration costs related to visual inspections, withdrawal, management,
QA/QC inspections, preservation, transportation of materials included in its own Scope of Work.
After handover from SUBCONTRACTOR to CONTRACTOR, CONTRACTOR will be responsible until handover
to COMPANY.
When CONTRACTOR performs the activity with its own personnel and equipment (Direct Hiring) its duties
and responsibilities shall be the same of SUBCONTRACTOR.
SUBCONTRACTOR will be responsible for material/equipment storage and preservation for material under its
Scope of Work.
SUBCONTRACTOR shall submit its own procedures for material preservation within sixty (60) days before
arrival of any material or equipment to WORK Site.
The Manufacturer/VENDOR will provide procedures to be followed for protection of relevant
material/equipment. CONTRACTOR/SUBCONTRACTOR shall comply with Manufacturers/ VENDORs
maintenance and preservation requirements, including periodic rotation of mechanical equipment during the
storage, and until handover to CONTRACTOR.
In case of any conflict between Manufacturer/ VENDOR recommendation and requirements of this
specification, CONTRACTOR shall determine the procedures to be followed. SUBCONTRACTOR shall keep
record of equipment and material protection activities.
These records shall be submitted as a part of the Pre-commissioning Record Book.

6. OBJECTIVE

The objectives to be achieved by the CONTRACTOR are:


- delivering materials and equipment to SUBCONTRACTORs.
- carrying out all operations connected with the receipt, inspection, storage and issuance of materials.
- ensuring identification, labeling, protection, storage, retrieval, preservation and control of materials
handled.
- issuing and circulating information documents concerning the materials to the Site Organization.

6.1 Definition of warehouse organization structures

The warehouse(s) dimensions and warehouse equipment will be sized considering the following parameters:
- Quantities and typology of material to be handled.

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- Duration of the project.
- Environmental conditions.
- Level of management required.
- Preservation requirements.
- Any other relevant factor.
- Warehouse safety standards
Warehouse shall also be provided with electrical energy, telephone, water, toilets, drains (septic tanks),
firefighting systems, and air conditioned room for sensitive material such as electronic cards, instruments,
etc.

6.2 Warehouse Organization and Responsibilities

The composition of the CONTRACTOR warehouse management organization will generally comprise the
following positions:
- Warehouse Superintendent
- Material delivery assistant
- Material collection assistant
- MAGA/MARIAN Operator and data entry
- Warehouse supervisor(s)
- Warehouseman(s)
- Equipment and Vehicle Operator
- Rigger(s)
- Labors for opening crates and the physically stock materials with proper PPEs
- Handling equipment (cranes, fork-lifts, etc.).
SUBCONTRACTOR shall assign similar positions in its own warehouse ad shall provide adequate personnel
and equipment in CONTRACTOR warehouse to withdraw, locate and collect material and equipment.
Warehouse management shall ensure that Warehouse staff implements and records all protection measures
necessary for the preservation of materials and equipment and bin cards.
Recorded data must be kept by the Warehouse staff. Copies of these data must be provided upon request
from the Warehouse management.
The monitoring and management of these materials will be implemented through dedicated software such
GEMAPI, MAGA, MARIAN or spreadsheets, which allow the identification of the different items and the
control of the bulk materials.
The management of materials in stock consists of the following activities:
- Receipt and inspection of materials.
- Management of non-conforming material.
- Materials take-over for management, storage/preservation, material administration, delivery/return of
materials and stock taking.

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CONTRACTOR and SUBCONTRACTOR are responsible for planning, implementation and recording of all the
protection measures necessary or required for the preservation of equipment and material. Preservation
activities shall be recorded in a log book and shall be updated and made available at the warehouse.
Documentation shall include:
- Log with entries regarding the equipment stored and/or erected with internals under a nitrogen
blanket till pre-commissioning. Log shall include nitrogen pressure maintained in the items.
- Status of materials, equipment and spools upon arrival at the WORK Site and any and all remedial
actions taken to restore items to original cleanliness as specification.
After delivery of materials/equipment to SUBCONTRACTOR, and until the handover of FACILITIES to
CONTRACTOR, SUBCONTRACTOR shall continue the implementation and recording of planned protection
measures.

6.3 Receipt and inspection of materials

The activity of Receipt and Inspection of materials will comply with the Project Quality Plan. It will include at
least:
- Material Control.
- Traceability of shop and field fabricated piping materials.
Received material will be unloaded in established areas according to relevant quantity and type.
WRS or Material Controllers shall perform the following operations:
- Check that all incoming material is at least accompanied by packing list, shipping advice, invoice,
waybill, shop inspection reports, inspection release notes. The order number of packages, the weight,
quantity and type of material are indicated on these documents.
- Verify that operating and maintenance manuals and any other type of documentation accompanying
the equipment match with those listed in the delivery note.
- Physical check of the materials received ascertaining that both the quantity and type correspond to
what is stated in the shipping documents.
- Prepare the Material Receipt Report (Att. A).
- Records any damage which has occurred during transportation (Att. B).
- Notify CM/DS/FEM/FSE/QCS of any material non conformity.
- Check the markings/color codes of materials.
- Check, using PMI technology, the piping material for which PMI check is required.
- Assign an appropriate storage area according to the type of material.

6.4 Non-Conforming material

FPQM manages the administration of non-conformances. Working with the assistance of FSEs action is taken
to solve non-conformances on site by WRS for non-conformances identified in the Warehouse, by DS non-
conformances identified during erection and by COM for non-conformances identified during pre-commissioning

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and commissioning activities. When necessary support and approval from the Home Office organization will be
requested.
Once the existence of non-conformance has been confirmed, WRS shall ensure that:
- The bulk material is marked (i.e. "NON-CONFORMING MATERIAL - ITS USE IS NOT ALLOWED") and
is kept separate from other material to avoid improper use.
- Equipment (i.e. skidded machinery, package, etc.) is kept under control by the non-conforming
register.
Where specifically instructed by CM/FEM and agreed by COMPANY, the non-conforming equipment/material
could be erected if the non-conformance can be solved after the installation.
The resolutions of non-conformances will be approved by FEM and PM and distributed as showed in table
below:
NONCONFORMANCEDITRIBUTIONTABLE
NCRcategory PM CM COM FPQM FEM FSE DS FMC PSL TM
1.NonConformancereport
A C V/E* A C C E Z Z
forwarehousematerials
2.NonConformancereport
A C V/E* A C E Z
duringerectionworks
3.NonConformancereport
A E V/E* A C Z Z
duringprecommissioning

4.NonConformanceregister E

A:Approval
V:Review
E:Execution
C:Comments
Z:Tobeinformed
*:Forhisareaofresponsibility

6.5 Material take-over for management

This activity consists in assigning a code and recording all significant data required to draw up "data cards" for
the materials, like:
- Purchase order number(s)
- Name of Supplier
- Date of arrival of materials
- Shipping File
- Name of ship/air freight
- Number of Packages, Weight, Description of materials.
- Location in the warehouse
- Packing Lists Port of Origin
- etc.
These data, which certify that materials are actually stored in the warehouse, are suitably grouped and made
available to concerned personnel.

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The data are processed by software, used by the WRS to manage materials in stock and to be handled.
Updated data, periodically sent to the WORK Site by the Home Office make possible to insert automatically
data pertaining to the Purchase Order and its positions.
After materials arrive to WORK Site, the CONTRACTOR warehouse personnel enter the quantities received.
Piping Field Engineer will use GEMAPI to verify piping feasibility according to material availability.
This program also manages the handling of piping materials by issuing "collecting notes" and storing stock in
memory.
The operation carried out by the warehouse personnel is the confirmation of the quantities delivered to the
SUBCONTRACTOR through the collecting notes duly signed by the CONTRACTOR DS.

6.6 Storage/Preservation of the material

Storage/Preservation of material received by SUBCONTRACTOR shall be carried out in accordance with the
requirements of the relevant technical specifications, project requirements and VENDOR recommendation right
from the commencement till the handover of FACILITIES to CONTRACTOR.
Additional measures required by the Manufacturer/VENDOR shall be implemented to protect
equipment/material against extreme heat or cold, humidity, water and windblown sand. Weather sensitive
materials and equipment (i.e. instruments, small tools, welding electrodes, delicate equipment and equipment
for special uses) shall be stored inside covered area or other weather proof structures.
All materials stored outdoors will be positioned at least 100 mm off of the ground and above ground water
pooling by use of railroad ties, timbers, wooden beams, pallets, concrete slabs or other appropriate means.
Hole covers shall be fully intact and shall not have any damage or cutting.
Preservation of equipment shall be in accordance to relevant preservation procedures.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36.

6.7 Materials to be stored inside the warehouse


The following materials (list is indicative and not complete) shall be arranged, differentiated and kept separate
in the shelving inside the warehouse:
- gaskets
- fittings, flanges and valves smaller than or equal to 2"
- bolts and tie rods
- dry transformers
- switchboards, cabinets
- accumulator batteries and accessories
- spare parts
- lighting equipment
- telephone equipment, clocks, loudspeakers, intercoms, electronic components, i.e. for
telecommunications
- mineral insulated heating cables
- coils of cables and conductors
- fiber optic and electrical heat tracing cables

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- cables accessories (couplings, terminal ends, mixtures, tapes, crimps, etc.)
- materials for cathodic protection
- equipment, machines, worktops and instruments for laboratories and electrical workshops
- all electrical installation materials such as boxes, sockets, manipulators, lighting fixture accessories,
fittings and all small sized materials
- relays, instruments, etc.
- circuit breakers, disconnect switches, fuses
- control panels, analyzers, local switchboards, flow devices, levels, accessories and instrument
assembly equipment
- particularly delicate materials for which storage in a closed area or even in an air-conditioned
environment is requested
- recorders, earthing equipment, dielectric liquid oils, different liquids in appropriate, labelled
containers, and similar liquids
- refractory materials that do not need to be assembled immediately.

6.8 Materials to be stored in open fenced area covered with tarpaulin

Materials that can be exposed to the weather as long as they are protected by the original, undamaged
wrapping can be stored in the shed. These include but not limit to:
- complete rotating machines
- transformers, high-voltage equipment, generating sets
- lighting fixtures for outdoor installation
- machinery, safety valves and control valves
- internals for columns and reactors
- catalysts
The materials shall be stored off of the ground and protected with tarpaulin or polyethylene sheets. Safety and
control valves in particular must be stored in their own casing. These items are usually included in seaworthy
packing with silica gel bags to absorb humidity.

6.9 Materials to be stored in uncovered area

The following materials (list is indicative and not complete) can be stored in open fenced areas:
- Aggregate material
- Filling material in general
- flanges, fittings, valves, filters over 1
- pipes below or equal than 2"
- stainless steel pipes
- machinery
- metal sheets and various steel sections.

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- prefabricated supports
- pressurized containers, heat exchangers, air coolers
- pipes of diameter greater than or equal to 2"
- structural steel works
- grating
- prefabricated piping

6.10 Traceability and Identification of Materials

The following rules help warehouse staff to locate the position of materials and to identify them without the
risk of error:
- An accurate map of covered and uncovered storage areas must be drawn up indicating a proper
coding system which facilitates identification of all areas and each shelf.
- The location codes shall be highlighted in the areas by means of signs and also written on the
shelves.
- All piping material shall be segregated by type of material grade, and arranged by size schedule and
rating, in ascending way from the biggest to the smallest. This will allow to easy track the items in
the yard, furthermore it will keep distance between similar material, same size schedule and rating
but with different base material, avoiding to be confused one each other by mistake during marking
and/or wrongly pick it up during issuance.
- All steel pipes shall be identified with bands of paint coloured according to specifications issued by
the Layout and Piping department. It is advisable to extend this system to the fittings too.
- Non piping materials belonging to the same order must be arranged, when possible, in the same
area, and packages or materials marked with the number of the order and the package.
- The location code must be accurately transferred to computer at the moment the materials are
logged.

6.11 Use and application of rust preventives

If required, all interior and exterior surfaces shall be clean and dry before any rust preventive materials are
applied.
Mineral spirits or any standard solvent shall be used for cleaning surfaces before the application of any rust
preventive. In special cases blasting, pickling or other chemicals shall be used for cleaning and inert gas used
for rust prevention when specified by Manufacturer/VENDOR.
Kerosene or gasoline shall not be used as cleaning agents. CONTRACTOR/SUBCONTRACTOR shall specify the
rust preventive compounds to be used for each application.

7. PRESSURE EQUIPMENT
The equipment shall be placed on supports using the same criteria used by VENDOR during transportation.
All equipment shipped with protective covers or plugs over openings, and with rust preventive coatings applied
on exterior machined and threaded surface further, shall be treated as follows:
- Protective covers plug and coatings shall be replaced if damaged.

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- If water or dirt has entered the equipment through damaged or improperly secured covers and plugs,
the equipment shall be cleaned before covers, plugs and coatings are restored.
- If vapor phase inhibitors or desiccants are used to protect the interiors or mechanical equipment, the
seals shall be examined.
- Any damaged vapor seals shall be repaired or replaced and the inhibitor or desiccant renewed if
necessary. Vapor seals shall be protected until the equipment is ready for pre-commissioning. Any
damage to seals before such time shall be immediately repaired.
When specified by the Manufacturer/VENDOR, all items arrived under nitrogen pressure shall be regularly
monitored for the pressure variation and recorded in order to assure that there is constant required pressure
available.
The following instructions shall be complied with to protect the equipment until start-up:
- manholes covered with gasket;
- the flanges of equipment with permanent blanks or with covers shall be provided with the proper
gasket and tie-bolts. As minimum they shall be secured with at least four tie bolts equidistant from
one another.
- Vent holes of reinforcing plates shall be sealed with grease.
- all other openings and clamp properly closed as established by VENDOR's technical document;
- threaded connections shall be protected with caps.
- rust-proofing product to flanges and exposed parts of bolts applied if required;
- condition of external primer and touch up, where required, checked.
Replaced inhibitor fluid and hygroscopic products shall be chlorine-free, suitable for the purpose and shall not
cause intergranular corrosion.
Where marking is carried out, products used must be free of lead, sulphur, zinc, cadmium, mercury, chlorides
and other halogens.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36.

8. VESSELS
The equipment shall be placed on saddles using the same criteria as those used by VENDOR and during
transportation.
Freestanding metal enclosed equipment shall be stored in an upright position. After the installation, the interior
shall be cleaned and inspected. The following procedures shall be followed to protect vessels until erection
and/or pre-commissioning:
- Cover all manholes with gasket covers.
- Close all other openings tightly.
- Coat all exposed bolts and flanges with rust preventive agent.
- Check exterior primer for any damage and touch up where necessary.
- When specified by the Manufacturer/VENDOR, all items arrived under nitrogen pressure shall be
monitored for the pressure variation regularly and recorded in order to assure that there is constant
required pressure available.

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- Interior parts already installed inside equipment (e.g. wire mesh pads, distributors, etc.) shall be
inspected to check their conditions; temporary supports will be checked and restored where
necessary.
- Plates, packing, distributors and special parts have to be stored inside the warehouse or under a
shelter.

9. ADDITIONAL INSTRUCTIONS FOR SHELL AND TUBE BUNDLE


OF HEAT EXCHANGERS
The main flanges of tube heat exchangers which are normally closed with service gaskets will not be opened,
unless specifically required.
Where required, unless otherwise specified by VENDOR, nitrogen shall be maintained at a pressure of 0.5
barg.

10. ADDITIONAL INSTRUCTIONS FOR AIR COOLERS


All electrical and moving parts such as fan blades, hubs, actuators, belts, pulleys, vibration switches, etc. shall
be stored under cover in a dry place with no humidity.
All parts delivered packaged such as: dampers, protective mesh, conveyor blades, etc., shall be inspected upon
arrival at the site. Damaged parts shall be repaired or replaced and then stored in the warehouse according to
the VENDOR's instructions.

11. ADDITIONAL INSTRUCTIONS FOR SPECIAL PRESSURE


EQUIPMENT
Stainless steel plate heat exchangers shall be protected with a non-toxic and easily removable vapour phase
corrosion inhibitor (recommended quantity 1kg per cubic meter). Openings shall be closed suitably to avoid
leakage of the inhibitor, to ensure it remains efficacious.
The junction box of heating elements of heaters exchangers shall be inspected to check there is no water or
condensate; should these be present, the box shall be completely dried, cleaned and inspected to check the
condition of electrical connections between heating elements. The main switchboard shall be stored in covered
area.

12. FIRED HEATERS, BOILERS AND STACKS


Actions to be taken to protect and preserve heaters, boilers and stacks are those indicated by VENDOR.
After heaters have been installed, the following procedures must be followed until hand-over to
CONTRACTOR/COMPANY:
- Hinges of headers and access doors shall be coated thoroughly with heavy grease to permit
immediate functioning.
- Movable parts on burners shall be greased to permit the threads or adjustment of mechanisms.
- External surfaces, which are not painted, shall be sprayed or brushed with rust preventive that
provide metal protection.
- Refractories shall be kept dry at all times.

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Manufacturers additional storage requirements through the receiving, storage, and erection phase shall be
strictly followed.

13. MACHINERY
Machinery should preferably be kept inside their original packaging until erection. They shall be stored raised
from the ground and protected from bad weather.
Both during storage and after assembly, the following periodic checks shall be made: sealing of all openings,
weekly rotation of the drive shaft, cleaning of motor coupling and preservation of machined surfaces and the
filling of mechanical seals with preservation agents. Special preservation requirements shall be looked for in the
suppliers instructions.
After installation at their final service location, turbines, centrifugal fans, gear unit cases, agitators, centrifugal
pumps and centrifugal compressors shall be protected as follows:
- Coat internal bearing, housings, gear unit cases, motor joints and unpainted machined surfaces with
the appropriate protective agent. Turn the shaft of machines with roller bearings once a week,
following the indication of the way of rotation.
- For the machine with sleeve bearing VENDOR instructions shall be followed.
- Vent and drain connections shall be plugged, capped or blinded as applicable, using steel fittings.
- Blinds shall be equipped with gasket.
- Clean shaft couplings and not painted machined surfaces and coat them with the appropriate
protective agent.
- Spacers shall be stored in warehouse and duly identified.
- Suction and discharge nozzles of centrifugal compressors, pumps and steam turbines shall be
covered with leak-tight metal enclosures.
- The closures shall remain in place or be replaced with blanks until hydrostatic testing (if required) and
flushing of connecting piping is completed.
- All centrifugal pumps with mechanical seals installed shall be filled entirely with an appropriate
protective agent, according to the mechanical seal manufacturer instruction.
- Spare rotating elements shall be stored indoor as per the manufacturers recommendations.
After packing removal, reciprocating pumps, reciprocating compressors and internal combustion engines shall
be checked and protected as follows:
- Exposed rods, eccentrics, plungers and machined surfaces shall be coated with an appropriate
protective agent.
- Gas and liquid cylinders and valve chambers shall be filled with an appropriate protective agent.
- The drive mechanism of proportioning and metering pumps shall be filled with an appropriate
protective agent.
Internal combustion engines shall be protected per paragraphs above and the following:
- Electrical accessories such as magnets, which can be damaged by moisture, when feasible shall be
stored in a dry, warm place where condensation or humidity do not occur.
- A small amount of the appropriate protective agent shall be sprayed into each cylinder, through the
spark plug or injection nozzle openings.

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- Additional appropriate protective agents shall be sprayed into the cylinders each time the crankshaft
is rotated, in accordance with the manufacturers recommended schedule.
Other not painted mechanical equipment shall be protected as follows:
- Fill the units with the appropriate protective agent until all internal surfaces are coated.
- Apply a coating of the appropriate protective agent to all shafts, couplings and not painted machine
surfaces.
- Clean chains (if any) with solvent, coat with the recommended protective agent.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36.

14. PIPES/SPOOLS

- In the loading, unloading and stacking operations, the pipes shall be handled at all times in a manner
that prevents damages (such as cuts, cracks, bends, buckles, etc.) to the pipe-walls, beveled ends,
and to the coating (including internal coatings, if applied).
- Pipe shall not be stored directly on the ground but at least 100 mm above, surfaces on which the pipe
is laid or stacked shall be flat and free of protrusions, assuring full uniform bearing for the pipe length
or shall be provided with suitable bearing strips equally spaced to avoid pipe bending/deformation.

- Pipes shall not be drawn or rolled on the ground.


- Separate stacks shall be prepared for the different pipe diameters, thickness and material grade of
project, each stack shall not be higher than 2 meters.
- PVC/GRP pipes shall be adequately supported, and the supports shall be spaced so as to avoid
bending, which would also damage pipe coating.
- Threaded ends shall be protected with grease and fitted with metal, wood, or plastic caps.
- All openings of austenitic stainless steel and internal lined spools shall also be sealed to prevent entry
of moisture.
All shop fabricated and field prefabricated piping spools requiring storage at the pipe spool storage area shall be
prepared as follows:
- If chemical cleaning is to be followed, flanges for shop fabricated piping shall be protected over the
entire gasket surface with metal hardboard or wood firmly fixed after applying and or renewing rust
preventive agent on the flange coupling surface.
- Rust preventive or grease must not be used on pre-cleaned pipe spools.
- All fabricated piping materials shall be stored so that shall not be in contact with the ground.
Non-metallic pipe (thermoplastic and RTR pipe) shall be stored as follows:
If loose pipes are stacked on each other, the stack height shall not exceed 1.5 m. Adequate side support shall
be provided to prevent slipping or rolling.
If pipe is stored on racks or bearing boards, the supports shall be at least 75 mm wide. Supports shall be
spaced on 3 m centers maximum with the first supports 1.5 m from the end of the pipe.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36.

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15. ADDITIONAL REQUIREMENTS FOR COATED PIPES

- Flanges shall be covered with a timber, metal or plastic cap fastened to the flange by bolting or
wiring. The cap dimensions shall ensure protection of the whole flange face and bevels shall be
protected by means of covers fastened to the pipe.
- Ends of threaded couplings shall be protected by means of caps.
- Large bore (NPS 30") pipes shall be internally protected by means of suitable removable spiders or
cross-pieces to prevent flattening or deformation during transportation.
- Coated pipe shall not be rolled or dragged on the ground. The pipes are to be placed at least 150 mm
elevated from the ground on a wooden spacer planks, or sand bags wide enough to avoid damaging
the coating.
- Internally coated pipes shall be handled from the outside diameter only. Lined and coated pipes and
fittings shall be handled with wide fabric or rubber-covered slings and padding shall be used cloth or
hemp belts, of a size appropriate for the weight to be lifted, or with hooks at the ends.
- FBE coated pipes shall not be stacked directly against each other at any time during storage. They
shall be separated by full encirclement non-compressible rubber padding or equivalent at least 10 mm
thick. Two full encirclement separation pads, two shall be located 1 to 3 m from each end of the pipe,
others pads shall be placed to support the center section of the pipe so that the distance from one
pad to each other is approximately 5 meters. Additional separation pads shall be used, if required, to
keep the FBE coated pipes from touching each other. The separation pads shall be attached by some
mechanical means that ensures they will stay in place. Padding must be fastened fixed to the pipes
to ensure they remain in position.

16. FLANGES

- Flanges shall be stacked in pyramid shaped stacks, with a height of about 1 m.


- They shall be coupled in pairs, separated by discs made out of soft material (cardboard, strips of soft
wood, etc.) in order to protect the resting surfaces of the gaskets.
- They shall be raised off the ground on wooden planks.
- Flanges shall be protected with grease or other suitable preservative agent, over the entire gasket
surface.
- O-Ring grooves shall be protected with lubricating grease.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36

17. FITTINGS
- The fittings shall be properly arranged in stacks in order to prevent them from sliding down, the
height of the stack shall be proportionate to the diameter, and shall not exceed 1.5 m.
- They shall be placed on a planked floor and in such a position that rain water does not stagnate inside.
- They shall be handled in the same way as the pipe.
- Suitable measures shall be taken for material grades subject to corrosion in order to avoid it.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36.

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18. VALVES
Indoor storage is required for all valves except the following:
- Manually operated valves size 2 NPS or larger may be stored outdoors on wooden strips, with the
valve stem upright
- Large automatic control valves 2 NPS or larger may be stored outdoors on dry paved area, or on
pallets if a shed, roof or tarpaulin siding (or equivalent) are provided
- Actuators on control valves and motor operated valves shall be protected against mechanical damage
- All exposed metal parts which may be affected by corrosion shall be protected with a suitable preventive
agent.
- Pressure relief and safety valves shall be stored in an up-right vertical position in weather protected
areas.
- The flanged ends shall be properly plugged, sealed and covered to prevent entrance of sand, dirt and
rain.
- All valves stored outdoors shall be entirely protected with plastic sheet.
- After being stored, all valves shall be in the closed position except plug and ball valves.
- All other manually operated valves shall be provided with protective sheating.
- In addition to the above, all flange facings (ring joint, raised and flat) shall be covered with Nitrile
Butadiene (based) Rubber (NBR) Self-Adhesive protection.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36.

19. GASKETS AND BOLTING


Gaskets, bolting, stud and nuts shall be stored under cover in dedicated areas according to various diameters.

20. STAINLESS STEEL (INCLUDING AUSTENITIC)


The stainless steel material, including the austenitic one, shall not be exposed to salt water or other products
containing salt and to the effects of the weather.
Stainless steel equipment components and materials, including the austenitic ones, shall be protected as
follows:
- Under cover (only for pipes fittings or other small items)
- Not in contact with carbon steel and alloy steel to prevent contamination
- Not in contact with the ground or with porous supports such as raw wood

21. STEEL STRUCTURES


Steel structure material shall be placed at least 150 mm above the ground with the intersection of padding or
plastic between the elements.
For the handling, soft slings shall be used not to damage the painting.
Gratings shall be properly stocked to avoid bends and damages to toe plates.

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22. ELECTRICAL AND INSTRUMENT MATERIAL


Actions to be taken to protect and preserve the electrical and instrument materials are those indicated by
VENDOR.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36.

23. BATTERIES
Batteries shall be stored indoor in accordance with the manufacturer's instructions.
Battery caps shall be checked upon arrival at the Site and replaced if damaged.
For batteries shipped already filled with acid, the electrolyte level shall be checked upon arrival at the Site and,
if low, restored to the correct level.
The storage periods from the date of shipping to the date of installation and initial charging must not exceed
those indicated by the manufacturer.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36.

24. LOW VOLTAGE EQUIPMENT


All low voltage equipment such as lighting fixtures, transformers, push buttons, pilot lights, relays, meters, etc.
shall be stored indoors in a dry place where condensation of humidity cannot occur.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36.
Indoor storage is required for all transformers except for the transformers intended for outdoor installation which
may be stored outdoors without protective covering.
When delivered at the Site and on monthly basis, level of the liquid and the ambient temperature of
transformers shipped with main tank filled with insulating liquid (except for expansion space) and blanketed or
filled with gas under pressure will be measured and recorded. If the level falls, leaks will be repaired and
insulating liquid to keep the level within tolerance will be added. VENDOR responsibility about will be evaluated.
Main recommendations about storage, protection and preservation are listed at the Paragraph 36.

25. SWITCH-GEAR, STARTERS AND ELECTRICAL CONTROL


EQUIPMENT
Equipment not provided with adequate seaworthy packing, shall be stored indoors in a dry, warm place where
condensation of humidity cannot occur and as follows:
- Shelter shall have good ventilation
- If high relative humidity or large, rapid changes in temperature are experienced, heaters shall be used
to maintain the shelter temperature at a level approximately 6 C above minimum daily temperature
(alternatively may be set 4C under the dew point calculated with the minimum daytime temperature
and higher daytime relative humidity).
- The temperature shall not exceed 40 C.

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- In humid locations, it may be necessary to remove the equipment from the shipping cases to permit
adequate ventilation and to avoid mildew.
Free standing metal enclosed equipment shall be stored in an upright position.
Circuit breakers and similar items which are shipped dry shall be stored indoors.
Switch-gear buildings shall be air-conditioned after installation of switch-gear, starters and control equipment (if
the permanent air-conditioning is not available, portable air-conditioning units shall be used to maintain the
temperature below 40 C).

26. INSTRUMENTS AND PROCESS CONTROL EQUIPMENT


- All instruments shall be stored indoors and marked with proper tag number.
- The indoor temperature shall be controlled to prevent the condensation of humidity.
- Prefabricated panel boards shall be left in their shipping cases until moved into their final position.
- Instruments, for which the manufacturer does not specify temperature requirements, shall be stored at a
temperature ranging from 6 to 40 C.
- Potentiometers shall never be exposed to temperatures below 0 C or above 50 C.
- Instruments including control valves and motor actuators installed at outdoor locations shall be
protected from the weather and mechanical damage.
- Wood covers over glass fronts may be used, all openings/orifices shall be dust tight covered or plugged.
- Control valves shall be protected in the same manner as valves (refer to paragraph 5.12)
- Motorized actuators shall be protected in the same manner as motors (refer to paragraph 5.22)
All instrumentation equipment, including control consoles, microprocessors, video consoles, process computer
and related equipment shall be unpacked in a dust free air conditioned environment, with a maximum of 30 C.
Installation in the control rooms shall be performed when such rooms are air-conditioned at the time of
installation. Manufacturers requirements shall be followed for analyzers, control system equipment and all
indoor electronic panel board's equipment such as chassis, computer equipment, programmable controllers,
etc.Main recommendations about storage, protection and preservation are listed at the Paragraph 36.

27. MOTORS AND GENERATORS


Indoor storage is required for all motors and generators except motors designed for outdoor use, which may be
stored outdoors without protective covering. 75 kW motors and greater are supplied with internal space heaters.
The heaters shall be energized after receipt at the Site with an AC voltage source as indicated on the motor
nameplate. Upon the arrival of motors and generators, the insulation resistance value of windings shall be
measured and recorded. For motors and motorized valves stored outdoors without protection the following shall
be observed:
- All inlets not intended to be open during operation of the equipment, such as conduit and cables entries
in terminal boards, shall be closed with watertight caps.
- All valve actuators shall be stored in their normal operating position, e.g. vertical motors in an upright
position with the shaft extension downward.
After installation at the final service location, motors with oil lubricated bearings and AC motors and generators
with collector rings shall be protected as per Manufacturers instructions requirements.

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Every three months the insulation resistance of each coil with a value equal to or greater than 2300 Volts shall
be measured and recorded. Record of temperature and weather conditions at time of reading are also taken. If
resistance is low corrective actions will be taken.
If grease lubricated units are at the Site for more than one year from the factory without having been operated,
inspect the bearing grease, before use. If there has been any visible deterioration of the lubricating properties of
the grease they shall be cleaned out and bearings subsequently re-filled per manufacturers recommendations.
Shafts of motors greater than 75 kW shall be rotated per month, or more frequently as per manufacturers
recommendations, to eliminate permanent shaft deflection during storage.Main recommendations about
storage, protection and preservation are listed at the Paragraph 36.

28. CABLES
Cables stored in reels without covering shall be protected from direct sunlight. Ends of cables shall be taped to
prevent entry of moisture into insulation (if not provided by the VENDOR). Cable drums should be on pallets
with plastic covers, shall not be stacked and arranged in parallel double rows, separated at such a distance as
to allow the movement of vehicles. The storage method shall ensure that there is no danger of the drums rolling
or sliding. To simplify locating them, drums shall be arranged systematically in sections and numbered
accordingly.
Fiber optic cables and electrical heat tracing cables shall be stored in a covered and dry area.

29. PAINTING
The material shall be stored in well ventilated places, far away by fire ignition sources and with
fabrication/expiration date well indicated. Special precautions shall be adopted in accordance with vendor and
safety recommendation.
Material Safety Data Sheet (MSDS) will apply for all paint(s) coming from Manufacturer.

30. INSULATION
The storage should be in a covered and dry area and the materials should be left in original packing.
An air gap should be provided between the products and the floor and stacking should be limited to 2 heights
(2.40 m maxi). The storage shall be done in accordance to vendor and safety instructions.

31. MISCELLANEOUS AND OPERATING MATERIALS


The storage and handling of all catalyst materials are to be carried out strictly in accordance with the Licensors
and Suppliers Instructions. Any containers damaged during transportation are to be repaired and stored
separately as per advice by COMPANY/CONTRACTOR. Drums of lubricating oil shall be stored outdoors and
positioned with the oil pouring spout facing upward and in any case in a manner that prevents spillage of oil.
Soft wood must be used to prevent direct contact of drums with the ground.
Storage of operating materials shall be in a segregated area, precaution shall be taken as per VENDORs data
sheets recommendation.
The chemical and lubricants shall be stored following the precautionary measures indicated in the VENDOR's
data sheets and in case that are hazardous in accordance to HSE requirements.

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32. CONSUMABLES
Where required SUBCONTRACTORs shall provide procedures for receiving, handling and storing the
consumables supplied by them.
The electrodes, especially the covered one and rods, shall be stored in a conditioned, dry and water tight area
to avoid moisture pick-up and contamination. VENDORs recommendations shall be followed.
As per general indication here below some data about the temperature and humidity level to be maintained:
- 5-15 C max 60% RH
- 15-25 C max 50% RH
- > 25 C max 40% RH
If the electrodes are included in vacuum pack can stay at higher temperature that shall be verified inside vendor
datasheets.
Low hydrogen covered basic electrodes should be re-dried before use whenever there are application
requirements relating to weld metal hydrogen content and/or radiographic soundness (not needed for vacuum
packed).
Acid rutile stainless electrodes and all types of basic electrodes may produce pores in the weld metal if they
have not been stored in sufficiently dry conditions. Re-drying the electrodes will restore their usability.
Mild steel rutile and acid electrodes normally need no re-drying.
Cellulose electrodes must not be re-dried.
The electrodes that are seriously damaged by moisture, cannot be restored to their original condition by baking
and should be scrapped.
The electrodes shall not be stacked more than four layers of electrodes in the redrying oven and its
recommended not to redry covered electrodes more than three times.
The maximum storage time for all the electrodes is 3 years. After this time the product should be thoroughly
checked before use.

33. CONSUMABLE MATERIAL STORAGE


The material shall be stored in well ventilated areas/places, far away from ignition sources and with
fabrication/expiration date well indicated. Special precautions shall be adopted in accordance with VENDOR
and safety recommendations.

34. HAZARDOUS MATERIALS


Storage of hazardous materials shall be in a segregated area, precaution shall be as per VENDOR data sheets
recommendation.
Hazardous materials will be dealt in compliance with the Loss Prevention Program.

35. CONTROL OF OPERATING AND MAINTENANCE MANUALS


Operating and maintenance manuals and any other documentation shipped with the equipment, on receipt shall
be immediately checked against the delivery note. FEM shall ensure tracking and the delivery of such
documents to the COMPANY.

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36. MAIN RECOMMENDATIONS ABOUT MATERIAL STORAGE,


PROTECTION AND PRESERVATION

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The table below summarizes the main recommendations to be followed for material storage, protection and
preservation:
Material Storage/Protection Preservation Notes
Pipesshallbehandledwithcareduringloading, WRSandDSshallensurethe
unloadingandstorageoperations,using availabilityofmaterialcertificates
Theendsshallbeprotected.
appropriatemeanstoavoidaccidents,cuts,tears whererequiredbytheproject
Threadedendsshallbegreasedandprotected.
andotherdamages,especiallyattheends. requirements.
Stainlesssteelmaterialsshallbekeptseparatefrom
Pipesshallberaisedfromthegroundandrested Checkingofthecontents,ataskof
othermaterialssuchascarbonsteel,alloysteel,etc.
Barepipes onwoodensupportsformingpilesno theacceptanceinspectorassigned
Inaddition,thesupportsforstainlesssteelpipes
higherthan2m.Thepileshallbearrangedina tothesupply,isperformedbefore
shallbeofnonporouswood.
mannerthatavoidspipesaccidentallyrollingoff, transporttosite.Forlocally
Anysuperficialdamagetostainlesssteel(scratches,
beslightlyinclinedtoavoidstagnantdepositsand purchasedmaterials,checkingof
etc.)shallbetreatedusingpassivation.
shallconsistofpipesofthesamematerial, thecontentsisataskoftheDS
thicknessanddiameter. involved.
Wrapped Meettherequirementsspecifiedforbarepipes
pipesand/or withthedifferencethattheyshallberaisedfrom Specialprecautionsshallbetakenwhenhandling
pipeswith thegroundbyusingsandbags,whichshallalsobe thesepipes(hempliftingslings,rags,etc.)toavoid Applythenotesforbare
othertypesof usedbetweenonepipeandanother. damagingthesurfacesduringloading,unloadingand pipes
external ForpipesmadeofPE,itisnotnecessarytokeep transport.
protection thepipesseparatedbysandbags.
Thepipesshallbeadequatelysupportedto Specialattentionshallbepaidtothelevelof
Internally
minimizetheriskofbendingthatwoulddamage humiditytobemaintainedinsidethepipesduring Applythenotesforbare
cemented
thecementation.Pileswithmorethanthree storagetominimizepossibledamagetothe pipes
pipes
layersarenotallowed. cementedsurfaces.
Nonmetallic Meetstherequirementsspecifiedforbarepipes Provide,ifrequired,forpossibleprotectionfrom
pipes withthedifferencethattheyshallbelaidonan ultravioletrays,incompliancewiththesuppliers
Applythenotesforbarepipes
(PVC/RTRP/GR adequatenumberofsupportstoavoidpipe specificationsandalsoinconsiderationofthe
Eetc.) flexing. estimatedstoragetime.
Thefacesoftheflangesshallbecoupledandthe
Flangesshallbestockedinpilesapproximately1m
gasketseatsprotectedusingcardboardand/or Applythenotesforbare
Flanges high.Theyshallberaisedabovethegroundusing
anothermaterial.Thegasketseatsoftheflangering pipes
supports.
jointsshallbegreased.
Fittingsshallbeorderlystackedinpilesaccording
tothetypeofmaterial.Theheightofthepiles Thematerialshallbestoredinamannerthatavoids Applythenotesforbare
Pipefittings
shallbeproportionaltothediameter,butshallnot waterstagnationinside. pipes
exceed1.5m.
Duringhandling,valvesshallbegrippedbythe Allmechanicalpartssubjecttocorrosionshallbe
bodytoavoidaccidentalbreakageordeformation preservedwithprotectiveagents.Inaddition,all
Applythenotesforbare
Valves ofthestemsand/orhandwheels. valvesstoredoutsideshallbecoveredwithplastic
pipes
Theyshallberaisedabovethegroundusing sheeting.Allvalvesshallbekeptinthevertical
woodenprotectionapronsandstockedvertically. positionandintheclosedposition.
Bothduringstorageandafterassembly,thefollowing Forequipmentwithspecial
Generally,toavoidhandlingtheseitemsof periodicchecksshallbemade:closureof internalpreservationcriteria,
equipmenttwice,theyarestoredinproximityto manholes,closureofallnozzlesandgreasingofnuts storageinaninertenvironment
Pressure
therelativeareasofinstallation.Thetransport andbolts.Inthecaseofinternalpreservationwith mayberequired.Such
equipment
saddlesshallbekeptandusedassupportbases nitrogenand/orotherproducts,itisnecessaryto requirementsshallbestatedin
forstoragepurposes. recordtheperiodicchecksonprojectdedicated COMPANYand/orsupplier
forms. specifications.
Bothduringstorageandafterassembly,thefollowing
periodicchecksshallbemade:sealingofall
Thesemachinesshouldpreferablybekeptinside openings,weeklyrotationofthedriveshaft,cleaning
WRSand/orDS/FSSshalllookfor
Rotating theiroriginalpackaginguntilerection.Theyshall ofmotorcouplingandpreservationofmachined
specialpreservationrequirements
machines bestoredraisedfromthegroundandprotected surfacesandthefillingofmechanicalsealswith
inthesuppliersinstructions.
frombadweather. preservationagents.Specialpreservation
requirementsshallbelookedforinthesuppliers
instructions.

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Material Storage/Protection Preservation Notes
Wrapped Meettherequirementsspecifiedforbarepipes
pipesand/or withthedifferencethattheyshallberaisedfrom Specialprecautionsshallbetakenwhenhandling
pipeswith thegroundbyusingsandbags,whichshallalsobe thesepipes(hempliftingslings,rags,etc.)toavoid Applythenotesforbare
othertypesofusedbetweenonepipeandanother. damagingthesurfacesduringloading,unloadingand pipes
external ForpipesmadeofPE,itisnotnecessarytokeep transport.
protection thepipesseparatedbysandbags.
Thepipesshallbeadequatelysupportedto Specialattentionshallbepaidtothelevelof
Internally
minimizetheriskofbendingthatwoulddamage humiditytobemaintainedinsidethepipesduring Applythenotesforbare
cemented
thecementation.Pileswithmorethanthree storagetominimizepossibledamagetothe pipes
pipes
layersarenotallowed. cementedsurfaces.
Nonmetallic Meetstherequirementsspecifiedforbarepipes Provide,ifrequired,forpossibleprotectionfrom
pipes withthedifferencethattheyshallbelaidonan ultravioletrays,incompliancewiththesuppliers
Applythenotesforbarepipes
(PVC/RTRP/GR adequatenumberofsupportstoavoidpipe specificationsandalsoinconsiderationofthe
Eetc.) flexing. estimatedstoragetime.
Thefacesoftheflangesshallbecoupledandthe
Flangesshallbestockedinpilesapproximately1m
gasketseatsprotectedusingcardboardand/or Applythenotesforbare
Flanges high.Theyshallberaisedabovethegroundusing
anothermaterial.Thegasketseatsoftheflangering pipes
supports.
jointsshallbegreased.
Fittingsshallbeorderlystackedinpilesaccording
tothetypeofmaterial.Theheightofthepiles Thematerialshallbestoredinamannerthatavoids Applythenotesforbare
Pipefittings
shallbeproportionaltothediameter,butshallnot waterstagnationinside. pipes
exceed1.5m.

Duringhandling,valvesshallbegrippedbythe Allmechanicalpartssubjecttocorrosionshallbe
bodytoavoidaccidentalbreakageordeformation preservedwithprotectiveagents.Inaddition,all
Applythenotesforbare
Valves ofthestemsand/orhandwheels. valvesstoredoutsideshallbecoveredwithplastic
pipes
Theyshallberaisedabovethegroundusing sheeting.Allvalvesshallbekeptinthevertical
woodenprotectionapronsandstockedvertically. positionandintheclosedposition.
Bothduringstorageandafterassembly,thefollowing Forequipmentwithspecial
Generally,toavoidhandlingtheseitemsof periodicchecksshallbemade:closureof internalpreservationcriteria,
manholes,closureofallnozzlesandgreasingofnuts storageinaninertenvironment
equipmenttwice,theyarestoredinproximityto
Pressure
andbolts.Inthecaseofinternalpreservationwith
therelativeareasofinstallation.Thetransport mayberequired.Such
equipment
nitrogenand/orotherproducts,itisnecessaryto
saddlesshallbekeptandusedassupportbases requirementsshallbestatedin
forstoragepurposes. recordtheperiodicchecksonprojectdedicated COMPANYand/orsupplier
forms. specifications.
Bothduringstorageandafterassembly,thefollowing
periodicchecksshallbemade:sealingofall
Thesemachinesshouldpreferablybekeptinside openings,weeklyrotationofthedriveshaft,cleaning
WRSand/orDS/FSSshalllookfor
Rotating theiroriginalpackaginguntilerection.Theyshall ofmotorcouplingandpreservationofmachined
specialpreservationrequirements
machines bestoredraisedfromthegroundandprotected surfacesandthefillingofmechanicalsealswith
inthesuppliersinstructions.
frombadweather. preservationagents.Specialpreservation
requirementsshallbelookedforinthesuppliers
instructions.
Inthecaseofatransformershippedwitha
Theseitemsshallallbestoredinsidethe preservationfluid,thelevelofthefluidandthe
Transformers warehouse,exceptforthosethatoperate ambienttemperatureshallbeperiodicallychecked
outdoors. andrecorded.Anylossoffluidshallberectifiedby
toppingup.
Incertaincases,whererecommendedbythe
supplier,itmaybenecessarytoremovethe
Equipmentshippedwithprotectivepackingfor WRSand/orDS/FSSshalllookfor
Electrical equipmentfromitspackagingtopermitadequate
transportbyseathatisfoundtobedamagedshall specialpreservationrequirements
equipment ventilationandavoidtheriskofmouldand/or
bestoredinsidethewarehouseinadryplace. inthesuppliersinstructions.
oxidation.Afterreceipt,itisnecessarytoenergizeall
ofthespaceheaters(anticondensationresistances).

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Material Storage/Protection Preservation Notes
Formotorsandmotorizedvalvesstoredoutdoors
withoutprotection,itisnecessarytoensurethatall
openingsofthemotorcasingsthatwillnotbe
openedwhentheitemisinoperation(e.g.cable
inletsorconduitentrances)aresealedwith
waterproofplugs.Inaddition,itisnecessaryto
Motorsandgeneratorsthatoperateinclosed ensurethatallvalveactuatorsareintheirnormal
WRSand/orDS/FSSshalllookfor
Motors environmentsshallbestoredindoors.Materials operatingpositions.
specialpreservationrequirements
Generators thatoperateoutdoorscanbestoredinopenareas, Afterinstallation,motorswithlubricatedbearings,
inthesuppliersinstructions.
evenwithoutprotection. ACmotorsandgeneratorsshallbeprotectedin
accordancewiththesuppliersrecommendations.
Afterreception,thespaceheatersshallbeenergized
inallhighandmediumvoltagemotors.
Thedriveshaftsshallberotatedmonthly,orasper
supplierinstructions,toavoidpermanent
deformation.
Leadbatteriesshippedwithacidalreadyinsideshall
behandledasfollows:theelectrolytelevelshallbe
Allbatteriesshallbestoredinsidethewarehouse. WRSand/orDS/FSSshalllookfor
Batteries checkeduponarrivalandtoppedupwherenecessary.
Plugsshallbecheckeduponarrivaland,if specialpreservationrequirements
Accumulators Othertypesofbatteryshippedwithacidshallbe
necessary,toppedup. inthesuppliersinstructions.
storedinaccordancewiththesuppliers
recommendations.

Thisequipment(e.g.relays,sundryswitches,etc.)
Lowvoltage Thisequipmentshallbestoredinsidethe
shallbevisuallycheckedtoensurethatno
equipment warehouse.
condensationhasformed.
Drumsshallbealignedindoublerows,set
sufficientlyaparttoallowthepassageofvehicles Drumswithoutprotectionshallbecoveredtoavoid
forhandling.Stacksarenotpermitted. directsunlight.
Electricaland
Drumsshallbeblockedinamannerthatprevents Cableendsshallbeadequatelysealedtoprevent
instrumentati
themfromrolling.Instrumentcablesandmulti humidityinfiltratinginsidetheinsulation.
oncables
conductorcablesshallbestoredunderashelter. Ensurethattheradiusofcurvatureofthecablesisin
Fibreopticcablesshallbehandledwithcareand accordancewiththesuppliersrecommendations.
storedinsidethewarehouse.
Acleanenvironmentshallbeprovided,freeofdust
and/orsandanddrytoavoidcondensationforming
ontheinstruments.
Panelsshallbekeptintheiroriginalpackinguntil
erection.Anyspecificstoragetemperaturelimits
WRSand/orDS/FSSshalllookfor
Allinstrumentsshallbestoredinsidethe indicatedbythesuppliershallbeassured.Control
Instruments specialpreservationrequirements
warehouse. consoles,microprocessors,videoconsoles,
inthesuppliersinstructions.
computersandrelativeaccessoriesshallberemoved
fromtheirpackingincleandustfreeareas,andinan
airconditionedenvironmentwherethetemperature
shallnotexceed30Cand/orthatrecommendedby
thesupplier.

Alloftheseproductsshallbestoredincovered
Catalysts
andventilatedareasandatacontrolled WRSand/orDS/FSSshalllookfor
Refractory Eachproductshallbehandledinaccordancewiththe
temperaturewhenrecommendedbythesupplier. specialpreservationrequirements
materials suppliersrecommendations.
Astherecanbeproductswithexpirydates,the inthesuppliersinstructions.
Paints
storageruletobefollowedisfirstinfirstout.

Inprinciple,sparepartsshallbestoredinsidethe
coveredwarehousebyordernumberand
Therequirementsdescribedinthistableandthe
equipmentreference.Inaddition,thebiennial
Spareparts suppliersspecialrecommendations,ifany,are
sparepartsshallbekeptseparatefromthespare
appliedaccordingtothetypeofmaterial.
partsforplantstartup,whilstrespectingthe
storagerequirementsapplicabletotheparts.

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Material Management at site

37. DELIVERY AND RETURN OF MATERIAL


DS will issue 3 withdrawal vouchers, 2 copies will be delivered to SUBCONTRACTOR, one
of which is signed by DS in blue ink.
Upon delivery of materials SUBCONTRACTOR personnel in charge will countersign the
withdrawal voucher for successful delivery.
After delivery the WRS will make withdrawal vouchers confirmation, in order to update the
software system related to stocks, and to allow CONTRACTORs engineering department to
verify the actual withdrawal of materials.
Materials are returned to the warehouse through a return voucher, released by DS, on which
the condition of the given back material is described. Only materials in good condition can be
accepted back and recorded by the warehouse.

38. STOCK-TAKING AND SPARE PARTS


WRS, assisted by SUBCONTRACTOR where required, is responsible for arranging
transportation and delivery of material based on agreed schedule and venue. All operating
spares supplied should bear original manufacturer labels/tag, providing vital information on
the spare (i.e. item description, part no., material specification, etc.).
WRS is also responsible for the physical handover of spare parts material. In particular,
WRS will assure that materials received from VENDORs will be packed in compliance with
the requirements referred to in the P.O. WRS will also ensure that all required preservation
methods are applied.
All spare parts shall be received, inspected and stored accordingly by WRS and his
organization. WRS shall segregate these spares from construction materials.
During the spare parts handover WRS shall provide a document package listing all the
documents to be transferred, in particular this package shall include:
- Preservation and maintenance actions record.
- Packing list with shipping and inspection certificates.
- Copy of Over/Short Damage Report (if any).
- Notes indicating if CONTRACTOR used some of these items, and relevant record of any
reconciliation actions.
- Copy of full P.O. signed by all parties.
- Certificate of origin.
- Copy of Airway bill/Bill of landing.
- Material Receiving Report (MRR) that should have:
o WRS signature along with COMPANY representative signature.
o WRS endorsement on MRR of Nil Discrepancy in the case no discrepancies
were observed by COMPANY and WRS.
- G-SPIR form approved by COMPANY.
- Material test certificates where it is required in relevant Purchase Order.
WRS will raise joint/visual inspection with COMPANY representative (if requested).

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Material Management at site

39. MATERIAL RECONCILIATION


CONTRACTOR will keep a record of replacement materials issued to SUBCONTRACTOR
for materials either lost or damaged by it, advice Engineering and Project Control teams of
such replacements and initiate action to back-charge the related costs in compliance with
the Backcharge procedure.

40. DOCUMENTS
The documents issued to carry out the various activities connected with the management of
the warehouse shall include, as minimum, the information described below.

41. MATERIAL RECEIPT REPORT (ATTACHMENT A, FOR


REFERENCE ONLY)
This document is used by the warehouse personnel to take over materials and to inform the
project personnel concerned of their availability in the warehouse. It shall include the
following information:
- Progressive document number
- Purchase order number
- Name of Supplier
- Date of receipt of materials
- Shipping file
- Name of ship/air freight
- Number of packages
- Net weight
- Description of materials
- Reference/location
- Number of Over/Short Damage Report (if any).

42. OVER/SHORT DAMAGE REPORT (ATTACHMENT B, FOR


REFERENCE ONLY)
This document is issued to record damage, loss and shortage of materials. It shall include
the following information:
- Date of receipt of materials
- Progressive document number
- Purchase order number
- Name of Supplier
- Shipping file
- Name of shipment
- Name of Carrier

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- Description of damage/loss.

43. MATERIAL NON-CONFORMANCE REPORT (NCR)


This document is used by the warehouse personnel to notify a non-conformance of arrived
material.

44. MATERIAL RETURN VOUCHER


This document is used to return materials to the warehouse. It shall include the following
information:
- Date of receipt
- Origin
- Quantity
- Condition of material returned
- Description of material returned including heat number, if any.
- Name of SUBCONTRACTOR
- Collection voucher

45. ATTACHMENTS
- Attachment A: Material Receipt Report TO ADD FORMAT
- Attachment B: Over/Short Damage Report TO ADD FORMAT
- Attachment C: Site Non Conformance Report TO ADD FORMAT

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